Recordall® Turbo
Series Meters
Sizes 1 ½", 2", 3", 4", 6", 8",
10", 12", 16" and 20"
Installation &
Operation Manual
RTS-IOM-5
BadgerMeter,Inc.
®
P/N: 53407-004 Rev. 6
10-03
PREFACE
SCOPE OF MANUAL
This manual contains information concerning the installation, operation and maintenance of Recordall® Turbo Series meters with magnetic drive.
To ensure efficient operation of the meters, the instructions in this manual should be thoroughly read and understood. Retain this manual in a
location where it is readily available for reference.
Section I
GENERAL INFORMATION
1-1. DESCRIPTION
Recordall® Turbo Series meters utilize proven design features such
as thrust compensated rotor geometry, direct drive magnetic coupling
and dual outboard rotor bearings to achieve high accuracy over a broad
flow range. Extended product service life is achieved at higher levels
of accuracy, in addition to lower meter maintenance costs. Recordall
Turbo Series meters are available in 1 1/2", 2", 3", 4", 6", 8", 10", 12",
16" and 20" sizes.
Incorporating unitized construction with corrosion-resistant assemblies, the basic components of the Recordall Turbo Series consist of
the housing and completely removable measuring element. Permanently sealed for greater product reliability, the straight-reading local
register and Recordall Transmitter Register (RTR®) allow in-line
servicing. The meter housing and cover plate are bronze (1 1/2" - 10").
The 12" - 20" meter housings are cast iron with a heat fused epoxy
coating. The measuring element is constructed of high-impact
strength thermoplastics. Recordall Turbo Series meters are also
equipped with an integral calibration mechanism for in-line accuracy
calibration.
In the operation of a turbo meter, water flows through the straightening
vanes and a nose cone at the inlet side of the meter so that the swirling
effect of upstream piping is minimized. The water then strikes the rotor
blades, causing the rotor to turn. A downstream nose cone includes
straightening vanes to limit the downstream effects of flow profile
distortions. Optional NPT test ports are provided for field performance
testing.
Motion of the rotor is transferred by means of a worm drive to a vertical
shaft driving a gear set, which transmits the rotation to the meter's
registration device. The direct drive magnetic coupling provides
accurate flow registration during line surges, and allows the permanently sealed register to be easily removed to facilitate in-line service.
A pictorial description of the meter's components and location can be
found in the illustrated parts list RTS-P-1 which is provided as a
supplement to this manual. Each assembly or part has an item number
that is cross-referenced to an associated parts list which consists of
the service assemblies and parts shown in the exploded illustration.
The list provides the following information:
a. Item number
b. Name of part
c. Part number
1-2. CONFIGURATIONS AND SPECIFICATIONS
A descriptive brochure, exploded parts list, pressure loss and accuracy
charts are available and show the available sizes, flow range, head
loss, laying length and weight for Recordall Turbo Series meters. The
difference between various meter configurations relate primarily to
flange connections and options for units of registration, i.e., U.S.
gallons, cubic feet, etc. Materials used in the construction of the
meters are also described in the accompanying literature.
1-3. ACCESSORIES
Badger's Recordall Transmitter Register (RTR) is available as an
option for Recordall Turbo Series meters. The RTR provides system
connectivity to the Itron® ERT®, ORION® and TRACE® meter reading
systems.
Badger Plate Strainers 2" - 20" are also available. Recommended for
use with all turbo meters, Badger Plate Strainers provide exceptional
meter protection while improving meter accuracy and reliability. The
1 1/2" - 4" Turbo Series meters are available with integral stainless
steel plate strainers.
Section II
INSTALLATION
2-1. UNPACKING AND INSPECTION
To avoid damage in transit, Badger® Recordall Turbo 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.
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 the 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.
2-2. INSTALLATION
Procedures for installing Badger Turbo Series meters are essentially
the same for all meter sizes. Any special instructions required for the
installation or connection of accessory devices such as strainers will
be provided as supplements to this manual. Figure 1 outlines a
recommended meter installation.
A. PRELIMINARY 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
Badger Recordall Turbo Series meters are designed for
operation in HORIZONTAL piping arrangements.
1. Be sure that the meter flow range and size of the meter coincide
with the intended service and demand for water.
