McCrometer Water Specialties ML04D User manual

30119-05 Rev. 4.0/07-09
1
2”-20”
ELECTRONIC
MAIN LINE METERS
MODELS
ML04D, ML08D, ML12D, ML16D, ML20D, ML22D, MLI1D
OPERATION AND MAINTENANCE MANUAL
PARTS LIST
FEATURING:
*MODEL FC101 FLOWCOM REGISTER INDICATOR-TOTALIZER
*CERAMIC BEARING CARTRIDGE PROPELLER
* ONE PIECE SEPARATOR/SPINDLE AND THREADED REVERSE THRUST BEARING CARTRIDGE
3255 WEST STETSON AVENUE
HEMET, CALIFORNIA 92545 U.S.A.
PHONE:
FAX:
VISIT OUR WEBSITE:
951-652-6811
951-652-3078
www.mccrometer.com

30119-05 Rev. 4.0/07-09
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WARNING
BEFORE REMOVING THE METER HEAD FROM THE PIPELINE THE WATER MUST BE TURNED OFF AND PRES-
SURE MUST BE RELIEVED FROM THE LINE. SERIOUS INJURY CAN RESULT FROM REMOVING A METER HEAD
UNDER PRESSURE.
WARRANTY
This Warranty shall apply to and be limited to the original purchaser consumer of any McCrometer product. Meters
or instruments defective because of faulty material or workmanship will be repaired or replaced, at the option of
McCrometer, free of charge, FOB the factory in Hemet, California, within a period of one (1) year from the date
of delivery.
Repairs or modifications by others than McCrometer or their authorized representatives shall render this Warranty
null and void in the event that factory examination reveals that such repair or modification was detrimental to the
meter or instrument. Any deviations from the factory calibration require notification in writing to McCrometer of
such recalibrations or this Warranty shall be voided.
In case of a claim under this Warranty, the claimant is instructed to contact McCrometer, 3255 W. Stetson Ave.,
Hemet, California 92545, and to provide an identification or description of the meter or instrument, the date of
delivery, and the nature of the problem.
The Warranty provided above is the only Warranty made by McCrometer with respect to its products or any parts
thereof and is made expressly in lieu of any other warranties, by course of dealing, usages of trade or otherwise,
expressed or implied, including but not limited to any implied warranties of fitness for any particular purpose or
of merchantability under the uniform commercial code. It is agreed this Warranty is in lieu of and buyer hereby
waives all other warranties, guarantees or liabilities arising by law or otherwise. Seller shall not incur any other
obligations or liabilities or be liable to buyer, or any customer of buyer for any anticipated or lost profits, incidental
or consequential damages, or any other losses or expenses incurred by reason of the purchase, installation, repair,
use or misuse by buyer or third parties of its products (including any parts repaired or replaced); and seller does
not authorize any person to assume for seller any other liability in connection with the products or parts thereof.
This Warranty cannot be extended, altered or varied except by a written instrument signed by seller and buyer.
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to
state.
McCrometer reserves the right to make improvements and repairs on product components which are beyond the
Warranty period at the manufacturer’s option and expense, without obligation to renew the expired Warranty
on the components or on the entire unit. Due to the rapid advancement of meter design technology, McCrometer
reserves the right to make improvements in design and material without prior notice to the trade.
All sales and all agreements in relation to sales shall be deemed made at the manufacturer’s place of business in
Hemet, California and any dispute arising from any sale or agreement shall be interpreted under the laws of the
State of California.
Copyright © 2000-2007 McCrometer. All written material should not be changed or altered without permission of McCrometer. The published technical data and instructions are subject to change
without notice. Contact your McCrometer representative for current technical data and instructions.

