The Hydro-Guard® SMART Flushing System utilizes an ATI Chlorine analyzer (Free Chlorine or Total Chlorine) to actively monitor Chlorine levels at the installation site. The readings recorded by the ATI analyzer are then translated and logged by the logic of the Hydro-Guard® SMART Systems controller.

The logic will determine, based on the owner/operator’s settings, whether or not the recorded readings are within tolerance. If the water quality condition, in this case Chlorine, is out of tolerance the device will initiate a flush sequence. Water will continue to flush from the Hydro-Guard® until the water quality reading from the Chlorine analyzer is above the set points programmed by the owner/operator. At this time the water will stop flushing. The logic of the Hydro-Guard® SMART controller can be programmed by the owner/operator to monitor various water quality conditions, in addition to Chlorine. The device can measure temperature, pH, turbidity, flow, pressure, TOC, DOC, conductivity, etc. To monitor these other conditions it is necessary to order additional analyzers and/or probes (all of which are available from Mueller and are delivered with the SMART System as a “plug and play”).

NOTE: The Hydro-Guard® SMART System is expandable; therefore, an owner/operator can budget for additional water quality monitoring equipment that can be added to the original device as budgets will allow.

The logic of the SMART Flushing System also allows the owner/operator to program a maximum run time and a minimum off time for the flushing sequence. The maximum run time can be set so that no matter what the water quality condition at the time this setting is reached the flush event will stop. The minimum off time setting can be programmed so that once the flush sequence stops the unit will remain at rest for a period of time determined by the owner/operator. Both of these features can be bypassed by the owner/operator.

The Hydro-Guard® SMART Flushing System requires that a constant flow of water pass through the flow cell of the ATI Chlorine analyzer. This flow is estimated at just 10 gallons per hour.

The typical flow rate of the Hydro-Guard® SMART Flushing System depends on the water pressure at the installation site.  For example, if the sustained pressure at the installation site is 75 psi, the flow rate will be approximately 155 gallons per minute. 

Installation and wiring diagrams are provided to customers purchasing the Hydro-Guard® SMART Flushing System, as are owner manuals for the overall system and every major component used in construction of the device (i.e., ATI Chlorine Analyzer; Double Check Valve*; combination Flow Meter/Control Valve*; pH, temperature, turbidity, pressure, etc., probes and analyzers; and any other specified analyzer equipment).

* Optional equipment

Communication Options: Hydro-Guard® SMART Flushing System with Ethernet Port on PLC
This option would allow you to have an operator visit the site and connect directly to the unit. Via direct connect, you can upload programming and download data logs for the chlorine levels, temperature, pH, turbidity, pressure, and/or flow (depending on what features you wish to have included on the device). This option does not require any additional equipment of cost. This option does not require a communication service plan with a third-part service provider

Hydro-Guard® SMART Flushing System with Bluetooth Communication
This option would allow you to have an operator visit the site and connect remotely to the unit from within 300’ (line of sight). Via the BlueTooth connection, you can upload programming and download data logs for the chlorine levels, temperature, pH, turbidity, pressure, and/or flow (depending on what features you wish to have included on the device). This option does not require a communication service plan with a third-part service provider.

Hydro-Guard® SMART Flushing System with Cellular Communication
This option would allow you to connect remotely to the unit from within via GSM or CDMA cellular machine to machine service. Via the cellular modem, you can upload programming and download data logs for the chlorine levels, temperature, pH, turbidity, pressure, and/or flow (depending on what features you wish to have included on the device) remotely from anywhere, provided cellular communication is available. This option does require that the owner/operator contract with a third-party vendor for cellular service (i.e., AT&T, Verizon, T-Mobile, Sprint, etc.). This option will allow the owner/operator the ability to receive SMS text messages and/or email alerts from the Hydro-Guard® SMART Flushing System for condition alerts.

Pros for HG-4 SMART:
This design would allow you to have a bury depth of 36” to 108” on the flushing component of the device.

Cons for the HG-4-SMART:
Requires two above ground pedestal enclosure; the enclosure with the chlorine analyzer would need to be heated. Requires a ¼” water line be run to the outside of the in-ground PVC protective sleeve of the HG-4, as well as electrical conduit for the power lines. Construction costs will likely be higher with this design than the All-In-One design due to the complication of the installation and the extra enclosure.

