Badger Meter Cox User manual

TUR-UM-00477-EN-01 (May 2014) User Manual
Precision Meters
Turbine Flow Meters

Precision Meters, Turbine Flow Meters
Page ii May 2014

CONTENTS
Description and Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Symbol Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Meter Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use of Pipe Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cox Precision Ball Bearing Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Procedure for Cleaning a Turbine Meter after Water Calibration and/or Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Technical Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
K-Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Linearity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
K-Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
20-Point Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30-Point Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
UVC-Universal Viscosity Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dimensions (Liquid). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AN End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
NPT End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flange End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hose Barb End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tri-Clamp End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
High Pressure End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dimensions (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AN End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Page iiiMay 2014

NPT End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flange End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Factors Aecting Linearity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pickos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specic Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Associated Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Recalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LoFlo Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Precision Meters, Turbine Flow Meters
Page iv May 2014

DESCRIPTION AND USE
Cox Precision Turbine Flow Meters are a precisely manufactured and calibrated instruments used in accurate rate-of-flow and
total-flow measurement of all types of fluids, whether liquid or gas.
They also have many applications as sensors in process flow control.
The flow meter mounts directly in the flow line and consists of a cylindrically bored housing, a flow straightener and turbine
assembly, and magnetic or carrier frequency pickoffs, as shown in Figure 1.
On all Precision Flow Meters, the magnetic or carrier frequency pickoff is located directly above the turbine, near the
downstream end of the flow meter. The flow straightener and turbine assembly is retained in the housing by a snap ring and
can be easily removed for cleaning and further disassembly.
Figure 1: Turbine flow meter
Cox Precision Turbine Flow Meters are provided with flow straighteners at the downstream and upstream ends. The flow
straighteners diminish any turbulence created by the turbine. Other physical differences are illustrated in exploded views. See
Figure 2 and Figure 3.
Fluid passing through the meter causes the rotor and bearing to revolve at a speed directly proportional to fluid velocity.
As each rotor blade passes the pickoff, it varies the pickoff’s reluctance, producing an output signal. Since turbine speed is
directly proportional to fluid velocity, signal frequency is similarly proportional to the volumetric rate-of-flow. The output
signal can be fed into various types of instruments to indicate the rate-of-flow, such as indicators, frequency converters,
counters, recorders and controllers.
Cox uses two pickoff technologies, magnetic and carrier frequency (RF). The magnetic pickoff has a self-generating mV
frequency output. The RF carrier pickoff senses eddy current losses as the rotor blade passes the pickoff. It does not use an
internal permanent magnet and therefore eliminates magnetic drag on the rotor. This results in linear flow ranges up to 100:1
and repeatable operating flow ranges up to 150:1. The RF carrier pickoff requires a signal conditioner to generate an output. A
high level signal offers the advantage of high output signal to noise ratio over the entire range of the flow meter and permits
long distance signal transmission.
All Cox Precision Turbine Flow Meters are designed to provide a high frequency output voltage at the maximum of their
flow range. This high frequency signal improves resolution and standardized output permits several overlapping range flow
meters to be connected in series to one indicating instrument. Data concerning extended ranges, specific output voltage
and other frequency ranges is available from the Badger Meter Sales Department. As with any precision instrument, the full
capabilities of the Cox Precision Turbine Flow Meter can be realized only through close adherence to the installation and
maintenance instructions discussed in this manual.
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Page 5May 2014