30119-05 Rev. 4.0/07-09
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ELECTRONIC MAIN LINE METER
INDEX
I. UNCRATING
II. INSTALLATION
1. Flanged Tube Meters
2. Plain End Tube Meters
3. Welding Saddle Meters
A. Align
B. Scribe
C. Cut Out
D. Straightening Vanes
E. Welding Saddle To Pipe
F. Meter Assembly
III. MAINTENANCE
IV. WORKING AREA
V. DISASSEMBLY & INSPECTION
1. Meter Head Removal
2. Propeller Removal
3. Reverse Thrust Bearing Cartridge
4. Water Lubrication
5. Ceramic Bearing Cartridge
6. Spindle Ceramic Sleeve
7. Separator/Support Spindle Assembly
VI. REASSEMBLING METER
1. Propeller Installation
2. Thrust Bearing Cartridge Assembly
3. Propeller Bearing
VII. SENSOR & FC101 DIGITAL INDICATOR-
TOTALIZER
1. FC101 Digital Indicator
2. FC101
3. Sensor Housing
4. Replacing Sensor Housing
5. Inspect O-ring
6. Lithium Battery
7. FC101 Digital Indicator-Totalizer
VIII. PREPARATION PRIOR TO INSTALLING
METER
1. Propeller Assembly
2. FC101
3. Meter Head O-ring
IX. ORDERING PARTS OR RETURN TO FACTORY
ELECTRONIC MAIN LINE METER
INSTALLATION
I. UNCRATING. When uncrating the meter, any damage due
to rough or improper handling should be reported to the
transportation firm and McCrometer. If for any reason it
is determined that the unit or parts of the unit should be
returned to the factory, please contact McCrometer for
clearance prior to shipment. Each unit must be properly
crated to prevent any further damage. The factory assumes
no responsibility for equipment damage in return shipment
due to improper packaging. The shipping crate contains the
following items:
Main Line Meter Assembly with
FC101 Digital Register .............................................1
Operation and Maintenance Manual .........................1
Tool T-2402X-1........................................................1
II. INSTALLATION of Water Specialties Main Line Meters varies
depending upon the type and model of meter selected for
each application. The meter must have a full flow of liquid
for proper accuracy. The meter installations fall into three
basic categories:
1. FLANGED TUBE METERS can be installed exactly as
you would install any short length of flanged pipe. Flanged
ends are standard pattern and drilling for each meter size.
Fully opened gate valves, fittings, or other obstructions that
tend to set up flow disturbances should be a minimum of five
pipe diameters upstream and one pipe diameter downstream
from the meter.
2. PLAIN END TUBE METERS can be installed similar
to replacing a short length of plain end pipe in the line by
either welding, or by using one of a variety of pipe couplings
available. NOTE: Meter head assembly (#25) should be
removed before welding (see Section VI Step 1). Fully
opened gate valves, fittings, or other obstructions that tend
to set up flow disturbances should be a minimum of five
pipe diameters upstream and one pipe diameter downstream
from the meter.
3. WELDING SADDLE METERS can be installed on an
existing pipeline by cutting a hole of proper size and welding
a meter saddle (furnished with the meter) to the pipe. The
installation steps outlined below should be followed carefully
to achieve proper mounting of the meter:
A. ALIGN the cutout template in the desired position for
the meter on the pipe. Make certain that the center line
of the pipe and the center line marked on the template are
parallel with each other. Some people prefer to use the
saddle as the template.
B. SCRIBE the pipe along the line specified for your meter
size cutout.

30119-05 Rev. 4.0/07-09
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C. CUT OUT the section of pipe within the scribed line
and remove all burrs, slag, and rough edges from the inside
and outside of the cutout section.
D. STRAIGHTENING VANES are recommended when there
are less than ten pipe diameters of straight pipe (no fittings
or obstructions) directly upstream from the meter location.
Straightening vanes are available from the factory and, when
required, should be installed in the following manner prior to
welding the saddle to the pipe:
a.) HOLD the vanes on the outside of the pipe ten
inches upstream from the center of the cutout opening.
