Brodie Non-Ferrous BiRotor Plus User manual

1
Installation and Operation Manual
Model Non-Ferrous BiRotor Plus
Engineering the Future
TM
BI-NFBRPLUS
Revision 03
Feb 2017

Table of Contents
1.0 Read Me First i
2.0 Receipt of Shipment 1
3.0 Return Shipment 1
4.0 Storage 2
5.0 Introduction 2
6.0 Specications 3
7.0 Installation 6
8.0 Maintenance 9
9.0 Troubleshooting 12
10.0 Parts List 14
11.0 Model Code 16
12.0 Warranty Claim Procedures 17
Decontamination Statement 18
Notes 20
Notes 21

i
1.0 Read Me First
TM
Notice
Brodie International, a Brodie Meter Co., LLC Company (“Brodie”) shall not be liable for technical or
editorial errors in this manual or omissions from this manual. Brodie makes no warranties, express or
implied, including the implied warranties of merchantability and tness for a particular purpose with
respect to this manual and, in no event, shall Brodie be liable for any special or consequential damages
including, but not limited to, loss of production, loss of prots, etc.
Product names used herein are for manufacturer or supplier identication only and may be trademarks/
registered trademarks of these companies.
The contents of this publication are presented for informational purposes only, and while every eort has
been made to ensure their accuracy, they are not to be construed as warranties or guarantees, expressed
or implied, regarding the products or services described herein or their use or applicability. We reserve
the right to modify or improve the designs or specications of such products at any time.
Brodie does not assume responsibility for the use or third party maintenance of any product.
Responsibility for proper use and maintenance of any Brodie product remains solely with the purchaser
and end-user.
Brodie International
Statesboro, Georgia, USA
All rights reserved. No part of this work may be reproduced or copied in any form or by any means -
graphic, electronic or mechanical - without rst receiving the written permission of Brodie International.,
Statesboro, Georgia, USA.

ii
Essential Instructions General
Brodie Meter Co., LLC designs, manufactures and tests its products to meet many international
standards. As the instruments are sophisticated technical products they must be installed, used and
maintained properly to ensure they continue to operate within their normal specications. The
following instructions must be adhered to and incorporated into onsite safety programs where
possible.
Read all instructions prior to installing, operating or servicing the product. If the instruction manual
is not the correct one, telephone [phone]. Retain the instruction manual for future
reference.
If you do not understand any of the instructions, contact your local Brodie representative for
clarication.
Follow all warnings, cautions and instructions marked on or supplied with the product. It is the end
users responsibility to operate the instrument with in the specications as dened with in the
instruction manual or marked on the instruments name plates.
Install the equipment as specied in the installation instructions of the appropriate manual and in
accordance to local and national codes.
To ensure proper performance, use qualied personnel to install, operate, program and maintain the
product.
Some types of equipment contain Carbon Steel, Cast Iron and/or Aluminium wetted parts, these
instruments are not for use on water service.
It is the end users responsibility to assess the surface temperature of the device when it is in service,
and if required take the necessary precautions to avoid personnel injury or damage to other
equipment.
When replacement parts are required, ensure that qualied people use replacement parts specied
by the manufacturer. Unauthorised parts and procedures can aect the products performance and
place the safe operation of the process at risk. Look alike substitution may result in explosion, re,
electrical hazards, improper operation or personnel injury.
Use of this equipment for any other purpose than it is intended for may result in property damage
and/or serious personal injury or death.

iii
Essential Instructions for Measuring Equipment Including the European
Union (Directive 2004/22/EC MID)
Although measurement transducers are not specically included in the MID regulations as they
do not form a complete measuring (system) instrument ref Article 1 and 4, Annex I and Annex
MI-005. Brodie Meter Co., LLC implements the same stringent regulations for all products and
tests to the same standards which are used for complete (systems) instruments.
The complete system must contain all the necessary components to meet the requirements of
the local regulations. These components may include, pumps, air eliminators, strainers, valves,
ow computers, etc.
The unit must be sealed in accordance with the local regulations; it is the end users
responsibility to ensure this happens
Flow measuring devices are provided with two labels which specify ow ranges. The name
plate label which includes the factory serial number; details the operating ow range, this is
the ow range the device will operate within without causing damage, and the custody
transfer label; this label details the working ow range associated with a particular weights
and measures approval. It should be noted that these may not be the same; therefore in trade
applications the ow ranges specied on the custody transfer label should be followed.