The life of the turbo meter will be curtailed if operated at
flow rates higher than specified. (Reference Technical
Briefs).
2. The meters are designed for use in cold water service (up to
120°F or 49°C) within the applicable flow requirements for turbo
Page 2
meters. For use with water at higher temperatures, consult your
Badger Meter representative or nearest Badger regional sales office.
3. Installation of a strainer is recommended 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 Badger® Plate Strainers.
4. Avoid locating the meter in close quarters. Allow sufficient
space to permit access for meter reading, testing, and maintenance.
BY-PASS
(PERMANENT OR
TEMPORARY)
VALVE
(open)
MINIMUM OF FIVE
DIAMETERS OF
STRAIGHT PIPE
B. INSTALLING THE METER. Overall dimensions and laying lengths
of each meter size are shown on the Technical Briefs. After reviewing
the applicable dimensional requirements, choose an appropriate installation point in the piping and proceed as follows:
1. Measure precisely the overall length of the meter with gaskets
attached to the inlet and outlet flange connections.
2. Provide proper gap length in service piping.
3. Install meter in the pipeline so that the flow arrow on the meter
housing points in the same direction as water flow.
MINIMUM TWO
PIPE DIAMETERS
DOWNSTREAM
OF TURBO
METER
TEST TEE
UPSTREAM
BADGER PLATE
STRAINER AND TURBO
SERIES METERS
Figure 1. Recommended Meter Installation
5. 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 tee can be installed
downstream of the meter for field accuracy testing.
6. The Recordall® Turbo Series 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. To insure valid registration and
proper performance, the following factors should be considered when
installing Recordall Turbo Series meters and Turbo Series meters with
integral strainers.
a. When installing the meter with a separate Badger Plate
Strainer or integral strainer, a minimum of five (5) pipe diameters of
straight, unobstructed pipe is recommended upstream of the meter.
For optimum protection and accuracy, this straight pipe spool piece
should be installed between the separate strainer and meter as
illustrated in Figure 1. (A minimum of ten (10) pipe diameters (minimum
of 25 pipe diameters for smallest size) of straight unobstructed pipe
is recommended upstream of a meter installed without a plate strainer.
The deletion of a strainer, however, is not recommended.) This allows
for dampening of velocity profile distortions caused by elbows, pumps,
dirt traps, etc., prior to the meter. Where spiral flows are created by
three dimensional elbows or rotary pumps, additional distance to
dampen the effect is beneficial. If a basket or Y-type strainer is utilized,
it is recommended that it be placed five (5) to ten (10) pipe diameters
prior to the meter to dampen velocity profile distortions created by this
design.
b. Do not install check valves or pressure reducing devices
upstream of the meter.
c. Valves immediately upstream of the meter should only be
fully-open gate valves. Butterfly valves are acceptable if they are five
(5) pipe diameters or more upstream from the meter. Downstream,
fully open gate or butterfly valves can be used.
d. The service saddle (or reducing tee) which is used for field
accuracy testing should be at least two (2) pipe diameters downstream
of the meter's outlet flange.
e. Unweighted check valves should not be located closer than
three (3) pipe diameters downstream of the meter.
f. Externally weighted check valves and pressure reducing
devices should not be located closer than five (5) pipe diameters of the
meter.
g. When installing a turbo meter and plate strainer of a size
smaller than the pipe installation, to reduce the effect of jetting caused
by the increase in flow velocity, a minimum of five (5) pipe diameters
is recommended upstream of the meter. Additional length is recommended if a sharp contraction or an eccentric reducer, rather than a
concentric, tapered reducer is used.
DOWNSTREAM
COUPLING
ADAPTOR
SERVICE
SADDLE
SHUT-OFF
VALVE
4. With meter and gaskets in place, tighten flange connection bolts.
5. To relieve possible strain on the piping, it is recommended that
a meter support be used under the meter housing where appropriate.
Turbine meters must operate in a completely filled line
at all times. The downstream piping must always be
arranged to provide sufficient back pressure to maintain
a full line at the meter. By eliminating air in the line, as
well as sudden flow surges, inaccurate registration and
damage to the turbine mechanism can be avoided.
