Badger Industrial Turbo Meter User Manual
Contents
1. Upstream Downstream Badger Meter plate Coupling Service shutoff saddle strainer and Turbo meter adapter valve Figure 1 Recommended meter installation Performance Checks Complete the following checks for proper installation and operation 1 Slowly open the upstream valve to apply liquid pressure to the meter and check the flange connections for possible leaks Retighten the flange bolts as required 2 Perform a functional test of the turbo meter following Calibration Check and Adjustment on page 8 Page 6 TUR UM 00530 EN 19 October 2014 Operation OPERATION General Operating Instructions REGARDLESS OF THE OPERATING PROCEDURE USED THE VALVES OR DEVICES CONTROLLING THE FLOW OF LIQUID THROUGH THE TURBO METER MUST ALWAYS BE OPENED AND CLOSED SLOWLY OR IN STAGES TO PREVENT SHOCK LOADS THAT MAY DAMAGE THE METER S ROTOR ASSEMBLY Manual Operation These procedures are intended for use in simple metering applications where the flow of liquid through the meter is controlled by hand operated valves located in the facility piping upstream and downstream of the meter 1 Slowly open the upstream valve to allow liquid to flow to the meter 2 Slowly open the downstream valve to initiate metering 3 Adjust the downstream valve so that the rate of flow does not exceed the maximum continuous flow rate specification of the meter 4 stop metering slowly close the downstream valve then close the upstream valve Acce2. Clean all dust dirt grease moisture or other foreign material from the exterior of the meter and meter mounted accessory 2 If the piping arrangement of the facility includes a flushing system shut off the liquid flow to the meter Flush the interior of the meter with an appropriate cleaning fluid to remove any buildup of deposits or corrosion on the internal portion of the meter Calibration Check and Adjustment The accuracy of Badger Meter turbo meters is tested at the factory with water However due to possible use of liquids that could vary in viscosity it may be necessary to recalibrate a meter under operating conditions The following instructions are to assist in performing a calibration adjustment Accuracy Test 1 Place atest tank of known volume at the output of the meter 2 Operate the meter until the test tank is filled to a calibrated level Run at the actual flow rate used in the operation 3 Record the quantity indicated on the meter accessory 4 Perform the following calculations to determine percent of accuracy of the meter accessory combination Qty Indicated on Accessory EETA X 100 Meter Accuracy Actual Quantity in Test Tank Example 1 95 Gallons x 100 95 Accuracy 100 Gallons In this example the accessory is slow and must be sped up by a change gear or electronic scaling correction Example 2 104 Gallons X 100 104 Accuracy 100 Gallons In this example the accessory is fast and must be
3. in the wall adjacent to the top plate of the gear train assembly 4 Grip the change gear spindle and lift to remove the gear train assembly with magnet from the register base 5 Remove the accessory change gear or coupling from the gear train spindle Before removing note the location of the change gear or coupling on the spindle so that it can be reinstalled in the same location NOTE A flat surface is provided at the top of the spindle of the change gear assembly so that the setscrew in the change gear or coupling can be properly seated and tightened to the spindle 6 Gear train assemblies are packaged with the magnet and spindle assembly disassembled from the gear train assembly Before assembling carefully check the spindle for minute burrs on the threaded end of the spindle If there are burrs use a crocus cloth and carefully remove them from the spindle This will prevent damage to the surface of the jewel bearing when inserting the magnet spindle through the jewel bushing in the bottom plate of the gear train assembly An E ring should be mounted on the spindle If missing remove the E ring from the replacement spindle and snap it into the grooved collar near the threaded end of the spindle TOP PLATE SPINDLE MOUNTING HOLES CHANGE GEAR LOWER PLATE JEWEL BUSHING GR OOVED COLLAR E RING MAGNET amp SPINDLE ASSEMBLY Figure 7 Installing the magnet spindle assembly to the gear train assembly October 2014 TUR UM 00
