(Sanitized)

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP02-06298R000900070003-5
• Release Decision: RIFPUB
• Original Classification: K
• Document Page Count: 75
• Document Creation Date: December 22, 2016
• Document Release Date: May 4, 2012
• Sequence Number: 3
• Publication Date: October 22, 1985
• Content Type: MISC

Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
7649 Dynatech Court
Springfield. Virginia 22153
Address replies to
P C Box 2786
Spnngfleid Virginia 22152
Telephone [phone]
TWX 710-831-0333 MCI ALE
CLIENT:
SUBMITTAL DATE:
SUBMITTAL NUMBER:
SPEC. SECTION:
EQUIPMENT DESCRIPTION:
STATUS:
C.Q.C. REPRESENTATIVE:
General Services Administration
CIA Headquarters Expansion
Bid Package 3 - Powerhouse Modifications
October 22, 1985
VENDOR: Potanac Water & Waste
Systems, Inc.
O&M Manual: Hot Zeolite Return Condensate Softener System
Approved for submittal as clarified
Brian J. Fleming
VARIATIONS AND CLARIFICATIONS
1. This operation and maintenance manual submittal applies to the hot
zeolite return condensate softener system as described in Specification
Section 15616, Paragraph 17.
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
ir,nRATIN
I10'~'d'd3~T~'d'dO1@TS
i~ P,
CIA BID PKG.
SUBMITTAL
RESUBMITTAL
Lo`
POTOMAC WATER
WASTE SYSTEMS, INC.
262'WF4EATOkPLAZA BUILDING NOR4
~X/-HEATQj+I-=;?k~3.,#~I+~t~ ;:Z@!~Q2
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
4
/01' WATER CONDITIONING EQUIPMENT
OPERATING INSTRUCTIONS
Prepared for C. I. A. (POWER HOUSE) __
Langley, VA
Date Octoher, 1985
Job No. Vt7- 9 4 3
Contract No. GS-11B-1.9067
4
4
Potomac Water &
Waste Systems.. Inc.
202 Wheaton Plaza, Bldg, N
Wheaton, MD 20902-14965
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
4
TABLE OF CONTENTS
AQUA-MATIC CONTROLLER Model 1606-2C
STAGERS Model 481-11
Print 48A-1184 (Dwg. E-48-123)
Bulletin 48/51-682
AQUA-MATIC DIAPHRAGM VALVES
Bulletin 8000-1182
4
BADGER TURBO METER, 2"
Meter Bulletin MT-4702
Meter O&M Manual IOM-003-07
AR Register Head Bulletin IAR-3011
AR Register Head O&M Manual IOM-024-06
FISCHER & PORTER RATE-OF-FLOW INDICATOR
Series 71K1020
Instruction Bulletin 71K1020-C, Rev. 2
Parts List 71K1020-C
Reference Drawings:
Layout -- 943-1P, Rev. A
Internal Details -- 943-2P
4
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
OPERATING INSTRUCTIONS
These units, water softeners operating on the sodium
cycle, are used to remove calcium and magnesium hardness
from the returning condensate. Such hardness enters into
the return system generally from unexpected leaks involving
a city water source. The degree of hardness in the con-
densate is a matter of how many leaks are producing these
undesirable contaminants in the boiler feeder cycle. Ncm-
ally a well maintenance system should only show hardness
of a few parts per million (ppm), certainly less than 10
PPM-
The ability of each softener to remove hardness is a
function of how much is in the condensate to begin with and
how many cubic feet of water softening resin is available
in each unit. Based on data available in the job specifica-
tions, the expected operating data is as follows:
Each 84" dia. unit
4
Service Run:
Normal flow rate . . . . . . . . . . . 450 gpm
Length between regenerations
(assuming 10 ppm hardness
in raw water) . . . . . . . . . . . . 2,000,000 gal.
Expected pressure drop . . . . . . . . 15 psi max.
Expected operating temperature . . . . 1.800 F max.
It is expected that only one unit need be on line at
the known flow rate with the other in stand-by. Since it
may be several days before the on-line unit exhausts, the
build up in pressure drop should be monitored. Even though
the hardness is still being removed, it is suggested that a
P of 12-15 psi be the indication that it is time to reaen.---
erate. The off-line unit should be secured manually until
such time as it is needed on line. For flow rates up to 450
gpm, having only one unit on line will provide a better_ sus-
pended particle removal (iron and other products of corro-
sion in the condensate.) At this rate the resin bed is
sufficiently compressed to provide its best filtering action.
4
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 4
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
OPERATING INSTRUCTIONS
Regeneration (Using ambient temperature city water)
Step 1 Backwash: 200 gpm for 12-15 minutes
Step 2 Brine step:
Salt required . . . . 1,170 lbs. or 470, gal
of saturated brine solution
Dilution water . . . . 470 gallons
Diluted brine . . . . 47 gpm for 20 min.
Step 3 Slow rinse . . . . . . . 23 gpm for 3{ miii.
Step 4 Fast rinse . . . . . . .230 gpm for 12 min.
4
Operating Notes
1. Before each regeneration is initiated, the operator
must be sure that the brine measuring tank is full.
The required draw-down to produce the 470 gal. of
brine is 50". The actual brine draw is on an ad.--
justable timed basis with 20 minutes being the ex-
pected setting.
2. As a unit comes off line (assuming only one in serv-
ice at a time), it should be secured via the effluent
gate valve being closed. A card or sign should be.
hung on the valve to show its closed position, The
regeneration should not be done until just prior to
its expected return to service.
4
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Alk
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
O?OO 000O
PILOT CONTROL
STYLE I
IIOTCIED
STYLE It
NOTCHIS,
STYLE III
BUTTERFLY
10
SERIES 48 MOTORIZED STAGER - STANDARD
II I
STAGER
SERFS
48-0
48-1
48-4
48-3
48-11
48-12
48-8-3
48-8-4
1.8
(0
2J
87
APPROX.
SERIES 480 MANUAL
STAGER
TOTAL
POS.
SOFTENER
FLIER
SOFTENER
SOFTEIER
FLTER
48-0-6
480
ASSEMBLY 148-AE)
-DRAIN PORT
1/8-27 N.P.T.
CHART
PORTS VENTED AT CAM POSITION (TEMPLATE
A
(SERVICE)
B - D E F PART NO.
3-4
g_4
3-4
48-CM
48-CM 6-1 48-CM
48-CM
48-CM
48-CM
CAM CAM
PART NO. STYLE
48-OHM I
48-GEM I
48-B~Cr580
r -_
DIAL
PART NO.
48-EHM
f48{EM
j 488-EFM
48-EBM-4
1 48-EBM-5
NSU AT OR
SWITCH ACTUATOR
CAM
1 6WRCN
1s RD. NB. Auclwr scREw (z-sB x 1
NOTE:
UNLESS OTHERWISE SPECRIED.
1. DIMENSIONS AM NOMINAL.
INCH
MILLIMETER
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
ITEMI DESCRIPTION 'PART NO. QTY.
MD. MACHINE SCREW (8 PLATE BAC '02 X 7/8) SC 8-0078 ;
5 STEMPLATE SEE CHART 1
B :O-RINGER. _--. - _ OR8-010 1
9 BONNET 1....46-8 /
O STRAINER ASSEMBLY__. ___+ 48-O 1 J
11PILOT CONTROL ASSEMBLY 1
124 CABLE CLAMP
F 13 }RD HD MACHINE SCREW (8-32 8 1/4) ILSCB-OOB7 1
41
17 MOUNTING PLATE AMA 1 {8-BB ~..
N.S. MOUNTING PLATE GASKET 1 OR 12 48-m_ t 18 STAND OFF 48-KA2
18 NSIKATOR 51-R
20 SWITCH ACTUATOR ] 510-AU i
'~2I CAM SEE CHART 1 .
22 DIAL 115 TSO HZ 5-
23 /-M
MOT01 230 t 60 NZ 61-MA
Z/ NZ. 61-MB
24 VOLT 60 N2. 51-MC
2~LOGKWASIIER (10. OF WAS-0003 2
25,8D ND
25 R. . MACIYIE SCREW (6-32 % 3/0i SCS-0070 1 4
D
SERFS 48 MOTORI2ED STAGER 0(1) SWITCH
1/ SWTCM _._,_ _ 31g.-0 2
a
18 INSI LATOR
T---
20 SWRCN ACTUATOR
21 CAM
SERIES 480 MANUAL STAGER
30 SELECTOR PLATE 400.4 I
31 FLAT ID. MACNeE SCREW 18-32 X 3/4) 00"INI0 1
2 (SELECTOR KNOB _ _-. _._ 4N O 1 _.
REPAIR PARTS KITS - FOR STANDARD OILY
r - TINTERNAL PARTS FROM 48-AE
INCLUDES ITEM NOS. 3 T1MU 8
MOTOR - CAM - DOLL PARTS
48, MA INCLUDES ITEM S. 16(2),18,21,22,23,24, & 25
48-SA SWITCH PARTS
INCLUDES ITEM NOS. 14,(W17H WIRES ATTACHED) 19, S;
48-RA INCLUDES KITS "AA, 48-MA, & 4W-BA
SERIES 48 MOTORIZED STAGER AND
SERIES 480 MANUAL STAGER
 STAGGER
POSITION
FUNCTION
PORTS
VENTED
1
BACKWASH
4
3&4
2
BRIE AND SLOW RINSE
5
SAO
3
FAST NIBS
1
Gal
4
SERVICE
1 A 2
11 99S 18 18 17
14
G 1
AUXIURY ewMCN NOTES
0. {
Rim 1. WIOI OIEEEE IIOT01117m BT"M WITH
EITa 01E OS TWO (TWO E MAXBwN)
ADX{IARY swom"m mew. IN WNW
STAGER PosmoN{{) SIGNAL N REQUIRED
12. ROTARY {TWTON (OPTION X) CANNOT N
Ir -8TA DARD W9-M DIAGRAM (1) AUXILIARY SWRCW WIRING DIAGRAM
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
APPROX.
O
8$,_58
4
STANDARD PROGRAM
FOR SERIES 48-0, 48-3, AND 480-0
C.W. R~OATION
5/18 (.312) 8IA_ SEE NOTE 8
(4) MOUNTING HOLES T
!F 28 d,
1.188 ~__
30
FOR:
- I STAGER (3 POSITION FILTER) OMIT POSITION 2
4 STAGER (2 POSITION FILTER) OMIT POSITIONS 2 A 3
SERIES 48 MOTORIZED STAGER - ROTARY SWITCH
-
1 JPILOT CONTROL A84lBLY (SEE E 48-122) 48-AE 1
2 CABLE CLAMP - _ 4319-U 1
3 RD. M. MACHINE SCREW (8-32 % 1; 4)_ -_. -- SCS-0081 1
4 SWITCH 319-P
5 RD. HD. MACHINE SCREW (2-56 % 1, 2) SCZ-0088 2
6 FLAT HD. MACHINE SCREW (5-32 % 3/8) SCS-0105 6
7 MOUNTING PLATE FOR NEMA 1 48-BC I
OFF - ~ _-~48-KA 2
S AND
r9 INSULATOR - --- 51-R 1
10 SWITCH ACTUATOR 510-AU i
_ 11 CAM SEE CHART 1
12 fNLL ON E-48-122 1
15 MOTOR 230 VOLT 50 HZ. 319-KX 1
24 VOLT 50 HZ. 319-BX
16 LOCKWASHER (10. 6) WAS-0003 2
17 RD. HD. MACHINE SCREW X 3/SI __ 1 SCS-0070 2
SERES 481 MOTORIZED VALVE
18 ENCLOSURE
19 FL. HD. MACH. SCR. (10-32 X 1/4)
F20 STAGER
21 MOUNTING PLATE
22 MOUNTING PLATE GASKET
23 HEX HD. MACH. SCR. (10-32 X
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
INCH
MILLIMETER
4B XC
11-.V ouT 80 HZ. 51-MX
FOR
EMA 4
OR
4. STAGERS WITH INVERTED PROGRAM ARE AVAILABLE.
S. CONTROL PRESSURE TO THE STAGED CAMSB EITHER HYDRAULIC OR
PNEUMATIC AND MUST BE WITHIN 10% OF WE SYSTEM PRESSURE;
NOT TO EXCEED 100 P.SJ. (5.8 ATM.).