SAFETY INFORMATION
The installation of the Cox Precision Turbine Flow Meters must comply with all applicable federal, state, and local rules,
regulations, and codes.
Failures to read and follow these instructions can lead to misapplication or misuse of the Cox Precision Turbine Flow Meters,
resulting in personal injury and damage to equipment.
Safety Symbol Explanations
DANGER
INDICATES A HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED IS ESTIMATED TO BE CAPABLE OF CAUSING DEATH OR
SERIOUS PERSONAL INJURY.
INDICATES A HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED COULD RESULT IN SEVERE PERSONAL INJURY
OR DEATH.
INDICATES A HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED IS ESTIMATED TO BE CAPABLE OF CAUSING MINOR OR
MODERATE PERSONAL INJURY OR DAMAGE TO PROPERTY.
UNPACKING & INSPECTION
Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such
as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment.
OTE:NIf damage is found, request an inspection by the carrier's agent withing 48 hours of delivery and file a claim with the
carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.
Precision Meters, Turbine Flow Meters
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INSTALLATION
Meter Orientation
Cox Precision Turbine Flow Meters may be installed in any position without affecting performance. Be sure direction of flow is
in the direction of the arrow engraved on the flow meter body. Exception: Position gas service meters as calibrated.
Piping
Recommended layout for Cox Precision Turbine Flow Meters specifies a straight section of pipe or tube in the same size as the
flow meter and equal in length to 10 diameters on the upstream side, and a similar section equal in length to 5 diameters in
order to retard the formation of swirls in the liquid, which can cause incorrect flow meter output. If space prohibits the use
of these straight sections, use extreme care in arranging the piping to produce as straight and smooth a flow as possible.
Available Cox Flow Straighteners are listed in the Cox Flow Straighteners Product Data Sheet. Go to www.badgermeter.com.
Use of Pipe Compound
The 37-degree flared tube connections of Cox Precision Turbine Flow Meters DO NOT require any sealing compound or Teflon
tape, and none should be used. The use of these on adjacent piping should be held to a minimum in order to avoid coating
the bearings and rotor blades with compound, causing premature rotor failure and erratic performance.
OTE:NCopper conical seals or crush rings may be used, if necessary.
BLEED ALL AIR AND VAPOR FROM THE LIQUID AFTER INSTALLING OR REINSTALLING A FLOW METER.
START FLOW SLOWLY TO AVOID SENDING A “SLUG” OF HIGH VELOCITY AIR OR VAPOR THROUGH THE FLOW METER
AND CAUSING IT TO OVERSPEED. START REQUIRED FLOW AFTER FLOW METER IS FULL OF LIQUID. AERATED LIQUIDS
FLOWING THROUGH A FLOW METER WILL RESULT IN INCORRECT FLOW RATES.
DISASSEMBLY
Cox Precision Ball Bearing Type
1. Firmly hold ow meter and, using tweezers, carefully remove internal snap ring from the upstream end.
2. Use long nose pliers and grasp one vane of ow straightener and gently pull ow straightener and rotor assembly from
the body. Use slight twisting motion. Snug t at transition.
3. Press down on the hub to relieve spring pressure on C-washer and remove with tweezers or thin nosed pliers. Remove
hub, spring and spacer.
4. Carefully remove rotor from shaft.
5. Remove a snap ring from side of bearing and push bearing out of rotor.
OTE:NModels CLFA6 and CLFB6 must be returned to factory for bearing change.
CLEANING
Immerse all parts, except pickoff, in a clean, filtered solvent suitable for removing residue from the liquid the flow meter has
been used with. If necessary, use a soft bristle brush.
If there is foreign matter in the ball bearings, allow them to soak in the solvent for approximately 10 minutes and then dry
with filtered compressed air. Do not use excessive air pressure.
OTE:NDo not sonic clean bearings!
EXERCISE EXTREME CARE DURING THE CLEANING PROCESS SO THAT NONE OF THE PARTS ARE DROPPED,
SCRATCHED OR DAMAGED IN ANY WAY. NO ATTEMPT SHOULD BE MADE TO FURTHER POLISH ANY OF THE PARTS,
ESPECIALLY THE ROTOR.
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Page 7May 2014