2-3. RECORDALL TRANSMITTER REGISTER OPTION
Badger Meter Recordall Transmitter Registers are designed for use
with the Recordall Turbo Series. If the meter has been purchased with
a RTR®, the installation guidelines as outlined in the Installation Data
Sheet should be followed.
Before proceeding with the installation, be sure that the Recordall
Transmitter Register corresponds to the meter size, and unit of
measure.
2-4. PERFORMANCE CHECKS
Any valves or devices controlling the flow of water through a turbo
meter must always be opened and closed SLOWLY to prevent shock
loads that may damage the meter's rotor assembly.
Complete the following checks to ensure that a turbo meter is properly
installed and operational:
a. Slowly open upstream valve to apply water pressure to the meter
and check to see if there are any leaks. Tighten flange bolts as
required.
b. Perform a functional test of the meter. Slowly open valve on
downstream (consumer) 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 of downstream valve or
valves. Observe register for correct direction of flow. The large test
pointer will now move in the proper direction. Now open all applicable
service valves.
c. Adjust rate of flow by throttling with the downstream valve so the
flow does not exceed the maximum continuous duty specification as
defined in the Technical Briefs. The rate of flow can be quickly checked
by timing the quantity registered through the meter in one minute.
2-5. SHUTDOWN INSTRUCTIONS
If the turbo meter is to be shut down for an extended period of time or
if it is being removed from service, Badger recommends that the meter
and measuring components be thoroughly flushed to prevent the
settling out of undissolved solids or the accumulation of corrosive
deposits. If there is an upstream strainer in the line, it also should be
flushed at this time.
Page 3
Section III
MAINTENANCE
3-1. GENERAL
This section is limited to information about general preventative
maintenance and calibration procedures for Badger® Recordall® Turbo
Series meters, whereas instructions for disassembling the meters for
servicing can be found in Section IV. A repair parts list, exploded views
and other illustrations are provided as a supplement to this manual.
3-2. MAINTENANCE EQUIPMENT
The tools and equipment recommended for servicing and maintenance of Recordall Turbo Series meters consist of the usual complement of hand tools used by plumbers and mechanics.
3-3. PREVENTATIVE MAINTENANCE
The purpose of preventative maintenance is to ensure efficient
operation and long life by detecting and correcting any condition that
may damage the meter or cause it to fail. Maintenance intervals are
a function of the water quality and operating flows experienced by the
meter. Preventative maintenance includes periodic inspection, accuracy testing and cleaning procedures.
a. PERIODIC INSPECTION
1. Visually inspect the meter for missing hardware, loose screws,
broken or scratched register lens or any other signs of wear or
deterioration. Replace worn parts as required.
2. Verify that the meter operates 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 strainer or the meter itself is
clogged and needs cleaning.
b. CLEANING
1. Clean all dirt, grease, moisture or other foreign material from
the exterior of the meter. Use a cleaning solvent or volatile mineral
spirits to remove grease or oil. To clean the measuring element, soak
for 12 hours in a mild soap-based cleaner or detergent, and then use
a stiff nylon bristle brush to remove any deposits. After cleaning, rinse
thoroughly with water and dry.
2. In the event that the system pressure has been reduced and the
upstream strainer or meter is clogged, the foreign material must be
flushed out. To flush the strainer, open the cleanout plug and purge the
foreign material with fresh water from the service line. After the strainer
has been cleaned, purge the meter with fresh water and run discharge
out the nearest downstream outlet.
3. Integral Strainer Units. Before attempting service/maintenance of strainer section, system pressure must be removed. See
Section 4-2 to prepare meter for service. After system pressure is
removed, remove cover bolts and cover. Clean out/flush strainer
section of all loose particles/debris. After cleaning is complete,
reinstall screen and reassemble. See Section 2-4 and follow instructions to return meter to normal service.
3-4. CALIBRATION CHECK AND ADJUSTMENT
The accuracy of Badger Recordall Turbo Series meters is tested at the
factory before shipment. However, after a long period of service, it may
be necessary to recalibrate a meter. The meter can be tested for
accuracy using appropriate connections with either a test tank of
known volume or a test meter. The meter can be tested in the setting
by running output flow through the optional test port, if so equipped.
The Recordall Turbo Series integral calibration mechanism can be
adjusted under line pressure, simplifying and reducing calibration time.