6. FOR PROGRAMS OTHER THAN SHOWN, COMELY FACTORY.
8. NEMA 12 ENCLOSURE HAS (1) CLAMP AND MESA, 4 ENCLOSURE
HAS (3) CLAMPS.
NOTE:
UNLESS OTHERWISE SPECIFIED:
1. DIMENSIONS ARE NOMINAL.
2. MODEL 48-3 STAGER SUPPLED WIRMETTTERFLY CAM (4 POSITIONS
ONLY): FOR USE WITH SHIFT OUTPUT TYPE TIER. (SEE CHART ON
E-48-122)
3. ALL OTHER MOTORIZED STAGERS SIPPIEO WITH NOTCHED CASK
FOR USE WITH PULSE OUTPUT TYPE Tom. (BEE CHART ON
E-48-1221
7. ALL STAGERS CAN BE MANUALLY ADVANCED BY NOTATING TIE DIAL
IN DIRECTION SHOWN.
E-48-123
SERIES 48 (OPTION X) AND 4h
SERIES 481 MOTORIM STA40
 '0*
i. a a s
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
4
4
Diaphragm Valves
^ Lowest pressure loss.
Y pattern permits higher flows at lower
pressure loss than any comparable valve.
^ Positive control.
Separate flow and control chambers
permit positive closing without springs;
and only nominal cost for spring assist
opening for low pressure and self
draining considerations.
^ Cost effective.
Both initially and in lifetime
maintenance.
^ Extended diaphragm life.
Separate chamber protects diaphragm
from flow stream; allows replacement
without disrupting service. Pre-formed,
stress relieved diaphragm minimizes
fatigue:, maximizes valve responsiveness
and diaphragm lifetime.
^ Durable.
Cast iron, brass, bronze, stainless steel,
and engineering thermoplastic
components. Average maintenance free
life of 5 years.
^ Design/Application engineering
service.
^ Optional seal and diaphragm
materials for special
applications.
^ Handles liquids or gases.
^ Adaptable to a variety of control
devices.
^ Optional adjustable flow rate
control.
^ Optional spring assist.
^ Optional position indication.
Metal Body Valves
Series 421 through 429
Body and cap of cast iron or brass.
Pre-formed, stress relieved
diaphragm of Buna N on Nylon for
long life. Stainless steel and brass
internal parts.
Pipe sizes of 3/4" through 3"
threaded (N.P.T. or B.S.P.); 3"
through 6" flange drilled in
accordance with ASA 16.1, Class
125, or B.S. 4504 (ISO/R 2084).
Operating specifications:
Pressure-Standard 125 psi
(8.5 Atm.) rating.
(300 psi available).
Temperature-
Maximum 150?F (65?C);
optional 250?F (120?C).
PRINCIPLES OF ERATION
Drip-Tight Closing: Closure is obtained by directing
line pressure or equivalent Independent pressure
into the upper chamber. This pressure on the large
diaphragm area causes the valve disc to seal against
the seat.
Plastic Body Valves
Series 520 through 526
Designed for de-ionized water,
corrosive liquids or gases, caustics
and acids (Not applicable for
aromatic hydrocarbons). Body and
cap molded of 30% glass
reinforced engineering
thermoplastic resin. Diaphragm is
Buna N on Nylon and static seals
are ethylene' propylene. Viton and
Butyl seal options available. Line
fluid never contacts a corrodable
surface.
Pipe sizes range from 3/8" to 3"
with optional fittings-threaded,
solvent bond, or flanges.
Operating specifications:
Pressure-Maximum 125 psi
(8.5 Atm.).
Temperature 32?F to 140?F
(0? to 60?C).
Full Open Operation: When closing pressure, in
upper chamber, is relieved by venting the pilot line,
the valve opens, positively, by line pressure on the
disc.
Pnn'ed n U S A
Bully.,, HCir. ..
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Isolated Bonnet Valves
Series 4421 through 4429
Designed for high temperature
applications that might cause
accelerated deterioration of
diaphragm in standard valve.
Isolated bonnet prevents heat from
reaching diaphragm.
Any leakage that may occur is
quickly obvious around dynamic
seal. Line fluid cannot contaminate
pneumatic/hydraulic control
because diaphragm is not
accessible to fluid carrying
chamber of valve.
Optional indicator on valve stem
permits positive, direct reading of
valve position. Also, includes all
the options and features of standard
"Y" pattern valves; and available in
same sizes and construction as
standard "Y" pattern valves.
Operating specifications:
Pressure-Standard 125 psi
(8.5 Atm.) (300 psi available).
Temperature-Maximum 300?F
(148?C). (Consult factory for
higher temperature
applications).
Note:
Chart applies to all
metal diaphragm
valves illustrated in
this catalog:
Series 421-429;
Series 4421-4429;
Series 3500; and
Series 3000.
Cv = Flowrate
(G.P.M.) of water at
60?F (15.5?C) at
1 P.S.I. pressure
drop.
Liters per minute =
G.P.M. x 3.78.
Flowrates - mete1 diaphragm valves
-CONTINUOUS FLTW 2: FEET PER SLCOND
,' i ---INTERMITTENT F_OW 30 FEET pER T ?CONC
i,
i
D
AM 3000
VALVE
WITH
'REMOTE
CONTROL
Model 348LC Level Control
For mounting float actuated pilot
remote from diaphragm valve.
Control fluid is delivered to and
from the diaphragm chambers
through ports P1 and P2 of the
pilot. Up and down positions of the
float determine which port is
pressurized, and which port is
vented. May be used with either
metal or plastic valves.
DIMENSIONS
1100
TED BO
NNET VALVES
Size
Ends
Series
As
AF
Bs
BF
CS
CF
as
BF
Cs
CF
D
E
F
3/
-1
SCRD
421
In.
3.68
4.25
3.75
5.62
4.62
2.75
4
4421
mm.
94
108
82
140
115
70
11
11
SCRD
424
In.
4.75
5.37
4
7.62
6.25
3.50
/4-
/2
4424
mm.
120
136
101
190
160
89
2
SCRD
425
In.
6.62
7.25
5.37
9.37
7.50
4.87
4425
mm.
168
184
136
240
190
123
2 2
SCRD
426
In.
7.37
8
5.75
10.5
8.25
6.25
;2
4426
mm.
187
203
146
265
210
155
3
S
SCRD
427-S
In.
9
9.75
6.75
12.25
9.25
7.25
-
4427-S
mm.
228
247
171
310
235
184
3
F
FLGD
427-F
In.
10.62
10.75
7
13.00
10.75
7.25
6
0.75
-
4427-F
mm.
270
273
178
330
275
184
160
18
4
F
FLGD
428-F
In.
11.75
14.75
10
18.00
13.75
8.75
7.5
0.75
-
4428-F
mm.
298
375
254
455
350
222
180
18
6 F
FLGD
429-F
In.
17
19
13.50
25
18.50
15.75
9.5
0.87
4429-F
mm.
431
482
343
635
470
402
240
20
B.S.P. threads optional on series 421 thru 427, and 4421 through 4427.
European flanges optional on series 427 thru 429. and 4427 through 4429.
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Series 3500 SOLENOID-CONTROLLED Series 3000 FLOAT-CONTROLLED
4
Series AM-3500 (Energize to open)
Series AM-3510 (Energize to close)
Equipped with solenoid for control by timer, flow
meter, pressure or temperature sensor, liquid level or
manual switch.
Specify "independent pressure" if a separate source of
control fluid is used.
Ideal for automated, continuous process systems.
2'" 57 MM.a
TRAVEL
Float provides accurate control of liquid levels in
constant cycling reservoir wit lout surge or shock
Positive open or closed positions--not affected by mina
changes in liquid levels. Rem Dte float mounting
Note: Diaphragm valve and float actuator
assembly may be remote from each other.
See illustration of Model 348LC Level
Control on preceeding page.
5" DIA.
127 MM. j
4
SERIES 3500
SERIES 3000
SIZE
SERIES
DIM.
A
B
C
D
E
SIZE
A
B
C
D
E
F?
3/4"-1
421
In.
3.75
4.37
3.25
5.12
4.12
7.20
6.50
1.70
3.00
3.68
29
mm.
95
111
82.5
130
105
1.82
165
43.1
76.1
93
735
W
11/4"-11/2"
424
In.
4.75
5.00
3.50
6.00
5.00
11/
? 11/
?
8.29
7.81
4.20
1.75
4.75
28
mm.
121
127
89
152
127
4
2
210
198
107
44.4
120
711
W
2"
425
In.
6.62
6.75
4.12
8.25
6.37
2"
9.29
8.37
5.20
2.69
6.62
27
mm.
168
171
105
209
162
236
212
145
68.2
168
686
N
U
2"-21/2"
426
In.
7.37
7.25
4.25
9.00
6.75
2? 21
/2
9.87
9.56
5.20
3.06
7.37
26
mm.
187
184
108
229
171
250
243
145
77.6
187
660
3"S
427
In.
9.12
8.50
4.50
10.75
7.75
3?S
10.8
10.56
6.20
3.62
9
25
mm.
231
216
114
273
197
274
268
157
91.8
228
635
3" F
427-F
In.
10.62
8.50
4.50
11.75
8.00
3" F
11.6
10.56
6.20
3.75
10.62
25
W
mm.
270
216
114
298
203
294
268
157
95.1
270
635
Z
4" F
428-F
In.
11.75
10.75
6.47
15.75
11.00
4? F
12.8
13.81
6.20
4.50
11.75
22
Q
mm.
298
273
164
400
279
325
350
157
114
298
659
ILL
6" F
429-F
In.
17.00
15.75
7.87
20.00
14.50
6? F
10.9
16.94
8.81
7.25
17
37
mm.
432
400
200
508
368
278
430
223
184
432
940
Solenoid Specifications
Standard AC voltages: 115, 230-50 or 60 Hz. Consult factory for other Enclosures: General-purpose NEMA 1 normally supplied. Explosion-
voltages. proof and water-tight (NEMA 4, 7 & 9) available, add 1.25"
Power consumption: 9.4 watts ac. Volt amperes: 16 holding, 25 `Float Rods are 18 inches (457mm) long sections. Valves up to 4" sizE'
inrush. are supplied with two sections. 6' valves are supplied with 3 sections
Coil: Class "B" molded, continuous duty. High temperature coils
available on request.
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 - Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Series 520-Szb solenoid (Jperatect valve oll!VA FLOW RATE (GPM)
Molded of 30% glass
reinforced engineering
thermoplastic resin.
Line fluid never
contacts corrodable
surface. Series 5500
Isolated Bonnet Valves
also available.
Series AM-4500 (Energize to open)
Series AM-4510 (Energize to close)
Series 520-526 equipped with
solenoid for control by timer,
flow meter, pressure or
temperature sensor, liquid
level or manual switch. Ideal
for automated, continuous
process systems. Specify
"independent pressure" on
purchase order if a separate
source of control fluid is used.
SOLENOID SPECIFICATIONS:
Standard AC Voltages: 115, 230-50 or 60 Hz. Consult factory for
other voltages.
Power Consumption: 9 watts AC. Volt amperes: 15.6 holding,
24.6 inrush.
Coil: Class "B" molded, continuous duty.
Enclosures: General purpose NEMA 1 only.