The vanes must be parallel to the center line of the pipe
and should be equally spaced radially 120° apart.
b.) MARK the pipe around the straightening vane
bolts and drill holes for vane mounting (9/16” hole for
4-inch through 12-inch meters or 11/16” dia. hole for
14-inch through 20-inch meters).
c.) INSERT the vanes into the pipe through the
cut-out opening after installing the brass and stain-
less/rubber washers over the vane bolts. The brass
washer should be installed against vane bolt head with
the stainless/rubber washer installed against the brass
washer (rubber side away form vane). Position the
vanes inside the pipe with the bolts protruding through
the vane mounting bolt holes. Place stainless/rubber
washers over each bolt, rubber against the pipe. The
brass washer should be placed between the stainless
washer and the vane mounting nut. Secure nuts to hold
the vanes to the pipe (approx. 60 ft/lbs. torque). The
vanes can be welded to the pipe if desired; however,
the washers should not be used. NOTE: Meter head
assembly (#25) should be removed before welding (see
Section VI Step 1).
E. WELDING SADDLE should be centered over the cutout
section of the pipe. Make certain that no part of the pipe
protrudes past the inside edge of the welding saddle. Tack
weld the saddle to the pipe prior to welding a continuous
bead around the saddle. NOTE: Meter head assembly (#25)
should be removed before welding (see Section VI Step 1).
F. METER ASSEMBLY should be placed in the line with
the propeller nose facing the upstream flow in the pipe. Use
care when installing the meter not to damage the propeller
as it passes through the saddle opening. The meter head
O-ring should be covered with a thin coat of silicone grease
before installing the meter. Tighten the meter head bolts
securely.
III. MAINTENANCE. McCrometer products have been carefully
designed to be as maintenance free as possible. Periodic
preventive maintenance, however, is highly recommended
and should be practiced according to schedule to assure
continuous accuracy and trouble-free performance of your
propeller meters. The maintenance and inspection procedure
can also be used as a guide to locating a problem in the
unit that may be the cause of abnormal meter operation.
Routine preventative maintenance should be performed on
all meters, which includes cleaning and an inspection of the
propeller and its bearing. The intervals between inspections
depend on the water quality and the usage of the meter.
The initial inspection should be performed after one to two
years of service to determine the period between future
inspections. After five to ten years, the complete meter
should be inspected to ensure years of dependable service.
IV. WORKING AREA chosen for disassembly and reassembly of
the meter components should be clean to reduce the chance
of dust or dirt particles being introduced into the propeller
area.
V. DISASSEMBLY AND INSPECTION OF METER includes
cleaning the propeller assembly (#1), ceramic bearing cartridge
(#8), separator/support spindle assembly (#12), and drive
magnet (#9).
1. METER HEAD REMOVAL*. Meter head assembly (#25)
should be removed from the service line by removing the
meter head bolts (#24) and lifting up the rear (downstream)
portion of the meter head (#25), carefully pulling the assembly
back (downstream) and up at the same time to allow the
propeller (#1) to clear the inside of the meter saddle and
be lifted free. Inspect the meter head O-ring (#22) for any
sign of damage and replace if necessary. Replace the meter
assembly (#25) with a dummy cover plate if the service line
is to remain in operation.
* NOTE: 8-inch meter only:
a) Remove the meter head bolts (#24).
b) Lift the meter assembly and tilt it forward.
c) Slide the assembly back out of the saddle opening.
The propeller may have to be rotated to fit through the
saddle opening.
2. PROPELLER REMOVAL can be accomplished by first
removing the thrust bearing cartridge assembly (#5). Loosen
the set screw (#3) in the side of the nose of the propel-
ler. Remove the thrust bearing cartridge (#5) by turning it
counterclockwise while holding the propeller in place.