The following instructions are provided to assist in performing a
calibration check and adjustment.
a. ACCURACY TEST
If the optional test port is to be used, upstream and
downstream valves must be closed prior to removing
plug and installing appropriate connections. Failure to
do so can lead to plug being ejected from housing,
causing personal injury and/or property damage. Wherever an installation is equipped with a drain valve for
meter flushing, open the drain valve to relieve pressure
within the meter. If the installation does not have a drain
valve, carefully loosen test plug until it begins leaking.
Stop and wait for pressure to bleed down, then continue
to slowly loosen, making certain pressure is completely
bled off before removing.
1. After installing appropriate connections, meter can be tested
by leaving setting downstream valve closed (if using integral test port),
and slowly opening upstream valve. Finally, the test circuit downstream valve can be slowly opened and used to throttle flow for test
purposes.
2. Place a test tank of known volume at the output of the meter.
(An alternative is to connect a calibrated test meter to the output.)
Accuracy testing requires test volumes at least as large as the register
test circle.
3. As in testing the accuracy of any meter, the Recordall Turbo
Series meter must first be purged of air by running water through the
meter.
NOTE
Good test practices are required to perform reliable field
accuracy tests such as those outlined in the AWWA M6
manual. Register "jump" can occur in some instances if
valves are abruptly opened or closed. While this jump is
not accumulative (no affects in service billing), it can
affect accuracy results (1% per division on a one test
circle volumetric test). Care during tests must be taken
to insure this does not occur.
LOCK SCREW
CALIBRATION
SHAFT O-RING
CALIBRATION
SHAFT SEAL
PLUG
CALIBRATION
SHAFT
Figure 2. Calibrating Recordall Turbo Series Meters, shown with
Optional Test Plug
4. Operate the meter until the test tank is filled to the calibrated
level or the predetermined quantity has registered on the calibrated
test meter. Because accuracy may vary slightly with flow rate, it is
recommended that the meter be tested at low, intermediate and high
flows.
5. Record the quantity registered on the meter during the test.
6. Perform the following calculations to determine meter accuracy:
Quantity Registered on Meter
Test Tank or Test Meter Quantity
x 100 = Meter Accuracy
b. CALIBRATION. The meter's calibration ring is preset at the
factory and sealed. In normal service, it should not have to be reset.
If a retest is required in which a calibrated test stand reveals that the
meter needs recalibration, proceed as follows (see Figure 2):
Page 4
COVER
SCREEN
1. Remove calibration shaft seal plug by puncturing plug in slot
provided and twist/pry plug from hole.
2. Loosen calibration shaft lock screw.
3. Adjust calibration ring with screw driver as follows:
TO INCREASE REGISTRATION. Turn the calibration shaft
clockwise. This will speed up the rotor, increasing registration.
TO DECREASE REGISTRATION. Turn the calibration shaft
counter clockwise. This slows down the rotor, decreasing registration.
NOTE
The total range of the calibration adjustment is about
10%. Tested and calibrated at the factory, the calibration mechanism will allow for a ±5% adjustment in the
field.
Section IV
SERVICING
4-1. GENERAL
When the performance of the meter indicates a need for servicing,
refer to the following instructions pertaining to removal, inspection and
installation of service parts and assemblies. With the Recordall® Turbo
Series unitized construction, service is simplified with a reduction in
required product maintenance training. Also refer to the illustrated
repair parts list RTS-P-1 for part numbers of replaceable components
for ordering information. If satisfactory repair cannot be achieved,
contact the Utility Division of Badger Meter, Inc.
4-2. REMOVAL OF METER HEAD
Recordall Turbo Series meters can be serviced without removing them
from the line. A typical installation would be equipped with drain and
piping valves. To inspect or replace components of the head assembly, close the upstream and downstream valves. However, if the
installation does not have a drain valve, proceed as follows to relieve
pressure:
Due to the floating rotor design principle, the calibration
mechanism contains some clearance for proper part fit
resulting in some hysterisis or "deadband" when changing
directions with calibration shaft. Adjustments should be
made in small increments in one direction to avoid need for
counter rotation. If desired setting is exceeded, counter
rotations in small increments should be made, even though
first reverse setting may result in no apparent change.
This is normal, and subsequent changes will cause reverse accuracy curve shift.
