User Manual - Badger Meter Europa GmbH
Contents
1. o o o o hrs 17 Specifications corri A XH RAE duet Ru ets e ERU ERR 18 1 2 2 Meters ca eed a EE ER a a Q Se 18 Materials os ER EG E da he a daa baa eta ees 18 16 and 20 Meters 2 bate See eGR HED GEM EAS eed Eua acis REG ES 19 Materials T TT 19 January 2015 RTS UM 00380 EN 09 Page iii Recordall Turbo Series Meters Page iv RTS UM 00380 EN 09 January 2015 Scope of this Manual SCOPE OF THIS MANUAL This manual contains installation operation and maintenance procedures for the Badger Meter Recordall Turbo Series meters with magnetic drives To ensure efficient operation of the meters read and understand the instructions in this manual Retain the manual in a location where it is readily available PRODUCT INFORMATION Product Description The Recordall Turbo Series meters use proven design features such as thrust compensated rotor geometry direct drive magnetic coupling and dual outboard rotor bearings to achieve high accuracy over a broad flow range Extended product service life is achieved at higher levels of accuracy in addition to lower meter maintenance costs The Turbo meters are available in 1 1 2 2 3 4 6 8 10 12 16 and 20 sizes Incorporating unitized construction with corrosion resistant a2. APPROPRIATE CONNECTIONS FAILURE TO DO SO CAN LEAD TO PLUG BEING EJECTED FROM HOUSING CAUSING PERSONAL INJURY AND OR PROPERTY DAMAGE WHEREVER AN INSTALLATION IS EQUIPPED WITH A DRAIN VALVE FOR METER FLUSHING OPEN THE DRAIN VALVE TO RELIEVE PRESSURE WITHIN THE METER IF THE INSTALLATION DOES NOT HAVE A DRAIN VALVE CAREFULLY LOOSEN TEST PLUG UNTIL IT BEGINS LEAKING STOP AND WAIT FOR PRESSURE TO BLEED DOWN THEN CONTINUE TO SLOWLY LOOSEN MAKING CERTAIN THE PRESSURE IS COMPLETELY BLED OFF BEFORE REMOVING 1 After installing the appropriate connections test the meter by closing the downstream valve if using integral test port and slowly opening the upstream valve Slowly open the test circuit downstream valve to throttle flow for test purposes 2 Place a test tank of known volume at the output of the meter An alternative is to connect a calibrated test meter to the output Accuracy testing requires test volumes at least as large as the register test circle 3 Asin testing the accuracy of any meter the Recordall Turbo Series meter must first be purged of air by running water through the meter NOTE Good test practices such as those outlined in the AWWA M6 manual are required to perform reliable field accuracy tests Register jump can occur in some instances if valves are abruptly opened or closed While this jump is not accumulative no affects in service billing it can affect accuracy results 1 per division on a one test circle volum
3. Periodic Inspection s uox e na m ic oe CR d de us ce UO vale dow ORT Ro RR ia 9 Sl ai c r TIT eine ak 9 Shutdown InstructiOns a3 anu ue GR AS S eee ea 9 Calibration Check and Adjustment sieaa anega aar etag eea iaa E ras 10 Accuracy Test us ausa ai oU Ee a A Be ek NR od 10 Calibrations saeara cs d dtd dus A uk ga 11 Servicing Parts and Assemblies irs 4 aw CN OMA CMON ERY Nee ORE ROG Nu E E NOR ee 12 Removing the Meter Head 54 aere e ase ee Hale ee eae UR 12 Removing the Local RegisterorEncoder 3 a am aa dirii diacr d i d al kK din d kk a 4 12 Removing the Measuring Element sla s a a aa lad ak a l d adar y kl dk dial hh 13 Removing the Magnet Carrier kul aka dal aa h ADR KEN an aa kin UR RR ina UR 13 Removing the Straightening Vanes Nose 13 Removing the Calibration Mechanism 2 0 0 eee eee eee 14 Inspecting the Rotor and Bearings a kw xu lk a a ala a ka daa a hend aia dne l l ee hh 15 Reinstalling the Turbo Meter Head Assembly 17 Placing the Meter Back Service
4. meter head will not turn and the rotor will remain perpendicular to the flow eliminating any potential flow distortion Tighten the head bolts to 10 11 ft lb for the 1 1 2 and 2 sizes and 35 40 ft lb for the 3 4 and 6 sizes e Reinstall the local register or encoder to the meter Placing the Meter Back in Service 1 Close the flushing system drain valve 2 Open the upstream valve partially then open the downstream valve slightly to purge air from the service line 3 Open both valves completely January 2015 RTS UM 00380 EN 09 Page 17 Specifications SPECIFICATIONS 1 1 2 to 12 Meters 100 1 5 0 9 45 4 m h 0 9 70 4 m h 1 1 124 9 m3 h 2 3 284 m hr 4 5 568 m h 6 8 1022 m h 11 4 1590 m h 160 200 450 1000 2000 3500 5500 6200 Turbo Series Mogel 1 1 2 40 mm 2 50 mm 3 80 mm 4 100 mm 6 150 mm 8 200 mm 10 250 mm 12 300 mm Meter Flanges Round AWWA 125 Elliptical Elliptical or Round Round Round Round Round Round AWWA 125 lb Pound Class class Typical Operating Range 4 200 gpm 4 310 gpm 5 550 10 1250gpm 20 2500gpm 30 4500gpm 50 7000gpm 90 8800 gom 20 5 1998 m h Typical Low 65 9596 min OW o gpm 0 6 m h 2 5 gpm 0 6 m h 4 gpm 0 9 m h 1 4 m h 12 gpm 2 7 m h 20 gpm 4 5 m h 30 gpm 6 8 m h 14 8 nh Max Continuous 160 gpm 200 gpm 450 g
