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1. 49 7025 9208 0 Czech Republic Badger Meter Czech Republic s r o Marikova 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 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 RCS IOM 1
2. is transmitted to each Recordall register or encoder by means of ceramic magnets The register or encoder is permanently sealed in a controlled environment relative to humidity and cleanliness thus assuring longevity of performance Related Literature e The Recordall Compound Series Meters Product Data Sheet contains information on operating principle meter construction materials tolerances and specifications e The Recordall Compound Series Meters Parts List contains illustrations of parts part numbers and part descriptions Safety Information The installation of the Recordall Compound 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 Recordall Compound Series meters are shipped to the 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
3. replace the gear 5 Liftthe gear off the shaft Removing the Straightening Vanes Nose Cone The straightening vanes are an integral part of the upstream and downstream nose cone assemblies 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 To remove the nose cone 1 Unscrew the upstream nose cone setscrew For 2 3 and 4 meters slide the calibration linkage into the cage insert stop 2 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 12 3 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 4 Remove the retaining ring that holds down the calibration drive plate located under magnet carrier magnet see Figure 8 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
4. AccuracyTesting s oo acesar es ge ee RAED REE RARER ER DRESS ER RRR QUEE AUR ERO QUE RR OR RR CORR REOR ER OE RR 10 Maintenance EQUIPMENT oig acea cen er RO oe ou RES RUE BS AE RAE TE 8 HOA IUS A AOE Se o ORE 10 Preventive Maintenance i ssec hac po EE ERE EG OE ER AGREE RETR ERG RETR HES ERE ROS 10 Periodic Inspections acc x odore st toe EE ee IR D sl TR ee Roe A Oe Bed 11 Cleaning cose yd aco yedataco aoe ph Pade ed ap aco get fa halls amp Wa Wate qutd a ex ee aU Sot dog a e RUP 11 SERVICING PARTS AND ASSEMBLIES se 2 ox Rn THU ide Se OG PER es ES OOM ed Bae eae ees 12 Removing the High Flow Turbo Meter Head Assembly 2 2 0 eee Rh 12 Removing the Turbo Measuring Element Assembly from the Cover Plate 14 Removing the Magnet Carrier Top Gear Sei 14 Removing the Straightening Vanes Nose Cone 1 ee ee 14 Removing the Calibration Mechanisms szans 6 ee hh 14 Inspecting the Rotor and Bearings 6 1 lee hh he 16 Removing the Rear Nose GONE sah esc hake cd eh aR oe ERE RD ES RO RRS EDAEN EEEE PENERE tees 17 Reinstalling the High Flow Turbo Meter Head Assembly 17 Removing the Low Flow Side isses ey RR ERES RE ER OE EME ee HE EATS CHES EP Easy 18 Servicing the Chamber and Disc 2 0 en nen eee 18 Valve Assembly as 2 ura spine sra sa pad Pe Rae eae Cee See EM ad oR Sale eee ee Ca CR ue 19 Removing the Valve Assembly nee eee teens 19 Replacing the Valve Assembly 0 ee eee eee eee 19 Reinstalling th
5. C RETAINING RING CALIBRATION DRIVE PLATE Figure 11 Calibration ring linkage assemblies Reassembling the Calibration Mechanism 1 Align the pin on the perimeter of the calibration ring with the arrow tip located on the nose cone assembly see Figure 11 on page 15 2 For 2 3 and 4 sizes install the calibration 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 11 on page 15 3 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 4 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 the Recordall Turbo Series Meter User Manual September 2013 Page 15 Recordall Compound Series Meter Sizes 2 3 4 and 6 Inspecting the Rotor and Bearings To inspect the rotor remove the nose cone assembly from the measuring element insert as described in Removing the Magnet Carrier Top Gear Set on page 14 Check the rotor worm and blades for signs of damage
6. O RING AX ASSEMBLY HighFlowTurbo g Se Low Flow THRUST ROLLER Meter Head NS yi Register A Assembly DISC ASSEMBLY don DOVETAIL INSERT ds Cover BOTTOM inc a f ia CHAMBER Assembly RETAINING STRAP Cage Seal Figure 9 Chamber and disc assembly Drain Plug vi Figure 8 Removing the high flow turbo meter head assembly Page 12 September 2013 User Manual Seal plug O ring Lock screw Eyebolts Head bolt i Cover M To shaft HR M e gear Head O ring um Calibration drive plate pe Transmission shaft gear Sat Magnet carrier c Protection tube Nose cone setscrew SS Cage insert Mose cone setscrew 1 Retaining ring Bearing Nose cone straightening vane assembly 2 Transmission shaft E d Calibration ring rear Cage setscrew 1 B S Calibration ring front Cage seal asher 4 6 Calibration shaft seal plug O UM rH shaft lock screw r cen o EN Cover PER Calibration shaft E CUM O ring Magnet carrier ert uU vi Rotor Hold down strap Transmission shaft gear Protection tube Nose cone setscrew ee linkage tege cone setscrew Nose cone straightening vane assembly 2 Transmission ies bottom bearing A opes ring front Calibration ring rear E Cage seal LM 2 3 and 4 Figure 10 High flow turbo measuring element assemblie