iv
Essential Instructions for Pressure Containing Equipment, Including the
European Union (Directive 97/23/EC)
When installing the equipment the bolting must conform to the requirements of ASME B16.5
paragraph 5.3 and to the material requirements of ASME B16.5 Table 1B. Gaskets must conform
to the requirements of ASME B16.20.
Although it is not expected for the device to be used in a service where it would come in to
contact with unstable uids, it is the end users responsibility to assess any risks and take any
precautions necessary.
It is the end users responsibility to ensure that piping and other attachments connected to the
Brodie instrument do not place adverse stresses upon it, the design of the instrument has not been
assessed for the eects of trac, wind or earthquake loadings.
It is the end users responsibility to ensure that the instrument is mounted when required on suitable
supporting foundations.
It is the end users responsibility to install the device in a well designed system to avoid potential
hazards such as water hammer, vacuum collapse or uncontrolled chemical reactions.
It is the end users responsibility to provide re protection measures and equipment in accordance
with the local regulations.
It is the end users responsibility to install suitable straining and air/gas elimination systems.
The instrument has been designed without allowance for corrosion or other chemical attack. The
end user should implement a periodic inspection and maintenance program to ensure that none of
the instruments pressure containing components has been subject to any corrosion. It is possible to
examine the instrument for evidence of corrosion through the inlet and the outlet.
When the ambient temperature is below the minimum operating temperature specied on the
device, it is the end users responsibility to ensure that the devise is warmed to an appropriated
temperature before being pressurised.
Do not exceed the operating pressure and temperature limits of the instrument as stamped on the
nameplates.
It is the customer’s responsibility to install this equipment in a system that provides adequate over
pressure protection, and that limit pressure surges to 10% of the maximum allowable working
pressure of the instrument.
It is the end users responsibility to provide re protection measures and equipment in accordance
with the local regulations.

v
Essential Instruction When Equipments Is To Be Used In Hazardous
Locations, Including the European Union (Directive 94/9/EC)
Any Hazardous area approval applies to equipment without cable glands. When mounting the ameproof
enclosure in a hazardous area only cable glands / conduit seals certied to meet or exceed the rating of
the equipment should be used, refer to the type approval documentation for further details. It is the end
users responsibility to ensure this happens.
Cable glands and cable must be suitable for the operating temperature of the device under its rated
conditions, this is especially important is the device has an operating temperature above 700C (1580F)
The meter has been provided with an approved sealing device in one of the cable entries, the other entry
has been closed with a plastic cap plug. It is the end users responsibility to remove the cap plug and
replace it with a suitable cable gland or conduit seal before the equipment is put into service.
It is the end users responsibility to ensure when the instrument is located in a hazardous area that all Cable
glands and conduit seals must be installed in accordance with the local codes and regulations.
It is the end users responsibility to ensure that before opening an electronic enclosure in a ammable
atmosphere; all the electrical circuits must be interrupted.
If replacement of the screws which secure the sensor housing, the UMB cover of the electronic register and
its cover are required, they must be replaced with either factory direct parts or M6-1 x 16 (6g) mm hex
socket head screws of equal length. The screws must be made from stainless steel grade A1-70 or A2-70
and be torqued to a value of 55 in lbs upon installation, its is the end users responsibility to ensure this
happens.
It is the end users responsibility to assess the maximum surface temperature of the device and the equipment
the device is attached to and located next to as this may exceed the temperature ratings of the device itself.
If this happens, additional safety precautions will need to be implemented by the end user.
Flame proof housings contain Aluminium; although the composition of these enclosures is carefully
maintained to prevent any risk of an ignition source it is the end users responsibility to ensure that the
housing is not struck by rusty tools or objects.
If the equipment is to be installed in an area where dust deposits and build up are to be expected, a
maintenance plan should be arranged to include regular removal of the dust build up. This will prevent the
dusts forming a possible source of ignition.
The power supply requirements for this product are specied with in the operating and maintenance
manual, it is the end users responsibility to operate the product with in these specied limits.