5. normal and subsequent changes will cause reverse accuracy curve shift CALIBRATION LOCK SCREW SHAFT SEAL COVER PLUG CALIBRATION __ CALIBRATION SHAFT O RING P SHAFT ju lt y d lt P SCREEN i 7 Figure 2 Calibrating turbo meter shown with optional test plug 1 Remove the calibration shaft seal plug by puncturing the plug in the slot provided and twisting or prying the plug from the hole 2 Loosen the calibration shaft lock screw 3 Adjust the calibration ring with a screwdriver as follows Toincrease the registration turn the calibration shaft clockwise This speeds up the rotor increasing registration decrease the registration turn the calibration shaft counterclockwise This slows down the rotor decreasing registration 4 With the calibration shaft turned to the desired setting tighten the lock screw while maintaining the calibration shaft position 5 Retest the meter to confirm the accuracy of the calibration setting If the meter is still out of calibration repeat the procedure 6 Replace the calibration shaft seal plug with a new one January 2015 RTS UM 00380 EN 09 Page 11 Servicing Parts and Assemblies SERVICING PARTS AND ASSEMBLIES When the performance of a Turbo meter indicates a need for servicing refer to the following instructions pertaining to removal inspection and installation of service parts and assemblies Also see the Recordall Turbo Serie
6. the upstream valve to apply water pressure to the meter and check for leaks Tighten the flange bolts as required e Performa functional test of the meter Slowly open valve on downstream side of the meter to evacuate any air that may have been trapped in the service line When air has been eliminated increase demand flow rate by further opening the downstream valve or valves Observe the register for correct direction of flow Continue to open the demand side valves to a flow rate sufficient to open the valve assembly in the meter a procedure which will start water flowing through the turbo high side rotor The high flow pointer will now move in the proper direction Now open all applicable service valves Check the flow rate to verify that the flow does not exceed the maximum continuous duty specification The rate of flow can be quickly checked by timing the quantity registered through the meter in one minute Page 8 RTS UM 00380 EN 09 January 2015 Maintenance MAINTENANCE This section is limited to information pertaining to the general maintenance of Badger Meter Recordall Turbo Series meters An exploded view of the meter along with part numbers and descriptions are provided in the Recordall Turbo Series Meters Parts List Maintenance Equipment The tools and equipment recommended for use in servicing and maintaining of Recordall Turbo Series meters consist of the usual complement of hand tools used by plumbers and mechanics Pre
7. AGES BOTH THE FRONT AND REAR ROTOR BEARING PINS PRIOR TO PRESSING THE NOSE CONE ASSEMBLY FULLY INTO THE CAGE INSERT 6 Press the nose cone assembly fully into the cage insert and turn it counter clockwise catching the calibration linkage in the slot M Verify that the rotor spins freely If it does not remove the nose cone assembly and repeat the procedure eo Install and tighten the nose cone assembly setscrew so Holding the cover plate in one hand align the thermoplastic cage bayonet like tabs with the slots in the cover plate 1 1 2 to 4 only 10 Rotate the element clockwise until the cage setscrew hole is aligned Install and tighten the cage setscrews quantity of 1 1 2 to 4 meters a quantity 4 for the 6 meter Page 16 RTS UM 00380 EN 09 January 2015 Servicing Parts and Assemblies Reinstalling the Turbo Meter Head Assembly e Use a new O ring after each teardown and reassembly To provide a tight seal make sure the surfaces of the housing and meter head are clean and free of any old O ring material e Be careful not to force the measuring element insert into the meter housing If you experience any binding do not force the element into the housing Remove the element from the housing and properly reinsert the unit NOTE Head bolts should be tightened similar to that on car tire First insert the bolts and snug fit each Then using a crisscross pattern tighten the bolts down Following this pattern the