Pros for HG-7 SMART All-In-One:
Flush device and electronics are all in a single (33” or 60” tall enclosure); easy access. Both sides of enclosure—water and electric—are heated; heat tape can be added to the piping and valve to give an extra level of protection. Recommend adding flushing on water temperature by way of a temperature sensor to give a third level of redundancy to protect the water lines from freezing. Use of the single enclosure, seated on a 4” high concrete pad (by others; design drawings provided by Mueller) will give an added layer of protection for the piping located directly below the enclosure.

Click here to learn more about SMART flush management options.

The Hydro-Guard® HG-6 is battery powered. The device is capable of being programmed by either a built-in controller or one that is removable. The built-in style controller utilizes a 9-volt alkaline battery to power the HG-6. The removable (requires the use of a handheld controller) uses a 9-volt lithium battery. Typical battery life Is between six months and one year, depending upon how often the device is scheduled to turn on and off flush events.

The short answer to this question is no; however, if the HG-6 were managed by Mueller’s Hydro-Guard® SMART Monitoring and Flush Management System then the HG-6 could communicate with SCADA.  For more details on the Hydro-Guard® SMART Monitoring and Flush Management System please see the Mueller animated video for this product.

You can measure flow by inserting a flow meter between the hydrant and the HG-6. The HG-6 features a swivel adapter that will allow it to swivel onto the outlet of a 2-inch meter. The device is typically 'stand-alone' with no communication capabilities; however, it can be coupled with the Hydro-Guard® S.M.A.R.T. Monitoring and Flushing Management System that allows it to capture and relay data related to chlorine, temperature, pH, turbidity, flow, and pressure. Additionally, the Hydro-Guard® S.M.A.R.T. Monitoring and Flushing Management System the HG-6 has the ability to flush on a wide variety of water quality parameters, including chlorine, temperature, pH, and turbidity (depending on what sensors and/or analyzers are incorporated with the Hydro-Guard S.M.A.R.T. Monitoring and Flushing Management System.)

Yes. The Hydro-Guard® HG-6 is only attached ot a single nozzle. The remaining nozzles are still available for use. The hydrant is live when the HG-6 is being used for flushing; therefore, the fire department personnel will need to turn off the hydrant prior to attempting to remove the nozzle caps. Once the hydrant is turned off and the caps removed, the fire department can remove the HG-6 by cutting any locks used to lock it to the hydrant. If they prefer, they can utilize the available nozzles and leave the HG-6 in place. If the HG-6 were to attempt to go into a scheduled flush event during the time of use by the fire department the device would likely not activate due to the flow being drawn from the other nozzles.

In the event the HG-6 was flushing at the time a fire hydrant were to be put in to service for fire fighting the fire department personnel will need to turn the hydrant off; remove the other nozzle caps; attached their hose; and charge the hydrant. The HG-6 may attempt to turn on; however, the low pressure at the HG-6 will likely prevent the device from operating. In the event the device did run during fire flow from the other nozzles the demand on the line from the HG-6 should have a minimal effect on the flow from the hydrant’s other nozzles.

Start with the first hydrant nearest where the new main connects into the system, and work toward the farthest hydrant. Open the first hydrant as fast as possible until fully open, and allow it to run for five minutes, then close it fully. Do this on successive hydrants until the entire system of pipes has been flushed.

The first number in the code is the number of threads per inch. The last three digits are the pitch diameter as demonstrated in this example: 60454 – 6 threads per inch with a pitch diameter of 4.54.

Instead of using a standard MJ connection with an add-on bolted restraint system, which can leave several bolts out of reach underneath the pipe, use the Mueller® AquaGrip® system, which includes an MJ-type connection and pipe restraint without any bolts underneath the pipe. Plus, the AquaGrip systems involves far fewer bolts to tighten when it’s installed.

The Mueller® Vertical AquaGrip® Hydrant allows the use of any length of standard ductile iron pipe to be used to extend from the hydrant shoe directly down to the main’s level. A companion AquaGrip Elbow can be used at the lower end of the DI pipe to make the 90º turn for the run to the main. Using the vertical AquaGrip hydrant also allows one standard bury depth to be stocked for use with any main depth in the system.