4. 530 EN 19 Page 13 Industrial Turbo Meters Sizes 2 through 6 Instructions for Removing the Local Register 1 remove the register cover and clamp ring remove the seal screw that acts as a hinge pin Remove the clamp ring by spreading it slightly apart at the open side to provide clearance so it can be lifted off the meter head 2 Slide out the register lock plate located between the register base and the meter head at the entrance side of the rotor cage 3 Rotate the register 45 degrees in either direction to release it from the bayonet lock detents on the head assembly 4 Release the retaining ring surrounding the register extension tube inside the rotor cage Using a Truarc right angle pliers expand the retaining ring and at the same time pull the register tube out of the head unit removing the register assembly Page 14 Register Cover Sealed Register _ Retaining Ring _ _ a Seal Screw ar Clamp Rin a Seal Nut p A Head Bolt O Ring Seal __ y Meter Head Rotor 67591191 C 8 Nut Lock Plat Se 224 TetraSeal Gasket Rotor Cage Head Gasket Figure 8 Register and operating head assembly 2 and 3 meters shown TUR UM 00530 EN 19 October 2014 Maintenance INTENTIONAL BLANK PAGE October 2014 TUR UM 00530 EN 19 Page 15 Transit Time Meter Sizes 2 through 6 Control Manage Optimize Trademarks appeari
5. E RS EOD ER 8 Preventive Maintenance ai 6 4 ei erase eee Peewee dee awe dad 8 Periodic Inspections acd4e wd ee ane AED a RE A Tea CARs awa a ate a ee Rae 8 8 Calibration Check and Adjustment 8 Accuracy TeSt tc eae ei a ae es QA AGAR ELLOS CRETE ES CAE RIEDEL EEE ROOT ee 8 Change Gear Corrections SRE HERR SLE WEEE SD AS RHR AS PE Eee Rae 9 Electronic Scaling Conmectiony 34 1404 fa eS ood da en Bee Hh a ie a ood Ad 9 Calibrating 2 eel ade eked a Ge eed ee REE ee RES ee ee Ls 10 Register Base Replacements eers rss rar E4086 e404 oP OEE EAT O EES EAE OEE REET REESE RE OOS 10 SEVING dike a Sw aw RHR Ee EE ARR ORR a RE Ae eee te eS 12 Change Gear Replacement nen eee eee 12 Instructions for Removing the Gear Train Assembly with Magnet 0 0 13 Instructions for Removing the Local Register 1 ee eee 14 October 2014 TUR UM 00530 EN 19 Page iii Industrial Turbo Meters Sizes 2 through 6 Page iv TUR UM 00530 EN 19 October 2014 SCOPE OF THE MANUAL Scope of the Manual This manual contains information concerning the installation operation and maintenance of Badger Meter magnetic drive turbo meters To efficiently operate the meters you must read and und
6. Industrial Turbo Meters Badger Meter Sizes 2 through 6 TUR UM 00530 EN 19 October 2014 U 5 r M a u a Industrial Turbo Meters Sizes 2 through 6 Page ii TUR UM 00530 EN 19 October 2014 User Manual CONTENTS Scopeof the Manual sues saa peaa ia 04 SEE ME Oe OEP bea hee aera beta 5 SPECiNCatiONsSi 2 e280 Bahan ated a dates ae e hack ae Pa Sa eee ahaa Ee RSS a Ee eS 5 Product Unpacking and Inspection 1 eee 5 Installations sinc chase eee doe aah aw eee Ae A OWE Oe ORE REDE EE RAS oS ee Rea SS 5 Preliminary Considerations e 4 5 26444 45546444 39 EOS OR EN EOE EEE HER EE ES 5 Installing the Meter saa sh ata ee Seda awa ee haces EN es 6 Performance CHECKS 24 0 ede sana bees daa Ge wane 6 Operation a Baw Sw hack Se a aca we dace baa deck ee ey a BOR eee ae ee eet 7 General Operating Instructions 2 ene 7 Manual Operation ee eee kee hate ds Meee Re REAM O ERRORS RRA CD OS Ree eae as 7 Accessory Controlled Operation 7 Shutdown INSthUCliONS 24 cade ee Te Dh aoe Pe eS aE REE eS Ae eS 7 MaintenanGe Se ede ON Bo hs a a ae ee ge 8 Maintenance ce EATERY
7. erstand the instructions given in this manual Retain the manual in a location where it is readily available for reference SPECIFICATIONS Maximum Operating Temperature 250 5 F 120 5 C Maximum Operating Pressure 150 psi 10 bar Optional 300 psi bronze 250 psi cast iron Accuracy Over Entire Range 1 5 Repeatability 0 5 or better Connections Round flange ASA or DIN Body Materials SS 316 bronze cast iron Rotor and Nose Cone Materials Ryton Head Assembly Materials SS 316 or bronze Straightening Vane Material SS 316 Head Gasket Materials Asbestos Nitrile or Chloroprene O Ring Materials EPR Buna Viton A Bearing and Magnet Material Ceramic Spindle SS 316 PRODUCT UNPACKING AND INSPECTION Upon opening the shipping container visually inspect the product and applicable accessories for any physical damage such as scratches loose or broken parts or any other sign of damage that may have occurred during shipment NOTE If damage is found request an inspection by the carrier s agent within 48 hours of delivery and file a claim with the carrier A claim for equipment damage in transit is the sole responsibility of the purchaser INSTALLATION The procedures for installing Badger Meter turbo meters are essentially the same for all meter sizes Any special instructions required for the installation and or electrical connection of meter mounted o
