Installation & Operation Manual
Contents
1. Isolation Isolation Valve x Valve x E U 10 Pipe Diameters 5 Pipe Diameters Minimum Minimum 221 J Bypass Line FIGURE 3 INSTALLATION WITH BY PASS LINE This is true with any restriction in the flow line that may cause the liquid to flash If necessary air eliminators should be installed to ensure that the meter is not incorrectly measuring entrained air or gas It is recommended that a minimum length equal to ten 10 pipe diameters of straight pipe be installed on the upstream side and five 5 diameters on the downstream side of the flow meter Otherwise meter accuracy may be affected Piping should be the same size as the meter bore or threaded port size y Display Isolation Valve FloClean Turbine 5 54 10 Pipe Diameters 5 Pipe Diameters Minimum Minimum FIGURE 4 INSTALLATION WITHOUT A BY PASS LINE Form No 02 TUR UM 00107 08 12 Do not locate the flow meter or connection cable close to electric motors transformers sparking devices high voltage lines or place connecting cable in conduit with wires furnishing power for such devices These devices can induce false signals in the flow meter coil or cable causing the meter to read inaccurately CAUTION Damage can be caused by striking an empty meter with a high velocity flo2. 235 5854181 4 20 TROUBLESHOOTING 20 3 A CERTIFICATE ccsessccccccsdcscevsccnscesaccscesscncvesececcossescnsesestecsosssesvenss 21 CONTACTS AND 22 LIMITED WARRANTY AND DISCLAIMER cccccccccccccceccccccccccccese 23 NOTE Blancett reserves the right to make any changes or improvements to the product described in this manual at any time without notice 2 Form No 02 TUR UM 00107 08 12 FIGURES FIGURE 1 MODEL CONSTRUCTION 5 FIGURE 2 THEORY OF OPERATION cccscsccscscescesccncsvsncsscnsosccssccesscscssccssssessssesse 5 FIGURE INSTALLATION WITH BY PASS LINE 7 FIGURE 4 INSTALLATION WITHOUT A BY PASS 7 FIGURE 5 WIRING FOR NEMA 6 MAGNETIC PICK UPS 9 FIGURE 6 WIRING FOR NON NEMA 6 MAGNETIC 5 9 FIGURE 7 WIRING FOR ACTIVE MAGNETIC 5 10 FIGURE 8 DIMENSIONS 12 FIGURE 9 FloClean CROSS 5 5 13 FIGURE 10 B16C 3 A SERIES FloClean EXPLO
3. OF LIABILITY This warranty shall not apply to any Product repaired or altered by any Product other than Badger Meter The foregoing warranty applies only to the extent that the Product is installed serviced and operated strictly in accordance with Badger Meter instructions The warranty shall not apply and shall be void with respect to a Product exposed to conditions other than those detailed in applicable technical literature and Installation and Operation Manuals IOMs or which have been subject to vandalism negligence accident acts of God improper installation operation or repair alteration or other circumstances which are beyond the reasonable control of Badger Meter 02 TUR UM 00107 08 12 Badger Meter Warranty FloClean Sanitary Flow Meter With respect to products not manufactured by Badger Meter the warranty obligations of Badger Meter shall in all respects conform and be limited to the warranty extended to Badger Meter by the supplier THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES WHATSOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE except warranties of title Any description of a Product whether in writing or made orally by Badger Meter or its agents specifications samples models bulletins drawings diagrams engineering sheets or similar materials used in connection with any Customer s order