4. With the calibration shaft turned to the desired setting, tighten the
lock screw while maintaining the calibration shaft position.
5. Retest the meter to confirm the accuracy of the calibration
setting. If the meter is still out of calibration, repeat the procedure.
6. Replace the calibration shaft seal plug with a new one.
SEAL
SCREW
SEAL
SCREW
Upstream and downstream valves must be closed before
attempting to remove meter head from housing. Failure
to do so can lead to head being "ejected" from housing,
causing personal injury and/or property damage!
a. Loosen each of the head bolts about one and one-half turns.
Do not completely remove the bolts.
b. If the O-ring between the meter head 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 to create a
shock hazard.
c. Allow the meter to drain and relieve internal pressure.
d. When pressure is relieved, remove the head bolts. Lift the
measuring element assembly from the housing.
NOTE
A dummy cover plate is available to close the meter in
the line and continue service while the measuring ele-
ment assembly is being inspected or serviced. (See
illustrated repair parts list RTS-P-1.)
4-3. LOCAL REGISTER AND RTR REMOVAL
The Recordall Turbo Series meter register is easily removable to
facilitate in-line service. Remove the register lid and shroud by
removing the seal screw. The shroud is removed by rotating the
register assembly counter clockwise until it stops. This provides
clearance so it can be lifted off the measuring element assembly (see
Figure 3a and 3b). To reinstall the register, follow the above procedure
in reverse order.
Page 5
COVER PLATE
HOLD DOWN
STRAP
TRANSMISSION
SHAFT GEAR
TRANSMISSION
STRAIGHTENING
VANE ASSEMBLY (2)
PROTECTION
SHAFT
BOTTOM
BEARING
NOSE CONE/
NOSE CONE
SET SCREW (2)
CALIBRATION
CALIBRATION
SHAFT O-RING
TUBE
MAGNET
CARRIER
ASSEMBLY
CAGE
INSERT
TRANSMISSION
SHAFT
ASSEMBLY
SHAFT SEAL
PLUG
ROTOR
CALIBRATION
SHAFT LOCK
THRUST WASHER
CALIBRATION
CAGE SET
SCREW
CAGE SEAL
Figure 3a. Register and Measuring
Element Assembly, 1 1/2" - 4"
SCREW
SHAFT
HEAD
O-RING
CALIBRATION
LINKAGE
CALIBRATION
RING
EYEBOLTS
TRANSMISSION
SHAFT GEAR
NOSE CONE
SETSCREW
TRANSMISSION
SHAFT ASSEMBLY
NOSE CONE/
STRAIGHTENING
VANE ASSEMBLY (2)
COVER
RETAINING
LOCK SCREW
CALIBRATION GEAR
PLATE
RING
CALIBRATION
DRIVE PLATE
PROTECTION
TUBE
ROTOR
CALIBRATION
RING (REAR)
BEARING
CAGE SEAL
O-RING
SEAL PLUG
THRUST WASHER
CALIBRATION
SHAFT
MAGNET
CARRIER
CAGE
INSERT
HEAD BOLT
HEAD
O-RING
CALIBRATION
RING (FRONT)
CAGE
SETSCREW (4)
WASHER (4)
Figure 3b. Register and Measuring
Element Assembly, 6"
4-4. MEASURING ELEMENT ASSEMBLY
Remove the O-ring and cage seal. Check for damage and clean or
replace prior to reassembly.
NOTE
A cage seal is installed in the 1 1/2" - 6" Recordall® Turbo
Series so that the entire water volume flows through the
measuring element.
To remove measuring element from cover, remove calibration shaft
seal plug and lock screw (see Figures 3a and 3b). Place cover register
side down on table or flat surface. Lightly tap or press calibration shaft
from wet side out of bore in cover (1 1/2" - 4" only). Care should be
taken not to strike or bend the calibration linkage.
The measuring element insert can be removed from the cover plate for
service or replacement by removing the cage set screw (see Figures
3a and 3b, quantity 4 for 6" size. Holding the cover plate in one hand,
rotate the thermoplastic element counter clockwise until the bayonettelike tabs are aligned with open areas of the cover plate (1 1/2" - 4" only).
Remove element from cover plate.