8. AT ANY WATER COMING OUT OF THE METER HEAD Lock screw DOES NOT SPRAY ONTO ELECTRICAL EQUIPMENT AND CREATE cmd aN HEAD BoT A SHOCK HAZARD CALIBRATION GEAR A SHART TRANSMISSION ANE um u 3 Allow the meter to drain and relieve internal pressure A Z O RING NOSE CONE RING MAGNET 4 When pressure is relieved remove the head bolts Lift the T I d d CARRIER measuring element assembly from the housing evene NER Es PISEAT y Removing the Local Register or Encoder The Recordall Turbo Series meter registers and encoders are easily removable to facilitate in line service ROYOR 8 TRANSMISSION CALIBRATION 1 Remove the register lid and shroud by removing the seal akad vind RING FRONT S SETSCREW 4 2 Remove the shroud by rotating the register assembly AA WASHER 4 counterclockwise until it stops This provides clearance so EE it can be lifted offthe measuring element assembly See Figure 3 and Figure 4 Figure 4 Removing the meter head assembly 6 meters To reinstall the register follow the above procedure in reverse order Page 12 RTS UM 00380 EN 09 January 2015 Servicing Parts and Assemblies Removing the Measuring Element NOTE cage seal is installed in the 1 1 2 to 6 Recordall Turbo Series so that the entire water volume flows through the 8 measuring element Remove the O ring and cage seal Check for damage and clean or replace prior to reassembly To remove the mea
9. All reading options can be removed from the meter without disrupting water service Badger Meter encoders provide years of reliable accurate readings for a variety of applications and are also available pre wired to Badger Meter approved AMR AMI solutions See details at www badgermeter com A strainer is recommended to provide optimal flow conditioning and protection for the measuring element An integral strainer is available as an option for 1 1 2 through 4 meter sizes The stainless steel strainer is built into the inlet end and includes a removable cover plate to permit easy access for routine cleaning External strainers are available in sizes 2 through 12 Related Literature The Recordall Turbo Series Meters Product Data Sheet contains information on operating principle meter construction materials tolerances and specifications The Recordall Turbo Series Meters Parts List contains illustrations of parts part numbers and part descriptions January 2015 RTS UM 00380 EN 09 Page 5 Product Information Safety Information The installation of the Recordall Turbo Series meter must comply with all applicable federal state and local rules regulations and codes Failure to read and follow these instructions can lead to misapplication or misuse of the meter resulting in personal injury and damage to equipment Unpacking and Inspection To avoid damage in transit Badger Meter Recordall Turbo Series meters are shipped to t
10. METERS OF FIPE DIAMET STRAIGHT PIPE a UPSTREAM Ti DOWNSTREAM BADGER PLATE COUPLING SERVICE SHUT OFF STRAINER AND TURBO ADAPTOR SADDLE VALVE SERIES METERS Figure 1 Recommended meter installation Preinstallation Considerations Before proceeding any further with the installation first read the instructions in the paragraphs immediately following to become familiar with the requirements and procedures involved NOTE The Recordall Turbo Series meters are designed for operation in HORIZONTAL piping arrangements Be sure that the meter flow range and size of the meter coincide with the intended service and demand for water THE LIFE OF THE TURBO METER WILL BE CURTAILED IF OPERATED AT FLOW RATES HIGHER THAN SPECIFIED meters are designed for use in cold water service up to 120 F or 49 within the applicable flow requirements for Turbo meters For use with water at higher temperatures consult your Badger Meter representative or nearest Badger Meter regional sales office e If solid material is present in the water to be metered a strainer must be installed in the service piping upstream of the meter The strainer in addition to protecting the meter from debris in the line minimizes the effect of velocity profile distortions or turbulence caused by changes in pipe direction or valving resulting in more accurate registration Avoid locating the meter in c
11. Recordall Turbo Series Meters Badger Meter Models 160 1 1 2 200 2 450 3 1000 4 2000 6 e 3500 8 5500 10 6200 12 6600 16 amp 10000 20 RTS UM 00380 EN 09 January 2015 U se r M a n u a Recordall Turbo Series Meters Page ii RTS UM 00380 EN 09 January 2015 User Manual CONTENTS Scope of this Man al s sue carr A a 5 Product informati n uas et RE PER we bee a Bede os a 5 Product Description Ee a a ee aA n wan 5 ACCESSOMNES dq na Jl a an a RET ET ETO EHR Ree GRRE Ga wee Sawa 5 Related Literature iii d UR RON RUN d n baa E UR She E UR ee AA ee eG 5 Safety Informations eae ile ala UR a 4 dh DECR ae cak a 6 Unpackingand Inspection ea RN pow a ne a a Wl nb E ed an l a ald Re RUN SOR a 6 Installation 20006 TT 7 Preinstallation Considerations ws aa nasa bemenne anena aa a aa a ieoa i e a a a e a i a 7 Installing tha Meter maran xw we salna na aloe alle eat ow a a l eq om ak lk e b UR waa e dg RR 8 cle aine abatir duns Bowl ob iaa a ah Baw hs eka Wea a ia a a 9 Maintenance Equipments sito acatar ee 9 Preventive Maintenance doe hence obe d ec shea Ae wick dea Aron de sl ae ke winked due 9