8. gasket aligned and the head assembly properly positioned in the housing reinstall and tighten the head bolts between 90 180 in lb of torque 11 Close the flushing system drain valve Open the upstream valve partially then open the downstream valve slightly to purge any air from the service line Then open both valves completely October 2014 TUR UM 00530 EN 19 Page 11 Industrial Turbo Meters Sizes 2 through 6 Servicing This section covers the removal inspection and installation of service parts and assemblies Any service or repair procedures that apply to a meter mounted or free standing accessory are provided in the user manual pertaining to that device If satisfactory repair cannot be made contact Badger Meter Change Gear Replacement 1 Replacing the change gear on the register base spindle requires gage to properly mesh this gear with the register change gear A shoulder stop is built in to the spindle at the proper gear height to eliminate the necessity to adjust the gear 2 The change gear in the register should be installed with a Badger Meter change gear mesh gage P N 21747 000 for proper gear mesh GEAR MESH GAGE METER MOUNTED P N 21747 000 ACCESSORY amp SETSCREW ACCESSORY HUB amp SETSCREW CHANGE GEAR GEAR MUB CHANGE GEAR FIXED GEAR POSITION REGISTER BASE GAGE NOT REQUIRED Figure 5 Replacing turbo meter change gears a Place the bottom of the register on the top edge of t
9. he gage See Figure 2 on page 9 b Adjust the change gear on the register spindle so that it rests against the top of the slot in the gage Holding the change gear in this position tighten the setscrew in the hub of the change gear NOTE Install the change gears on the spindles with the hub of the gears in the UP position c Carefully install the register on the base Make sure that the gears fully mesh Install and tighten the register seal screws DO NOT BEND THE SPINDLES WHEN INSTALLING THE GEARS OR REASSEMBLING THE REGISTER TO THE REGISTER BASE Page 12 TUR UM 00530 EN 19 October 2014 Maintenance Instructions for Removing the Gear Train Assembly with Magnet The gear train assembly can be removed and replaced without removing the turbo meter from the line Two gear train assemblies are used with industrial turbo meters To find out what the gear train ratio is count the number of spindles gear and pinions that protrude through the five mounting holes provided in the top plate of the gear train assembly If there are only three spindles the gear ratio is 366 1 and if there are five spindles the gear ratio is 1200 1 1 Remove the register transmitter or adapter mounted on the register base 2 Release the retainer ring from the groove to free the gear train assembly from the base RETAINER RING GROOVE IN WALL Figure 6 Release the retainer ring 3 Usea small screwdriver to release the retainer ring from the groove
10. ide Remove the head gasket 7 To remove the register base from the head assembly loosen the seal screw on the base with a screwdriver Rotate the base 45 degrees in either direction to release it from the bayonet lock detents on the head assembly 8 The register base retaining ring is accessible through the rotor cage in the head assembly With a Truarc right angle pliers 1549 expand and remove the register retaining ring on the extension tube then remove the register base from the head assembly 9 To reinstall or replace the register base repeat the procedure above in reverse making sure that the retaining ring has been reinstalled on the extension tube NOTE The head unit has a gasket bonded to the periphery of the rotor cage Depending on the chemical solution to be metered the gasket will be made of EPR Buna N or Viton A material Re inserting the head assembly into the meter housing correctly will require compressing the gasket slightly This is done by tilting the top of the register base on the head toward the inlet side of the meter The meter head has a pilot diameter machined into the cage at the gasket face This pilot diameter must extend through the housing gasket inner diameter and into the housing bore After lowering the head assembly into the housing move the entire head assembly straight toward the inlet side of the meter The pilot diameter must snap into the bore of the housing to provide a tight seal 10 With the head