4. Rotate During Extraction Remove Retaining Rings Remove Rotor Thrust Ball Extraction Hole Rotate Rotor Support Clean and Inspect Component Parts Through 180 To Per 3 A Sanitary Standards Reverse Extract Thrust Ball Dismantling Procedure to Reassemble B16C 3 A SERIES FLOCLEAN EXPLODED VIEW FIGURE 10 Form No 02 TUR UM 00107 08 12 16 B16C Series COP SOP 3 A Turbine Installation NOTE This procedure applies to installation of replacement turbine repair kits and re installation of cleaned or sanitized turbine IMPORTANT Before reassembly note there are weep holes on A each rotor support these weep holes must be facing down toward the bottom of the meter body when installed The meter must be reassembled with the arrowheads on the rotor pointed in the direction of fluid flow The magnetic pick up side of the body signi fies the up position This is the position that the repair kit was calibrated and this is the position to be used to ensure meter accuracy Due to the polished surfaces there are no arrows on the rotor support to indicate which rotor support is to be placed upstream or downstream Please install the repair kit as it was received in the box using the arrow on the rotor to determine the placement of the rotor support 1 If required by process procedures the meter should be cleaned prior to installation into the piping system 2 Drop a thrust ball into a rotor s
5. 14 Form No 02 TUR UM 00107 08 12 SERVICE PROCEDURES WARNING High pressure leaks are dangerous and cause personal injury Make sure that fluid flow has been shut off and pressure in the line re leased before attempting to remove the meter 3 A Turbine Disassembly and Cleaning Procedure NOTE Refer to Figure 10 for relative positions of repair kit components 1 Remove the magnetic pick up from the meter body to avoid dam age during procedure 2 Remove the retaining ring from one end of the meter 3 Keeping the meter upright pick up port at the top remove the rotor support from the body taking care not to rotate it in the pro cess If the rotor support is jammed in the body use a pair of pliers or vice grips to break it free 4 Hold the rotor support over a suitable container and rotate it through 180 The thrust ball will drop out Take care not to lose the ball 5 Remove the rotor assembly 6 Remove the second retaining ring from the opposite side of the meter 7 Repeat steps 3 and 4 for the remaining rotor support 8 Identify parts and flow direction to match with original meter body 9 Clean and or sanitize parts to meet appropriate sanitary standards Form No 02 TUR UM 00107 08 12 15 Meter Body Jam Nut Sleeve Bearing Magnetic Pickup Rotor Support Retaining Ring SECTION A A Thrust Ball Rotor Assembly Release Jam Nut and Remove Magnetic Pick Up Remove Rotor Supports Do Not
6. DED 17 FIGURE CERTIFICATE Tu EP UP Te RUN MINE avi T Su Tere vade 21 TABLES TABLE 1 FloClean FLOW RATE 5 TABLE 2 FILTRATION RECOMMENDATIONS 6 TABLE 3 PICKUP OPTIONS scsscisssinssscsicnsacsccecsscseveccctustsnscnsenseseciosdeusowssuesasuaivaesstes 8 TABLE 4 DIMENSIONYS i RU YE ME en OU eo NY eUFERUVI ERE 12 TABLE 5 B16C 3 A SERIES COP SOP FloClean 5 14 Form No 02 TUR UM 00107 08 12 3 INTRODUCTION The Blancett FloClean turbine flow meter is designed with wear resistant moving parts to provide trouble free operation and long service life The durable 316L stainless steel construction provides a cost efficient flow measurement system that offers excellent accuracy and repeatability The FloClean turbine meter repair kit is designed for easy field service of a damaged flow meter rather than replacing the entire flow meter See the Appendix for repair kit information SERIES INFORMATION 16 X X X Sanitary Rating Bearing Material Calibration C COP SOP 3A Compliant A Ni Bindery A 5 Point std Tungsten B 10 Point Ferrule Si