SIZE
%"-1/z"
3/4"_1"
1%"-2"
21/2"-3"
SERIES
520
521
524
526
CV
1
5.5
16
48
130
2
7.7
22.6
63
183
3
9.5
27.6
83
225
4
11
32
96
260
5
12.3
36
107
290
6
13.4
39.2
117
320
7
14.5
42.1
127
345
8
15.5
42.2
135
365
9
16.5
48
144
390
10
17.4
50.5
151
410
15
21.3
62
185
504
SIZE
MISS
END CONNECTION
'~. A
A
B?
C
D
E
F
G
H
3/e
520
Ring Nut
)n
z; '.93
2.
= 1.25
1.0
5.87
4.12
mm
89.8
31.7
25.4
149
105
In.
4.5
4.08
1.62
2
75
6
52
5
12
3/4'-1"
521
Ring Nut
.
.
.
.
mm.
114.3
103
41.1
69.7
166
130
In.
7.75
5.06
2.28
1
0
7
62
6
25
11/4-'1%_
524
Ring Nut
.
.
.
mm.
136.8,
128,4
58
25.4
193.5
159
524F
Flange
In.
9.56
5.
2.28
3.00
7.62
6.25
7.0
mm.
242.8
128.4
58
76.0
193.5
159
177
Female
In.
10.5
5.06
2.28
7.62
6
25
2"
524W
.
Socket Weld
mm.
266.7
128:4
58
193.5
159
Male
in.
10
5
5.
2.28
7
62
6
25
524WA
.
.
.
Socket Weld
Mm.
266.7
128.4
58
193.5
159
526F
Flange
in.
11.5
7.31
3.12
3.50
9.62
7.87
8.37
21/
"
Ihm.
292.1
1 7
79.2
89.0
244
200
212
2
Female
In.
15.0
7.31
3.12
9
62
7
87
526W
Socket Weld
mm.
381
185.7
79.2
.
244
.
200
3
256F
Flange
In.
12.0
7.
3.12
3.75
.50
9.62
7.87
8.62
mm.
304.8
185.7
79.2
95.0
12.7
244
200
218
Adaptor Dimensions
I E
VALVE
0IMEN.
LENGTH
LOCATION
DIA.
WIDTH
SERIES
UNIT
A
B
C
D
6
520
INCHE
225
0.50
0.730
0.115
0.14
MM.
57
12.7
18.5
2.92
3.73
521
INCHES
3.00
0.50
1.200
0.115
0.179
MM.
76
12.7
30.4
2.92
4.54
524
INCH
4.00
0.875
1.800
0.115
.20 0
MM.
101
22.2
45.7
2.92
5a t
4v"441zn~
Remote Float Control
Direct mounting of float
control on plastic SUPPLY P2
valves is not
recommended. Use
Model 348 LC Level
Control for remote
mounting. See illustration
on page 2 of this catalog.
AquaMatic, Inc., 2412 Grant Avenue, Rockford, Illinois 61103-3991 ^ 815/964-9421 ^ Cable "Aqua Matic"-Telex 257-355
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5 N
m
4
4
0
A stager is, essentially, a rotary pilot valve with multiple
ports through which control fluid is directed, thereby
operating diaphragm valves installed in a process
system. AquaMatic stagers are constructed of durable,
non-corroding, self-lubricating material for long,
maintenance free life. They are available in three basic
designs: Series 48 with six ports; Series 51 with eight
ports; and Series 58 with sixteen ports (see separate
bulletin).
Stagers may be manually operated or driven by an
electric motor that is operated through an adjustable
timer. If, for any reason a motor driven stager is manually
indexed, it must be re-synchronized with the timer.
As an optional feature, stagers can be equipped with an
electrical switch to energize display lights, or initiate
ancillary equipment. Consult factory for details.
The stager functions by opening and closing its ports,
singly or in combination, in a sequence that fits the needs
of the system. The "positions" in the sequence correspond
to the number of "stages" in the process. The ports that
are opened when the stager is in any given position allow
pressurized fluid to flow to and operate some diaphragm
valves, while venting other valves-allowing them to
return to their normal positions.
AquaMatic stagers can use either hydraulic or
pneumatic control fluid. Process fluid, if pressurized, and
not damaging to internal parts of the stager or
diaphragm valve, may be drawn from the main line to the
inlet of the stager. Otherwise, an independent source of
control fluid is required. The pressure of the control fluid
must be equal to or greater than the line pressure of the
system.
AquaMatic stagers provide the versatility needed to
control complex water treatment systems, or the
simplicity of a two valve operation. The system's
diaphragm valves are operated by hydraulic or
pneumatic pressure (control fluid). Continuous electrical
power is not required to maintain the positions of the
valves such as in a solenoid operated system.
Consequently, the danger of disrupting the process is
minimized.
Specifications Series 48 and Series 51
Maximum pressure
Maximum temperature
Power port size
Inlet, drain ports
Electrical supply
100 psi (6.8 Atm.)
150?F (65?C)
1/8'
1/8"
120Vac/6OHz
230Vac/50Hz
Electrical enclosures:
Standard - NEMA, Type 1
6" x 6" x 4"
Optional-NEMA, Type 12
6" x 6" x 4"
(Indoor, watertight)
Optional - NEMA, Type 4
(Outdoor- watertight)
6" x 6" x 4"
WHEN ORDERING, specify stager model, valve programming
requirements, electrical specifications, and type of enclosure.
2412 Grant Avenue, Rockford, Illinois 61101 ^ 815/964-9421 ^ Cable "Aqua-Matic"-Telex 257-355
m
N
Printed in U S A - 1 48/51-682
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003
4
STAGERS
Typical Circuit Applications for
Series 48 and Series 51 Stagers
Piping fitted with AquaMatic
diaphragm valves which are operated
by pressurized control fluid from stager
pilot. 1/4" O.D. flexible tubing connects
stager ports to diaphragm valves. When
water is turbid, or contains high iron
content, a cartridge filter should be
placed ahead of stager inlet port.
Tables show which valves are open at
each stager position.
STAGER
POSITION
SOFTENER
FUNCTION
VALVES
OPEN
4
SERVICE
1,2
1
BACKWASH
3, 4, (2A)
2
BRINE
5, 6, (2A)
3
FAST RINSE
6, 1, (2A)
STAGER
POSITION
SOFTENER
FUNCTION
VALVES
OPEN
1
BACKWASH
3, 4, (2A)
2
BRINE
5, 6, 7, (2A)
3
SLOW RINSE
5, 6, (2A)
4
FAST RINSE
1, 6, (2A)
5
BRINE REFILL
1, 2, 8, (2A)
0
SERVICE
1,2
'Note: Valve 2A is optional; provides raw water
service during regeneration.
SERIES 48
STAGER
D
EJECTOR
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IL
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Turbo Meter
With Pneumatic
Batching Register
BadgerMeter,Inc. Industrial Products Division
4545 W. Brown Deer Road, P.O. Box 23099
Milwaukee, WI 53223 [phone]
SIZES 2" T
COM.IPACT
LIGHT+I WEIG
O?
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
MAGNETIC DRIVE TURBO METERS...
HIGH ACCURACY OVER BROAD FLOW RANGE
Badger's magnetic drive turbo meters provide industrial
processors with higher accuracy over a broader flow
range than traditional turbine meters with vertical rotors.
Accuracy of the turbo meter can be maintained within
? 11/2 % over the meter's entire flow range-not just at
one point. Repeatability is within 1/2 of 1 %.
The straight-through flow design makes it possible to
operate the turbo at a higher continuous flow than a
comparable turbine. In addition, the low flow range on
most models is extended about 50% below the minimum
for vertical-rotor turbines.
Because of the magnetic drive design, Badger turbo
meters also help to reduce maintenance problems.
There are no gears in the flow stream, no packing glands
to cause leaks.
Badger turbo meters are offered in four different housing
materials for measuring liquids up to 250?F. They can
handle a wide variety of chemical solutions, paper
coating materials, oils, water and food ingredients.
WIDE FLOW RANGE
METERING CAPABILITY
FLOW RANGE-G.P.M.*
MAXIMUM
METER SIZE
MINIMUM
MAXIMUM
CONTINUOUS
FLOW
2"
8
160
160
399
10
350
350
4"
25
1000
1000
6f!
40
2000
2000
*Consult your Badger representative about accuracy
performance above and below flow rates shown.
Badger's turbo meter, with straight-through flow design, is
equipped with straightening vanes and a nose cone at the inlet
side. These minimize the swirling effect of upstream piping.
Liquid flowing through the meter tube strikes the blades of a
rotor, causing the rotor to turn. By means of a magnetic coup-
ling, this motion is transferred to a vertical spindle and then to
gears in the meter's register.
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
LONG-WEARING
The rotor bearing, rotor
spindle and endstone in
the Badger turbo meter
are made of a ceramic
material developed
especially for this appli-
cation. Because of their
hardness, the ceramic
parts provide long-life
service, even if the
meter is run continously
at maximum flow.
ROTOR TO
ENDST
~~. BACN
ENDSTONE (CERA'AIC)
a
COMPACT,
LIGHTWEIGHT...
EASY TO INSTALL
Badger turbo meters
are easy to install and
service because of their
compact size and light
weight. A 3" turbo
meter, for example,
weighs just 40 pounds
compared with more
than 300 pounds for a
vertical-rotor turbine.
The laying length is only
12".
AUTOMATIC
RESET
REGISTER
WIDE CHOICE OF REGISTERS AND ACCESSORIES
TOTALIZING
RESET SIGNAL MANUAL
REGISTER REGISTER REGISTER
QQQQ
ELECTRIC
BATCH
REGISTER
I --- --- ------- - ----1-------L--------
ELECTRIC
CONTACTING
REGISTER MODEL 258
(ADJUSTABLE) TOTALIZING
REGISTER
01 am
2",3",4" OR 6"
TURBO METER
MODELS MS-ER-1
AND MS-El
PULSE
TRANSMITTER
MODEL EPT-2 ~ - - -
TRANSMITTER
r I
C!IF
MODEL EPU MODEL RBC-210
PROCESSOR REMOTE BATCH
CONTROLLER
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SERVICE
WITHOUT REMOVAL
FROM LINE
For easy servicing, the
rotor and head assem-
bly in the turbo meter
can be removed without
disconnecting the me-
ter from the line. Just
loosen the head bolts
on top of the housing
and lift out the entire
assembly.
ON-SITE
CALIBRATION
A convenient bypass
valve, for precise cali-
bration, is built into the
bronze and cast iron
housings of 2" and 3"
meters. Simply remove
the locking nut and turn
the valve with a screw-
driver to adjust flow.
Choice of Registra-
tion in Gallons.
Cubic Feet, Pounds,
Metric Units, etc
PNEUMATIC
BATCH
REGISTER
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
MATERIALS ADDITIONAL ACCESSORY INFORMATION
......... ................................ Cast Iron
........................................ Cast Steel
Cast Bronze
Rotor and Nose Cone, 2" through 6" .................. Ryton
Kynar
Rotor Bearing, Spindle and Endstone ................ Ceramic
Magnet .......................................... Ceramic
Straightening Vanes .......................... 316 Stainless
Register Base ................................... Aluminum
Bypass Valve .............. 316 Stainless-2" and 3" Meters
Head Gasket .................... Nonasbestos/Nitrile Binder
.............. Nonasbestos/Chloroprene Binder
..................... Asbestos/Special Binder
"O" Ring and Tetraseal .............. EPR, Buna N or Viton A
Badger turbo meters operate with less
pressure loss than turbines with
vertical rotors. The pressure loss
curves on adjoining chart were cali-
brated without a strainer ahead of the
meter. Since many different strainers
can be applied, industrial processors
should be aware that system pressure
drop could result.
Specify turbo meter size (flow
range) and type of housing
material (for compatibility
with liquid).