12. a sharp contraction or an eccentric reducer rather than a concentric tapered reducer is used Installing the Meter Overall dimensions and laying lengths of each meter size are listed in the Recordall Turbo Series Meter Product Data Sheet Review the dimensional requirements choose an installation point in the piping and proceed as follows 1 Measure precisely the overall length of the meter with gaskets attached to the inlet and outlet flange connections Provide proper gap length in service piping Install meter in the pipeline so that the flow arrow on the meter housing points in the same direction as water flow With meter and gaskets in place tighten flange connection bolts gt w oM To relieve possible strain on the piping position a meter support under the meter housing where appropriate TURBINE METERS MUST OPERATE IN A COMPLETELY FILLED LINE AT ALL TIMES THE DOWNSTREAM PIPING MUST ALWAYS BE ARRANGED TO PROVIDE SUFFICIENT BACK PRESSURE TO MAINTAIN A FULL LINE AT THE METER BY ELIMINATING AIR IN THE LINE AS WELL AS SUDDEN FLOW SURGES INACCURATE REGISTRATION AND DAMAGE TO THE TURBINE MECHANISM CAN BE AVOIDED Performance Checks Any valves or devices controlling the flow of water through a Turbo meter must always be opened and closed SLOWLY to prevent shock loads that may damage the meter s rotor assembly Complete the following checks to ensure that a Turbo meter is properly installed and operational Slowly open
13. blies See Figure 3 and Figure 4 To gain access to them remove the measuring element from the cover Removing the upstream nose cone provides access to the rotor calibration ring and the transmission assembly Removing the upstream nose cone 1 Unscrew the upstream nose cone setscrew For 1 1 2 to 4 meters slide the calibration linkage into the cage insert stop Take hold of the nose cone straightening vanes and turn them clockwise thereby disengaging the calibration linkage from the tab on the calibration ring and unlocking the bayonets of the nose cones from the cage see Figure 5 If the tab of the calibration ring has not disengaged the linkage rotate the ring carefully by pushing the struts at the interior of the element between the straightening vanes and the rotor Pull the nose cone assembly out from the measuring element insert For 6 meters remove the transmission gear by lifting it off the shaft noting the alignment of the D shaped bore with the flat on the shaft required to align for assembly Remove the retaining ring that holds down the calibration drive plate located under magnet carrier magnet See Figure 4 and Figure 6 Remove drive plate Rotate calibration ring until pin clears slot of cage Take hold of the nose cone straightening vanes and turn clockwise Pull the nose cone assembly out from the measuring element insert Remove rotor assembly January 2015 RTS UM 00380 EN 09 Page 13 Servicing Parts an
14. d Assemblies Removing the rear nose cone To remove the rear nose cone you must remove the transmission shaft See Figure 3 Figure 4 Figure 5 and Figure 6 1 Remove the strap over the gear 1 1 2 to 4 only 2 Lift the gear off the shaft NOTE The shaft has a flat spot that matches with the D shaped bore in the gear required to align for assembly 3 Remove the nose cone set screw 4 Remove the protection tube by carefully pressing with the flat surface of a blade screwdriver on bottom of tube located inside rear nose cone 5 Press to release the detent lock approximately 1 4 vertical travel then lift the tube out from the top of the cage insert 6 Lift the transmission shaft assembly up and out of the bottom bearing then slide the shaft downward and diagonally out towards you to remove it from the nose cone cage assembly 7 Hold the cage firmly with one hand rotate the nose cone clockwise with the other hand then carefully lift it off the cage To reinstall the nose cone follow these instructions in reverse Removing the Calibration Mechanism To disassemble the calibration ring assembly see Figure 3 Figure 4 Removing the Meter Head on page 12 and Removing the Straightening Vanes Nose Cone on page 13 1 Remove the calibration shaft seal plug and unscrew the calibration shaft lock screw from the cover plate 2 Remove the calibration shaft thrust washer and calibration shaft Press the calibration shaft
15. emoved remove cover bolts and cover Clean out flush strainer section of all loose particles debris After cleaning is complete reinstall screen and reassemble Return meter to normal service Shutdown Instructions If the turbo meter is to be shut down for an extended period of time or if it is being removed from service Badger Meter recommends that the meter and measuring components be thoroughly flushed to prevent the settling out of undissolved solids or the accumulation of corrosive deposits If there is an upstream strainer in the line it also should be flushed at this time January 2015 RTS UM 00380 EN 09 Page 9 Maintenance Calibration Check and Adjustment The accuracy of the Recordall Turbo Series meters is tested at the factory before shipment However after a long period of service it may be necessary to recalibrate a meter The meter can be tested for accuracy using appropriate connections with either a test tank of known volume or a test meter The meter can be tested in the setting by running output flow through the optional test port if so equipped The Recordall Turbo Series integral calibration mechanism can be adjusted under line pressure simplifying and reducing calibration time The following instructions are provided to assist in performing a calibration check and adjustment Accuracy Test IF THE OPTIONAL TEST PORT IS BE USED UPSTREAM AND DOWNSTREAM VALVES MUST BE CLOSED PRIOR TO REMOVING PLUG AND INSTALLING