NFPA sets the guidelines which govern the spacing for private and recommended spacing for public water systems.  Most engineers will follow the guidelines set forth by NFPA but with public systems they set their own rules and regulations. NFPA 1, Section 18.3.3.1 says the maximum spacing for residential lots 20,000 square feet or larger should be 1,000 ft; 750 feet for residential lots of less than 20,000 square feet; and 500 feet for townhomes and apartments. For more information, please click here.

17-1/4 turns on all Centurion® hydrants.

Such a situation can occur if the hydrant has been left idle for many years without annual exercise, or if the main valve is brass and it is threaded directly into an iron mounting. Mueller hydrants have brass-on-brass main valve mountings to help avoid corrosion that can occur with brass-on-iron. For a main valve assembly that cannot be loosened using a seat wrench, try pumping out all accumulated water, pour in one to two liters of a cola soft drink, and let it soak – overnight might be necessary.

Placing a special brass sleeve, part number A-368, made for this purpose over the stem threads before removing the bonnet will not only protect the stem O-rings, it also retains the oil in the reservoir and keeps it from running down into the hydrant barrel.

A-31: Lower Stem, A-32: Lower Barrel, A-27: Safety Flange Gasket, A-38: Drain Ring Gasket

A-1: Operating nut (specify size, shape, and opening direction), A-2: Weather cap – Hydrants 1987 or earlier, A-4: Hold down nut – Hydrants 1987 or earlier, A-84: Hold down nut – 1988 or later, A-8: Bonnet (Prior to 1988 Centurion® Hydrants did not have a directional arrow cast on the bonnet to indicate the opening direction. Instead, it was indicated on the weather cap of the hydrant. On Centurion® 200 hydrants, the arrow is cast on the bonnet.), A-11: Upper Stem (Specify year and valve opening size.)

Specify thread gauge and order the following: A-15: Pumper Nozzle Gasket, A-17: Pumper Nozzle Cap (Specify size and shape of operating nut.), A-19: Hose Nozzle Gasket, A-21: Hose Nozzle Cap (Specify size and shape of operating nut.), A-1: Operating Nut (Specify size, shape, and opening direction.), A-311: Operating Wrench (Specify size and shape.), A-22: Cap Chain w/Ring, A-23: Chain Hook(s)

Specify size of pumper nozzle and thread gauge and order the following: A-13: Nozzle Lock; A-14: Pumper Nozzle; A-15: Pumper Nozzle Gasket; A-16: Pumper Nozzle O-ring; A-17: Pumper Cap (Specify size and shape of operating nut.); A-22: Cap Chain w/Ring; A-23: Chain Hook(s)

Many systems still specify the use of ground key valves in service lines, which are only rated to 100 psi. Testing new lists at 200 psi, even 150 psi push these valves to their limit and sometimes leakage can cause a test failure. Using Mueller 300® Ball Valves, which are rated at 300 psi can help assure successful testing. Mueller® Oriseal® Valves are plug style valves with O-ring seals, and are rated at 175 psi, and offer an alternative. When using ground key valves, it is helpful to rotate or “cycle” the key to redistribute the grease when installing the valve. Never tamper with the nut on the bottom of the key, as in Mueller valves, this nut is factory tightened to a precise torque, and loosening it can change the valve’s pressure holding capability.

First, make sure the hydrant is well lubricated – if it’s a Mueller® hydrant made 1954 or after, this is easily done by removing the oil fill plug and adding oil if necessary according to hydrant maintenance instructions. If lubrication isn’t the issue, it could be the hydrant has been over tightened and the stem bent. In this case, the stem will have to be replaced. If the hydrant is old or has not been exercised in sometime, corrosion or build up of deposits in the main valve could be a problem in which case, the main valve will have to be serviced. If it is an especially old hydrant, over fifty years old for instance, sometimes the best solution is to replace it.

Consult our fire hydrant and gate valve troubleshooting guides for a step by step process to find and fix most problems.

Since the machines are very similar in construction, it comes down to deciding which machine has the range needed. The D-5 machine accommodates up to 2” dia. cutters – 3/8” larger than the E-5 machine. Both are rugged machines rated to 500 psi and can be hand or power operated.