11. is not equipped with a drain valve proceed as follows to relieve pressure within the meter 1 Do not remove the register base from the operating head assembly The entire head assembly must be removed as a complete unit See figure below 2 Loosen each of the head bolts about one and one half turns Do not remove the bolts completely 3 If the gasket seal between the meter head and the housing is not leaking at this time pry the head assembly loose by inserting a screwdriver from the outlet side of the head assembly where the head and housing join together Page 10 TUR UM 00530 EN 19 October 2014 Maintenance OPERATING HEAD REGISTER BASE ASSEMBLY HEAD METER GASKET HOUSING Figure 4 Turbo meters serviced without removal from the line MAKE SURE THAT FLUID DOES NOT SPRAY FROM THE METER THE LIQUID SPRAY COULD CONTACT ELECTRICAL EQUIPMENT AND CREATE AN ELECTRICAL HAZARD 4 Allow the meter to drain and relieve internal pressure 5 When pressure is relieved remove the head bolts and shift the head assembly toward the outlet end of the meter to release the head to housing seal Then lift the entire head assembly from the housing and at the same time tilt the operating head up to prevent the rotor from falling off the rotor spindle NOTE Rotors are furnished with two pole or four pole magnets depending on the type of accessory 6 When the operating head has been removed lift the rotor out of the rotor cage and set it as
12. ndicular to the axis of the meter line of flow This will restrict the amount of volume flowing through the bypass and increase flow through the metering chamber b To DECREASE registration turn the slot in the valve parallel to the axis of the meter This will increase liquid volume through the bypass and decrease flow through the metering chamber NOTE The total range of the bypass adjustment occurs within a 90 degree or quarter turn of the valve from the parallel inline position to the perpendicular position or vice versa The total range of adjustment is about four percent Tested and calibrated at the factory the bypass valve will be set at about 45 from the full open or closed position This setting will allow for a 2 adjustment to recalibrate the meter in the field 3 With the valve turned to the desired bypass setting tighten the valve lock ring 4 Install and tighten the bypass valve cover nut 5 Retest the meter to confirm the accuracy of the bypass adjustment If the meter is still out of calibration repeat the procedure outlined above Register Base Replacement Badger Meter turbo meters can be serviced without removing them from the system To inspect or replace component parts of the head assembly close the upstream and downstream valves If the installation is equipped with an inlet and drain valve for flushing the meter open the drain valve to relieve pressure from within the meter However if the meter piping
13. ng on page 12 for instructions on the proper method of installing and meshing change gears On meters with 76 Series registers provision for change gear adjustment is built in See the applicable register s user manual for recalibrating instructions REGISTER REGISTER BASE Nae REGISTER CHANGE GEAR TURBO METER REGISTER BASE OPERATING HEAD CHANGE GEAR ASSEMBLY Figure 2 Change gear location register base and register assembly Electronic Scaling Correction If the test results indicate an adjustment is required see the instruction manual for that accessory for the procedure to change the scale factor October 2014 TUR UM 00530 EN 19 9 Industrial Turbo Meters Sizes 2 through 6 Calibrating 2 and 3 Meters The 2 and 3 turbo meters with bronze and cast iron housings and bronze heads are equipped with a bypass valve for minor calibration adjustment in the field Test the meter s accuracy to determine if recalibration is required If the meter is out of calibration proceed as follows CALIBRATE METER TURN VALVE WITH SCREWDRIVER BYPASS VALVE ON SIDE OF TO ADJUST FLOW HOUSING Figure 3 Calibrating 2 and 3 turbo meters 1 Remove the bypass cover nut with a wrench 2 Using a wide bladed screwdriver loosen the bypass valve lock ring 3 Adjust the bypass valve with a screw driver a To INCREASE registration turn the slot in the valve perpe
14. ng in this document are the property of their respective entities Due to continuous research product improvements and enhancements Badger Meter reserves the right to change product or system specifications without notice except to the extent an outstanding contractual obligation exists 2014 Badger Meter Inc All rights reserved www badgermeter com The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee WI 53224 9536 800 876 3837 414 355 0400 M xico Badger Meter de las Americas S A de C V Pedro Luis Ogaz n N 32 Esq Angelina 24 Colonia Guadalupe Inn 01050 M xico DF M xico 52 55 5662 0882 Europe Middle East and Africa Badger Meter Europa GmbH Nurtinger Str 76 72639 Neuffen Germany 49 7025 9208 0 Europe Middle East Branch Office Badger Meter Europe PO Box 341442 Dubai Silicon Oasis Head Quarter Building Wing Office 209 Dubai UAE 971 4 371 2503 Czech Republic Badger Meter Czech Republic s r o Ma kova 2082 26 621 00 Brno Czech Republic 420 5 41420411 Slovakia Badger Meter Slovakia s r o Racianska 109 B 831 02 Bratislava Slovakia 421 2 44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21 06 Parkway Parade Singapore 449269 65 63464836 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412 Legacy Document Number IOM 003 17 EN PN 53400 003