16. end of the bearing pin must not show any drag lines and or wear January 2015 RTS UM 00380 EN 09 Page 15 Servicing Parts and Assemblies BEARINGS 2 ROTOR WORM NOSE CONE ASSEMBLY lt lt ARING Q 7 Z l PIN Figure 6 Rotor and nose cone assembly 1 1 2 2 3 4 and 6 turbo head assemblies NOTE Only highly polished bearing pin ends provide a minimum of friction and optimal meter performance Bearing pins are an integral part of the straightening vane and nose cone assembly Wear or damage would require the replacement of this component Reassembling the Rotor and Bearings 1 Install the rear nose cone to the cage See Removing the Magnet Carrier on page 13 2 Placethe rotor assembly with the worm gear side leading through the cage 3 Placethe rotor assembly on the rear rotor bearing pin while tipping the assembly back so that the opening is up See Removing the Calibration Mechanism on page 14 for instructions on assembling the calibration rings with the nose cone assembly 4 Insert the front nose cone assembly partially onto the cage insert engaging the bearing pin with the front bearing of the rotor 5 Tilt the measuring element insert assembly forth and back to verify that the rotor now engages the bearing pins on the straightening vane nose cones and is free to rotate and slide DO NOT FORCE THE NOSE CONE ASSEMBLY INTO THE CAGE INSERT BE SURE THAT THE ROTOR ENG
17. ess steel Calibration Mechanism Stainless steel amp thermoplastic Magnet Ceramic Register Housing amp Cover Thermoplastic or bronze Trim Stainless steel January 2015 RTS UM 00380 EN 09 Page 19 Recordall Turbo Series Meters Making Water Visible MAKING WATER VISIBLE ORION RECORDALL and RTR are registered trademarks of Badger Meter Inc Other trademarks appearing in this document are the property of their respec tive 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 2015 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 N 24 Colonia Guadalupe Inn CP 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 C 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 Repub
18. etric test 4 Operate the meter until the test tank is filled to the calibrated level or the predetermined quantity has registered on the calibrated test meter Because accuracy may vary slightly with flow rate it is recommended that the meter be tested at low intermediate and high flows 5 Record the quantity registered on the meter during the test 6 Perform the following calculations to determine meter accuracy Quantity Registered on Meter Test Tank or Test Meter Quantity x 100 Meter Accuracy Page 10 RTS UM 00380 EN 09 January 2015 Maintenance Calibration The meter s calibration ring is preset and sealed at the factory In normal service it should not have to be reset If a retest is required in which a calibrated test stand reveals that the meter needs recalibration proceed as follows see Figure 2 The total range of the calibration adjustment is about 10 Tested and calibrated at the factory the calibration mechanism will allow for a 5 adjustment in the field Due to the floating rotor design principle the calibration mechanism contains some clearance for proper part fit resulting in some hysteresis or deadband when changing directions with calibration shaft Adjustments should be made in small increments in one direction to avoid need for counter rotation If desired setting is exceeded counter rotations in small increments should be made even though first reverse setting may result in no apparent change This is
19. he customer in special shipping containers Upon receipt of shipment be sure to follow these unpacking and inspection procedures NOTE If damage to a shipping container is evident upon receipt of a meter request that a representative of the carrier be present when the meter is unpacked a Carefully open the shipping container following any instructions that may be marked on the container Remove all cushioning material surrounding the meter and carefully lift the meter from the container Keep the container and all packing material for possible use in reshipment or storage b Visually inspect the meter and applicable accessory devices for any signs of damage such as scratches loose or broken parts or other physical damage that may have occurred during shipment NOTE If damage is found request an inspection by carrier s agent within 48 hours of delivery Then file a claim with the carrier A claim for equipment damaged in transit is the responsibility of the customer Page 6 RTS UM 00380 EN 09 January 2015 Installation INSTALLATION Procedures for installing Recordall Turbo Series meters are essentially the same for all meter sizes Any special instructions required for the installation or connection of accessory devices such as AMR AMI technologies or strainers is provided in the literature for those devices Figure 1 shows a recommended meter installation BY PASS 2 polit lie ii VALVE MINIMUM OF FIVE MINIMUM TWO B open DIA