Since the machines are very similar in construction, it comes down to deciding which machine has the range needed. The D-5 machine accommodates up to 2” dia. cutters – 3/8” larger than the E-5 machine. Both are rugged machines rated to 500 psi and can be hand or power operated.

No. Mueller machines are designed for water use. Certain machines can be used on pipe containing different types of fluids, but you must check with Mueller Co. (800-423-1323) for compatibility before using this machine on lines containing fluids other than potable water.

The C1-36-99002 Machine has an eight (8) thread per inch feed screw and the C1-36 Machine has a six (6) thread per inch feed screw. This means the C1-36-99002 machine boring bar will advance slower than the C1-36. This is important when making cuts over 12” in size. The slower feed allows the C1-36-99002 to make cuts through 14” to 24” valves.

Use a combined shell cutter & tap (CSC&T) when customer is concerned about the amount of chips a CD&T will generate on 1 ¼” thru 2 ½” taps. The combined shell cutter and tap will produce fewer pipe chips than a combined drill and tap. The combined shell cutter and tap will remove a coupon of pipe instead of turning it into chips. The customer may also require a CSC&T so they can inspect the coupon to determine the condition of the interior of the pipe at the point of tap.

The power clevis is used to control the boring bar movement when working at line pressures above 90 psi.

This means the machine has been repaired. The numbers represent the date the machine was repaired. We keep a record of the repair date code and can provide more information about the repair.

A new machine should have its first oil change after ten (10) hours of operation and after each fifty (50) hours of operation thereafter.

A new machine should have its first oil change after ten (10) hours of operation and after each fifty (50) hours of operation thereafter.

Although you should verify such compatibility with your Mueller Sales Person when ordering the machine, in general the following is true: Mega-Lite® Machine cutters are compatible with CL-12 tools C1 Series cutters are compatible with CC tools E-5 and E-4 machine tools are compatible. D-5 and D-4 machine tools are compatible. D and E series cutters are interchangeable, but the adapters are not.

Use four pints of EP220 Permagear oil, MUELLER #89347 (1 gallon can), in both the front and rear cases. The machine should be horizontal with the plugs on top when being filled. The front gear case oil plug (end that attaches to the drilling machine adapter) is located on the face of the torque tube (long body) and is a plug with square wrench flats. The rear gear case oil plug is the holder that is used to store the crank handle located under the tray that houses the two indicators. Do not overfill the gear cases. The two gear cases are not connected, so filling one will not fill the other. To check oil, the machine should be horizontal with the plugs 90° from the top and oil should be even with the bottom of the plughole.

Model three (3) and earlier, use Mueller lubricant part number 580685 (Amovis 5x). Model four (4) and newer, use Mueller lubricant part number 89347 (EP220 Permagear, non-foaming). The machine should be horizontal with the plugs at the top when being filled. The front (flange end that attaches to the drilling machine adapter) gear case requires four (4) pints of lubricant and the rear gear case requires 1.6 pints of lubricant. These two gear cases are not connected and must be filled separately. DO NOT OVERFILL. To check oil, the machine should be horizontal with the plugs 90° from the top and oil should be even with the bottom of the plughole.

Yes, but you will need to use the B-101 friction collar (part #580610) and you will need to change out the feed nut and yoke to the B-101 style (part #580611).

Check your combined drill and tap or combined shell cutter and taps to make sure the cutting edges are sharp and your tools are not missing any tapping teeth. Replace the combined drill and tap if worn or damaged. Check the friction collar (part #580610) to make sure the top and bottom bearings rotate freely. If the top and bottom bearings do not rotate freely, replace the friction collar and check the underside of feed yoke for damage. Replace the feed yoke (580611) if damaged. Check threads on the feed sleeve and cap (500685) for wear and replace if necessary.

Yes. The E-5 drills, shell cutters, holders and adapters can be used with the E-4 machine.

These threads are left hand threads used with extracting tools to remove gas tee completion plugs, valve stems and small line stopper fitting completion plugs. Operating instruction manuals for the E-5 and D-5 Machines (Form 9335) are available by contacting Mueller Co. Customer Service Dept. at 1-800-423-1323. These manuals are also available on line at www.muellercompany.com. Mueller Co. offers a sharpening service for the cutting equipment. Contact your local distributor for pricing and details.