7. and can be used for field accuracy testing The Recordall Compound 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 When installing the meter with a Badger Meter Plate Strainer a minimum of 5 pipe diameters of straight unobstructed pipe is required upstream of the meter A minimum of 10 pipe diameters of straight unobstructed pipe is required upstream of a meter installed without a plate strainer The deletion of a strainer however is not recommended This allows for dampening of velocity profile distortions caused by items such as elbows pumps and dirt traps upstream of the meter Where spiral flows are created by three dimensional elbows or rotary pumps use additional distance to dampen the effect 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 Page 6 September 2013 User Manual Do not install check valves or pressure reducing devices upstream of the meter Valves immediately upstream of the meter should only be fully open gate valves Butterfly valves are acceptable if they are 5 pipe dia
8. nose cone assembly out from the measuring element insert Remove rotor assembly Removing the Calibration Mechanism To disassemble the calibration ring assembly 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 out of the cover plate from below Page 14 September 2013 User Manual 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 the straightening vane nose cone must be removed See Removing the Magnet Carrier Top Gear Set on page 14 for instructions 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 CALIBRATION RING i PIN 5 ARROW TIP CALIBRATION NOSE LINKAGE CONE Siew TOP SIDE INTO CAGE D THIS END LARGE HOLE WITH CHAMFER DOWN CAGE INSERT SMALL HOLE WITH CHAMFER UP 2 3 and 4 CAGE INSERT PIN OF TOP VIEW ET CALIBRATION RING TRANSMISSION GEAR
9. 6 cover assemblies to 35 40 ft Ib SPECIFICATIONS Compound Series Model 2 50 mm 3 80 mm 4 100 mm 6 150 mm 2 elliptical or round 3 round 4 round 6 round Meter Flanges Class 150 50 mm 80 mm 100 mm 150 mm Typical Operating Range 0 5 200 gpm 0 5 450 gpm 0 75 1000 gpm 0 75 2000 gpm 100 1 5 0 1 45 m h 0 1 102 m h 0 17 227 m h 0 17 454 4 m h Low Flow Registration 9796 minimum 0 25 gpm 0 06 m h 0 25 gpm 0 06 m h 0 375 gpm 0 09 m h 0 375 gpm 0 09 m h Maximum Continuous Flow 170 gpm 38 3 m h 400 gpm 90 3 m h 800 gpm 181 6 m3 h 1500 gpm 340 5 m h Pressure Loss at Maximum 5 4 psi at 170 gpm 6 0 psi at 400 gpm 11 0 psi at 800 gpm 9 3 psi at 1500 gpm Continuous Flow 0 38 bar at 38 3 m h 0 41 bar at 90 3 m h 0 75 bar at 181 6 m h 0 64 bar at 340 5 m h Crossover Flow Rate Typical 12 gpm 12 gpm 20 gpm 30 gpm Pressure Loss at Crossover 3 5 psi 0 24 bar 4 0 psi 0 28 bar 4 0 psi 0 28 bar 5 0 psi 0 35 bar Minimum Crossover Accuracy 97 97 97 95 Maximum Operating Pressure 150 psi 10 bar Maximum Operating Temperature 105 F 41 C Test Plug 1 1 2 2 Materials Meter Housing amp Cover Lead free bronze alloy Turbo Cast Head Lead free bronze alloy Nose Cone amp Straightening Vanes Thermoplastic R
10. 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 September 2013 Page 5 Recordall Compound Series Meter Sizes 2 3 4 and 6 INSTALLATION Procedures for installing Recordall Compound 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 Permanent or Temporary Valve Minimum of Five Open Diameters of Straight Pipe Upstream l Downstream M Badger Plate Strainer and Coupling Shut Off Compound Meter Adaptor Valve 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 Compound Series meters are de