7. FloClean Sanitary Flow Meter gt Badger Meter Form 02 TUR UM 00107 August 2012 Installation amp Operation Manual TABLE OF CONTENTS INTRODUCTION 2518 Al SERIES INFORMATION 4 FloClean FLOW RATE CHART ccccccccccccccccccccccccccccccccccccccccccccccecs 5 THEORY OF OPERATION ccccccccccccccccccccccccccccccccccees 5 INSTALLATION INSTRUCTIONS 6 PLUMBING anu R SERRE eaa epa No EEPN SE SES E vPaFEPSPEEe e eas Seu nau EE OPE 6 WRITING 8 OPERATIONAL START UP cccccccccccccccccccccccccccccccccccccccccccccccccecs 11 DIMENSIONS DRAWINGQGS cccccccccccccccccccccccccccccces 12 METER REPAIR AND 14 REPAIR TUE S 14 TURBINE REPAIR KITS PART NUMBERG cccccccccccccccccccccccccccccccees 14 SERVICE PROCEDURES ccccccoccccccccccccccccccccccccccccccccccccccccccccccces 15 B16C SERIES COP SOP 3 A TURBINE INSTALLATION 17 6 19 APPENDIX 2 65 02 525385008025855 095309 902 255553585 4455
8. RTIFICATE INITIALLY ISSUED 3 19 1998 AUTHORIZATION NO 956 THIS IS TO CERTIFY THAT Blancett Division of Racine Federated Inc 8635 Washington Avenue Racine WI 53406 Is hereby authorized to continue to apply the 3 A Symbol to the models of equipment conforming to 3 A Sanitary Standards for Flow Meters Number 28 04 set forth below B16C 003A xxx B16C 005A xxx B16C 007A xxx B16C 105A xxx 16 107 B16C 108A xxx B16C 110A xxx B16C 115A xxx B16C 220A xxx VALID THROUGH December 31 2012 Timothy R Rugh Executive Director 3 A Sanitary Standards Inc The issuance of this authorization for the use of the 3 A Symbol is based upon the voluntary certification by the applicant for it that the equipment listed above complies fully with the 3 A Sanitary Standards designated Legal responsibility for compliance is solely that of the holder of this Certificate of Authorization and 3 A Sanitary Stan dards Inc does not warrant that the holder of an authorization at all times complies with the provisions of the said 3 A Sanitary Standards This in no way affects the responsibility of 3 A Sanitary Standards Inc to take appropriate action in such cases in which evidence of nonconformance has been established NEXT TPV INSPECTION REPORT DUE March 2016 FIGURE 11 3 A CERTIFICATE Form No 02 TUR UM 00107 08 12 21 22 NOTES Form No 02 TUR UM 00107 08 12 Hance PRODUCTS COVERED The Badger Mete
9. are for the sole purpose of identifying the Product and shall not be construed as an express warranty Any suggestions by Badger Meter or its agents regarding use application or suitability of the Product shall not be construed as an express warranty unless confirmed to be such in writing by Badger Meter EXCLUSION OF CONSEQUENTIAL DAMAGES AND DISCLAIMER OF OTHER LIABILITY Badger Meter liability with respect to breaches of the foregoing warranty shall be limited as stated herein Badger Meter liability shall in no event exceed the contract price BADGER METER SHALL NOT BE SUBJECT TO AND DISCLAIMS 1 ANY OTHER OBLIGATIONS OR LIABILITIES ARISING OUT OF BREACH OF CONTRACT OR OF WARRANTY 2 ANY OBLIGATIONS WHATSOEVER ARISING FROM TORT CLAIMS INCLUDING NEGLIGENCE AND STRICT LIABILITY OR ARISING UNDER OTHER THEORIES OF LAW WITH RESPECT TO PRODUCTS SOLD OR SERVICES RENDERED BY BADGER METER OR ANY UNDERTAKINGS ACTS OR OMISSIONS RELATING THERETO AND 3 ALL CONSEQUENTIAL INCIDENTAL AND CONTINGENT DAMAGES WHATSOEVER Badger Meter Warranty 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 2012 Badger Meter Inc All rights reserved info blancett com www blancett com www ba
10. dgermeter com Phone 262 639 6770 Fax 262 417 1155 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 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 Czech Republic Badger Meter Czech Republic s r o 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 Rm 501 11 Longyue Apartment 180 Longjin Rd Jiuting Songjiang District Shanghai China 201615 86 21 5763 5412