4-5. STRAIGHTENING VANES/NOSE CONE
The straightening vanes are an integral part of the upstream and
downstream nose cone assemblies (see Figures 3a and 3b). To gain
access, the measuring element must be removed from cover as
outlined in Section 4-4 above.
Removal of upstream nose cone provides access to rotor, calibration
ring and transmission assembly. To remove nose cone, unscrew the
upstream nose cone setscrew. For 1 1/2" - 4", slide calibration linkage
into cage insert stop. Take hold of the nose cone/straightening vanes
and turn clockwise, thereby disengaging the calibration linkage from
the tab on the calibration ring and unlocking bayonettes of nose cones
from cage (see Figure 4a). If tab of calibration ring has not disengaged
linkage, rotate ring carefully by pushing struts at interior of element
(between straightening vanes and rotor). Pull the nose cone assembly
out from the measuring element insert. For 6", remove transmission
gear by lifting off shaft, noting alignment of "D" shaped bore with flat
on shaft (required to align for assembly). Next remove retaining ring
that holds down calibration drive plate, located under magnet carrier
magnet (see Figures 3b and 4b). 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 nosecone assembly
out from the measuring element insert. Remove rotor assembly.
Rear nose cone removal requires transmission shaft removal (see
Figures 3a, 3b, 4a and 4b). First, remove strap over gear (1 1/2" - 4"
only). Gear is removed from shaft by simply lifting off. Note shaft has
a flat that matches with "D" shaped bore in gear (required to align for
assembly). Remove nose cone set screw. Remove protection tube by
carefully pressing (with flat surface of blade screwdriver) on bottom of
tube located inside rear nose cone. Press to release detent lock,
approximately 1/4" vertical travel, then lift tube out from top of cage
insert. Lift transmission shaft assembly up and out of bottom bearing,
then slide shaft downward and diagonally out (towards you) to remove
from nose cone/cage assembly. Finally, holding cage firmly with one
hand, rotate nose cone clockwise with other hand, then carefully lift off
cage. Reinstallation is reverse of removal.
Refer to Section 4-8 of this manual to correctly reassemble components.
4-6. CALIBRATION MECHANISM
To disassemble the calibration ring assembly, the following procedures are required (see Figures 3a and 3b). Refer to Sections 4-2
through 4-5 above. Remove the calibration shaft seal plug and
unscrew the calibration shaft lock screw from the cover plate. Remove
the calibration shaft thrust washer and calibration shaft. The calibration shaft can be pressed out of the cover plate from below. The
calibration shaft O-ring may be removed if a leak exists at this point in
the disassembly of the meter. If replaced, the O-ring should be coated
slightly with a silicon grease before insertion. Clean all parts as
required.
To gain access to the calibration ring, the straightening vane/nose
cone must be removed. See Section 4-5 to remove. To remove
calibration ring from nose cone assembly, align the ring slots with
bayonettes of nose cone assembly located on inner ring of calibration
ring. To remove, carefully lift the calibration ring from the nose cone
assembly. Reinstallation is the reverse of this procedure.
CALIBRATION
CAGE
INSERT
CALIBRATION
LINKAGE
SMALL HOLE
WITH
CHAMFER UP
RING
TOP SIDE
PIN
NOSE
CONE
LARGE HOLE
WITH
CHAMFER
DOWN
Figure 4a. Calibration Ring/Linkage Assembly, 1 1/2" - 4"
Page 6
ARROW
TIP
INTO CAGE
THIS END
CAGE INSERT
(TOP VIEW)
TRANSMISSION
GEAR
CALIBRATION DRIVE
PIN OF
CALIBRATION
RING
RETAINING RING
PLATE
Figure 4b. Calibration Ring/Linkage Assembly, 6"
NOTE
When reassembling, the pin on the perimeter of the
calibration ring must be aligned with the arrow tip located
on the nose cone assembly (see Figure 4a). For 1 1/2"4" sizes, the calibration linkage is to be installed into cage
with larger hole to engage calibration ring tab, and side of
chamfered edge of hole towards nose cone assembly
(see Figure 4a). With calibration linkage fully inserted to
cage stop, install nose cone onto cage and rotate counterclockwise. This rotation engages pin of ring to 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. The
calibration shaft lock screw should also be tightened
securely to hold the calibration ring in its desired position.