Check the brushes (#505005A) and replace if necessary. Also, if you use an extension cord between the H-603 and your generator, use an extension cord that is one size larger than the power cord on the H-603. The H-603 power cord is a #14 wire. Try to use as short of extension cord as possibl

Check the linkage where the indicator shafts attach to the gearing to make sure they are connected properly. If the indicators are properly connected, recalibrate the indicators using the instructions in the CL-12 Operating Instruction manual (Form 8895, Page 20).

Some pipe chips or cutting grease is probably blocking the by-pass/relief valve or the machine “channels” in the body leading to the valve. To clean the channels, remove the by-pass valve and use a small wire to push the blockage out of the channels. The by-pass relief valve should be cleaned as well. Re-attach the by-pass valve.

Excessive torque can cause these studs to bend or shear. Excessive torque is caused by the use of dull combined drills and taps or dull combined shell cutters and taps or trying to final tighten a corporation stop into the main using the A-3 machine. The studs are not field replaceable. A new boring bar (580967) is required. Improper insertion of the tool shank in the boring bar. If the tool shank is not inserted far enough into the boring bar to allow the retaining screw to engage the “dimple”, the tool will be loose during the operation and cause the damage. The tool retaining screw (62501) should also be checked to make sure the bullet nose of this screw is not damaged. Replace, if damaged.

Yes. To convert your A-2 machine to an A-3 machine you will need to replace the boring bar with the A-3 boring bar complete (#580893) and replace the feed nut and yoke with the A-3 feed nut and yoke (#580894). All other parts are the same.

You have probably damaged the commutator on the armature. This happens if you reverse the motor while it is running. You must only change the direction of the operation (reverse switch) after motor comes to a complete stop. You must replace the armature (#505008) and brushes (#505005A).

You must replace the brush holders and brush caps as well as the brushes using brush replacement kit (#682269). The motors having a plastic fan on the armature only require the brushes (#505005A) unless the brush caps or holders are damaged or worn.

The only authorized repair service for Mueller made machines and tools is at our Decatur, Illinois factory. We do not repair machines or tools made by other manufacturers. Contact your Mueller Distributor for repairs or call Mueller Customer Service at 1-800-423-1323 for further details or the name of your nearest Mueller Distributor. Mueller offers a (1) year warranty on machine repairs performed at our Decatur plant. We rebuild the machines to “as new condition” and warranty the repair to be free of defects in workmanship and materials for one year from the shipment of the repaired machine. The operating instruction sheet, Form 11758, is available by contacting MUELLER Customer Service Dept. at 1-800-423-1323. This instruction sheet is also available on line at www.muellercompany.com.

Mueller machines and power operators have been designed to be rugged and with reasonable care, provide many years of reliable service. Normal in-service wear and tear can take a toll, however, and we offer a repair/rebuild service for certain machines and tools (see “Repair Services” section of this web site for details) to restore them to “almost new” condition. Still, there are a number of things you can do to troubleshoot, and in some instances, perform simple repairs. For details, search this page using key words relevant to your specific situation.

This is a normal function of the CL-12 Machine. This is caused by friction between internal components. Not all CL-12 Machines will do this. An operating instruction manual for the CL-12 Machine (Form 8895) is available by contacting Mueller Customer Service Dept. at 1-800-423-1323. This manual is also available on line. Mueller Co. offers a repair and sharpening service for the CL-12 Drilling Machine and cutting equipment. Contact your local Mueller Distributor for details and pricing.

The indicator wheel set screw has probably loosened allowing the wheel to slip on the indicator shaft. With the boring bar retracted fully, remove the cover plate (54446) from the indicator body and rotate the indicator shaft until the indicator arrow is set to zero. Tighten the wheel set screw to secure the wheel to the indicator shaft and replace the cover plate and indicator knob. If the set screw loosens again, repeat procedure and put a thread locking compound on the screw. The wheel set screw can loosen if the C1 Machine Boring Bar is retracted under power with the Mueller H-600 or H-601 Air Power Operators and the power operator continues the run in reverse after the boring bar reaches its rear most position.