3. REVERSE THRUST BEARING CARTRIDGE (#6) must
now be removed. Turn the propeller (#1) so that the Allen
wrench clearance hole is lined up with the set screw (#7)
in the side of the reverse thrust bearing cartridge (#6). The
location of the set screw is marked by a small hole drilled
in the face of the reverse thrust bearing cartridge. With a
5/64” Allen wrench, loosen the set screw (#7) in the reverse
thrust bearing cartridge (#6) one turn, which will allow
the set screw to protrude about 1/32” and should allow
cartridge to be unscrewed without damaging the spindle
thread. NOTE: If the bearing area appears to be clogged
with dirt or sediment, making it difficult to locate the set
screw (#7) or to allow the Allen wrench to fit into the set
screw socket, then the bearing area should be flushed out
with water. Insert tool T-2402X-1 into the propeller through
the threaded nose. The tabs in the tool should engage in
the screwdriver slot in the end of the reverse thrust bear-
ing cartridge (#6). Remove the propeller assembly (#1)

30119-05 Rev. 4.0/07-09
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and reverse thrust bearing cartridge (#6) by turning tool
T-2402X-1 counterclockwise unscrewing the reverse thrust
bearing cartridge (#6) from the spindle (#12). The propeller
assembly with reverse flow cartridge will now slide off the
spindle. WARNING: If the reverse thrust cartridge does not
unscrew easily, it may be because the set screw was not
unscrewed enough. If unscrewing of reverse flow cartridge is
continued with set screw binding on spindle thread, damage
to thread could occur.
4. WATER LUBRICATION of the ceramic bearing cartridge
(#8) is achieved by means of two openings in the end of the
thrust bearing cartridge (#5), which allow air to be purged
from the bearing area. These should be cleared of any
foreign material by running a small wire through the holes
on either side of the screwdriver slot.
5. CERAMIC BEARING CARTRIDGE (#8) and drive magnet
(#9) should be cleaned of any foreign material and inspected
for damage. Using a bottle brush, thoroughly clean the
ceramic bearing surface (#8) and the magnet inside diameter
(#9). After cleaning the propeller, flush the inside out with
water. The outside surfaces of the propeller should also be
cleaned to assure a smooth, unrestricted flow across the
surface of the propeller. Do not use an oil based solvent
in cleaning, as damage to the assembly could occur.
6. SPINDLE CERAMIC SLEEVE and the O.D. or surface
of the separator/support spindle (#12) should be cleaned and
inspected for any substantial amount of wear (separator face
is located where the propeller magnet (#9) aligns over the
separator). The thrust bearing (#5) should be checked for
any damage. If it is determined that the spindle ceramic
sleeve or separator (#12) are worn excessively, the separa-
tor/support spindle assembly (#12) should be replaced.
7. SEPARATOR/SUPPORT SPINDLE ASSEMBLY (#12)
can be removed for replacement by removing the four mount-
ing screws (#13) which thread into the gearbox. Separator
O-ring (#14) should be replaced and the new O-ring (#14)
covered with a thin coat of silicone grease. The separator/
support spindle assembly (#12) can then be replaced in the
front of the gearbox (#16) with a firm push, gently rotating
the assembly at the same time. Replace and tighten the
four mounting screws (#13).
VI. REASSEMBLING METER
1. PROPELLER INSTALLATION is accomplished by fol-
lowing these steps:
a) The reverse thrust cartridge set screw (#7) should be
protruding 1/32” out of the reverse thrust cartridge so it
will not bind up on the spindle thread. NOTE: Look through
the hole in the reverse thrust cartridge to be sure the set
screw is not protruding.
b) Slide the propeller assembly onto the support spindle
(#12) until the reverse thrust bearing cartridge (#6) contacts
the threads on the end of the spindle (#12). If you feel
any resistance when threading the reverse thrust cartridge
on, stop at once and check to be sure the set screw is not
binding on the thread. Be careful not to cross-thread the
reverse thrust bearing cartridge.
c) Thread the reverse thrust bearing cartridge on the
spindle (#12) until the trailing edge of the propeller contacts
the gearbox (#16).
d) Set the proper end play by using tool T-2402X-1 to
loosen the reverse thrust bearing cartridge (#6) approximately
one half to one full turn counterclockwise. There should be
minimal clearance between the gearbox (#16) and trailing edge
of the propeller, however the propeller must not contact the
gearbox. Remove tool T-2402X-1 to determine the location
of the set screw in the reverse thrust cartridge and then
reinsert the tool and hold it while turning the propeller until
the clearance hole in the propeller lines up with the set
screw in the reverse thrust bearing cartridge.
e) Tighten the set screw (#7) in the side of the reverse
thrust bearing cartridge (#6).
