AW Gear Meters GEAR METERS User Manual

POSITIVE DISPLACEMENT

GEAR METERSGEAR METERS

OperaƟon & InstallaƟon Manual

Rev. 2.2

Positive Displacement Flow Meters

Operation and Installation Manual

Table of Contents

Safety Definitions and Information ............................................................................................................... 3

Unpacking ..................................................................................................................................................... 3

Quick Start ..................................................................................................................................................... 3

Install Pickup Sensor ................................................................................................................................. 3

Flush Piping ............................................................................................................................................... 4

Filtration .................................................................................................................................................... 4

Location ..................................................................................................................................................... 4

Orientation ................................................................................................................................................ 4

Flow Direction ........................................................................................................................................... 4

Product Description and Principle of Operation ........................................................................................... 5

Filtration .................................................................................................................................................... 5

Installation .................................................................................................................................................... 5

Preferred Flow Direction ........................................................................................................................... 5

Preferred Orientation ............................................................................................................................... 5

Location ..................................................................................................................................................... 6

Installing a Bypass ..................................................................................................................................... 6

Pickup Sensor ............................................................................................................................................ 6

Location ................................................................................................................................................. 6

Installation ............................................................................................................................................ 7

Operation ...................................................................................................................................................... 7

Overview ................................................................................................................................................... 7

Running the Flow meter ........................................................................................................................... 8

Ramp Up.................................................................................................................................................... 8

Regular Cleaning ....................................................................................................................................... 8

End of Shift and Overnight Preparations .................................................................................................. 8

Breakdown ................................................................................................................................................ 9

Plugging ..................................................................................................................................................... 9

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Positive Displacement Flow Meters

Operation and Installation Manual

Filtration .................................................................................................................................................... 9

Maintenance ............................................................................................................................................... 10

Use the Maintenance Guides .................................................................................................................. 10

Flow Testing ............................................................................................................................................ 10

Plugging and Filtration ............................................................................................................................ 10

Calibration ............................................................................................................................................... 10

Storage .................................................................................................................................................... 10

Flow Meter Do’s and Don’ts ....................................................................................................................... 11

Calibrations ................................................................................................................................................. 12

If flow readings are too high ................................................................................................................... 12

If flow readings are too low .................................................................................................................... 12

If it is necessary to adjust the existing k-factor ...................................................................................... 12

If it is necessary to re-calculate a new k-factor ...................................................................................... 12

Trouble-Shooting Guide .............................................................................................................................. 13

Limited Warranty ........................................................................................................................................ 14

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Positive Displacement Flow Meters

Warning!

Caution

Notice

Caution

Notice

Operation and Installation Manual

Safety Definitions and Information

Do not attempt to install or use your AW Gear Meters product until you have read the safety
instructions in this section. Save this manual and keep it in an easily accessible place.

Warning means that failure to follow this safety statement may result in extensive product damage,
serious personal injury, or death.

Caution means that failure to follow this safety statement may result in minor or moderate personal
injury, property or equipment damage.

Notice is a statement that informs about installation, operation, maintenance, performance issues, or
general tips that are important but do not create a hazard or safety concern.

Unpacking

Separate the flow meter from packaging materials and check for any visual signs of damage. If you
determine there has been damage caused by shipping, file a claim with the shipping company. If the
flow meter appears to have been improperly assembled or does not operate properly, return the
product for replacement or repair (see Limited Warranty information at the end of this manual).

Quick Start

To set up, install and operate your flow meter quickly, follow these step-by-step instructions. Detailed
installation, operational, and maintenance instructions begin on page 5 in this manual. More
information is also available in the Maintenance Guide appropriate for your flow meter.

Install Pickup Sensor

Before attaching the sensor to the flow meter, check for any potential clearance issues. It may be easier
to install the sensor after you have installed the flow meter in the line.

Whether the sensor requires tool or hand installation, tighten with hand-tighten torque only.

Some flow meters are shipped with the sensor already installed.

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Positive Displacement Flow Meters

Figure 1: Typical flow meter installation with bypass

Figure 2: Flow meter with direction of flow
marked with arrow

Operation and Installation Manual

Flush Piping

If feasible, flush piping to remove dirt and debris before installing flow meter.

Filtration

Filtration is recommended to prevent contaminants from entering the flow meter. See flow meter Data
Sheet for specific filter, including mesh weight and size.

Location

It’s best to install the flow meter upstream from control valves
and fluid regulators, if possible. See Figure 1.

Orientation

Positive displacement gear flow meters can be installed either a
horizontal or vertical (flow up) orientation. 2-3 psi of
backpressure is required to assure the meter is always full of
fluid. No straight run pipe is required upstream or downstream
of the meter.

Flow Direction

Flow direction is marked with an arrow on the flow meter.
See Figure 2.

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