Industrial Turbo Meter User Manual
Contents
1. Qty Indicated on Accessory 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 speeded 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 slowed down yu al A Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com D www jamiesonequipment com User Manual 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 a No of Teeth on Register Change Gear atio _ 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 o 42 Teeth Existing Change Gear Ratio 0 976 43 Teeth Meter Accuracy 95 95 Corrected Change Gear Ratio 0 976 x aaa 0 927 4 Select a combination of new change gears that match the corrected change gear ratio If stocked change gears are not available submit order for change gears2. GASKET HEAD METER GASKET HOUSING Figure 4 Turbo Meters Serviced Without Removal from the Line EXERCISE PRECAUTION TO MAKE CERTAIN THAT FLUID DOES NOT SPRAY FROM THE METER THE LIQUID SPRAY COULD CONTACT ELECTRICAL EQUIPMENT AND CREATE AN ELECTRICAL HAZARD 4 J Allow the meter to drain and relieve internal pressure 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 aside Remove the head gasket NOTE A dummy cover plate is available to close the meter in the line and continue service while the operating head assembly is being inspected or parts are being replaced 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 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 When this is
3. sales jamiesonequipment com www jamiesonequipment com Trademarks appearing 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 2013 Badger Meter Inc All rights reserved Legacy Document Number IOM 003 17 EN PN 53400 003 al E Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com C www jamiesonequipment com
4. Nae OREN straight pipe downstream of a nce Temporary Turbo meter Hp ss Ff CH y Y y i i y i lt A eL ls El Pi Upstream A Pa Downstream Badger Meter plate Coupling Service Shutoff strainer and Turbo meter adapter saddle valve Figure 1 Recommended Meter Installation Performance Checks Complete the following checks to ensure that the meter is properly installed and operational 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 using the adjustment and calibration procedure in this manual Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com www jamiesonequipment com G User Manual 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 apply liquid to meter 2 Slowly open th
5. 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 Jamieson Equipment Company 5314 Palmero Court Buford GA 305
6. 18 800 875 0280 sales jamiesonequipment com www jamiesonequipment com Industrial Turbo Meters Sizes 2 through 6 Instructions for Removing the Local Register 1 To 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 Register Cover Sealed Register ANA tt Retaining Ring 4 Seal Screw Ie ees Nut Head Bolt O Ring Seal Meter Head _ 53 Rotor GQ o SE Nut Head Figure 8 Register and Operating Head Assembly 2 and 3 Meters shown al la Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com bL www jamiesonequipment com User Manual INTENTIONAL BLANK PAGE al lau Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280
7. Industrial Turbo Meters Badger Meter Sizes 2 through 6 TUR UM 00530 EN 18 November 2013 U se r M a n u al al E Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com C www jamiesonequipment com Industrial Turbo Meters Sizes 2 through 6 al Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com www jamiesonequipment com User Manual CONTENTS SCOPE OF THE MANUAL se s eee AG Hee See Re Dee ee Eee Re Cee eae ee Ee eee oe eee ees 5 SPECIFICACIONS 2 244h 28 eee Ge risa tesa ash eee seen ees eee a e arar sees eee 5 Product Unpacking and Inspection gt aa sese in cee Ga ee rd Aaa 5 INSTAULATION 3 42 wn 6 bate ee eee ed eee eed eee eee DEAE SEE BH He SESE ERED GRRE eRe rasa 5 Preliminary Considerations seca saareke ba Od ok OE Oe RAPHE ENE TREES ES EERE SARE HES OG ees 5 Installing the Meter corra arder os ee eee eH AR AA 6 Pertormance CHECKS a 22240 26 vee Ba hee e e Ae eee he e ara e Be eee Oe eS eee 6 OPERANION 224 24 45 Gaece eae sanas iras ea cee sea ee eae ene Poe eee eee eee eee seas she 7 General Operating Instructions ss esse 4 wwe one Yew eke BOA Re Bw Ok aw be ea Me SEA EA 7 Man al Operation sss ca ke ob coe ek ee ee eA ee ee ee ee Edad ekridas Basa 7 Accessory Controlled Operation nnsa dea a A ERE EH ES EAS OE EOR ERE EEE EES PES EHH OS 7 SIMUUGOWIMINGUIUICHONS lt span radares aaa oe Ree Gee e
8. accomplished the register base can be removed from the head assembly 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 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 which will purge any air from the service line Then open both valves completely Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sa
9. e 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 Tostop metering slowly close the downstream valve then close the upstream valve Accessory 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 IOM manuals covering the applicable accessories for specific operating instructions Shutdown Instructions If the turbo meter is to be shutdown for an extended period of time it is recommended that the measuring chamber be thoroughly flushed to prevent the settling out of undissolved solids or the accumulation of corrosive deposits Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com www jamiesonequipment com 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 Inspect
10. e valve lock ring 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 turbo meters can be serviced without removing the meters 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 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 with a screwdriver To accomplish this insert the screwdriver from the outlet side of the head assembly where the head and housing join together al IE Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com F www jamiesonequipment com Ji Am F User Manual OPERATING HEAD REGISTER BASE ASSEMBLY ROTOR CAGE ROTOR ASSEMBLY 7 AR