Procedure for Cleaning a Turbine Meter after Water Calibration and/or Service
OTE:NWhen cleaning flow meters, keep the body, sleeve and pickoff together. Sleeve is fitted to body and pickoff has a
protruding pin. Replacement pickoffs are supplied with a nut and have no protruding pin.
1. Remove the meter from the line and let all excess water drip out.
2. Fill the meter with alcohol (at least 50% Isopropyl, Ethyl or Methyl) and let it stand for 5 minutes.
3. Discard the alcohol and let the meter dry for 2 minutes.
4. Fill the meter with MIL-C-7024 Type 2 calibration uid (or similar solvent) and let it stand for 1 minute.
5. Discard the calibration uid and ush the meter with an approved uorocarbon solvent, such as Isotron.
OTE:NIf this procedure is not possible, the turbine meter should always remain filled with water when not in use, to prevent
internal wetted parts from being exposed to air.
CLFC6, CLFD6, CLFE6
CLFB6, CLFA6
CLFF6
CLFC6, CLFD6, CLFE6, CLFF6
1. Body *
2. C-washer
3. Hub *
4. Spring *
5. Spacer
6. Bearing retainer ring *
7. Bearing
8. Rotor *
9. Straightener assembly *
10. Body retaining ring
CLFB6, CLFA6
1. Body *
2. C-washer
3. Hub *
4. Spring *
5. Spacer
8. Rotor *
9. Straightener assembly *
10. Body retaining ring
* Replaceable at factory level only.
OTE:NOrder parts by name and basic number shown, followed by flow meter
size designation. For example, order a bearing for a CLFF6 flow meter
as bearing #1400-63. Flow meter serial number must be provided when
ordering parts.
Figure 2: Cox Precision LoFlo turbine flow meter
Figure 3: Cox precision turbine flow meter
DO NOT INTERCHANGE FLOW METER PARTS OTHER THAN BEARINGS AND RETAINING RINGS. THIS PRECAUTION IS
NECESSARY TO PRESERVE LINEARITY AND REPEATABILITY.
Precision Meters, Turbine Flow Meters
Page 8 May 2014

REASSEMBLY
Reassembly is the reverse of disassembly except for the following:
• On Precision Turbine Flow Meters where shaft bearings are provided with a
retainer, always install with the retainer flange facing upstream.
• Inspect rotor for markings as shown in Figure 4 to indicate flow direction before
assembly.
• Flow meters having broached slots in the body for flow straightener vanes
should be carefully assembled.
• Align straightener vanes with the slots and push gently until the assembly
is seated.
Figure 4: Scribed lines
User Manual
Page 9May 2014

TROUBLESHOOTING
Issue Possible Cause Remedy
Meter indicates higher flow than actual. Cavitation. Increase back pressure.
Meter indicates high flow. Dirt blocking flow area rotor. Clean meter; add filter.
Meter indicates low flow. Dirt dragging rotor. Clean meter; add filter.
Meter indicates low flow. Worn bearing. Replace bearing; recalibrate when
required.
Meter indicates low flow. Viscosity higher than calibrated. Change temperature; change fluid;
recalibrate meter.
Erratic system indication; meter alone
works well.
Ground loop is shielding. Ground shield one place only. Watch for
internal electronic instrument grounds.
Indicator shows flow when shut off.
Mechanical vibration causes rotor to
oscillate without turning.
Mechanical vibration. Isolate meter; use potted pickoff.
No flow indication. Full flow of fluid
opened into dry meter. Impact of fluid
on rotor causes bearing separation.
Fluid shock. New bearing failed. Move meter to position where it is full
of fluid at start-up.
Erratic indication at low flow; good
indication at high flow.
Low instrument sensitivity. 10
mV rms turbine signal is being
lowered by loading of electronics or
instrumentation cannot sense low level
signals.
Amplify signal.
No flow indication. Faulty pickoff. Replace pickoff; recalibrate as
necessary.
System works perfectly, except
indicates lower flow over entire range.
Bypass flow, leak. Eliminate bypass valves, leak. Faulty
solenoid valves.
Meter indicating high flow. Upstream
piping at meter smaller than meter.
Fluid jet impingement on rotor. Critical
in gas.
Change piping.
Opposite effects as above. Viscosity lower than calibrated. Change temperature; change fluid;
recalibrate meter.
Mass flow indication wrong. Turbine
meter is volumetric; density correction
is electronic; must change with
temperature.
Wrong fluid density. Critical in gas. Check fluid, electronics.
Erratic or wrong indication of flow. Loose pickoff. Tighten pickoff.
Indicates high flow two hours after
installing new bearing.
Bearing wear-in; small meters critical. Recalibrate. 20…30 min. run-in is
required to stabilize friction.
Cannot reach maximum flow rate;
meter selection was with Delta-P at 0.75
sp. gr., now using on 1.0 sp. gr. Delta-P
is proportional to specific gravity.
High pressure drop. Install larger meter.
Does not repeat at low flows. Repeats at
high flows.
System resolution readability. Increase resolution, for example:
1 out of 100 = 1%
1 out of 1000 = 0.1%
Table 1: Troubleshooting
Precision Meters, Turbine Flow Meters
Page 10 May 2014