vi
The instrument contains surfaces that constitute ames paths, these surfaces should not contain any mars or
scratches, and if any are present the factory or the local representative should be contacted immediately to
obtain a new housing as the safety of the enclosure may be impaired. It is the end users responsibility to
inspect these surfaces every time the enclosure is opened.
When anged ame paths are re assembled the gap between them should be less than 0.0015” (0.038
mm) such that a ½” (12.5mm) wide feeler 0.0015”(0.038mm) gauge will not enter the gap more than
1/8” (3mm). It is the end users responsibility to ensure this happens each time the enclosure is reassembled.

1
2.0 Receipt of Shipment
When the instrument is received, inspect the
outside of the packing case for any damage that
may have occurred during shipment.
Any damage incurred during shipment
is the carrier’s responsibility and is
not part of the factory warranty. If the
packing case is damaged notify the
carrier immediately and follow their claim
procedures.
If the packaging is undamaged locate the envelope
containing the packing list, this will generally be
on the outside of the box. Carefully remove all
the contents from the packaging checking for any
damage, Check the items o against the packing
list for correct parts and quantities. If any items
are incorrect or damage please contact your sales
representative immediately, quoting the sales order
reference number.
If any item is returned to the factory, a returned
material report (RMR) will need to be completed,
The RMR forms can be obtained from the local
sales representative or the Brodie Meter Co., LLC
product service department.
If an instrument has been used with process uid,
then in addition to the RMR a decontamination
statement will also be required..
A decontamination form is included in section 13
of this manual.
Note: When an instrument is being removed
from service is must be thoroughly drained and
any hazardous substances neutralised. Care must
be taken to ensure any substance removed from
the instrument is disposed of in accordance to the
local regulations, Placing the instrument on its inlet
ange will aid drainage.
The process connections should be sealed to
prevent any residual substances leaking from
the meter during shipment. The type of seal will
depend on the mode of transport, the local carrier
should be contacted for details.
Any item should be securely packed, the larger
instruments should be mounted on wooden
pallets or skids for shipment, The exterior of pallet
mounted items should be protected but suitable
means, such as a solid wooden crate.
When packaging the instrument for return to
the factory, make two copies of the RMR and
decontamination statement, place one copy inside
the packaging and one copy on the outside of the
packaging,
Any equipment returned to the factory with out
the correct documentation will be returned to the
sender at their own expense.
Return shipping address:
Brodie International
Product Service Department
19267 Hwy. 301 North
Statesboro, GA 30461
Phone: [phone]
Fax: [phone]
[e-mail]
3.0 Return Shipment

2
5.0 Introduction
Description
The BiRotor Plus is an extremely accurate dual
cased ow measuring device. It produces via
the use of non wetted pickos a high resolution
signal which is directly proportional to the rate of
liquid ow through the meter. These signals can
be shaped by a simple internal pre-amplier for
transmission to ancillary equipment.
The BiRotor Plus Meter utilizes the exclusive BiRotor
principle. There are no sliding, oscillating, or
reciprocating parts.
Principle of Operation
The operation of the meter is embodied in
the function of the measuring rotors; they are
always dynamically balanced but hydraulically
unbalanced during operation. The rotors have
no metal to metal contact with each other or with
the housing with in which they rotate. Clearances
between moving components are maintained with
timing gears.
The BiRotor Plus is a positive displacement (PD)
meter. A PD meter uses a mechanical principle
that measures ow by continuously dividing the
owing stream into known volumetric segments,
isolating those segments momentarily, and then
returning them to the owing stream while counting
the number of displacements. This is a direct
volume measurement, there is no inferred
or software generated measurement.
4.0 Storage
Brodie International instruments are precision
devices and should be handled and stored with
care.
The inlet and outlet covers should remain in the
instrument until the unit is ready for installation.
If extended storage is required it is recommend
that the instrument be placed in an environmentally
controlled warehouse, if this is not possible the
instrument should be stored in a water proof lined
wooden box, desiccant packs should be taped to
the inside of the instrument end connections before
they are sealed to reduce the eect of humidity,
depending on the storage time is may also be
preferable to use a compatible corrosion inhibitor.
Care should be taken to remove any storage
protection items before installing the instrument.
If an instrument is removed from service for an
extended period of time it should be ushed with
an appropriate corrosion inhibitor before being
place in long term storage as mentioned above.