11. ee e 7 MAINTENANCE sacre oh bare Poe eae ee ee hae ee Se EN ES eeaeee ET Oare rea pe 8 Maintenance EQUIDIMGNL lt 4 44 4 4 45 244 Gee oe PES ERG ARA OPER REE EERE OGRE REGGE REESE HERS 8 Preventive WiaINMIGNANCe y 24 amp Nasa ae book RE Re MERE EE RES ee HR OEE RSS EA Se eS 8 P riodic Inspection 44 a4 a24 h 4b eae 3 eG eee ee ee Gh ee 8 E e os oe haw oe ea oe ee ae eh oe See he ee eS eee eae ee ee 8 Calibration Check and Adjustment eee eee 8 PCCUIAGY IGS ass sisas o Be o eo eet Gee a ee A eee ee eee 8 Change Gear COneCtIONS 4 416 044 ioe Oa eo eh ed EOE EEE EES EKA RAS OR RDA ERE 9 FIECHIONIC Scaling Correction oa 44446 444444 a4 ee A De ee d eee ee oe ee ee a ees 9 Calibrating 2 and 3 MeterS ua isa porras Ewe ORES AAA BES 10 Register Base Replacement s 4 4 dae on do wee e e ME A A a A 10 SCIVICING 4545 Gas e Baha eae AD ae ee Re AERTS EEO RESALE EEO GREK EE OEE SSeS 12 Change Gear Replacement 64 4464 i400 oho oe OS eRe Ee ORO EOE ad OE bee oe 12 Instructions for Removing the Gear Train Assembly with Magnet 0 00 eee ee eee eee 13 Instructions tor Removing the Local Register 405 2644 eK eeaXe ohooh eo OR EOE A ROR Oe eS 14 Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com www jamiesonequipment com Industrial Turbo Meters Sizes 2 through 6 al Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jami
12. esonequipment com www jamiesonequipment com YA je User Manual SCOPE OF THE MANUAL This manual contains information concerning the installation operation and maintenance of Badger Meter magnetic drive turbo meters To ensure efficient operation of the meters the instructions given in this manual should be thoroughly read and understood Retain the manual in a location where it is readily available for reference SPECIFICATIONS Maximum Operating Pressure 150 psi 10 bar Optional 300 psi bronze 250 psi cast iron spindle CEN 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 turbo meters are essentially the same for all meter sizes Any special instructions required for the installation and or electrical connection of meter mounted or free standing accessory devices such as registers pulse transmitters valves and remote batch controllers will be provided as a supplement to this manual Preliminary Considerations e The Badger Meter 2 through 6 i
13. 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 making sure that the gears fully mesh Install and tighten the register seal screws TAKE CARE NOT TO BEND THE SPINDLES WHEN INSTALLING THE GEARS OR REASSEMBLING THE REGISTER TO THE REGISTER BASE al lo Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com lL www jamiesonequipment com User Manual 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 Figure 6 Release the Retainer Ring 3 Use a small screwdriver to release the retainer ring from the groove in the wall adjacent to the top plate of the gear
14. ion 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 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 shutoff 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 Accuracy of Badger 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 output of 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
15. les jamiesonequipment com www jamiesonequipment com Industrial Turbo Meters Sizes 2 through 6 Servicing Refer to the following paragraphs for instructions covering 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 IOM instruction manual pertaining to that device also provided as a supplement to this manual If satisfactory repair cannot be made contact the Industrial Division of Badger Meter Inc Change Gear Replacement 1 Replacing the change gear on the register base spindle requires no gage to properly mesh this gear with the register change gear A shoulder stop is built into the spindle at the proper gear height thus eliminating gear adjustment 2 The change gear in the register should be installed with the aid of a Badger change gear mesh gage P N 21747 000 to ensure proper gear mesh The procedure is as follows GEAR MESH GAGE METER MOUNTED P N 21747 000 ACCESSORY lt q GEAR HUB AMD amp een iaa GEAR HUB 8 SETSCREW CHANGE GEAR 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 the gage see Figure page 6 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
16. ndustrial turbo meters are designed for operation in HORIZONTAL piping arrangements e 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 e To permit periodic cleanout of the meter and to provide a convenient means of stopping fluid flow during maintenance it is recommended that a flushing system be incorporated into the facility piping arrangement la Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com www jamiesonequipment com Ge Industrial Turbo Meters Sizes 2 through 6 Installing the Meter 1 Install the meter in the pipeline making sure that the flow arrow on the meter housing is in proper relation to the direction of liquid flow It is also recommended that ten pipe diameters upstream and five pipe diameters downstream of straight pipe be incorporated with no obstructions If this is not possible please contact factory to review acceptability of 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 it is recommended that consideration be given to installation of a meter support under the meter housing Permanent diameters of pipe diameters or
17. s 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 WITHOUT REMOVING FROM LINE TURN VALVE WITH SCREWDRIVER BYPASS VALVE TO ADJUST FLOW ON SIDE OF 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 drive in the following manner a To INCREASE registration turn the slot in the valve perpendicular 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 th
18. to your nearest Badger Meter representative or the Industrial Division of Badger Meter Inc 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 existing change gears Specify the corrected change gear ratio 5 Install the corrected change gears taking care that the correct change gears are assembled to the appropriate spindles see example in figure below For registers refer to Servicing section for instructions covering 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 IOM manual for recalibrating instructions REGISTER REGISTER BASE REGISTER CHANGE GEAR TURBO METER REGISTER BASE OPERATING HEAD Figure 2 Change Gear Location Register Base and Register Assembly Electronic Scaling Correction If the test results indicates an adjustment is required see the instruction manual for that accessory for procedure to change scale factor al l3 Jamieson Equipment Company 5314 Palmero Court Buford GA 30518 800 875 0280 sales jamiesonequipment com F www jamiesonequipment com 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 bypas
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