Badger Meter Recordall Turbo Series User manual

RTS-UM-00380-EN-09 (January 2015) User Manual
Recordall® Turbo Series Meters
Models 160 (1-1/2"), 200 (2"), 450 (3"), 1000 (4"), 2000 (6"),
3500 (8"), 5500 (10"), 6200 (12"), 6600 (16") & 10000 (20")

Recordall® Turbo Series Meters
RTS-UM-00380-EN-09Page ii January 2015

CONTENTS
Scope of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Preinstallation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installing the Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accuracy Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Servicing Parts and Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Removing the Meter Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Removing the Local Register or Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Removing the Measuring Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Removing the Magnet Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Removing the Straightening Vanes/Nose Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Removing the Calibration Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Inspecting the Rotor and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Reinstalling the Turbo Meter Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Placing the Meter Back in Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1-1/2" to 12" Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
16" and 20" Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
User Manual
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Recordall® Turbo Series Meters
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SCOPE OF THIS MANUAL
This manual contains installation, operation and maintenance procedures for the BadgerMeter® Recordall® Turbo 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 RecordallTurbo Series meters use 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. The Turbo 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 the completely removable measuring element. The meter housing and cover plate are lead-free
bronze (1-1/2" to 10" sizes). The 12" to 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.
Accessories
Meters and encoders are compatible with Badger Meter AMR/AMI meter reading systems and other approved reading
technologies. AMR/AMI solutions are available for all Recordall Turbo Series meters. All reading options can be removed from
the meter without disrupting water service. Badger Meter encoders provide years of reliable, accurate readings for a variety of
applications and are also available pre-wired to Badger Meter approved AMR/AMI solutions. See details at
www.badgermeter.com.
A strainer is recommended to provide optimal flow conditioning and protection for the measuring element. An integral
strainer is available as an option for 1-1/2" through 4" meter sizes. The stainless steel strainer is built into the inlet end
and includes a removable cover plate to permit easy access for routine cleaning. External strainers are available in sizes 2"
through 12".
Related Literature
• The Recordall Turbo Series Meters Product Data Sheet contains information on operating principle, meter construction,
materials, tolerances and specifications.
• The Recordall Turbo Series Meters Parts List contains illustrations of parts, part numbers, and part descriptions.
Scope of this Manual
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Safety Information
The installation of the Recordall Turbo 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 Meter 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:
OTE:N 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.
OTE:N 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.
Product Information
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INSTALLATION
Procedures for installing Recordall 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 AMR/AMI technologies or strainers is provided in the
literature for those devices. Figure 1 shows a recommended meter installation.
BADGER PLATE
STRAINER AND TURBO
SERIES METERS
COUPLING
ADAPTOR SERVICE
SADDLE SHUT-OFF
VALVE
TEST TEE
MINIMUM TWO
PIPE DIAMETERS
DOWNSTREAM
OF TURBO
METER
MINIMUM OF FIVE
DIAMETERS OF
STRAIGHT PIPE
VALVE
(open)
BY-PASS
(PERMANENT OR
TEMPORARY)
UPSTREA
MDOWNSTREA
M
Figure 1: Recommended meter installation
Preinstallation Considerations
Before proceeding any further with the installation, rst read the instructions in the paragraphs immediately following to
become familiar with the requirements and procedures involved.
OTE:N The Recordall Turbo Series meters are designed 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 TURBO 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 49° C) within the applicable flow requirements
for Turbo meters. For use with water at higher temperatures, consult your Badger Meter representative or nearest
Badger Meter regional sales office.
• 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.
• 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 and can be
used for field accuracy testing.
• The Recordall Turbo 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 separate plate strainer or integral strainer, a minimum of 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 (see Figure 1). A minimum of 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, and dirt traps upstream of 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 used, place it 5 to 10 pipe diameters upstream of the meter to dampen velocity profile
distortions created by this design.
Installation
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◊ 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 diameters or more upstream from the meter. Downstream, fully open gate or butterfly valves can be used.
◊ The service saddle (or reducing tee), which is used for field accuracy testing, should be at least 2 pipe diameters
downstream of the meter's outlet flange.
◊ 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 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 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 Turbo Series Meter Product Data Sheet.
Review the dimensional requirements, choose an 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 ange connections.
2. Provide proper gap length in service piping.
3. Install meter in the pipeline so that the ow arrow on the meter housing points in the same direction as water ow.
4. With meter and gaskets in place, tighten ange connection bolts.
5. To relieve possible strain on the piping, position a meter support 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.
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:
• Slowly open the upstream valve to apply water pressure to the meter and check for 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.
Installation
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MAINTENANCE
This section is limited to information pertaining to the general maintenance of BadgerMeter Recordall Turbo Series meters.
An exploded view of the meter, along with part numbers and descriptions, are provided in the Recordall Turbo Series Meters
Parts List.
Maintenance Equipment
The tools and equipment recommended for use in servicing and maintaining of Recordall Turbo 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 maintenance consists of periodic inspection, accuracy
testing, and cleaning procedures.
Periodic Inspection
• Visually inspect the meter for missing hardware, loose screws, broken or scratched register lenses or any other signs of
wear or deterioration.
• 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.
• In the 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 Turbo meter also should be flushed by purging
with fresh service water through the cleanout plugs located on the housing.
• Integral Strainer Units: Before attempting service/maintenance of strainer section, system pressure must be removed. 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. Return meter to normal service.
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 Meter
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.
Maintenance
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Calibration Check and Adjustment
The accuracy of the 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.
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
THE PRESSURE IS COMPLETELY BLED OFF BEFORE REMOVING.
1. After installing the appropriate connections, test the meter by closing the downstream valve (if using integral test
port) and slowly opening the upstream valve. Slowly open the test circuit downstream valve to throttle ow 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 rst be purged of air by running water
through the meter.
OTE:N Good test practices, such as those outlined in the AWWA M6 manual, are required to perform reliable field accuracy
tests. 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).
4. Operate the meter until the test tank is lled to the calibrated level or the predetermined quantity has registered on
the calibrated test meter. Because accuracy may vary slightly with ow rate, it is recommended that the meter be
tested at low, intermediate and high ows.
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
Maintenance
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