When ordering meter with
register, specify model of reg-
ister and unit of measure. If
BRE or BRP batch register is
required, specify dial capacity.
When ordering meter with
pulse transmitter, specify
pulse/unit of measure. Please
also list RBC-210 remote
batch controller, electric con-
tacting or totalizing/reset reg-
ister or electronic transmis-
sion system if required.
BRE
BRP
MR
AR
SR
TR
EC-A
RBC
MS-ER1
MS-E1
EPT& EPU
DESCRIPTION BULLETIN NO.
Batch Register, Electric; IBR-3010
Batch Register, Pneumatic IBR-3010
Batch Register, Manua' IBR-3010
Automatic Reset Register IAR-3011
Signal Register IAR-301 1
Totalizing Reset Register ITR-3012
Electric Contacting Register REC-5009
Remote Batch Controller IRC-3009
Pulse Transmitter XP-601 1
Pulse Transmitter XP-6008
Electronic Transmission System IEP-3013
INDUSTRIAL TURBO METER PRESSURE LOSS CHART
RATE OF FLOW IN GALLONS PER MINUTE
4 6 8 100 2 4
10
0
"
"
3
4"
s
2
6"
SPECIFICATIONS
2"
3"
4"
6"
Accuracy - Entire Flow Range............
? 1.5%
? 1.5%
? 1.5%
? 1.5%
Repeatability - Constant Flow and
Temperature ..........................
? 0.5%
? 0.5%
? 0.5%
? 0.5%
Head Loss - Maximum Flow (PSI) .........
4.5
6
5.5
5.5
Maximum Operating Temperature (?F)......
250
250
250
250
Maximum Operating Pressure (PSI).........
150 Std.
150 Std.
150 Std.
150 Std.
300 Opt.
300 Opt.
300 Opt.
300 Opt.
Approx. Weight (Lbs.) with 150 PSI Conn.
(Depends on Meter Material Selected)....
30-40
40-50
60-75
100-125
Laying Length (Inches) ....................
10
12
14
18
Height - w/o Register (Inches) ............
8
9
10
12
Connection Flanges ......................
Round
Round
Round
Round
Badger warrants meters and parts manufactured by it and supplied hereunder to be free from defects in
materials and workmanship for a period of 1B months from date of shipment or 12 months from date of
installation, whichever period shall be shorter- If within such period any meters or parts shall be proved
to Seller's satisfaction to be defective such meters or parts shall be repaired or replaced at Seller's
option Seller's obligation hereunder shall be limited to such repair and replacement and shall be coo-
ditloned upon Seller's receiving written notice of any alleged defect w'thln 10 days after its discovery
and at Seller's option, return of such meters or parts to Seller fo.b its factory THE FOREGOING
WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES WHAT-
SOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EXCEPT OF TITLE) OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Badger shall not be liable for any
detects attributable to acts or omissions of others after shipment, nor any consequential, ircidental or
contingent damage whatsoever
Equipment sold by Badger Meter. Inc is not n'ended for use in connection wi'h any
nuclear facility or activity unless covered by a spec,flc quotation where tie conditions of
such usage will be detailed If equipment ~s used in a nuclear facility or activi'y w'thout a
supporting quotation, Badger Meter disclaims all liability for any damage, injury or cor-
tammation, and the buyer shall indemnify and hoed Badger Meter, its officer, agents
employees. successors, assigns and customers whether direct or indirec', ham ess from
and against any and a 1 losses, damages or expenses of whatever fo'rr or nature
(including alto'neys' fees and oche' costs of defending anv action) which tiey or any of
them, may sustain or lieu', whether as a result of breach of con'ract, warranty, tor'
(including negligence) strict liab qty or o'her tneories of law. by'eason of such use
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5 M-003-07
INSTALLATION
OPERATION AND
MAINTENANCE
MANUAL
BADGER
INDUSTRIAL
TURBO METERS
J BadgerMeter,InC. Industrial Products Division
4545 W. Brown Deer Road, P.O. Box 23099, Milwaukee, WI 53223
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Changes or additions to the original edition of this
manual will be covered by a "CHANGE NOTICE" sup-
plied with the manual. The change notice will explain
any differences between the turbo meter received and
the meters described in this manual.
PREFACE
CHANGES IN THE MANUAL
This manual contains information concerning the in-
stallation, operation and maintenance of Badger mag-
netic drive turbo meters. To ensure efficient operation
of the meters, the instructions given in this manual
should be thoroughly read and understood. Retain the
manual in a location where it is readily available for
reference.
Badger's industrial turbo meters, available in sizes
from 2" through 6", utilize a straight-through flow
design to provide high accuracy over a broad flow
range. Meter housings are offered in four different
materials for measuring chemical solutions, water and
other liquids at temperatures up to 2500 F. The meters
are designed for use with a variety of meter-mounted
accessories such as registers or pulse transmitters.
Basic components of the turbo meter consist of the
housing, meter operating head, rotor assembly, straight-
ening vanes and register base. In addition, the 2"
and 3" sizes have an adjustable bypass valve for on-
site calibration.
In the operation of a turbo meter, liquid flows through
the straightening vanes and nose cone at the inlet
side of the meter so that the swirling effect of upstream
piping is minimized. The liquid then strikes the blades
of a rotor, causing the rotor to turn.
By means of a magnetic coupling, the rotor's motion
is transferred to a vertical spindle and then to gears
in the meter's register or pulse transmitter. The mag-
netic drive eliminates the need for packing glands and
minimizes the number of parts that come in contact
with the liquid being metered.
Each complete revolution of the rotor is directly pro-
portional to a specific volume of liquid. The volume
measured with each revolution increases with the
size of the meter.
Tables 1-1 provide a summary of configuration and
specification data pertaining to Badger's turbo meters
for industrial applications. As indicated in the tables,
there are four standard meter sizes - 2", 3", 4" and
6". In addition, each meter size is available with four
different housing materials - 316 stainless steel, cast
iron, cast steel and cast bronze.
The differences between the meter sizes are character-
ized by the flow range, head loss, laying length and
weight. The differences between configurations are
characterized by the flange connections, accessories
and the type of housing material that is compatible
with the liquid to be metered. When reviewing the
specifications, it is important to note that all flow
data is based on water or liquid with the same specific
gravity and viscosity as water at ambient temperature.
The size and configuration of the turbo meter selected
for use in a liquid metering application is determined,
primarily, by the flow and physical characteristics of
the liquid to be metered, i.e., rate of flow, operating
pressure, temperature, viscosity and chemical com-
position of the liquid. These meters can, for example,
handle a variety of chemical solutions, paper coating
materials, oils, water and food ingredients.
NOTE
When ordering a turbo meter, it is important
that the type of housing material will be
compatible with the liquid or chemical solu-
tion to be metered. In addition, the rotor
magnet must be compatible with the type of
transmitter selected.
For applications relative to a specific liquid, refer to
Badger's Application Note AN-10. If you have ques-
tions, contact your local Badger Meter representative
or the Industrial Products Division, Badger Meter, Inc.
(address on title page).
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 4
44
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SERVICE NOTE
Number 16
SCOPE: This service note provides instructions for
removing and installing the gear train assembly with
magnet located in the register base of 2" through 6"
industrial turbo meters.
PURPOSE: The gear train assembly can be removed and
replaced without removing the turbo meter from the line
and the register base from the operating head assembly.
Two gear train assemblies are used with industrial
turbo meters. To find out what the gear train ratio is,
count the number of spindles (gear and pinions) that
protrude through the five mounting holes provided in
the top plate of the gear train assembly. If there are only
three spindles, the gear ratio is 366:1 and if there are five
spindles, the gear ratio is 1200:1.
INSTRUCTIONS FOR REMOVING THE
GEAR TRAIN ASSEMBLY WITH MAGNET
1. Remove the register, transmitter or adapter
mounted on the register base. A screwdriver, pliers or
small box wrench can be used to remove the mounting
bolts (or screws) securing the accessory to the base.
2. To remove the gear train from the register base
of molded plastic, use a small screwdriver and loosen
three screws and special washers located on the top
plate of the gear train assembly.
3. Turn each washer until the flat edge frees the
washer from the groove on the inside wall.
SPECIAL
WASHER
GROOVE
IN WALL
Turbo meters with an aluminum register base have
a clip-type retainer ring to secure (or lock) the gear train
assembly in the base. Use a small screwdriver to release
the retainer ring from the groove in the wall adjacent to
the top plate of the gear train assembly.
GROOVE
IN WALL
Release the retainer ring from the groove to
free the gear train assembly from the base.
4. Grip the change gear spindle and lift to remove
the gear train assembly with magnet from the register
base.
5. Remove the accessory change gear or coupling
from the gear train spindle. Before removing, note the
location of the change gear (or coupling) on the spindle
so that it can be reinstalled in the same location.
NOTE
A flat surface is provided at the top of the
spindle of the change gear assembly so
that the setscrew in the change gear or
coupling can be properly seated and
tightened to the spindle.
6. Gear train assemblies are packaged with the
magnet and spindle assembly disassembled from the
gear train assembly. Before assembling. carefully check
the spindle for minute burrs on the threaded end of the
spindle. If there are burrs, use a crocus cloth and care-
fully remove them from the spindle. This will prevent
damage to the surface of the jewel bearing when
Turn each washer to free it from the groove
on the inside wall.
Badger Meter, inc. Industrial Products Division
4545 W. Brown Deer Road, P.0 Box 23099, Milwaukee. WI 53223
89
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
inserting the magnet spindle through the jewel-bushing
in the bottom plate of the gear train assembly. An "E"
ring should be mounted on the spindle. If missing,
remove the "E" ring from the replacement spindle and
snap it into the grooved collar near the threaded end of
the spindle.
INSTRUCTIONS FOR INSTALLING THE
GEAR TRAIN ASSEMBLY WITH MAGNET
1. Align the gear train assembly with magnet so
that the magnet and spindle can be easily lowered into
the shaft of the register base.
TOP PLATE ft SPINDLE MOUNTING HOLES
Lu_
Installing the magnet spindle assembly to
the gear train assembly.
LNOTE
On 366:1 and 1200:1 gear train assemblies,
the magnet and spindle assembly (P/N
56780-002) is installed by removing the
threaded gear (P/N 30229-000) from the
spindle. Using a needle-nose pliers, grip
the gear on the side and hold it on top of
and at the center of the jewel bushing
located in the bottom plate of the gear
train assembly. Insert the threaded end of
the spindle through the bushing and into
the threaded gear. Turn the spindle to
tighten it to the gear.
2. Rotate the gear train assembly until it seats into
each boss provided at the base. This configuration
aligns the three special washers on the top plate of the
gear train with the shoulder extensions on the inside
wall.
With the aluminum register base. the gear train
assembly seats in three recessions in the register base.
These recessions align with three gear train posts that
support the top and bottom plate of the gear train
assembly.
3. Loosen the three screws and special washers on
the top plate. Using a screwdriver, turn each washer
until the round edge locks under the shoulder
extension. Tighten each screw which secures the gear
train assembly in the register base
The retainer ring secures the gear train assembly in
the aluminum register base. With the gear train properly
seated in the base. insert the retainer ring in the groove
provided in the wall. The groove is adjacent to the top
plate of the gea, train assembly.
4. Reinstall the change gear or coupling on the
gear train spindle. Align the setscrew in the gear or
coupling with the fiat surface on the spindle and
tighten.
5. Mate the change gear or coupling to the register
or transmitter and install the accessory on the register
base.
6. Reinstall the accessory mounting bolts (or
screws) and tighten.
7. Test operate the meter to check the accuracy of
the register or transmitter with the replacement gear
train assembly.
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CONFIGURATIONS
METER
CONNEC-
DIMENSIONS
(INCHES)
MAX. OPERATING
MAX.