11. Recordall Compound Series Meter Badger Meter Lead Free Bronze Alloy Sizes 2 3 4 amp 6 e NSF ANSI Standards 61 and 372 Certified RCS UM 00076 EN 02 September 2013 U S e r M a n u a Recordall Compound Series Meter Sizes 2 3 4 and 6 Page ii September 2013 User Manual CONTENTS SCOPEOF THIS MANUAL 24 0 s 2 0 05 240 64 24 0 0 6 4 85 00069 844 040 64 a4 404084 4 Or qux AO qox d ar QR 5 PRODUCT INFORMATION e 3235 2373 9 da pd RENE bas a habans NOERU S Cea R aS PRR a eae E 5 Product Descriptioh s 2 2 8 vr once oka Qe ae B08 dow dis aos QU Lb I Testis Bow yi iu d Bs ws te d A e te 5 Related Literature qs aka tha ee y ee eae e SRLS ROWE C PERE CP RETA SS ERASE EE Redes 5 Safety Informations lt 4 sve oma AVA OUR XI Ow ea Ee OR oe ew a ON OL Cee oe Oe 5 Unpacking and Inspection a ee eee ona e edad EE REM EER SOROR Re ae ee eae SUR eae ae Rey 5 INSTALLATIONS 5 5 uo os T6 weve GE CP RURUN Wate i ae NOR NUR A a eS aoe NOR NUR Ce NUR D NER hee ee ee 6 Preinstallation Considerations x ex sd nx RR UR EAE GT SH ELE EE ELE AE ER NA 6 Installing the Meter 3s sees cep n dE A e Eh e NUR EU ee eh URNA e US Qu bawad ss 7 Adapter Spacets s sg EE ROSA RE ARTS Se RE TRAGEN NE Gm Ge a eq eer 8 Performance Checks pua a UES ROS CR ORO Gs RR ba NOR UA RES eee Ons ON ee NU de ORE 9 Reading the Recordall Registers and Encoder 2 rh 9 MAINTENANCE x oh on eR cO ae SUR IS ee NUR a ae hee acs COURIR Se RR HOS UR aa 10
12. Remove the lock pawl see Figure 14 2 Turn the valve assembly counter clockwise to unscrew it from the housing 3 Lift the valve assembly out of the housing Replacing the Valve Assembly If any portion of the valve assembly requires replacement we recommend replacing the entire valve assembly 1 Drop in the new assembly 2 Turn the assembly clockwise to thread it into the housing 3 Drop the lock pawl back into position to lock in the assembly NOTE The 4 and 6 assemblies cannot be disassembled and must be completely replaced Complete replacement of 2 and 3 is also recommended as noted but the seal can be replaced with a special tool Please contact Badger Meter for further details High Flow Register RS Low Flow gt Register pS Lock Pawl Figure 14 Valve assembly September 2013 Page 19 Reinstalling the Cover Assembly Badger Meter recommends that a new O ring be used after each teardown and reassembly of the cover assembly To assure a tight seal make sure O ring is positioned correctly on the housing and that the O ring and cover assembly are clean and free of dirt or residual traces of old O ring material If necessary use silicone grease to help retain the O ring and to serve as a lubricant in reassembling it to the housing Cover bolts should be tightened in a crisscross pattern similar to Turbo head bolts Torque 2 and 3 cover assembly bolts to 16 18 ft lb Torque the bolts for the 4 and
13. ance consists of periodic inspection accuracy testing and cleaning procedures Page 10 September 2013 User Manual Periodic Inspection 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 compound meter also should be flushed by purging with fresh service water through the cleanout plugs located on the housing September 2013 Page 11 Recordall Compound Series Meter Sizes 2 3 4 and 6 SERVICING PARTS AND ASSEMBLIES When the performance of a compound 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 Recor
14. and together 3 To determine the complete total flow add the low flow and high flow totals together September 2013 titm 0 Wi S Recordall ag Compound LT Gallons 3 s 6 Low Flow ab ss Total Flow High Low 5 ra Low Flow EE QM d ex Sv Vo Recordall 10 Compound SR a tu _ Gallons 305 0 0 00 DUR A 60 High Flow OS a 50 3 Trippy ays High Flow Figure 7 Reading the register example Page 9 Recordall Compound Series Meter Sizes 2 3 4 and 6 MAINTENANCE This section is limited to information pertaining to the general maintenance of Badger Meter Recordall Compound Series meters An exploded view of the meter along with part numbers and descriptions are provided in the Recordall Compound Series Meters Parts List Accuracy Testing The Compound Series meter can be tested for accuracy with a test meter or a test tank of known volume A test plug is provided on the meter The low flow register is for recording the amount of water passing through the disc or low flow side of the meter The high flow register is for recording the amount of water passing through the turbo or high flow side of the meter When testing at flow rates below the meter s cross over point only the low flow test hand will move Record the initial reading low flow odometer and low flow test circle To determine the amount of water that has passed through the m
15. and wear Also inspect the bearing bushings in the front and rear shaft If damage or wear has occurred replace the part see Figure 12 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 12 The spherical end of the bearing pin must not show any drag lines and or wear ROTOR N Va ROTOR WORM BEARINGS 2 NOSE CONE ASSEMBLY 2 BEARING PIN Figure 12 Rotor and nose cone assembly 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 Top Gear Set on page 14 2 Place the rotor assembly with the worm gear side leading through the cage 3 Place the 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 Insertthe fr