15. r free standing accessory devices such as registers pulse transmitters valves and remote batch controllers are provided with those devices Preliminary Considerations The Badger Meter 2 through 6 industrial turbo meters are designed for operation in HORIZONTAL piping arrangements If solid material is present in the liquid to be metered a strainer may be required in the facility piping upstream of the meter The 2 3 and 4 meters require a strainer with 1 16 diameter holes and the 6 meter requires a strainer with 1 8 diameter holes To permit periodic cleanout of the meter and to provide a convenient means of stopping fluid flow during maintenance incorporate a flushing system into the facility piping arrangement October 2014 TUR UM 00530 EN 19 5 Industrial Turbo Meters Sizes 2 through 6 Installing the Meter 1 Install the meter in the pipeline so the flow arrow on the meter housing is in proper relation to the direction of liquid flow Insall ten pipe diameters upstream and five pipe diameters downstream of straight unobstructed pipe If this is not possible contact factory to review your installation 2 Install and tighten the flange connection bolts 3 To relieve possible strain on the piping due to the weight of 4 and 6 turbo meters install a meter support under the meter housing Minimum of 5 Minimum of 2 Bypass Permanent diameters of pipe diameters straight ae or Temporary
16. slowed down Page 8 TUR UM 00530 EN 19 October 2014 Maintenance Change Gear Corrections If the test indicates that an adjustment is required proceed as follows 1 Remove the change gears from the spindles by loosening the setscrew NOTE Both the O D dimension in decimal inches and the number of teeth are stamped on each gear 2 Calculate the ratio of existing change gears as follows No of Teeth on Register Change Gear a No of Teeth on Meter Register Base 3 Calculate the new change gear ratio required by multiplying the ratio of existing change gears by percent of meter accuracy determined in test Example 42 Teeth Existing Change Gear Ratio 0 976 43 Teeth Meter Accuracy 95 95 Corrected Change Gear Ratio 0 976 x TOE 0 927 4 Select a combination of new change gears that match the corrected change gear ratio If stocked change gears not available submit an order for change gears to your nearest Badger Meter representative or to Badger Meter NOTE When ordering give the serial number of the turbo meter which is stamped on the outlet flange of the meter Specify the meter size and accessory employed along with the number of teeth and diameter on the existing change gears Specify the corrected change gear ratio 5 Install the corrected change gears taking care to assemble the correct change gears to the appropriate spindles see Figure 2 For registers see Servici
17. ssory Controlled Operation The step by step operating procedures used in accessory controlled metering applications are dependent on the specific function of the meter accessory employed and its electrical or pneumatic interconnection with the flow control device or devices Refer to the user manuals covering the applicable accessories for specific operating instructions Shutdown Instructions If the turbo meter is to be shut down for an extended period of time thoroughly flush the measuring chamber to prevent undissolved solids or corrosive deposits from accumulating October 2014 TUR UM 00530 EN 19 7 Industrial Turbo Meters Sizes 2 through 6 MAINTENANCE Maintenance Equipment With the exception of a special change gear mesh gage and a calibration test tank the tools required are the usual compliment of standard hand tools used by plumbers and mechanics Truarc Right Angle Pliers Truarc P N 1549 Badger Meter P N 57321 001 Change Gear Mesh Gage Badger Meter P N 21747 000 Preventive Maintenance Periodic Inspection 1 Visually inspect the turbo meter and meter mounted accessory Repair or replace components as required based on the visual inspection 2 Verify that the meter operates at the proper flow rate and pressure A loss in pressure coupled with the resulting decrease in flow rate may indicate the screen in the upstream pipeline is clogged with material and requires cleaning Cleaning 1
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