3
Materials of Construction
Meter Housing: Cast Aluminum A356-T6
Measuring Unit
End Plates and Body: Cast Aluminium A356-T6
Rotors: Cast Aluminium ALCO-319,
Hard Coat Anodized
Rotor Shafts: 17-4 Ph Stainless Steel
Timing Gears: 416 Stainless Steel
Bearings: Stainless Steel (Ceramic
Optional)
Elastomers: Viton A®, Low swell Nitrile,
Viton F®, or Fluoro Silicon
are standard
(other options available)
UMB Housing*: A356 T6 Cast Aluminium
* This part is not wetted.
Electrical Details
Pick o:
Non Wetted Reluctance Type
Sine Wave Amplitude: 40 mV P-P, min.
Preamplier
Supply Voltage:9 to 28 VDC
6.0 Specications Outputs (Jumper selectable):
Square wave: 0 to 5 KHz
5 V Powered Pulse: 0 – 5 VDC, 20 mA Max
Variable Voltage Pulses:
0 to Supply Voltage Less 5%
70 mA max
Open Collector:
Max voltage: 30 VDC
Max current: 125 mA
Max power: 0.5 W
Performance
AB29X Linearity, Standard Rotors
+/- 0.10% or Better Over 20:1 Flow Range
Repeatability: +/- 0.01%
Operating Temperatures Limits:
Dependant on pick o type and O-Ring
seals used, see Table 1.
Table 1: Operating Temperature Limits
Pick O
Type Seal Material
Minimum Operating Temp Maximum Operating Temp
Degree F Degree C Degree F Degree C
Standard Viton A -15 -25 167 75
Standard Low Swell Nitrile -20 -29 167 75
Standard Viton F -15 -25 167 75
Standard Fluoro Silicon -20 -29 167 75
High Temp Viton A 14 -10 230 110
High Temp Low Swell Nitrile 14 -10 212 100
High Temp Viton F 14 -10 230 110
High Temp Fluoro Silicon 14 -10 230 110

4
Flange Ratings PSI Kpa
4” and 6”Victaulic 200 1378
Table 2: Maximum Working Pressure at
100 deg F, 38 deg C
Meter
Size
Flow Rate Nominal
K-Factor
US GPM L/MIN
4”
Victaulic
1000* 3785*
96 PUL/
US GAL
+/- 10%
800 3028
40 151
40* 151*
6”
Victaulic
1200* 4542*
96 PUL/
US GAL
+/- 10%
1000 3785
40 151
40* 151*
Table 3: Flow Ranges
* Rates are in Extended Flow Ranges
To convert pressure drop value to the actual
process uid, use the following equation:
∆PA = (cPA)0.25 X (SGA)0.75 X ∆Pm
∆PA = Pressure Drop on Actual Fluid in PSI
cPA= Viscosity of Actual Fluid in cP
SGA = Density of Actual Fluid in SG
∆Pm = Pressure Drop on Mineral Spirits (See
Graphs 1 and 2 on Page 6 for Reference)
Model Size Unit Weight
AB295 4”Victaulic
Lb 138
Kg 62.6
AB296 6”Victaulic
Lb 140
Kg 63.5
Table 4: Shipping Weights
and Volume