16. dall Compound Series Meter Parts List for part numbers of replaceable components and correct ordering information If satisfactory repair cannot be made contact Badger Meter Removing the High Flow Turbo Meter Head Assembly A typical installation would be equipped with drain and piping valves To inspect or replace components of the High Flow Turbo Head Assembly close the upstream and downstream valves However if the installation does not have a drain valve proceed as follows to relieve pressure See Figure 8 on page 12 UPSTREAM AND DOWNSTREAM VALVES MUST BE CLOSED BEFORE ATTEMPTING TO REMOVE METER HEAD FROM HOUSING FAILURE TO DO SO CAN LEAD TO THE HEAD BEING EJECTED FROM HOUSING CAUSING PERSONAL INJURY AND OR PROPERTY DAMAGE 1 Loosen each of the High Flow Turbo Head Assembly bolts about 1 1 2 turns Do not completely remove the bolts 2 If the O ring between the High Flow Turbo Head Assembly and the housing is secure and not leaking pry the Measuring Element Assembly loose by inserting a screwdriver blade where the head and housing join together BE SURE THAT ANY WATER COMING OUT OF THE METER HEAD DOES NOT SPRAY ONTO ELECTRICAL EQUIPMENT AND CREATE A SHOCK HAZARD 3 Allow the meter to drain and relieve internal pressure 4 When pressure is relieved remove the head bolts Lift the Turbo measuring element assembly from the housing ZN cw High Flow L Register oo CHAMBER e 2 TOP Tol g CHAMBER amp DISC 7
17. e Cover Assembly resar ee nee eR es 20 SPECIFICATIONS a 4 03 cares Y age ha bares EET ag MEMS E EE qu PES H AMET ES qvi S 20 September 2013 Page iii Recordall Compound Series Meter Sizes 2 3 4 and 6 Page iv September 2013 User Manual SCOPE OF THIS MANUAL This manual contains installation operation and maintenance procedures for the Badger Meter Recordall Compound 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 Compound Series meters combine two metering technologies in one innovative package A positive displacement chamber measures low flow while a turbine chamber records high flow The compound meters are available in 2 3 4 and 6 sizes A spring loaded valve assembly controls the flow through each of the two measuring elements to provide maximum accuracy and performance The basic components of the compound meter are a housing Turbo Series head assembly and cover assembly with disc chamber assembly The Turbo head assembly includes a Recordall register or encoder for high flow totalization and complete turbo head components cage and rotor The cover assembly includes a Recordall register or encoder for low flow totalization and a complete chamber assembly The output of both measuring elements the disc and turbo
18. eter during test take the new reading from the low flow test circle If more than one revolution of the test circle take a new reading from both the low flow odometer and the low flow test circle The difference between the initial and final reading is then compared to that recorded by the test meter or test tank When testing flow rates at or above the meter s crossover point the high flow and low flow register test hands will move This is because both sides of the meter disc and turbo operate simultaneously at these flow rates The disc side of the meter operates at all flow rates to keep the chamber free of debris that might enter the meter Record the initial readings high flow odometer and high flow test circle low flow odometer and low flow test circle If less than one revolution of the high flow test circle record both the new high flow and low flow test circle readings The amount of flow recorded by the high flow and low flow test circles during test must be added together to determine the total flow through the meter Compare this to that recorded by the test meter or test tank If more than one revolution of the high flow test circle occurs take new readings from the low flow odometer high flow and low flow test circles and add all complete high flow test circle revolutions to this Once again the amount of flow recorded by the high flow and low flow test circles must be added together and combined to determine the total flow through
19. he meter and check to see if there are any leaks Tighten the flange bolts as required Perform a 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 Reading the Recordall Registers and Encoder To determine the total reading for meter the totals for both low and high flow must be added together 1 Determine the low flow total by reading the registere encoder identified as low flow Read only the moveable number wheels 2 From the high flow register read both the number wheels and the sweep hand Read the number wheels first Read only the moveable number wheels Note the position of the sweep hand round the number down to the nearest increment Add the reading from the number wheel and the sweep h