20. ibration linkage into the cage with the larger hole to engage the calibration ring tab with the side of chamfered edge of the hole towards the nose cone assembly see Figure 5 With the calibration linkage fully inserted to the cage stop install the nose cone onto the cage and rotate it counter clockwise to engage the pin of the ring to the calibration linkage The hole of the calibration linkage has to be aligned onto the calibration shaft engaging it fully so that the calibration ring cannot vibrate during operation Tighten the calibration shaft lock screw to securely hold the calibration ring in position After servicing or replacing the calibration mechanism check the accuracy and calibration according to the instructions in Calibration Check and Adjustment on page 10 Inspecting the Rotor and Bearings To inspect the rotor remove the nose cone assembly from the measuring element insert as described in Removing the Straightening Vanes Nose Cone on page 13 Check the rotor worm and blades for signs of damage and wear Also inspect the bearing bushings in the front and rear shaft If damage or wear has occurred replace the part see Figure 6 If water deposits are found remove any mineral deposits from the rotor blade surfaces cage insert interior disc and nose cone vanes and mating surfaces Inspect the rotor bearing pins in the straightening vane and nose cone assembly for signs of damage and wear see Figure 6 The spherical
21. lic 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 04 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 RTS IOM 5
22. lose quarters Allow sufficient space to permit access for meter reading testing and maintenance Because of the need to test large meters periodically to verify their performance it is recommended that a bypass system be incorporated into the piping arrangement This will also provide a means of performing periodic cleanout and routine maintenance without interrupting service to the customer A test port is incorporated in the meter housing and can be used for field accuracy testing The Recordall Turbo Series meter is accuracy and pressure tested prior to shipment therefore no field adjustments are required As turbine performance is directly related to the flow conditions of the water stream entering the meter upstream fittings and piping changes can adversely affect flow registration For valid registration and proper performance consider the following installation considerations 0 Wheninstalling the meter with a separate plate strainer or integral strainer a minimum of 5 pipe diameters of straight unobstructed pipe is recommended upstream of the meter For optimum protection and accuracy this straight pipe spool piece should be installed between the separate strainer and meter see Figure 1 A minimum of 10 pipe diameters minimum of 25 pipe diameters for smallest size of straight unobstructed pipe is recommended upstream of a meter installed without a plate strainer The deletion of a strainer however is not recommended This allo
23. ng Sapphire jewels Rotor Bearing Pivots Passivated 316 stainless steel Calibration Mechanism Stainless steel amp thermoplastic Magnet Ceramic Trim Stainless steel Register Housing amp Cover Thermoplastic or bronze Optional Strainer and Trim Stainless steel Page 18 RTS UM 00380 EN 09 January 2015 16 20 Meters Specifications Turbo Series Model Meter Flanges 6600 16 400 mm Raised Face Round 10000 20 500 mm Raised Face Round Typical Operating Range 100 1 5 150 13 200 gpm 34 1 3000 m h 300 19 800 gpm 68 1 4500 m h Typical Low Flow 95 minimum 130 gpm 29 5 m h 200 gpm 45 4 m h Maximum Continuous Flow 6600 gpm 1500 m h 10 000 gpm 2270 m h Maximum Intermittent Flow 13 200 gpm 3000 m h 19 800 gpm 4500 m h Pressure Loss at Maximum Continuous Flow 0 5 psi 0 03 bar 0 5 psi 0 03 bar Maximum Operating Pressure 150 psi 10 bar 150 psi 10 bar Maximum Operating Temperature 120 F 49 C 120 F 49 C Materials Meter Housing Blue epoxy coated cast iron Turbo Head Nose Cone amp Straightening Vanes Cast iron Thermoplastic Rotor Thermoplastic Rotor Radial Bearings Lubricated thermoplastic Rotor Thruster Bearing Sapphire jewels Rotor Bearing Pivots Passivated 316 stainl