5
-13 NC
C
D
F
B
H
G
A
J
TAP SIZE
K
1
E
2
Figure 1: Non-Ferrous BiRotor Plus Dimensions
Table 5: Non-Ferrous BiRotor Plus Dimensions [Tolerance +/- 1/8”(3mm)]
Model Size Unit A B C D E F G H J
AB295 4”Victaulic inch 26 1/2 6 5/8 15 7/8 13 1/4 6 5/8 6 1/4 1 3/8 6 11/16 13 1/8
mm 173 168 403 337 168 159 35 170 333
AB296 6”Victaulic inch 25 5/8 6 11/16 15 7/8 13 1/8 6 9/16 5 9/16 1 3/8 6 1/4 13 1/8
mm 651 170 403 333 167 141 35 168 333

6
7.0 Installation
General Requirements
The instrument should be mounted on a secure
foundation, If vertically mounted provisions should
be taken to ensure stability.
The process piping should not place any undue
stress on the instrument
Precautions should be taken to ensure that thermal
uid expansion does not raise the line pressure
above the maximum allowable working pressure of
the instrument
Process piping needs to be clean and free of any
foreign matter.
A strainer should be installed upstream of the
instrument.
If the process uid is expected to contain entrained
air, an air eliminator should be installed upstream
of the instrument
A ow limiting valve should be installed
downstream of the instrument, this will maintain a
back pressure and prevent excessive ow rates.
Isolation valves should be located at either ends of
the instrument run and a bypass section installed,
this will facilitate ease of component removal when
required and reduce loss of product.
Interference
The instrument should not be installed in a location
where excessive vibration is expected.
The instrument should not be located close to any
electromagnetic elds, for example those produced
by electric motors, transformers, solenoids etc.
Either of these factors could induce a signal into
the ow sensing pick o and interfere with the
measurement.
Installing the Instrument
Remove the inlet and outlet protection covers.
Install the instrument in to the pipe work using
suitable hardware as specied in the local codes
and regulations, ensure that the connections are
made tight and torqued to the correct values.
Connections the instrument wiring, refer to Figure
2 or Figure 3. Cable entry into the electrical
enclosure is by two 3/4-14 NPT female threads.
Use wiring appropriate for the location and
operating conditions, If the instrument is being
installed in a hazardous area wiring glands and/
or conduits must conform to the local electrical
code regulations.
Note: For additional requirements on installation
please refer to the essential instruction at the
beginning of this manual.
Attachment to Additional Accessories
If the instrument is being used with additional
accessories, the instructions for these accessories
should be read and understood before continuing
with the installation. The output signal from the
preamplier, if one is tted can be altered to
interface with most electronic accessories. This is
accomplished by the use of jumpers on the circuit
board, Table 6 shows their congurations.
Preamplifier Fitted
1 = V Supp 9-28 Vdc
2 = V Comm
3 = Channel A Signal
4 = Channel A & B Common
5 = Channel B Signal
TB1
Figure 2: Wiring Connections

7
Table 6: Input Settings
Jumper Position
J1 (Channel A) B
J2 (Channel B) B
Table 7: Output Settings
Jumper Open
Collector
5 VDC
Pulse
V
Supply
Pulse
J3 (Channel A) OUT A B
J4 (Channel B) OUT A B
Integral Brodie Electronic Rate Totalizer
(BERT)
If the instrument has been supplied with an integral
electronic register, the internal connection wiring
will already be in place. For additional functions
and wiring possibilities please refer to the BERT’s
instruction manual, BI-BERT.
Start up and Operation
Review the system to ensure all the components are
in proper sequence, all isolation valves are closed,
all electrical connections are complete and all
covers are in place.
Figure 3: Wiring Connections
No Preamplifier Fitted
To Pressurize the System
Slowly open the inlet valve so as to prevent system
shock. Slowly allow product to enter the system
whilst keeping the downstream isolation valve
closed.
Open the down stream valve (10 percent) to allow
any air to be ushed from the system. Do not over
speed the instrument.
Once the air has been ushed from the system
close the down stream isolation valve, and check
for any leaks. If any leaks are found check seals
and retighten connections.
To pressurize the system fully open the upstream
isolation valve.
Flow Start Up
Once the system is pressurized:
Turn on all electronic circuits and check function.
Open ow control valves and allow the instrument
to run at 20% of its rated ow for a minimum of 5
minutes.
During this initial run in, check all other
components in the system for functionality.
Once this run in is complete set the ow control
valve to the required ow, ensure that the maximum
ow for the instrument is not exceeded.
Higher Temperature Start Up
On higher temperature service above 212 Deg F,
100 Deg C, ( based on an ambient of 70 Deg F,
21 Deg C) special start-up procedures are required
to prevent damage to the owmeter components.
The following equation may be used to determine
the approximate owmeter warn up time. A similar
procedure should be followed on any thermal
shock in excess of 176 Deg F, 80 Deg C.
Warm up time ( Hrs) = [Nom Connection Size (in)
X (Oper temp (Deg F) – 212)]/100
During this warm up time the meter should be
operated at approx 5% of Max ow to allow the
temperature to stabilize.
Custody Transfer
If the instrument is being used for custody transfer