OPER.
HOUSING MATERIAL: 316
Stainless, Cast Iron, Cast
Steel & Cast Bronze
HEAD
LOSS AT
MAX.
SIZE
TION
FLANGES
A
B
C
D
E
(WIDTH)
PRESSURE(PSI)
TEMP.
(OF)
NORMAL FLOW
RANGE(GPM)
MAX. CONT.
FLOW(GPM)
FLOW
(PSI)
2"
Round
10
2
8
23/4
6
150 Std. - 300 Opt.
250
8 - 160
160
4.5
3"
Round
12
3
9
31/2
71/2
150 Std. - 300 Opt.
250
10 - 350
350
6.0
4"
Round
14
4
10
41/4
9
150 Std. - 300 Opt.
250
25 - 1000
1000
5.5
6"
Round
18
6
12
51/4
11
150 Std. 300 Opt.
250
40 - 2000
2000
5.5
ROUND FLANGE
METER WEIGHT - POUNDS (Approx.)
METER
HOUSING
CONNECTION
2"
3"
4"
6"
MATERIAL
150 psi
300 psi
150 psi
300 psi
150 psi
300 psi
150 psi
300 psi
150 psi
300 psi
316STAINLESS
R.F.
R.F.
40
50
50
65
60
80
115
145
CAST IRON
F.F.
R.F.
30
36
40
52
70
90
100
130
CAST STEEL
R.F.
R.F.
40
50
50
65
60
80
115
145
CAST BRONZE
F. F.
F. F.
30
36
40
52
1
75
95
125
160
APPROX. HEIGHT (Inches)
ACCESSORY
MODEL
2"
3"
4"
6"
EPT-2
12'/,e
13'/,e
14'/,6
16'/,8
Pulse Transmitter
MS-ER1
13'/1e
14'/, e
15'/16
173/,6
Low Profile Register
258
9"/,e
10'/,8
12'h
15%
BRE, BRP,
Series 76 Registers
AR, MR,
16'/2
17%
20'/,8
221/2
SR&TR
*
Read-o-Matic
ROM 570
13'/,8
14'/,6
15/,6
17'/18
Electric Contacting
EC-A
11'/,8
11 "/,e
14'/4
16%
Register, Adjustable
COMPONENT PARTS
MATERIAL
Housing ..........................
316 Stainless
..........................
Cast Iron
..........................
Cast Steel
..........................
Cast Bronze
Rotor .............................
Kynar
.............................
Ryton
Nose Cone ........................
Kynar
Rotor Bearing, Spindle and
Endstone .......................
Ceramic
Magnet (2-Pole and 4-Pole) .........
Ceramic
Operating Head ...................
316 Stainless
Straightening Vanes ...............
316 Stainless
Register Base .....................
Aluminum
Bypass Valve .....................
316 Stainless
(2" and 3" meters)
Operating Head Gasket............
Asbestos/
Special Binder
.......
Nonasbestos
Nit rile,
Chloroprene
Binder
"0" Ring and Tetraseal ............
EPR
............
BunaN
............
Viton A
Tables 1-1. Configuration and Specification Data for 2" through 6" Turbo Meters
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AUTOMATIC RESET MANUAL RESET SIGNAL ELECTRIC
REGISTER REGISTER REGISTER REGISTER
MODEL AR MODEL MR MODEL SR MODELBRE-1
MODEL BRE-2
T
P
un1Ve
COUPLING
+ METER CHANGE GEAR
PNEUMATIC
REGISTER
MODEL BRP-1
MODEL BRP-2
TOTALIZING
REGISTER
MODEL 258
MODEL
2630 SERIES
S ujl
PULSE INPUT
RECEIVERS
LOAD PACK
(OPTIONAL)
MODEL RBC
REMOTE BATCH
CONTROLLER
MODEL
EPL
PROCESSOR
TOTALIZING
RESET REGISTER
MODELTR
ELECTRIC
CONTACTING
REGISTER,
ADJUSTABLE
MODEL EC-A
MODEL MS-ER1
PULSE TRANSMITTER
W/LOCAL REGISTER
MODEL MS-El
PULSE TRANSMITTER
METER &TRANSMITTER
CHANGE GEARS
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it
A meter-mounted and driven accessory device such as
a register or pulse transmitter must be used with
Badger turbo meters to obtain a visual and/or signal
output that is directly proportional to the volume of
liquid flowing through the meter. Figure 1-1 illustrates
the many meter-accessory combinations available.
Figure 1-2 indicates the remote instruments and con-
trols that are available. When using the EPU proces-
sor, the meter is furnished with an EPT-2 transmitter
and the Kynar or Ryton rotor has a four-pole magnet.
For detailed information (such as function, dial capaci-
ties, unit of measure, pulse rates, etc.) regarding any
of the accessories shown, contact your local Badger
Meter representative or the Industrial Products Divi-
s ion of Badger Meter, Inc.
SECTION 11
INSTALLATION
To avoid damage in transit, Badger turbo meters are
shipped to the customer in special shipping containers.
Upon receipt of the order, perform the fol lowing unpack-
ing and inspection procedures:
I NOTE
If damage to a shipping container is evident
upon receipt of a meter, request the carrier
to be present when the meter is unpacked.
a. Carefully open the shipping container following
instructions that may be marked on the container.
Remove all cushioning material surrounding the
meter and carefully lift the meter from the container.
Retain the container and all packing material for
possible use in reshipment or storage.
b. Visually inspect the meter and applicable accessory
device for any physical damage such as scratches,
loose or broken parts or other signs of damage that
may have occurred during shipment.
I NOTE
If damage is found, request an inspection by
the carrier's agent within 48 hours of delivery.
Then file a claim with the carrier. A claim for
equipment damaged in transit is the responsi-
bi I ity of the customer.
The procedures for installing Badger turbo meters are
essentially the same for all meter sizes. Any special
instructions required for the installation and/or elec-
trical connection of meter-mounted or free-standing
accessory devices such as registers, pulse transmit-
ters, valves and remote batch controllers will be pro-
vided as a supplement to this manual.
a. PRELIMINARY CONSIDERATIONS. Before proceeding
with the installation, read the instructions given
in the following paragraphs to become familiar with
the requirements and procedures involved.
NOTE
Badger's 2" through 6" industrial turbo
meters are designed for operation in HORI-
ZONTAL piping arrangements.
1. Verify that the operating temperature range of
the meter is compatible with the temperature
range of the liquid to be metered. These meters
can be used to meter both cold and hot liquids
up to 250 degrees fahrenheit.
2. Ensure that the flow range of the meter coincides
with the flow rate of the liquid to be metered.
Refer to Tables 1-1 in Section I of this manual
for the applicable meter flow range specifica-
tion data.
I CAUTION
The life of the turbo meter will be impaired
if operated at flow rates higher than specified.
3. If solid material is present in the liquid to be
metered, a strainer must be installed in the
facility piping upstream of the meter. The 2",
3" and 4" meters require a strainer with `,46"
diameter holes and the 6" meter requires a
strainer with 18" diameter holes,
4. Avoid locating the meter in close quarters.
Allow sufficient space to permit access for
cleaning and maintenance.
5. To permit periodic cleanout of the meter and
to provide a convenient means of stopping fluid
flow during maintenance, it is recommended that
a flushing system be incorporated into the
facility piping arrangement (see Figure 2-1).
b. INSTALLING THE METER. Badger turbo meters are
designed for horizontal, in-line installation. The
overall dimensions (including laying lengths) of
each of the meter sizes are given in Tables 1-1
in Section I of this manual. After reviewing the
applicable dimensional requirements, proceed as
fol lows:
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1. Measure the overall length of the meter with the
gaskets attached to the inlet and outlet flange
connections of the turbo meter.
2. Provide proper gap length in the facility piping.
3. Install the meter in the pipeline making sure
that the flow arrow on the meter housing is in
proper relation to the direction of liquid flow.
4. Install and tighten the flange connection bolts.
5. To relieve possible strain on the piping due to
the weight of 4" and 6" turbo meters, it is
recommended that a meter support be installed
under the meter housing.
Complete the following checks to ensure that the
meter is properly installed and operational.
a. Slowly open the upstream valve to apply liquid
pressure to the meter and check the flange con-
nections for possible leaks. Retighten the flange
bolts as required.
b. Perform a functional test of the turbo meter using
the adjustment and calibration procedure given in
Section IV, Paragraph 4-4 of this manual.
SECTION III
OPERATION
The instructions for operating Badger turbo meters
depend on the meter-accessory combination employed
and the type of flow control devices used in the facil-
ity piping. In general, operation of the meter can be
either manually controlled or accessory controlled.
Manual operation applies to metering applications em-
ploying hand-operated valves or other manually-
activated, flow-regulating devices that are not func-
tionally controlled by a meter accessory device.
Accessory controlled operation is used in metering
applications involving meter accessories that provide
an electronic, electrical or pneumatic signal to acti-
vate and/or deactivate a valve or other type of flow
control device.
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10
I CAUTION
Regardless of the operating procedure used,
the valves or devices controlling the flow
of liquid through the turbo meter must always
be opened and closed slowly to prevent shock
loads that may damage the meter's rotor
assembly.
a. MANUAL OPERATION. Instructions for the manual
operation of a turbo meter are limited to the fol-
lowing start and stop procedures. The procedures
are intended for use in simple metering applica-
tions where the flow of liquid through the meter is
controlled by hand-operated valves located in the
facility piping upstream and downstream of the
meter.
1. Slowly open the upstream valve and apply liquid
to the meter.
2. Slowly open the downstream valve to initiate
metering.
3. Adjust the downstream valve so that the rate of
flow does not exceed the maximum continuous
flow rate specification of the meter (Refer to
Tables 1-1 in Section I of this manual for the
applicable flow rate specification data).
NOTE
On meters equipped with an accessory device
providing a totalizing indicator, the rate of
flow can be quickly checked by timing the
number of gallons registered through the meter
in one minute.
4. To stop metering, slowly close the downstream
valve, then close the upstream valve.
b. ACCESSORY CONTROLLED OPERATION. The step-
by-step operating procedures used in accessory
controlled metering applications are dependent on
the specific function of the meter-accessory em-
ployed and its electrical or pneumatic interconnec-
tion with the flow control device or devices. Refer
to the IOM manuals covering the applicable acces-
sories for specific operating instructions (included
as a supplement to this manual when required.)
If the turbo meter is to be shut down for an extended
period of time, it is recommended that the measuring
.chamber be thoroughly flushed to prevent the settling
out of undissolved solids or the accumulation of
corrosive deposits.
I
This section contains information for servicing and
maintaining Badger turbo meters. The information con-
sists of preventive maintenance, calibration and serv-
ice instructions. Exploded views, a parts list and other
illustrations are provided as a supplement to the text.
The tools and equipment recommended for use in serv-
icing and maintaining turbo meters are listed in Table
4-1. With the exception of a special change gear mesh
gage and a calibration test tank, the tools required
are the usual compliment of standard hand tools used
by plumbers and mechanics.
DESCRIPTION
SPECIFICATION
Tool Kit .....................
Std. Mechanics Tools
Truarc Right-Angle Pliers ....
PIN 1549
Change Gear Mesh Gage ....
Badger PIN 21747
Test Tank ...................
Calibrated Volume
The purpose of preventive maintenance for turbo meters
is to ensure efficient operation and long life by de-
tecting and correcting any defects before damage or
failure occurs to the meter. Preventive maintenance
consists of periodic inspection and cleaning pro-
cedures.The procedures should be performed at regular
intervals and any defects discovered should be cor-
rected before attempting further operation of the meter.
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1. Visually inspect the turbo meter and meter-
mounted accessory for missing hardware, loose
connections, broken or scratched register lens,
damaged wiring or any other signs of wear or
deterioration. Repair or replace components as
required.