20. mber 2013 Page 7 Recordall Compound Series Meter Sizes 2 3 4 and 6 Adapter Spacers The 2 and 4 Compound Series meters are supplied in 15 1 4 and 20 lay lengths respectively If you have an existing compound meter with a lay length of 17 for the 2 size or 24 for the 4 size a Flange Adapter Kit is available for each to accommodate the difference Mount the Flange Adapter to the outlet side of the meter Figure 2 2 adapter Figure 3 2 adapter with a 2 elliptical meter Figure 5 4 adapter Figure 6 4 with a 4 meter Description Part Number 2 Elliptical Flange Adapter Kit 64186 001 2 Round Flange Adapter Kit 64186 002 4 Flange Adapter Kit 64186 003 COMPOUND 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 Page 8 September 2013 Performance Checks User Manual Any valves or devices controlling the flow of water through a compound 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 compound meter is properly installed and operational Slowly open the upstream valve to apply water pressure to t
21. meters or more upstream from the meter Downstream fully open gate or butterfly valves can be used Unweighted check valves should not be located closer than 3 pipe diameters downstream of the meter Externally weighted check valves and pressure reducing devices should not be located closer than 5 pipe diameters of the meter When installing a compound 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 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 Compound Series Meter Product Data Sheet Review the dimensional requirements choose an installation point in the piping and proceed as follows 1 2 3 4 5 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 To relieve possible strain on the piping position a meter support under the meter housing where appropriate Septe
22. one set screw Remove the protection tube by carefully pressing with flat surface of blade screwdriver on the bottom of the tube located inside the rear nose cone Press to release the detent lock approximately 1 4 vertical travel then lift the tube out from the top of the cage insert Lift the transmission shaft assembly up and out of the bottom bearing then slide shaft downward and diagonally out towards you to remove it from the nose cone cage assembly Holding cage firmly with one hand rotate the nose cone clockwise with other hand then carefully lift it off the cage To reinstall the rear nose cone follow this procedure in reverse See Inspecting the Rotor and Bearings on page 16 for instructions on reassembling the components Reinstalling the High Flow Turbo Meter Head Assembly Useanew 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 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 meter head will not turn and the rotor will remain per
23. ont 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 see 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 ENGAGES BOTH THE FRONT AND REAR ROTOR BEARING PINS PRIOR TO PRESSING THE NOSE CONE ASSEMBLY FULLY INTO THE CAGE INSERT Page 16 September 2013 SS o User Manual Press the nose cone assembly fully into the cage insert and turn it counter clockwise catching the calibration linkage in the slot Check to see that the rotor spins freely If it does not remove the nose cone assembly and repeat the procedure Install and tighten the nose cone assembly setscrew Holding the cover plate in one hand align the thermoplastic cage bayonet like tabs with the slots in the cover plate 2 3 and 4 only 10 Rotate the element clockwise until the cage setscrew hole is aligned Install and tighten the cage setscrews quantity of 1 for 2 3 and 4 meters a quantity 4 for the 6 meter Removing the Rear Nose Cone Rear nose cone removal requires transmission shaft removal 1 ow M e TA Remove the strap over the gear 2 3 and 4 only Lift the gear off the shaft The shaft has a flat spot that aligns with the D shaped bore in the gear Remove the nose c
24. otor Thermoplastic Rotor Radial Bearings Lubricated thermoplastic Rotor Thrust Bearing Sapphire jewels Rotor Bearing Pivots Passivated 316 stainless steel Calibration Mechanism Stainless steel amp thermoplastic Measuring Chamber amp Disc Thermoplastic High Flow Valve Stainless steel amp thermoplastic Magnets Ceramic Register Lens Glass Register Housing amp Cover Thermoplastic or bronze Trim Stainless steel Drain Plug 3 4 Stainless steel or lead free bronze alloy Test Plug Stainless steel or lead free bronze alloy ORION Recordall and RTR are registered trademarks of Badger Meter Inc Other 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 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