8
applications, A meter factor will need to be
established under the actual operating conditions.
This initial proving run should be carried out
following the completion of the meter start up and
in accordance with the local regulations.
Note: There are no user adjustable parts in these
instruments, however the instrument housing is
provided with two cross drilled bolts and cross
drilled drain plugs to facilitate sealing if required
by the local weights and measures regulations.
Performance Considerations
The instrument will give many years of consistent
performance with little need for maintenance
or service. There are however several
recommendations which if followed will further
extend the instruments service life.
The instrument should be kept lled with the
process uids it is measuring. This prevents the
exposure to any product vapor, which in the case
of petroleum products are more corrosive than their
liquids. In addition this also prevents the formation
and build up of deposits or gums which would
cause increased mechanical friction.
The instrument should always be kept free of water,
keeping it full of the process uid will accomplish
this, but if this is not possible a regular inspection
program should be set up and any water drained
from the measuring system.
Filter and strainers baskets should be cleaned
frequently; Debris and foreign matter are the
biggest cause of meter wear and damage.
All other associated equipment with in the system
should be regularly maintained and checked for
functionality.
Maintenance Considerations
The amount of maintenance necessary for ecient
instrument performance is dependant on many
factors; some of these are listed below.
Continuity of Operation: An instrument that
operates continuously will required more
attention than one used intermittently
Working ow rate: The life of the instrument is
proportional to the speed of it operation. If the
instrument is operating at or near to it maximum
ow rate it will have a shorter life expectancy
than if it where operating at its minimum ow
rate.
Lubricity: The lower the lubrication properties of
the uid being measured than the lower the life
expectance will be.
Cleanliness: A product contaminated with abrasive
particulate will accelerate the wear of the
instrument.