2. Verify that the meter operates at the proper flow
rate and pressure. A loss in pressure, coupled
with the resulting decrease in flow rate, may
indicate the screen in the upstream pipeline is
clogged with material and requires cleaning.
1. Clean all dust, dirt, grease, moisture or other
foreign material from the exterior of the meter
and meter-mounted accessory. Use a dry clean-
ing solvent or volatile mineral spirits to remove
grease or oil. After cleaning, rinse with water
and dry thoroughly.
2. If the facility piping arrangement includes a
flushing system (See Figure 2-1 ), shut off liquid
flow to the meter and flush the interior of the
meter with clean water or other appropriate
cleaning fluid to remove any buildup of internal
deposits or corrosion.
Accuracy of Badger turbo meters is tested at the fac-
tory with water. However, since these meters will be
used to measure a wide variety of liquids that could
vary in viscosity, it may be necessary to recalibrate
a meter under operating conditions using the actual
liquid. The following instructions are provided to
assist the customer in performing an on-site calibra-
tion check and adjustment.
1. Place a test tank of known volume at the output
of the meter.
2. Operate the meter until the test tank is filled
to a calibrated level. Since the accuracy of the
meter may vary slightly with the flow rate, make
a test run at the actual flow rate used in the
operation.
3. Record the quantity indicated on the meter-
mounted accessory.
4. Repeat the test three times and take the average
of the readings.
5. Perform the following calculations to determine
percent of accuracy of the meter-accessory
combination:
Qty. Indicated on Accessory x 100 = Meter Accuracy
Actual Quantity in Test Tank
95 Gal Ions
100 Ga l Ions x 100 = 950/c accuracy
In this example the meter-mounted accessory is
slow and must be speeded up by a change gear
correction.
104 Gallons? ~nn_ ~nno;
In this example the meter-mounted accessory is
fast and must be slowed down by a change gear
correction.
b. CHANGE GEAR CORRECTIONS. If the accuracy
test of a turbo meter-accessory combination indi-
cates that an adjustment is required, proceed as
follows:
1. Remove the accessory from the register base
on the turbo meter. To remove the change gears
from the spindles on the register and the regis-
ter base, loosen the setscrew on the hub of the
change gears.
Both the C.D. dimension (in decimal inches)
and the number of teeth are stamped on each
gear.
2. Calculate the ratio of existing change gears
as fol lows:
Ratio - No. of Teeth on Register Change Gear
No. of Teeth on Meter Register Base
3. Calculate the new change gear ratio required by
multiplying the ratio of existing change gears
by percent-of-meter accuracy determined in
section 4-4a.
Existing Change Gear Ratio - 42 Teeth 976
43 Teet h
Meter Accuracy = 95%
95
Corrected Change Gear Ratio = .976 x 10
0 .927
4, Select a combination of new change gears that
match the corrected change gear ratio. If stocked
change gears are not available, submit order
for change gears to your nearest Badger Meter
representative or the Industrial Products Divi-
sion of Badger Meter, Inc.
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When ordering, give the serial number of the
turbo meter which is stamped on the outlet
flange of the meter. Specify the meter size
and accessory device employed along with
the number of teeth and diameter on existing
change gears. Specify the corrected change
gear ratio.
5. Install the corrected change gears on the regis-
ter base and register spindles taking care that
the correct change gears are assembled to the
appropriate spindles (See Figure 4-1). Assemble
the register to the register base on the meter.
Refer to section 4-7a for instructions covering
the proper method of installing and meshing
change gears. On meters with 76 Series regis-
ters, provision for change gear adjustment is
built into the registers. See the applicable
register IOM manua I for reca I ibrati ng instructions.
TURBO METER
OPERATING HEAD
ASSEMBLY
Figure 4.1. Change Gear Location
Register Base and Register Assembly
NOTE
For instructions on removing and installing the
gear train assembly in the new and old-style
register bases, request Service Note 16. The
Service Note explains and illustrates the dif-
ference between these two register bases.
Badger's 2" and 3" turbo meters with bronze and cast
iron housings are equipped with a bypass valve for
"minor" calibration adjustment in the field. Test the
meter's accuracy to determine if recalibration is
required. If the meter is out of calibration, proceed as
follows:
CALIBRATE METER
WITHOUT REMOVING
FROM LINE
BYPASS VALVE
ON SIDE OF
HOUSING
TURN VALVE
WITH SCREWDRIVER
TO ADJUST FLOW
1. Remove the bypass cover nut with a wrench.
2. Using a wide-bladed screwdriver, loosen the
bypass valve lock ring.
3. Adjust the bypass valve with a screwdriver in
the following manner (See Figure 4-2):
a. To INCREASE registration, turn the slot in
the valve perpendicular to the axis of the
meter (line of flow). This will restrict the
amount of volume flowing through the bypass
and increase flow through the metering
chamber.
b. To DECREASE registration, turn the slot in
the valve parallel to the axis of the meter.
This will increase liquid volume through the
bypass and decrease flow through the meter-
ing chamber.
I NOTE
The total range of the bypass adjustment
occurs within a 90 degree or quarter turn of
the valve from the parallel, inline position
to the perpendicular position, or vice versa.
The total range of adjustment is about four
percent. Tested and calibrated at the factory,
the bypass valve will be set at about 450
from the full "open" or "closed" position.
This setting will allow for a ?2% adjustment
to recalibrate the meter in the field.
4. With the valve turned to the desired bypass
setting, tighten the valve lock ring.
5. Install and tighten the bypass valve cover nut.
6. Retest the meter to confirm the accuracy of the
bypass adjustment. If the meter is still out of
calibration, repeat the procedure outlined above.
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Badger turbo meters can be serviced without removing
the meters from the system. A typical service (See
Figure 2-1) is equipped with drain and piping valves.
To inspect or replace component parts of the head
assembly, close the upstream and downstream valves.
If the installation is equipped with an inlet and drain
valve for flushing the meter, open the drain valve to
relieve pressure from within the meter. However, if
the meter piping is not equipped with a drain valve,
proceed as fol lows to relieve pressure within the meter:
1 . Do not remove the register base from the oper-
ating head assembly. The entire head assembly
must be removed as a complete unit (See
Figure 4-3).
2. Loosen each of the head bolts about one and
one-half turns. Do not remove the bolts com-
pletely.
3. If the gasket-seal between the meter head and
the housing is not leaking at this time, pry the
head assembly loose with a screwdriver. To
accomplish this, insert the screwdriver from
the outlet side of the head assembly where the
head and housing join together.
I CAUTION
Exercise precaution to make certain that fluid
does not spray from the meter. The liquid
spray could contact electrical equipment and
create an electrical hazard.
4. Allow the meter to drain and relieve internal
pressure.
5. When pressure is relieved, remove the head
bolts and shift the head assembly toward the
outlet-end of the meter to release the head-to-
housing seal. Then lift the entire head assembly
from the housing and, at the same time, tilt the
operating head up to prevent the rotor from
falling off the rotor spindle.
N
F OTE
Rotors made of Kynar or Ryton are furnished
with two-pole and four-pole magnets depend-
ing on the type of application. Rotors with
four-pole magnets are used with Badger's
EPT-2 transmitter and EPU processor (elec-
tronic transmission system).
6. When the operating head has been removed, lift
the rotor out of the rotor cage and set it aside.
Remove the head gasket.
NOTE
HEAD
GASKET
METER
HOUSING
Figure 4-3. Turbo Meters Serviced
Without Removal from the Line
A dummy cover plate is available to close
the meter in the line and continue service
while the operating head assembly is being
inspected or parts are being replaced.
7. To remove the register base from the head
assembly, loosen the seal screw on the base
with a screwdriver. Rotate the base 45 degrees
in either direction to release it from the bayonet
lockdetents on the head assembly.
8. The register base retaining ring is accessible
through the rotor cage in the head assembly.
With a Truarc right-angle pliers #1549, expand
and remove the register retaining ring on the
extension tube. When this is accomplished, the
register base can be removed from the head
assembly.
9. To reinstall or replace the register base, repeat
the procedure above in reverse making sure
that the retaining ring has been reinstalled on
the extension tube.
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The head unit has a gasket bonded to the
periphery of the rotor cage. Depending on
the chemical solution to be metered, the
gasket will be made of EPR,Buna N orViton A
material. Reinserting the head assembly into
the meter housing correctly will require com-
pressing the gasket slightly. This is done by
tilting the top of the register base on the head
toward the inlet side of the meter. The meter
head has a pilot diameter machined into the
cage at the gasket face. This pilot diameter
must extend through the housing gasket inner
diameter and into the housing bore. After
lowering the head assembly into the housing,
move the entire head assembly straight to-
ward the inlet side of the meter. The pilot
diameter must snap into the bore of the hous-
ing to provide a tight seal.
10. With the head gasket aligned and the head
assembly properly positioned in the housing,
reinstall and tighten the head bolts (between
90-180 in.-Ibs. of torque).
11. Close the flushing system drain valve. Open
the upstream valve partially, then open the
downstream valve slightly which will purge any
air from the service line. Then open both valves
completely.
For periodic inspection or when operation of the turbo
meter indicates a need for servicing, refer to the fol-
lowing paragraphs for instructions covering the re-
moval, inspection and installation of service parts and
assemblies. Refer to the illustrated parts list in Sec-
tion V of this manual for part numbers of replaceable
components and the correct ordering information. Any
service or repair procedures that apply to a meter-
mounted or free-standing accessory are provided in the
IOM instruction manual pertaining to that device (also
provided as a supplement to this manual.) If satis-
factory repair cannot be made, contact the Industrial
Products Division of Badger Meter, Inc.
1. Replacing the change gear on the register base
spindle requires no gage to properly mesh this
gear with the register change gear. A shoulder-
stop is built into the spindle at the proper gear
height thus eliminating gear adjustment.
2. The change gear in the register should be in-
stalled with the aid of a Badger change gear
mesh gage (P/N 21747) to ensure proper gear
mesh.The procedure is as follows:
GEAR MESH GAGE
P/N 21747
METER-MOUNTED
ACCESSORY
67
/ FIXED GEAR POSITION -
REGISTER BASE GAGE NOT REQUIRED
Figure 4-4. Replacing Turbo Meter Change Gears
Register Base and Register (or Accessory)
(a) Place the bottom of the register on the top
edge of the gage (See Figure 4-4).
(b) Adjust the change gear on the register spin-
dle so that it rests against the "top" of the
slot in the gage. Holding the change gear
in this position, tighten the setscrew in the
hub of the change gear.
I NOTE
Install the change gears on the spindles with
the hub of the gears in the "UP" position.
(c) Carefully install the register on the base
making sure that the gears fully mesh. In-
stall and tighten the register seal screws.
CAUTION
Take care not to bend the spindles when
installing the gears or reassembling the
register to the register base.
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The location and identification of assemblies and
parts comprising the 2", 3", 4" and 6" turbo meters
are shown on the exploded view illustration. Each
assembly or part shown is identified by an index num-
ber that is cross-referenced to an associated parts list.
a. Specify the turbo meter size.
b. Specify the type of meter housing material (for
compatibility with fluid).
c. Type of meter-mounted accessory:
(1) With register, specify the model of register and
unit of measure plus the dial capacity.
(2) With pulse transmitter, specify the model of
unit and pulse/unit of measure.
The parts list consists of the service assemblies and
parts that are shown in the exploded illustration. The
Iist provides the following information:
a. ITEM NUMBER
b. NAME OF PART
c. PART NUMBER
Order replaceable parts through your local Badger Meter
sales representative or directly from Industrial Sales
Section of the Flow Products Division, Badger Meter,
Inc. When placing an order, provide the following in-
formation:
(3) With free-standing accessory such as a remote
batch controller, specify the model and the
number of stages. If an EPU processor, specify
the options desired.
d. Complete description of the assembly or parts
required.
e. Part number of the item as indicated in the parts
Iist.
f. Quantity of parts required.