24. out of the cover plate from below 3 Ifa leak exists at this point in the disassembly of the meter remove the calibration shaft O ring Before reinserting the O ring apply a light coat of silicon grease to it 4 Clean all parts To gain access to the calibration ring remove the straightening vane nose cone Follow the instructions in Removing the Straightening Vanes Nose Cone on page 13 To remove the calibration ring from the nose cone assembly 1 Align the ring slots with the bayonets of the nose cone assembly located on inner ring of calibration ring 2 Carefully lift the calibration ring from the nose cone assembly To reinstall the calibration mechanism follow this procedure in reverse Page 14 RTS UM 00380 EN 09 January 2015 CALIBRATION RING PIN CAGE ARROWTIP INSERT CALIBRATION NOSE LINKAGE CONE p SMALL HOLE WITH CHAMFER UP TOP SIDE INTO CAGE LARA THIS END LARGE HOLE WITH CHAMFER DOWN 1 1 2 2 3 and 4 meters CAGE INSERT TOP VIEW po TRANSMISSION GEAR Figure 5 Calibration ring linkage assemblies Reassembling the Calibration Mechanism 1 2 4 Servicing Parts and Assemblies PIN OF CALIBRATION RING 7 RETAINING RING CALIBRATION DRIVE PLATE 6 meters Align the pin on the perimeter of the calibration ring with the arrow tip on the nose cone assembly see Figure 5 For 1 1 2 2 3 and 4 sizes install the cal
25. pm 1000 gpm 2000 gpm 3500 gpm 5500 gpm 6200 gpm Flow 36 m h 45 4 m h 102 2 m3 h 227 1 m h 454 m h 795 m h 1250 m3 h 1408 m h E 200 gpm 310 gpm 550 gpm 1250 gpm 2500 gpm 4500 gpm 7000 gpm 8800 gpm Flow 45 4 m h 70 4 m h 124 9 m h 284 m h 568 m h 1022 m h 1590 m h 1988 m h Pressure Loss at Max Continuous Flow 3 8 psi 0 26 bar 3 1 psi 0 21 bar 1 8 psi 0 12 bar 7 3 psi 0 50 bar 4 8 psi 0 33 bar 2 5 psi 0 17 bar 1 6 psi 0 11 bar 0 8 psi 0 05 bar Pressure Loss at Max Continuous Flow With Integral Strainer 9 9 psi 0 68 bar 8 3 psi 0 57 bar 5 psi 0 43 bar 17 8 psi 1 2 bar Max Operating Pressure 150 psi 10 bar Max Operating Temperature 120 F 49 C Optional Integral Strainer Built into inlet end Removable cover plate permits access to strainer for cleaning Optional External Strainer _ Available for Models 200 450 1000 2000 3500 5500 and 6200 Test Plug Standard with integral strainer optional for other models Optional for Models 2000 and 3500 Materials Meter Housing Lead free alloy EXCEPTION Model 6200 meter housing is blue epoxy coated cast iron Turbo Head Lead free alloy Nose Cone amp Straightening Vanes Thermoplastic Rotor Thermoplastic Rotor Radial Bearings Lubricated thermoplastic Rotor Thruster Beari
26. s Meter Parts List for part numbers of replaceable components and correct ordering information If satisfactory repair cannot be made contact Badger Meter Removing the Meter Head Recordall Turbo Series meters can be serviced without removing them from the line A typical installation would be equipped with drain and piping valves To inspect or replace components of CALIBRATION the head assembly close the upstream and downstream valves PLUGN 1 However if the installation does not have a drain valve proceed Sarr ORNO 2 as follows to relieve pressure COVERPLATE N go CALIBRATION HOLD DOWN wm STRAP PROTECTION AWARNING a Coy See ES UPSTREAM AND DOWNSTREAM VALVES MUST BE CLOSED ri ASSEMBLY wa BEFORE ATTEMPTING TO REMOVE METER HEAD FROM INSERT HOUSING FAILURE TO DO SO CAN LEAD TO THE HEAD BEING EJECTED FROM HOUSING CAUSING PERSONAL INJURY AND OR PROPERTY DAMAGE y 1 Loosen each of the head bolts about 1 1 2 turns Do not APT S U M Semen completely remove the bolts sonon TRANSMISSION X i Mg NOSE CONE ASSEMBLY SCREW 2 If the O ring between the meter head and the housing STRAIGHTENING is secure and not leaking pry the measuring element PM assembly loose by inserting a screwdriver blade where the SET SCREW 2 pee head and housing join together ACAUTION Figure 3 Removing the meter head assembly 1 1 2 to 4 meters SEAL PLUG BE SURE TH
27. ssemblies the basic components of the Recordall Turbo Series consist ofthe housing and the completely removable measuring element The meter housing and cover plate are lead free bronze 1 1 2 to 10 sizes The 12 to 20 meter housings are cast iron with a heat fused epoxy coating The measuring element is constructed of high impact strength thermoplastics Recordall Turbo Series meters are also equipped with an integral calibration mechanism for in line accuracy calibration In the operation of a turbo meter water flows through the straightening vanes and a nose cone at the inlet side of the meter so that the swirling effect of upstream piping is minimized The water then strikes the rotor blades causing the rotor to turn A downstream nose cone includes straightening vanes to limit the downstream effects of flow profile distortions Optional NPT test ports are provided for field performance testing Motion of the rotor is transferred by means of a worm drive to a vertical shaft driving a gear set which transmits the rotation to the meter s registration device The direct drive magnetic coupling provides accurate flow registration during line surges and allows the permanently sealed register to be easily removed to facilitate in line service Accessories Meters and encoders are compatible with Badger Meter AMR AMI meter reading systems and other approved reading technologies AMR AMI solutions are available for all Recordall Turbo Series meters