25. pendicular to the flow eliminating any potential flow distortion Tighten the head bolts to 10 11 ft lb for the 2 size and 35 40 ft lb for the 3 4 and 6 sizes September 2013 Page 17 Recordall Compound Series Meter Sizes 2 3 4 and 6 Removing the Low Flow Side Follow same removal steps for the cover as listed in Removing the High Flow Turbo Meter Head Assembly on page 12 Cw ua di Register 9 Turbo Head Assembly gt 2 Register Cue Low Flow Chamber Assembly em x Figure 13 Removing the low flow side Servicing the Chamber and Disc 1 Remove the screws holding the bottom plate on the cover assembly Remove the bottom plate Remove the chamber retaining strap Lift out the chamber and disc assembly H FW HM Inspect the chamber and parts see Figure 9 for visible signs of wear The thrust roller and dovetail insert should be replaced if worn Replace the chamber if wear is evident on disc spindle where it contacts the crossbar magnet drive or the balls or if the disc plate is worn by foreign material If water deposits are found remove any mineral deposits from the disc and chamber interior surfaces Before replacing the chamber in the meter head make certain that the area surrounding the magnet in the meter head is clean Page 18 September 2013 User Manual Valve Assembly Removing the Valve Assembly With the cover assembly removed the valve assembly is exposed for service 1
26. s Cage setscrew 1 September 2013 Page 13 Recordall Compound Series Meter Sizes 2 3 4 and 6 Removing the Turbo Measuring Element Assembly from the Cover Plate 1 Remove the O ring and cage seal 2 Check for damage and clean or replace prior to reassembly 3 To remove the measuring element from the cover remove the calibration shaft seal plug and the lock screw 4 Place the cover register side down on a table or flat surface 5 Lightly tap or press the calibration shaft from the wet side out of the bore in the cover 2 3 and 4 only Do not strike or bend the calibration linkage 6 The measuring element insert can be removed from the cover plate for service or replacement by removing the cage set screws quantity of one except for the 6 size 7 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 2 3 and 4 only 8 Remove the element from the cover plate Removing the Magnet Carrier Top Gear Set 1 To remove the magnet carrier from the measuring element insert lift it off the stainless steel pin 2 Checkthe 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 4 Check the condition of the transmission shaft gear for damage or wear If significant wear or damage is present
27. signed 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 COMPOUND METER WILL BE CURTAILED IF OPERATED AT FLOW RATES HIGHER THAN SPECIFIED The meters are designed for use in cold water service up to 120 F or 27 C within the applicable flow requirements for compound 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 Contact your Badger Meter representative for information on Recordall Plate Strainers e Avoid locating the meter in close 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
28. the meter This is then compared to that recorded by the test meter or test tank A simplified alternative to recording the initial and final odometer readings on the high flow and low flow odometers is to record the number of complete revolutions of the test hand on the high flow and or low flow test circles during test This is then added to the difference between the initial and final position of the test hands on the test circles to determine the total flow through the meter For correct testing procedures and test volumes based upon meter flow rates please refer to AWWA M 6 Manual Starting the test when the register test circle hands are on zero and operating the meters through complete revolution of the test circles are desirable operating procedures to follow THE TEST HANDS OPERATE INDEPENDENTLY OF ONE ANOTHER FOR EXAMPLE DURING METER OPERATION AT FLOWS BELOW CROSSOVER THE LOW FLOW TEST HAND WILL REVOLVE WHILE THE HIGH FLOW TEST HAND IS STATIONARY ALLOWING HIGHER READINGS ON THE LOW FLOW ODOMETER ONLY Maintenance Equipment The tools and equipment recommended for use in servicing and maintaining of Recordall Compound Series meters consist of the usual complement of hand tools used by plumbers and mechanics Preventive 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 mainten
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