2. THRUST BEARING CARTRIDGE ASSEMBLY (#5)
should be inspected for damage and replaced in the nose of
the propeller. The thrust bearing cartridge (#5) is used to
adjust the amount of longitudinal end play of the propeller
assembly on its spindle (#12), which should be about 1/64”.
End play can be adjusted after the set screw (#3) in the
side of the propeller (#1) is loosened by turning the thrust
bearing cartridge assembly (#5) clockwise until it tightens
against the end of the support spindle (#12), then turning
thrust bearing cartridge (#5) counterclockwise 1/8 of a turn.
Tighten set screw (#3). Check the longitudinal end play of
the propeller to ensure it is not excessive and does not al-
low the propeller (#1) to contact the gearbox (#16). Check
the clearance between the propeller (#1) and gearbox (#16).
The clearance should be minimal and the propeller assembly
(#1) must spin freely.
3. PROPELLER BEARING (#8) can be checked for exces-
sive radial play by rocking the propeller (#2) gently from side
to side on the spindle (#12). Some play is required for proper
operation of the water lubricated ceramic sleeve bearing.
VII. SENSOR AND FC101 DIGITAL INDICATOR TOTALIZER
1. FC101 DIGITAL INDICATOR (#34) should not be
removed from the meter unless battery or sensor replace-
ment is required. If the unit must be removed, proceed as
follows:
2. FC101 (#34) can be removed from meter head by
removing the four screws (#32), then slightly lifting unit up
and turning over to disconnect the two-lead sensor wires
from the bottom of the FC101.
3. SENSOR HOUSING should be removed only if replace-
ment is necessary. The sensor can be taken out of the
separator after removing the gearbox backplate (#17). Once
the backplate is removed, pull the sensor wire and sensor
assembly out the back of the gearbox.
4. BEFORE REPLACING THE SENSOR be sure the sepa-
rator is dry. Slide sensor housing and wire assembly into
the separator until it stops against the inside of separator.
Note: It does not make any difference what rotation posi-

30119-05 Rev. 4.0/07-09
6
tion sensor is installed, however, wire must be positioned
toward back (open end) of separator. Feed the sensor wire
up through the gearbox and out the meter head.
5. LITHIUM BATTERY should offer 6 to 10 years of
operation. The FC101 has a low battery display that comes
on when approximately six months of life is remaining. The
battery should test at least 2.8 to 3.6 volts to be considered
good. NOTE: Batteries should be disposed of in an
environmentally safe manner.
6. THE FC101 DIGITAL INDICATOR-TOTALIZER (#34)
can be rotated to one of four positions for more convenient
reading. Secure with four screws (#32).
VIII. PRIOR TO INSTALLING METER
1. PROPELLER ASSEMBLY (#1) should be dipped in
water to lubricate the propeller ceramic sleeve bearing (#8).
Spin the propeller gently to make certain the meter operates
smoothly and no bind or drag is apparent.
2. FC101 (#34) and sensor (#15) should be checked to
be sure they are connected and that the battery is good.
Turn the propeller by hand at a consistent speed and the
indicator display should display a flow rate.
3. METER HEAD O-RING (#22) should be inspected for
any sign of damage and covered with a thin coat of silicone
grease. The meter can now be installed in the service line.
When replacing the meter on the line, make certain that
the top of the welding saddle is smooth and free of any
foreign material. Make certain that no foreign materials are
attached to the inside of the service line pipe, as any flow
disturbance or obstructions may affect the accuracy of the
meter.
IX. ORDERING PARTS OR RETURN TO FACTORY
Inspection of all meter components that may be replaced in
the field has been accomplished at this point. Should any
of the meter parts, upon inspection, appear to be damaged
or excessively worn they must be replaced to assure proper
meter operation and prevent further damage. Costs for
replacement parts not covered by warranty are available by
contacting the factory. If it is determined that the meter
should be returned for repair, please notify McCrometer
prior to shipment. Each meter must be properly packaged
to prevent damage to the meter in shipment.