11. el Nickel Bindery Tungsten Carbide Nickel Plated CD4MCU Stainless Steel Nickel Bindery Tungsten Carbide Turbine Connections Sanitary Clamp Ends NEMA 6 150 F to 300 F 100 C to 149 C Pick Up option 0 Nore For other pick up options see page 8 Accuracy Accuracy 1 of reading 0 1 Repeatability Certifications Construction 150 F to 300 F 101 C to 149 C The meter should not be subjected to temperatures above 300 F 149 C or below 150 F 101 C Temperature or the freezing point of the metered liquid High temperatures will damage the magnetic pick up while lower temperatures will limit the rotation of the rotor 1000 psi maximum rating based on Tri Clamp Sanitary connection Contact Blancett to determine if operating liquid is compatible with materials of construction Corrosion Incompatible fluids could deteriorate internal parts and cause the meter to read inaccurately Specifications are subject to change without notice o O Form No 02 TUR UM 00107 08 12 19 APPENDIX TROUBLESHOOTING GUIDE Trouble Meter indicates higher than actual flow rate Meter indicates lower than actual flow rate Erratic system indication meter alone works well remote monitor application only Indicator shows flow when shut off No flow indication full or partial open position Erratic indication at low
12. flow good indication at high flow No flow indication System works perfect except indicates lower flow over entire range Meter indicating high flow upstream piping at meter smaller than meter bore Opposite effects of above 20 Cavitation Increase back pressure Debris on rotor support Clean meter Build up of foreign material Clean meter on meter bore e Install gas eliminator ahead of e Gas in liquid meter e Debris on rotor ebris o e Clean meter and add filter tion bead Install new repair kit e Viscosity higher than 1 e Recalibrate monitor calibrated Ground shield one place only Look for internal electronic instrument ground Reroute cables away from electrical noise Ground loop in shielding Mechanical vibration causes rotor to oscillate without turning Isolate meter Rebuild meter with repair kit and recalibrate monitor Move to location where meter is full on start up or add downstream flow control valve Fluid shock full flow into dry meter or impact caused bearing separation or broken rotor shaft Rotor has foreign material Clean meter and add filter wrapped around it Faulty pick up Replace pick up Repair or replace by pass valves By pass flow leak or faulty solenoid valves Fluid jet impingement on mes Change piping Change temperature change i ity lower than calibr Form No 02 TUR UM 00107 08 12 3 A CE
13. ique to the meter Output Signal Magnetic Pickup FIGURE 2 THEORY OF OPERATION Form No 02 TUR UM 00107 08 12 5 INSTALLATION INSTRUCTIONS PLUMBING The flow meter must be installed with the flow arrow etched on the exte rior of the meter body pointing in the direction of fluid flow Though the meter is designed to function in any position it is recommended where possible to install horizontally with the magnetic pick up facing upward The liquid being measured must be free of any large particles that may ob struct spinning of the rotor If particles are present a mesh strainer should be installed If small particles are present in the fluid Blancett recommends that a strainer be installed upstream of the meter See Table 2 for filtration recom mendations Bore Size Ferrule Size Strainer Size Clearance 3g 0 984 60 x 60 0092 0 984 60 x 60 0092 TABLE 2 FILTRATION RECOMMENDATIONS Severe pulsation and mechanical vibration will affect accuracy and shorten the life of the meter The preferred plumbing setup is one containing a by pass line that allows meter inspection and repair without interrupting flow See Figure 3 If a by pass line is not utilized it is important that all control valves be located downstream of the flow meter See Figure 4 6 Form No 02 TUR UM 00107 08 12 Display