If your machine was manufactured or repaired by Mueller Co. in 1995 or later, you have an over travel feature which activates when you extend the boring bar out past the limit line on the boring bar. This over travel feature allows the feed screw to disengage from the feed nut to prevent damage to the feed screw and machine. The feed nut and feed screw can be re-engaged under pressure with no disassembly required by simply working the boring bar back in using the crank at the rear of the machine. If the bar is too far out, you may need to remove the cotter pin in the castellated nut and back the nut off 2-3 turns. Caution - do not remove the nut. Then lightly tap the nut with a hammer and crank the boring bar back in. Tighten the castellated nut and replace the cotter pin. Call 1-800-423-1323 before performing the procedure if you have any questions. C1 machines with the over travel feature will have the letters “OT” stamped in the brass drive box or on the cast panel of the body. If the drive box is stamped, “Model 6”, it will have the over travel feature but will not have the OT stamp. If your machine does not have the over travel feature, you have probably damaged the feed screw and you will not be able to retract the boring bar. Call factory for further instructions, 800-423-1323. Note: The Operating Instruction Manual for the C1-36/C1-36-99002 Machines (Form 8513) is available by contacting Mueller Co. Customer Service Dept. at 1-800-423-1323. The Operating Instruction Manual is also available on line at www.muellercompany.com. Mueller Co. offers a repair and sharpening service for the C1-36-99002 Machine and cutting equipment. Contact your local distributor for details and pricing.

Check the body offset (where gate sits when fully open) to see if pipe chips and cutting grease has accumulated. If this is the problem, use the body cleaning Chisel (part # 40050) to remove the build up of chips and grease.

Make sure the knock out pin (part #500693) is moved into the correct position to allow full insertion of the shank. Check the tool retaining screw (part #500694) to make sure the “bullet nose” on this screw is not damaged or broken off. If the tool retaining screw is damaged, also check the inside of the boring bar for damage or “scoring”.

Check the body (part# 502046) sealing surface and the gate washer (part #500673) to make sure there are no “nicks” or “dings” or damage. Should damage be found, replace the damaged part. The gate assembly may be out of adjustment. To check this, apply a thin coating of cutting grease to the gate washer and close the gate. Open the gate and check the impression to see if the gate washer is sealing 360°. If a 360° seal pattern is not seen, adjust the brass gate arm by gently bending it up, down or side to side to achieve a 360° seal pattern. Check the gate assembly to make sure it spins and “pivots” in the gate arm. If the gate assembly is “locked-up” and does not spin or pivot, remove the gate lock screw (part #500675) and check the end of this screw to make sure it has a non-threaded machined end to allow the gate assembly to spin and pivot (wobble) as this is a self adjusting feature to assure a proper seal.

Check the bottom of the body for damage. If the surface is warped or damaged, replace the body (part #502046).

Several operational errors can cause improper threads. When tapping ductile or cast iron, the tapping line on the boring bar should be flush with the top of the feed sleeve to assure proper thread depth. Traveling past this point could produce an oversized hole. Stopping short of this point can cause an undersized hole. The feed nut and yoke should not be used to force the boring bar down during the entire thread-tapping portion of installation. This can deform the threads. The feed nut and yoke should be used only to catch a couple of CD&T threads in the main. Make sure the CD&T or CSC&T thread matches the corporation stop inlet thread, “cc” or “ip” threads and correct size. Call Mueller Customer Service (800-423-1323) if your have any questions.

Disassemble the by-pass relief valve assembly and clean all parts. Use the by-pass clean out tool (50529) to re-tap and clean out the threaded portion of the machine by-pass. Replace the seat washer (#42042) and the seat nut washer (#40049) and any other damaged parts and re-assemble.

Check the body offset (where gate sits when fully open) to see if pipe chips and cutting grease have accumulated. If this is the problem, use the body-cleaning chisel (part #40205) to remove the build up chips and grease.

Check the bottom of the body for damage. If the surface is warped or damaged, replace the body (part #503147).

Check the friction collar (#580610) to make sure the top and bottom washers are rotating freely. If the washers do not rotate freely, replace the friction collar and check the underside of the feed yoke (#580611) for damage. Replace the feed yoke if damaged. Check the feed tube and nut to make sure they are not out-of-round and the threads are not damaged. Check the drills or shell cutters and pilot drills to make sure they are not damaged and are sharp. Replace or re-sharpen.