A purchase order number plus exact return and
billing address.
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Figure 4.5. Typical Badger Turbo Meter/Accessory Combinations
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
13
NOTE:
Select items 16, 21, 22 and
32 to be compatible with
metered fluid. Item 21 -
four-pole rotors used with
EPT-2 transmitter.
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
PARTS LIST
i
ITEM
NO.
NAME OF PART
2" PART
NUMBER
3" PART
NUMBER
4" PART
NUMBER
6" PART
NUMBER
1
Hood Assembly, Register ...............................
58234-00200
58234-00200
58234-00200
58234-00200
2
Gasket, Register Cover .................................
58404-00100
58404-00100
58404-00100
58404-00100
3
Register Assy., Specify Meter Size & Registration Regd...
21228-00000
21228-00000
21228-00000
21228.00000
4
Screw, Cover to Register Base ..........................
55046-25100
55046-25100
55046-25100
55046-25100
5
Lockwasher ...........................................
55293-01000
55293-01000
55293-01000
55293-01000
6
Change Gear, Register (Specify no. of teeth and dia.) .....
- - - - - - -
- - - - - - -
- - - - - - -
- - -
7
Change Gear, Register Base (Spec. no. of teeth and dia.) ..
- - - - - - -
- - - - - - -
- - - - - - -
- - - - - - -
8
Setscrew, Change Gear .................................
1065-00000
1065-00000
1065-00000
1065-00000
9
Tetraseal ..............................................
22559-03400
22559-03400
22559-03400
22559-03400
10
Register Base Assembly, 3662/3:1 .......................
56786-00100
56786-00100
56786-00200
56786-00300
10
Register Base Assembly, 1200:1 .........................
56786-00400
56786-00400
56786-00500
56786-00600
11
Register Base, Only ...........................
56785-00100
56785-00100
56785-00200
56785-00300
12
Gear Train Assembly w/Magnet, 3662/3:1 .................
56782-00100
56782-00100
56782-00200
56782-00300
12
Gear Train Assembly w/Magnet, 1200:1 ..................
56782-00400
56782-00400
56782-00500
56782-00600
13
Ring, Gear Train Assy. Retaining ........................
1013-00000
1013-00000
1013-00000
1013-00000
14
Retaining Ring, Register Base (316 S.S.) .................
22886-01200
22886-01200
22886-01200
22886-01200
*14
Retaining Ring, Register Base (Bronze) ..................
22886-01300
22886-01300
22886-01300
22886-01300
*15
Spacer, Register Base ..................................
57337-00100
57337-00100
57337-00100
57337-00100
*16
*
"O" Ring, Register Base, Buna N ........................
55300-11000
55300-11000
55300-11000
55300-11000
16
"O" Ring, Register Base, EPR ...........................
31132-04600
31132-04600
31132-04600
31132-04600
*16
"O" Ring, Register Base, Viton A ........................
31132-04500
31132-04500
31132-04500
31132-04500
17
Bolt, Hex. Head ........................................
55030-16600
55030-16600
55031-11600
55031-11600
18
Head Only .............................................
57312.00100
57312-00100
57282-00100
57287-00100
19
Nut, Hex., Rotor Spindle ................................
55006-03500
55006-03500
55007-02800
55007-02800
20
Lockwasher, Rotor Spindle .............................
55274-00800
55274-00800
55274-01100
55274-01100
21
Rotor & Spindle, Kynar, 2-Pole (Buna N Seal) .............
56998.00500
56998-00600
56998-00700
56998-00800
21
Rotor & Spindle, Kynar, 2-Pole (EPR Seal) ................
56998-01300
56998-01400
56998-01500
56998-01600
21
Rotor & Spindle, Kynar, 2-Pole (Viton Seal) ...............
56998.00900
56998-01000
56998-01100
56998-01200
21
Rotor & Spindle, Ryton, 2-Pole (Buna N Seal) .............
56998.03400
56998-03500
56998-03600
56998-03700
21
Rotor & Spindle, Kynar, 4-Pole (Buna N Seal) .............
56998-02000
56998-02100
56998-02200
56998-02300
21
Rotor & Spindle, Kynar, 4-Pole (EPR Seal) ................
56998-02800
56998-02900
56998-03000 1
56998-03100
21
Rotor & Spindle, Kynar, 4-Pole (Viton Seal) ...............
56998-02400
56998-02500
56998-02600
56998-02700
21
Rotor & Spindle, Ryton, 4-Pole (Buna N Seal) .............
56998-04600
56998-04700
56998-04800
56998-04900
*22
Tetraseal, Head, Buna N ................................
22559-04300
22559-04300
22559-04400
22559-04500
*22
Tetraseal, Head, EPR ...................................
22559-04700
22559-04700
22559-04800
22559-04900
*22
Tetraseal, Head, Viton A ................................
22559-05000
22559-05000
22559-05100
22559-05200
23
Nose Cone ............................................
57341-00300
- - - - - - -
- - - - - - -
- - - - -
*24
Gasket, Head, Asbestos/Spec. Binder (Viton Seal only) ...
34899-00200
34899-00200
56331-00200
56327-00200
*24
Gasket, Head, Nonasbestos for Buna N Seal only ........
34899-00300
34899-00300
56331-00300
56327-00300
*24
Gasket, Head, Nonasbestos for EPR Seal only ...........
34899-00400
34899-00400
56331-00400
56327-00400
25
Housing, Bronze, 150# Flange ...........................
56079-00100
34841-00100
5/280-00100
57288-00100
25
Housing, Bronze, 300# Flange ...........................
56079-00200
34841-00200
57280-00200
57288-00200
25
Housing, Cast Iron, 125# Flange .........................
56079-00400
34841-00300
57280-00300
57288-00300
25
Housing, Cast Iron, 250# Flange .........................
56079-00500
34841-00400
57280-00400
57288-00400
25
Housing, Cast Steel, 150# Flange ........................
57640-00100
34841-00500
57280-00900
57288-00900
25
Housing, Cast Steel, 300# Flange ........................
57640-00200
34841-00600
57280-01000
57288-01000
25
Housing, 316 Stainless, 150# Flange .....................
57640-00300
34841-00700
57280-01100
57288-01100
25
Housing, 316 Stainless, 300# Flange .....................
57640-00400
34841-00800
57280-01200
57288-01200
26
Retaining Ring, Straightening Vane .....................
34900-00200
34900-00100
34900-00300
34900-00400
27
Straightening Vane Assembly, Complete ................
- - - - - - -
34880-00200
56340-00300
56340-00400
28
Straightening Vane .....................................
56082-00100
- - - - - - -
- - - - - - -
. - - - - - -
29
Straightening Vane .....................................
56083-00100
- - - - -
- - - - - - -
30
Straightening Vane .....................................
56084-00100
--- . ---
- - - - - - -
-------
31
Cover Nut, Bypass Valve ................................
34870-00200
34870-00200
- - - - - - -
- - - - - - -
"32
"O" Ring, Bypass Valve, Buna N .........................
55300-02200
55300-02200
- - - - - - -
. .
*32
"O" Ring, Bypass Valve, EPR ...........................
31132-04300
31132-04300
- - - - - - -
- -
*32
"O" Ring, Bypass Valve, Viton A .........................
31132-04400
31132-04400
- - - - - - -
- - - - - -
33
Lock Ring, Bypass Valve ................................
34897.00200
34897-00200
- - - - - - -
- - - - -
34
Valve, Bypass ..........................................
34869.00200
34869-00200
- - - - - - -
- - - - - - -
Dummy Cover (Not Shown) .............................
56813-00100
56813-00100
56814-00100
56815-00100
Gasket, Dummy Cover (Not Shown) ......................
57646.00100
57646-00100
57647-00100
57648-00100
35
Industrial Head Assembly, Complete, Specify Fluid ......
57381-00000
57381-00000
57381-00000
57381-00000
Service Note: For 2" and 3" turbo meters, "shims" are provided with the rotor spindle. It is important to reinstall shims when servicing
rotor and spindle assembly.
`Recommended spare parts.
Rotors with 4-pole magnets used only with EPT-2 transmitters.
NOTE: When ordering parts, give part numbers, name of parts model and size of meter. For prices, refer to Repair Parts Price List
PPL-903.
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
WARRANTY
Badger warrants meters and parts manufactured by it and supplied hereunder to be free from defects
in materials and workmanship for a period of 18 months from date of shipment or 12 months from
date of installation, whichever period shall be shorter. If within such period any meters or parts shall
be proved to Seller's satisfaction to be defective, such meters or parts shall be repaired or replaced
at Seller's option. Seller's obligation hereunder shall be limited to such repair and replacement and
shall be conditioned upon Seller's receiving written notice of any alleged defect within 10 days after
its discovery and, at Seller's option, return of such meters or parts to Seller f.o.b. its factory. THE
FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WAR-
RANTIES WHATSOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EXCEPT OF
TITLE) OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Badger shall not be
liable for any defects attributable to acts or omissions of others after shipment, nor any consequen-
tial, incidental or contingent damage whatsoever.
NUCLEAR DISCLAIMER
Equipment sold by Badger Meter, Inc. is not intended for use in connection with any nuclear facility or
activity unless covered by a specific quotation where the conditions of such usage will be detailed. If
equipment is used in a nuclear facility or activity without a supporting quotation, Badger Meter
disclaims all liability for any damage, injury or contamination, and the buyer shall indemnify and hold
Badger Meter, its officers, agents, employees, successors, assigns and customers, whether direct or
indirect, harmless from and against any and all losses, damages or expenses of whatever form or
nature (including attorneys' fees and other costs of defending any action) which they, or any of them,
may sustain or incur, whether as a result of breach of contract, warranty, tort (including negligence),
strict liability or other theories of law, by reason of such use.
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
BADGER
1 SERIES 76 METER REGISTERS
For Water Conditioning
4
MODEL AR
Automatic Reset Register
Register Models AR and SR are used to measure pre-
determined quantities of liquid and then transmit a
signal which activates other equipment. Their widest
application is in water conditioning systems.
The principal difference between the two registers is
that Model AR resets itself automatically for each water
conditioning cycle, whereas the SR is reset with a
register knob.
The AR register is equipped with a nickel-plated reset
pointer and a red sweep pointer which moves counter-
clockwise from the preset position. When the red
pointer reaches zero, a trip cam closes a signal switch
and a motor switch. The signal is used to start tank
regeneration, while the motor resets the pointers at
their original position.
With the SR register, the red pointer is used to preset
small quantities and the nickel pointer for larger
amounts. When both pointers reach zero, a double-
throw switch is actuated. This switch can be connected
to an electrical circuit to operate a warning bell or alarm,
a pump, valve or other equipment.
MODEL SR
Signal Register
Models AR and SR are part of the Series 76 line of inter-
changeable meter registers for use on Badger's
industrial-type meters. Three other Series 76 registers,
used primarily for liquid batching, are described in
Bulletin IBR-3010.
AR AND SR REGISTER SPECIFICATIONS
PHYSICAL
Housing: Glass-filled polycarbonate- NEMA4
Internal Plates: Brass
Gears: Brass or Thermoplastic
Shafts: 303 Stainless Steel
Register Size: 71/2 " width, 8'/e" height, 634" depth
Dial Size: 53/4"
Totalizer: Six-digit, non-reset
ELECTRICAL
Contact Rating: 7 amps at 115 VAC
AR register available for 24 VAC, 115 VAC, and 230
VAC
BadgerMeter,Inc. Industrial Products Division
4545 West Brown Deer Road, Milwaukee, Wisconsin 53223
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
OPERATION OF AR REGISTER OPERATION OF
SR REGISTER
The register is preset by loosening two screws in the
pointer hub and moving the pointers to the desired posi-
tion. This setting is then "locked in" by retightening the
hub screws. (For detailed instructions, see Installation
Manual IOM-024.)