14. lear A Power B Common C Output Signal FIGURE 6 WIRING FOR NON NEMA 6 MAGNETIC PICK UPS Form No 02 TUR UM 00107 08 12 Active Sensor 1 Pickup Option 4 1 Red 4 20 mA 2 Black 4 20 mA 3 White Not Used Active Sensor 0 5VDC Pickup Option 8 Socket End 1 Red 10 30 VDC 2 Black 0 5 VDC Output 3 White Ground 3 4 2 Pins 1 lt 10 to 30 VDC 2 0 5 VDC Output 3 Ground 4 N C 5 N C FIGURE 7 WIRING FOR ACTIVE MAGNETIC PICK UPS Form No 02 TUR UM 00107 08 12 OPERATIONAL START UP The following steps should be followed when installing and starting the meter WARNING Make sure that fluid flow has been shut off and pressure in the line released before attempting to install the meter in an existing system 1 After meter installation close the isolation valves and open the by pass valve Flow liquid through the by pass valve for sufficient time to eliminate any air or gas in the flow line 2 Open upstream isolating valve slowly to eliminate hydraulic shock while charging the meter with the liquid Open the valve to full open CAUTION High velocity air or gas may damage the internal components of the meter 3 Open downstream isolating valve to permit meter to operate 4 Close the by pass valve to a full closed position 5 Adjust the downstream valve to provide the required flow rate through the meter NOTE The downst
15. r warranty shall apply to the Blancett FloClean Flow Meter Product MATERIALS AND WORKMANSHIP Badger Meter warrants the Product to be free from defects in materials and workmanship for a period of 12 months from the original purchase date PRODUCT RETURNS Product failures must be proven and verified to the satisfaction of Badger Meter The Badger Meter obligation hereunder shall be limited to such repair and replacement and shall be conditioned upon Badger Meter receiving written notice of any asserted defect within 10 ten days after its discovery If the defect arises and a valid claim is received within the Warranty Period at its option Badger Meter will either 1 exchange the Product with a new used or refurbished Product that is at least functionally equivalent to the original Product or 2 refund the purchase price of the Product DO NOT RETURN ANY PRODUCT UNTIL YOU HAVE CALLED THE BADGER METER CUSTOMER SERVICE DEPARTMENT AND OBTAINED A RETURN AUTHORIZATION Product returns must be shipped by the Customer prepaid F O B to the nearest Badger Meter factory or distribution center The Customer shall be responsible for all direct and indirect costs associated with removing the original Product and reinstalling the repaired or replacement Product A replacement Product assumes the remaining warranty of the original Product or ninety 90 days from the date of replacement whichever provides longer coverage LIMITS
16. ream valve may be used as a control valve Form No 02 TUR UM 00107 08 12 11 DIMENSIONS DRAWINGS Cc Ferrule Size In mm 0 984 25 0 B16C 0XXA XXX 3 00 76 2 1 46 37 1 B16C 1XXA XXX 4 00 101 6 2 00 50 8 1 984 50 4 6 B16C 1XXA XXX 6 25 158 8 2 33 59 2 1 984 50 4 B16C 2XXA XXX 6 50 165 1 3 20 81 3 3 047 77 4 1 15 0 180 0 GPM flow range only TABLE 4 DIMENSIONS 12 Form No 02 TUR UM 00107 08 12 Thrust Ball Removable Rotor Support Retaining Ring Magnetic Pick Up Rotor Assembly Jam Nut Sleeve Bearing Meter Body 28 04 Auth 79 FLOW Manufacturer s Label and 3 A Symbol B16C 3 A Series COP SOP FloClean Meters FIGURE 9 FLOCLEAN CROSS SECTIONS Form No 02 TUR UM 00107 08 12 METER REPAIR AND CLEANING REPAIR KITS Each FloClean repair kit is factory calibrated to ensure accuracy through out the entire flow range Each kit is complete and includes a new K factor which is the calibrated number of pulses generated by each gallon of lig uid This K factor will be used to recalibrate the monitor or other electron ics to provide accurate output data Turbine Repair Kits Part Numbers Repair Kit Fits Repair Kit Bore Size Meter Part Number Part Number 0 984 B16C 003A XXX B16C K03A 0 984 B16C 005A XXX B16C K05A 0 984 B16C 007A XXX B16C KO7A 1 984 B16C 105A XXX B16C K05A TABLE 5 B16C 3 A SERIES COP SOP FLOCLEAN METERS