9
8.0 Maintenance
Notes:
If instrument is being used in hazardous area, all
instructions on the labels and in this manual must
be followed before the start of any maintenance.
If the instrument is removed from the process line,
the line should be sealed with suitable blanking
anges to prevent any possible leakage of product.
WARNING: The internal measuring
element contains closely meshed moving
parts, care should be taken not to insert
ngers into the rotors or timing gears as
this will cause injury.
Electronics
The instrument can be provided with up to
two inductive pick o sensors and an optional
preamplier.
Maintenance of the electronics does not require the
system line pressure to be drained or the instrument
to be removed from the system.
ESD precautions must be followed.
Removal/Replacement of Circuit Boards
1. Disconnect all power to the instrument.
2. Remove the electronics lid (36), or electronic
register if one is tted by undoing 4 Allen
screws item (25).
3. Disconnect terminals and wiring to the circuit
board.
4. Remove circuit board (38) by undoing the
screws that attach it to the housing.
To re-assemble reverse the removal instructions,
Torque the 4 Allen screws (25) to 55 in-lb.
Removal/Replacement of Pick-o Sensors
1. Remove the circuits boards as detailed above.
2. Remove the centre screw (25) from the sensor
housing (23) and lift o the hold down washer
(29).
3. Lift out the inductive sensor/s (27) and spring
(28).
Resistance between sensor leads:
For Sensor with ident marker on Sheath = 1000 Ohms
+/-15%
For Sensor with ident marker on sensor = 750 Ohms
+/-15%
Resistance between leads and housing when
installed: 10 M Ohms
If any of this is not the case the pick o should be
replaced.
To reassemble, replace the pick o into the sensor
housing, If only one pick-o is present it should
be inserted in the hole labelled A. Secure with the
hold down washer (29) and Allen screw (25) and
replace the circuit board (38).
Mechanical
Removal of the Measuring Unit from the
Process Line
1. Disconnect all power to the instrument.
2. Relieve all system pressure and drain the
meter.
3. Disconnect all external wiring form the
electronics unit.
4. Unbolt the instrument form the process
piping and remove to a work shop for further
disassembly. Care should be exercised to
prevent the intrusion of foreign material into the
instrument end connections.
Removing the Measuring Element from the
Instrument Body
1. Turn the meter on end so that it stands in its
inlet ange ( this will also nalize draining).
2. Remove screws (1 and 2) and lift of the outlet
housing (50). Remove O-ring (16).
3. Holding the measuring unit assemble by the
ribs, carefully lift straight up until the assembly
clears the inlet housing. Place the measuring
unit assembly in the horizontal position.
At this stage the assembly can be inspected for
wear or damage, If the assembly had jammed
it may also be possible to unblock the rotors by
ushing with cleaning solvent or kerosene with out
the need for further disassembly.
Disassembly of the Measuring Unit for
Inspection and Cleaning
Disassembling of the measuring unit can be
achieved by two methods, removal of the
mechanism while maintaining the clearance
settings or complete disassembly.

10
Disassembly While Maintaining the Clearance
Setting
1. Place a folded rag between the timing gears
(6 and 49) to prevent the rotors turning during
the disassembly.
2. Remove the pulse wheel (14) be removing
the screw (44) and washer (45) and retaining
washer (46).
3. Remove the screws (7) form end plate (8) at
the timing gear (6 and 49) end of measuring
assembly.
Figure 5: Measuring Unit Disassembly
A at head screw driver may be used in
conjunction with the slots on the endplate to aid
in its removal; Excessive force is not required.
4. Use a plastic or rubber mallet and strike
the rotor shafts at the pulse wheel end of the
housing to aid in removal of the rotor assembly.
Once the rotor assembly has been removed from
the housing any blockages or foreign material can
be cleaned away.
At this stage the meter can be reassembled
reversing the disassembly procedure without the
need to reset any clearances. Note: all elastomers
that have been removed should be replaced with
new parts during reassembly
Complete Disassembly
Continuing from part 4 above.
1. Restrict the rotor movement by placing a
folded rag between the timing gears (6 and
49).
2. Fold down the lock washer (5) tabs to enable
the nuts (4) to be undone then remove them
and the lock washers from the rotor shafts. The
timing gears (6 and 49) can be released from
the shaft by striking them on the at surface
with a plastic or rubber mallet.
3. Remove the rotors (11 and 48) from the end
plate by gently tapping the rotor shafts with a
plastic or rubber mallet. Remove the O-rings
(10) from the rotor shafts.
4. The bearings (9) can be removed from the
end plates by pressing on the inner race of the
bearings from the outside of the plate. If the
bearings are removed from the endplates, they
must be replaced.
5. Remove the other end plate from the
measuring element housing and remove
bearings.
6. Remove the sensor housing (23) from the inlet
housing (21) be removing the 4 Allen screws
(25) located in the counter sunk holes under the
circuit board (35).
Complete Reassembly
1. Ensure all parts are clean and free of debris.
2. Lubricate all bearings and internal o-ring
with a light oil, Note all O-rings should be
replace with new ones during reassembly, all
O-rings should be lubricated with a compatible
lubrication compound.
3. Press bearings (9) in to the end plates (8), use
a hand press and ensure that the bearing is
pressed on the outer race to avoid damage.
Figure 6: Rotor/Gear Orientation