Lubricate the “O” ring and boring bar with light oil. Replace the “O” ring (part #46726) for E-5 or #51458 for D-5, if necessary. Remove the boring bar and check the bar to see if it is bent. If the boring bar is bent, replace it (E-5 boring bar part #580999, D-5 boring bar part #580945).

The coupler (#501989) is probably broken. The coupler is designed to break if the machine is put into a severe over torque condition to reduce the possibility of damaging the motor or gearing. The cause of the over torque condition could be a dull combined drill & tap, or shell cutter, or hand feeding the drilling or tapping machine too fast.

The coupler (#501989) is probably broken. The coupler is designed to break if the machine is put into a severe over torque condition to reduce the possibility of damaging the motor or gearing. The cause of the over torque condition could be a dull drill, CD&T, shell cutter or hand feeding the drilling or tapping machine too fast. Another cause could be corrosion build up in the cylinder. To prevent corrosion from forming in the cylinder, use an airline lubricator. Also, check the vanes for wear.

The H-604 operators have an air strainer (#312261) basket in the handle to prevent dust, dirt and other foreign material from entering the cylinder. This strainer basket needs to be removed periodically for cleaning as it can fill up with debris to a point the air is blocked from entering the cylinder. Check pressure with a gauge at the handle where the air hose connects. The gauge should read 90 psig with the motor running. The operating instruction sheet, form 11758, is available by contacting MUELLER Customer Service Dept. at 1-800-423-1323. This form is also available on line at www.muellercompany.com.

• End users with multiple pressure zones or district metering areas
• End users with multiple elevation changes
• End users with high pressure
• End users that have multiple water sources
• End users that have frequent main breaks that are not due to freezing
• End users that have multiple main breaks in the same area of their systems
• End users that require pressure regulators on residential services
• End users that have lower than normal (<55 psi) pressure in their distribution system

In the event a client has multiple units in their system, the data limit of 1MB per unit will be shared between all of the units owned by the client. If one unit uses less than 1MB another unit can use more than the 1MB assigned to it. In the event the shared data usage volume exceeds the combined limit for all units in the client’s inventory the client will be charged a data overage rate of approximately $0.005 per KB.

Yes. The pin connectors are water proof.

A minimum of two (2) per district metering area, or DMA.

Yes. Client system integrators will be able to link the URL address of the device to the clients SCADA Network.

The mounting bracket should be mounted to the side wall of the Meter box. Be certain to mount the bracket so that the RTU is level and not positioned under a metal Meter box lid. Please refer to the Owner’s manual and Quick Installation Guide for specific installation instructions.

The initial purchase price of the unit includes the first year of cellular service. Additional years of cellular service may be purchased from Mueller Company to renew cellular service. Additional costs include installation of the unit.

Currently, the second year cell service is under $100.00.

An email reminder will be generated and transmitted to the Administrator who has been registered as the primary contact at the time of the initial order placement.

Yes. AT&T and Verizon will contract with third party providers to offer roaming coverage in areas where they are not the primary providers.

The current system is using 3G technology.

No. The cellular modem and SIM card is unique to each Pressure Monitoring device. Additionally, the modem and SIM card has been incorporated onto the device’s circuit board and potted into the body of the device for protection and longevity; therefore, modification of the board for the use of a user-specified SIM card is not possible.

Each Pressure Monitoring System allows for 1MB of data to be used per month. The current charge for overages is approximately $0.005 per KB.

The number of administrators allowed to be assigned to a single account are unlimited; however, we do not recommend making all users “administrators” since an Administrator has full system management rights. Mueller recommends using the Administrator level for only high level managers or operators. Technician level rights should be assigned to those who need to be able to alter reporting data settings. User level rights should be assigned to those who only need access to reported data.

Customer specific data will be uploaded to a secure cloud based system that is only accessible by the clients authorized personnel and the Mueller system administrator. In regard to ownership, all data captured by the device is the sole property of the client. Mueller does not review or analyze data unless specifically requested to do so for technical service purposes only.

Yes, data can be downloaded into Microsoft™ Excel® or other spreadsheet management software.

It will take effect at the next upload.

Yes. If you require more frequent readings the Administrator or Technician level users can alter the number of uploads per day. Such action will decrease the battery life expectancy.