17. upport through the hole provided in the side Insert rotor support into the meter body Keep the thrust bearing hole pointed upwards to keep the ball in place 3 Secure a retaining ring in the groove provided Be sure that the retaining ring is completely installed in the groove 4 Drop a thrust ball into second rotor support through the hole provided in the side Locate the rotor in the support sleeve bear ing Insert rotor support and rotor into the meter body and the first support sleeve bearing Keep the thrust bearing hole pointed upwards to keep the ball in place 5 Secure the second retaining ring in the groove provided Be sure that the retaining ring is completely installed in the groove CAUTION Excess air pressure may damage the rotor and bearings by overs pin Form No 02 TUR UM 00107 08 12 17 6 Check the meter by blowing air through the assembly If the rotor does not turn freely the meter should be disassembled and checked for anything that would obstruct movement of the rotor 7 Install the magnetic pick up NOTE After installing the new repair kit the electronics will need re calibration Re fer to the electronics installation and operation manual If there are any questions on re calibration contact Blancett at 1 800 235 1638 or contact the manufacturer of the associated electronics Form No 02 TUR UM 00107 08 12 SPECIFICATIONS Physical Body Internal Wetted Parts Bearings 316L Stainless Ste
18. w stream If problems arise with the flow meter and monitor consult the Troubleshooting Guide in the Appendix If further problems arise consult the factory If the internal components of the turbine flow meter are damaged turbine meter repair kits are available Information pertaining to the turbine meter repair kits is referenced starting on page 14 WIRING Typical wiring configurations for the available pickup options are shown in Figures 5 6 and 7 Number of Pins Acti Non NEMA 6 Magnetic High Temperature Non NEMA 6 Active 0 5 VDC No Pickup TABLE 3 PICKUP OPTIONS o0 KNEE o2 03 6 8 NEN 8 Form No 02 TUR UM 00107 08 12 Pickup Option 0 1 Green Signal Standard 2 Red Black Signal Mag Pickup Socket End 3 Red White Unused O Braided Shield to Earth Ground Pins 1 Signal 2 Signal 3 Unused e e Pickup Option 1 1 Green Common Mag Pickup 2 Red Black Power With Pre Amp Socket End 3 Red White Signal N O Braided Shield to Earth Ground Pins 1 Common Power return 2 Power 12 24 Vdc 3 Output Signal 10 VDC Square Wave FIGURE 5 WIRING FOR NEMA 6 MAGNETIC PICK UPS etin Pickup Option 2 amp 6 Socket End mm B Yellow Signal A Blue Signal Amplified Mag Pickup Pickup Option 3 Socket End A Red Power 5 to 30 VDC e _ B Black Common C Green Output Pulse or 0 to 10 VDC Pins C
19. ze Carbide C 20 Point 0 0 984 1 1 984 Meter Body Hub 2 3 047 A With Hub B No Hub Meter Size Flow Range Pick up Option 03 0 6 3 0 GPM 0 NEMA 6 Magnetic 05 0 75 7 50 GPM 1 NEMA 6 Magnetic Amplified 07 2 0 15 0 GPM 2 Non NEMA 6 Magnetic 08 3 0 30 0 GPM 3 Non NEMA 6 Magnetic Amplified 10 5 0 50 0 GPM 4 Non NEMA 6 Active 4 20 mA B220 950 15 15 0 180 0 GPM 6 Non NEMA 6 High Temperature 20 40 0 400 0 GPM 8 Non NEMA 6 Active 0 5 VDC B220 951 9 None 1 7 NPT hub for Body Size 0 1 NPT hub for Body sizes 1 and 2 Indoor use only FIGURE 1 MODEL CONSTRUCTION SCHEMA 4 Form No 02 TUR UM 00107 08 12 FLOCLEAN FLOW RATE CHART K factor Ferrulesize pulses Gal TABLE 1 FLOCLEAN FLOW RATE CHART THEORY OF OPERATION Liquids moving through the turbine flow meter causes the rotor to turn at a speed proportional to the flow rate The rotor blade cuts the mag netic field that surrounds the magnetic pick up which in turn generates a frequency output signal that is directly proportional to the volumetric flow rate Figure 2 The signal is used to represent mM flow rate and or totalization of a liquid passing through the turbine flow meter and is always expressed as the number of electric pulses that the meter produces per unit of volume This value called the K factor is constant over each flow me ter s range and is un
Download Pdf Manuals
Related Search