30119-05 Rev. 4.0/07-09
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MAIN LINE METER INSTALLATION INSTRUCTIONS

30119-05 Rev. 4.0/07-09
8
2”-20” ELECTRONIC MAIN LINE METERS
MODELS ML04D, ML08D, ML12D, ML16D, ML20D, ML22D, MLI1D
PARTS LIST
CONSULT FACTORY FOR PRICES
* INSERT METER SIZE TO COMPLETE PART NUMBER - FOR EXAMPLE:
INSERT -02 FOR 2”, -04 FOR 4”, -06 FOR 6”, ETC.
** USE 4” WHEN ORDERING SIZES 2” THRU 4”
‡ CONSULT FACTORY TO COMPLETE PART NUMBER
‡‡ 2” - 8” INSERT -1, 10” - 12” INSERT -2, 14” -20” INSERT -3
QTY
1
1
1
1
1
1
1
1
1
1
1
2
1
4
1
1
1
1
1
4
4
1
1
8
8
1
1
1
1
4
1
1
1
Part Number
7-MLI1D-*
5-2425-‡-PT
3-2425-‡-P
1-1125-6
1-1116-8-6
3-2356
3-2402-2
1-1101-8-5
2-2426-P-1
2-1601-2
1-2428-‡
1-1115-3-18
4-2455-2
1-1103-8-7
1-1551-24
4-2730-3-‡
2-2238-*
2-2731
1-1551-2
1-1103-8-7
1-1251-5-12
10110-10
1-1552-‡‡
1-1301-14
1-1251-8-24
3-2101-‡
2-2101-14
1-1707-19 or -20
1-1551-38
10605
FC101-M
FC101-*
10015-00K
Description
Model MLI1D Main Line Meter Head Assembly
Propeller Assembly (Items 2 thru 8)
Propeller
Set Screw, Nylon Point
Screw, Bearing Cartridge Mounting
Thrust Bearing Cartridge Assembly
Reverse Thrust Bearing Cartridge Assembly (Items 6 and 7)
Set Screw, Reverse Thrust Bearing
Ceramic Bearing Cartridge
Drive Magnet
Drive Magnet Retaining Plate
Screw, Magnet Retaining Plate (each)
Separator/Support Spindle Assy
Screw, Separator/Spindle Mounting (each)
O-ring, Separator
Sensor Housing, Sensor and Wire Assembly
Gearbox
Gearbox Backplate
O-ring, Gearbox Backplate
Screw, Gearbox Backplate Mounting (each)
Bolt, Gearbox Mounting (each)
O-ring, Gearbox
O-ring, Meter Head
Washer, Meter Head Bolt (each)
Bolt, Meter Head (each)
Meter Head (Sizes 2” thru 12”)
Meter Head (Sizes 14” thru 20”)
InLine Terminal (19) 2 Wire (-20) 3 Wire For Remote
O-Ring - 243 Buna
Screw 10-32 x 1.25” Long
Magnet Wand
FC101 Flowcom Ind.-Tot. & Bonnet Complete - See IOM Manual
Desiccant Bag
No.
none
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25
30
31
32
33
34
none
(Provide Meter Serial Number When Ordering Parts)

30119-05 Rev. 4.0/07-09
9
References to 26-29 not used.
2”-20” ELECTRONIC MAIN LINE METERS
MODELS ML04D, ML08D, ML12D, ML16D, ML20D, ML22D, MLI1D
*MODEL FC101 DIGITAL INDICATOR-TOTALIZER ASSEMBLY
*CERAMIC BEARING CARTRIDGE PROPELLER
*ONE PIECE SEPARATOR/SPINDLE AND
THREADED REVERSE THRUST BEARING CARTRIDGE

30119-05 Rev. 4.0/07-09
10
WARNING:
BEFORE REMOVING THE METER HEAD FROM THE PIPELINE THE
WATER MUST BE TURNED OFF AND PRESSURE MUST BE RELIEVED
FROM THE LINE. SERIOUS INJURY CAN RESULT FROM REMOVING
A METER HEAD UNDER PRESSURE.