Data is stored in the cloud-based storage for a period of two years. Data older than two years is automatically purged from the customer’s database.

Not currently.

In the event of a power failure, telemetry contact will cease and data transfers will not be available on the web site, thus indicating a power or communication failure. Site visit and evaluation will be required. Refer to Remote Pressure Monitoring System User Operation & Installation Manual, Technical Section, Page 18.

Batteries are field replaceable and can be ordered through Mueller Company. DO NOT disassemble the RTU until the replacement batteries have arrived with replacement instructions included. Contact Mueller Customer Service for safe handling and return instructions for used batteries.

The device is engineered to record pressure readings every 15 seconds. When a pressure event exceeds the Warning or Critical pressure settings set by the end user the system will look for a consecutive reading at or above the warning or critical level 15 seconds later to confirm that the initial reading was not an anomaly. If the initial reading is not substantiated by the second consecutive reading the device will not transmit an email or text message notification.

Currently, Mueller can provide technical service via phone between the hours of 8:00 a.m. and 5:00 p.m. (Eastern Standard Time) by calling (844) 263-5395. A technical service representative can also be reached by emailing Mueller at intelligentwater@muellercompany.com. You may also contact your area Mueller sales representative for support.

Mueller makes dual meter setters and boxes that accommodate connecting two meters to the service line.

When drilling and tapping the main using a power operated B-101 Drilling & Tapping Machine, the Automatic Feed of the power operator must be disengaged from the machine’s Feed Yoke when the drill has finished making its hole in the pipe (but before the tapping section of the tool engages the pipe wall). If it is not disengaged, the threads in the pipe wall will be mis-shaped or even stripped – the corporation valve might appear to be in place and might even hold for a period of time, but can eventually leak or pull out. A “tapping line” is provided on the B-101 machine boring bar and instructions in the manual (form 8910 paragraph E-A-3) describe how to use this line to determine when to disengage the Automatic Feed.

In addition to the year of manufacture, resilient wedge gate valves contain a six digit Julien number that represents the date and shift the bonnet was created. For example, if the code reads 071043, then 07 is the month, 10 is the day, 4 is the last digit of the year, and 3 is the shift. 

The valve may be larger than shown on the plans. Continue to operate based on the next size valve. Alternatively, the valve may have a bevel or spur gear to help during operation. Check the plans to see if it a gear was installed on the valve. Excessive torque may have been applied to the operating nut at some point and damaged the stem or stem nut. If this is the case, expose the valve and inspect the stem and stem nut. Replace if necessary.

First, be sure the valve is completely closed. Count the number of turns. Verify the required closing torque by comparing to the manufactures published information. The disc may have been closed on some debris. If this is the case, create flow through the valve (open a nearby downstream hydrant) and exercise the valve to loosen/remove the debris. Also, air may be trapped in the line. Flush the line to remove the trapped air. Add an Air release valve if necessary.

Tuberculation or debris may have built up in the seat area, particularly with double disc gate valves. To correct, create flow through the valve (open a nearby downstream hydrant) and then exercise the valve to loosen/remove the debris.

The valve box may be interfering with the operating key. Look down the valve box to see if it is too close to the operating nut. Reposition if necessary. Alternatively, the stuffing box bolts and nuts may have been tightened down unevenly during assembly. If that is the case, loosen and retighten stuffing box bolts and nuts evenly. In addition, debris or corrosion may have built up between the stem and stuffing box due to lack of operation or gritty backfill. This requires removal of the stuffing box (stem if needed) and clean and/or replace the stem and stuffing box. Lastly, debris could be wedged under the disc. Expose the valve. Isolate the valve from flow and relieve pressure. Remove the bonnet. Clean out the debris.

Make sure the bonnet bolts and nuts are tight. The bonnet gasket O-ring may be damaged or pinched. Isolate the valve from flow and relieve pressure. Remove the bonnet. Replace the gasket. Alternatively, the body or bonnet flange may be cracked or broken. Inspect the valve body and bonnet flanges. Replace damaged items.

It is possible that the stuffing box packing is allowing water to leak. If this is the case, remove the stuffing box and replace the stem O-rings and the stuffing box packing. Note that Mueller started using O-rings in 1952.