28. suring element from the cover remove the calibration shaft seal plug and the lock screw See Figure 3 and Figure 4 Place the cover register side down on a table or flat surface Lightly tap or press the calibration shaft from the wet side out of the bore in the cover 1 1 2 to 4 only Do not strike or bend the calibration linkage The measuring element insert can be removed from the cover plate for service or replacement by removing the cage set screws quantity of one for 1 1 2 to 4 quantity of 4 for the 6 size See Figure 3 and Figure 4 Holding the cover plate in one hand rotate the thermoplastic element counter clockwise until the bayonet like tabs are aligned with open areas of the cover plate 1 1 2 to 4 only Remove the element from the cover plate Removing the Magnet Carrier 1 5 To remove the magnet carrier from the measuring element insert lift it off the stainless steel pin See Figure 3 and Figure 4 Check the condition of the magnet and gear on the magnet carrier for damage or wear If significant wear or damage is present replace the magnet carrier Remove the hold down strap See Figure 3 and Figure 4 Check the condition of the transmission shaft gear for damage or wear If significant wear or damage is present replace the gear Lift the gear off the shaft Removing the Straightening Vanes Nose Cone The straightening vanes are an integral part of the upstream and downstream nose cone assem
29. ventive Maintenance The purpose of preventive maintenance is to ensure efficient operation and long life of the meter by detecting and correcting any defect that might damage the meter or cause it to fail Preventive maintenance consists of periodic inspection accuracy testing and cleaning procedures Periodic Inspection e Visually inspect the meter for missing hardware loose screws broken or scratched register lenses or any other signs of wear or deterioration e Verify that the meter is operating at the proper flow rate and pressure A loss in pressure coupled with a decrease in flow rate may indicate that the screen in the upstream pipeline or the meter itself is clogged with foreign material and needs cleaning Cleaning Clean all dirt grease moisture or other foreign material from the exterior of the meter After cleaning rinse thoroughly with water Inthe event that system pressure has been reduced and the upstream filter or meter is clogged the foreign material must be flushed out To flush the screen open the cleanout plug and purge the foreign material with fresh water from the service line If cleaning the screen does not restore system pressure the Turbo meter also should be flushed by purging with fresh service water through the cleanout plugs located on the housing e Integral Strainer Units Before attempting service maintenance of strainer section system pressure must be removed After system pressure is r
30. ws for dampening of velocity profile distortions caused by elbows pumps and dirt traps upstream of the meter Where spiral flows are created by three dimensional elbows or rotary pumps additional distance to dampen the effect is beneficial If a basket or Y type strainer is used place it 5 to 10 pipe diameters upstream of the meter to dampen velocity profile distortions created by this design January 2015 RTS UM 00380 EN 09 Page 7 Installation 0 Do not install check valves or pressure reducing devices upstream of the meter 0 Valves immediately upstream of the meter should only be fully open gate valves Butterfly valves are acceptable if they are 5 pipe diameters or more upstream from the meter Downstream fully open gate or butterfly valves can be used The service saddle or reducing tee which is used for field accuracy testing should be at least 2 pipe diameters downstream of the meter s outlet flange Unweighted check valves should not be located closer than 3 pipe diameters downstream of the meter 0 Externally weighted check valves and pressure reducing devices should not be located closer than 5 pipe diameters of the meter When installing a Turbo meter and plate strainer of a size smaller than the pipe installation to reduce the effect of jetting caused by the increase in flow velocity a minimum of 5 pipe diameters of pipe equal in size to the meter is required upstream of the meter Additional length is required if
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