After the calibration mechanism is serviced or replaced, be sure to check
the accuracy and calibration in accordance with the instructions in
section 3-4 of this manual.
4-7. MAGNET CARRIER/TOP GEAR SET
Remove the magnet carrier from the measuring element insert by lifting
it off the stainless steel pin (see Figures 3a and 3b). Check the
condition of the magnet and gear on the magnet carrier for damage or
wear. If significant wear or damage is present, replace the magnet
carrier.
Remove the hold down strap (see Figures 3a and 3b.) Check the
condition of the transmission shaft gear for damage or wear. If
significant wear or damage is present, replace the gear. Remove gear
by lifting off the shaft.
ROTOR
BEARINGS
ROTOR
WORM
NOSE CONE
ASSEMBLY
(2)
BEARING
(2)
PIN
Figure 5. Rotor and Nose Cone Assembly (1 1/2" - 6" Turbo
Meters)
4-8. ROTOR AND BEARINGS
The rotor can be inspected by removing the nose cone assembly from the
measuring element insert as outlined in section 4-5 of this manual.
Check the rotor worm and blades for signs of damage and wear. Also
inspect the bearing bushings in the front and rear shaft. If damage or
wear has occurred, replace the part (see Figure 5).
The rotor bearing pins in the straightening vane and nose cone
assembly should be inspected for signs of damage and wear (see
Figure 5). The spherical end of the bearing pin must not show any drag
lines and/or wear.
NOTE
Only highly-polished bearing pin ends insure 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.
To reassemble, the rear nose cone must be installed to cage. See
section 4-5. Now place the rotor assembly with worm gear side leading
through the cage, place on the rear rotor bearing pin, while tipping the
assembly back so that the opening is up. See section 4-6 to insure
calibration rings are properly assembled with nose cone assembly.
Insert the front nose cone assembly partially onto the cage insert,
engaging the bearing pin with the front bearing of the rotor. Tilt the
measuring element insert assembly forward 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 fore and aft.
Page 7
Be careful not to force the nose cone assembly into the
cage insert. Be sure that rotor engages both front and
rear rotor bearing pins prior to pressing the nose cone
assembly fully into the cage insert.
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 not, remove the nose cone
assembly and repeat the procedure. Install and tighten nose cone
assembly setscrew.
Holding the cover plate in one hand, align the thermoplastic cage
bayonette-like tabs with the slots in the cover plate (1 1/2" - 4" only).
Rotate the element clockwise until the cage set screw hole is aligned.
Install the cage set screws (quantity 1 for 1 1/2" - 4", quantity 4 for 6")
and tighten.
4-9. REINSTALLING METER HEAD ASSEMBLY
Badger recommends that a new housing O-ring be used after each
teardown and reassembly of the Recordall
®
Turbo Series. 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 allowing the rotor to
remain perpendicular to the flow and eliminating any
potential flow distortion. Head bolts should be tightened
to 10-11 ft. lbs. for 1 1/2" and 2" sizes, and 35-40 ft. lbs.
for 3" - 6" sizes.
The registration device should be reinstalled on the meter body.
To place the meter back in service, close the flushing system drain
valve. Open the upstream valve partially, then open the downstream
valve slightly to purge air from the service line. Then open both valves
completely.
ORDERING INFORMATION
Order replacement service parts for your Recordall Turbo Series
through your local Badger Meter sales representative. When placing
an order, please provide the following information:
a. Size of meter.
b. Registration units, i.e., U.S. gallons, cubic feet, etc.
c. Complete description of assembly or parts required.
d. Part number of item as shown in the repair parts list (RTS-P-1).
e. Quantity required.
f. Purchase order number, plus exact return and billing address.
Badger®, ORION®, Recordall® and RTR® are registered trademarks of Badger Meter, Inc.
TRACE® is a registered trademark of American Meter Company.
Itron® and ERT® are registered trademark s Itron, Inc.
Please see our website at
www.badgermeter.com
for specific contacts.
Copyright © Badger Meter, Inc. 2003. All rights reserved.
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 bid obligation exists.
BadgerMeter,Inc.
P.O. Box 245036, Milwaukee, WI 53224-9536
(800) 876-3837 / Fax: (888) 371-5982
®
www.badgermeter.com
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