11
The bearing races should be ush with the
bottom of the end plate once the bearings have
been pressed in correctly. The outer race of
an old bearing can be used to assist in proper
seating.
4. Attach one end plate (8) to the measuring unit
body (13) at the end with two dowel pins (12).
Align the dowel pins and gently tap into place
with a plastic mallet. Once fully seated secure
the end plate with screws (7).
Each rotor (11 and 48) and timing gear (6
and 49) is marked with a R or an L, During
assembly the inscriptions need to be matched.
To orientate the rotors during assembly the
measuring element body (13) has three holes
machined into it for manufacturing purposes.
These holes should be positioned so that they
face upwards. With these holes facing upwards
turn the housing so that the end with the ‘two’
dowel pins faces away from you. With the
housing in this position the rotor marked with
an ’R’ (48) goes in the right hand cavity and
the rotor marked with an‘L’ (11) goes in the left
hand cavity.
5. Lubricate O-rings (10) and install on the
rotor shafts. Mesh the two rotors together (11
and 48) ensuring that the tapered shafts are
at the same ends. The rotors should be held
together with the tapered end of the shaft
facing the end plate which is attached to the
measuring element housing. While keeping the
rotors meshed and even, insert them into the
measuring chamber, use a plastic or rubber
mallet to gently seat the rotor shafts into the
bearings.
6. Install the other end plate (8) and screws
(7) on to the other end of measuring element
body, ensure that the rotor shafts seat within the
bearings.
7. Place the timing gears (6 and 49) onto the
respective tapered rotor shaft, the timing gear
has a small hole for the location of the lock
washer tab; this should be facing outward from
the measuring element.
8. Install the lock washer (5) ensuring the 90
Degree tab locates in the hole of the timing
gears (6 and 49) and nuts (4) to the rotor
shafts, tighten these only nger tight until the
clearances have been correctly set. Refer to the
setting clearance section.
9. Replace the pulse wheel (14) on the right hand
rotor, Use thread locking compound on the
threads and secure with the retaining washer
(46) , washer (45) and screw (43).
10. Lower the complete measuring unit assembly
into the inlet housing (21), align the dowel pins
(12) and ensure they are fully located.
11. Position the main housing o-ring (16) in the
groove in the inlet housing, and position the
o-ring (47) on timing gear (6 and 49) end of
the measuring element body.
12. Lower the outlet housing (50) into the inlet
housing (21), the dowel pins (15) are used to
ensure correct location. Avoid damage to the
O-rings.
13. Complete the assembly be securing all the
screws (1 and 2) and tightening them to the
required torque value.
Torque (150# and PN16 - 80 ft-lbs., 300# and
PN40 - 150 ft-lbs.), ensure the two cross drilled
screws (1) are located in the top two holes of
the ange.
14. Install the o-ring (22) on the sensor housing
(23) and insert the assembly into the inlet
housing (21) secure with the 4 Allen screws
(24), torque to 55 in-lbs.
Setting Clearances
1. Restrict the gear movement by placing a
folded rag between the timing gears (6 and
49).
2. Tighten the nut (4) of the right hand timing
gear (49) to a torque setting of 15 – 20 ft-lbs.
3. Loosen the nut (4) of the left hand timing gear
(6).
4. Place 0.005”shims in front and behind the
tooth of the left hand rotor (11) (See Figure 7).
Once the shims are in place and with the rotor
movement still restricted tighten the nut (4) on
the left hand timing gear (6) to a torque of 15 –
20 ft-lbs.
5. Remove the shims and folded rag. Check to
rotors for correct clearance by rotating them.
The rotors should turn freely and not make
contact at any point, listen for sounds of the
rotors touching.
6. If the rotors bind or make noise repeat the
procedure but this time loosen the right hand
rotor instead of the left.
7. Once clearances are set use, a small at head
screw driver to bend up one tab on each timing
gear lock washer (5) to secure the location of
the nut (4).