As liquid is metered, the red sweep pointer moves
counterclockwise. At the zero reading, a cam on the
pointer shaft closes the signal and reset motor
switches.
The reset motor drives the nickel-plated reset pointer
counterclockwise until it also reaches zero. The nickel
pointer "picks up" the red pointer and carries it back to
the original preset position.
The motor switch opens, the motor stops, and the signal
to external equipment is terminated. The register is now
ready for the next metering cycle.
For installations with more than one water conditioning
tank, the AR can be supplied with a built-in relay which
can be wired into the control circuit in accordance with
the recommendations of the water conditioner
manufacturer.
Both Pointers
In Preset Position
Nickel Pointer
Also Moves to Zero
Red Pointer
Rotates to Zero
Both Pointers
Return to Preset
To preset Model SR, push in the knob on the front of the
register and turn it counterclockwise until the pointers
reach the desired setting. The nickel-plated inner
pointer will move one graduation for each complete
revolution of the red outer pointer.
Release the knob and the register will be ready for the
metering cycle.
As liquid is metered, the pointers will rotate toward
zero. When they reach zero position, a built-in cam
closes the signal switch. In a typical installation, the
signal is used to operate an alarm or light so the opera-
tor knows that a tank needs regeneration.
When regeneration is completed, the operator resets
the register to the desired quantity.
0 6
0 2
~
DIAL CAPACITIES
c
FOR AR AND
c
c
SR REGISTERS
D
-
B
,~
A
A
A
A--~I
AR REGISTERS
518" Disc
314" Disc
1" Disc
1Y2" Disc
2" Disc
2" Turbine
3" Turbine
4" Turbine
2" Turbo
3" Turbo
4"
Turbo
6" Turbo
100
x
x
x
200
x
x
x
500
x
x
x
1,000
2,000
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
5,000
x
x
x
x
x
x
x
x
x
x
10.000
x
x
x
x
x
x
x
x
x
x
20,000
x
x
x
x
x
x
x
x
x
x
50,000
x
x
x
x
x
x
x
x
x
x
x
x
100,000
x
x
x
x
x
x
x
x
x
x
x
x
200,000
x
x
x
x
x
x
x
x
x
x
x
x
500,000
x
x
x
x
x
x
x
x
x
x
x
x
1,000,000
x
x
x
x
x
x
x
x
x
2,000,000
x
x
x
x
x
x
x
x
x
5,000,000
x
x
x
x
x
x
x
x
x
10,000,000
x
x
Basic AR register dials in gallons. Metric dials in litres up to 50,000. Dials 100,000 and above are in equivalent M3.
SR REGISTERS
Inner Pointer
Outer Pointer
3,000
100 x
x
x x
x x
x
x x
x
30,000
1,000 x
x
x x
x x
x
x x
x
x
x
300,000
10,000 x
x
x x
x x
x
x x
x
x
x
3,000,000
100,000
x
x x
x
x x
x
x
x
Basic SR dials in gallons. Metric dials in litres up to 30,000.
Dials 300,000 and above are in equivalent M3.
DIMENSIONS
(In Inches)
fl,
14
16
18-3/8
2,-1/8
15-1 /4
24
10
14
B
7-1 /2
9
10-3/4
12-5/8
15-1 /4
co
15-1 /16
15-7/16
16-7/8
18-7/16
20-1/16
28-15/16
35-1 /2
35-7/8
16-7/8
17-1
/8
20-1/16
22-1
/2
D
1-3/8
1-3/4
2-1/4
2-5/8
3-7/16
8-1 /16
12-3/4
13-5/16
2-3/4
3-1
/2
4-1 /4
5-1
/4
Max. Depth
6-1/2
6-3/4
7-1/8
9-1/2
12-9/16
8-1/8
12-1 /2
12-3/4
6-13/16
7-1
/2
9
11
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
MODEL AR WIRING DIAGRAMS
AR With Relay
AR Less Relay
MODEL SR WIRING DIAGRAM
Badger warrants meters and parts manufactured by it and supplied
hereunder to be free from defects in materials and workmanship for
a period of 18 months from date of shipment or 12 months from
date of installation, whichever period shall be shorter. It within such
period any meters or parts shall be proved to Seller's satisfaction to
be defective, such meters or parts shall be repaired or replaced at
Seller's option. Seller's obligation hereunder shall be limited to such
repair and replacement and shall be conditioned upon Seller's
receiving written notice of any alleged defect within 10 days after
its discovery and, at Seller's option, return of such meters or parts
to Seller f.o.b. its factory. THE FOREGOING WARRANTY IS EXCLU-
SIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WAR-
RANTIES WHATSOEVER INCLUDING BUT NOT LIMITED TO
IMPLIED WARRANTIES (EXCEPT OF TITLE) OF MERCHANTABIL-
ITY AND FITNESS FOR A PARTICULAR PURPOSE. Badger shall
not be liable for any defects attributable to acts or omissions of
others after shipment, nor any consequential, incidental or contin-
gent damage whatsoever.
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
INSTALLATION
OPERATION AND
MAINTENANCE
MANUAL
0
MODELS AR AND SR
METER REGISTERS
BadgerMeter,Inc. Industrial Products Division
4545 West Brown Deer Road, Milwaukee, Wisconsin 53223
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 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
SCOPE OF THE MANUAL
This manual provides information pertaining to the in-
stallation, operation and maintenance of Badger Series 76,
Models AR and SR Meter Registers. Before attempting
installation, operation or maintenance, read the instructions
presented to become familiar with the procedures involved.
Retain the manual in a readily accessible location for future
reference.
CHANGES IN THE MANUAL
Changes or additions to the manual are covered by a
''CHANGE NOTICE'' form that is supplied with the manual
when applicable. The ''CHANGE NOTICE'will explain any
differences between the register received and the registers
covered in this manual.
Table 1-1. Technical Specifications
DRIVE ............................................. Mechanical 2-pin direct coupling (Adapter must be used
for magnetic drive meters)
MOUNTING ........................................ 4 holes equidistant on 3.665 in. diameter circle
DIMENSIONS
Height ........................................... 8-7/8 in.
Width ........................................... 7-1/2 in.
Depth ........................................... 7-1/2 in. SR
6-3/4 in. AR
WEIGHT ........................................... 8 lbs.
DIAL
Diameter ........................................ 5-3/4 in.
Display .......................................... White on black
TOTALIZER COUNTER
Type ............................................ Non-resettable
Display .......................................... Six-digit (to 999,999)
Numerals ........................................ 5/32 in. high - white on black
ENCLOSURE
Type ............................................ Moistureproof and dustproof
Housing and base ................................ NEMA-4, foam molded polycarbonate, glass filled
Bezel ............................................ Clear polycarbonate
MODEL AR -
AUTOMATIC REGISTER
Accuracy and repeatability ........................ Signal within ? 2% of dial capacity
Pointers ......................................... Two, nickel-plated outer reset and red inner reading
Switch and relay contact rating ..................... 7 amps, 125-250 vac
Motor and relay (one of the ratings listed) ............ 24 vac, 60 Hz, 20 rph
110 vac, 60 Hz, 20 rph
110 vac, 60 Hz, 4 rph
220 vac, 50 Hz, 20 rph
MODEL SR -
SIGNAL REGISTER
Accuracy and repeatability ........................ Signal within ? 1 % of outer circle
Pointers ......................................... Two, nickel-plated inner and red outer
Contact rating .................................... 7 amps, 110 or 220 vac, 1 /8 hp at 110 vac, 114 hp at 220
vac, 1/2 amp at 125 vdc, 1/4 amp at 250 vdc
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
AR Register
SR Register
Figure 1-1.
0
Section I
GENERAL INFORMATION
1-1. GENERAL DESCRIPTION
The Badger Model AR Automatic Reset Register and
Model SR Signal Register are designed primarily to control
the regeneration cycle of water softeners. (See Figure 1-1.)
Models AR and SR employ electrical switching to provide
the signal for external control, and both are equipped with a
6-digit non-reset totalizer. The basic configuration and
mounting of the instruments is the same. The registers are
available in a wide range of dial capacities and units of mea-
surement.
The Model AR is an automatic reset unit for repetition of
the same preset metered cycle. The instrument may be
preset to any quantity within the dial capacity by positioning
the nickel-plated outer reset pointer. The housing must be
removed to preset. The red pointer indicates the amount of
liquid remaining to be delivered. At the end of a cycle when
the red delivery pointer reaches zero, the motor-driven reset
pointer is turned one complete revolution to return the red
pointer to the preset point in readiness for the next cycle.
End of cycle and reset switching are cam actuated. The AR
can be automatically reset any time prior to the completion
of the cycle by an external momentary contact.
The Model SR is a manual preset register with two
pointers. The pointers are preset with the control knob on
the front of the unit. When both pointers reach zero, the
internal cam-actuated microswitch closes to provide the
control signal.
External electrical connections are made to the rear of
the instrument. The housings are easily removed for internal
access required for wiring, gear changes, settings and
adjustments.
1-2. INSTRUMENT CONFIGURATIONS
The Model AR is available with an internal relay for use in
multiple register systems. The relay may be connected into
the control circuit to lock out one register reset motor until a
second register regeneration cycle is completed.
1-3. APPLICATIONS
The Model AR and SR Registers are well suited for control
of industrial water softener installations, whether single
manual regeneration or multiple automatic regeneration. All
Series 76 registers can be used interchangeably on Badger
disc, oscillating piston, turbine, turbo and propeller meters,
both mechanical and magnetic drive. These registers are
ideal replacements for older similar registers.
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Section II
INSTALLATION
2.1. UNPACKING AND INSPECTION
The Model Series 76 Registers are shipped to the
customer in a special shipping container to avoid damage
during transit. Upon receipt of the instrument, perform the
following unpacking and inspection procedures:
T NOTE
If damage to the shipping container is evi-
dent upon receipt of the instrument, request
a representative of the carrier to be present
when the instrument is unpacked.
a. Carefully open the shipping container, following any
instructions that may be marked on the container. Remove
all cushioning material surrounding the instrument and
carefully lift the instrument from the container. Retain the
container and all cushioning material for possible use in
storage or reshipment.
b. Check the contents of the shipping container against
the packing list to verify that all equipment has been
received.
c. Visually inspect the instrument for physical damage
such as dents, scratches, loose or broken parts or any other
signs of physical damage that may have occurred during
shipment.
1. Remove the existing register if meter is so
equipped.
2. Check the mounting holes on meter. Re-drill to
17/64 inch to accept 1/4 inch screws if necessary.
3. Check the position and alignment of pin drive
coupling. Surface A must be 3/32" to 1/8" below Surface B
(See Figure 2-1). Be sure to tighten the set screw after
adjustment.
4. Place the square section gasket in the mounting set.
5. Align the drive holes in the base of register with
the drive coupling pins as closely as possible. Carefully
position the register on the meter mount or magnetic drive
adapter so the drive pins engage. Rotate the register to align
the mounting holes and position the register as desired.
6. Install 1/4-20 mounting screws to secure the
register.
b. ELECTRICAL CONNECTIONS. All electrical (power
and signal) connections to a register are made to a terminal
strip located inside the instrument enclosure. Remove the
four housing cover screws in the base and lift off the cover
to gain access. Caution must be exercised in cover removal
to avoid bending the pointers. When the screws are
removed, lift the cover in a slightly forward motion. It is
recommended that flexible conduit be used for a distance of
at least 2 feet from the register to allow access to the meter.
NOTE
If damage is found, request an inspection by
the carrier's agent within 48 hours of deliv-
ery. Then file a claim with the carrier. A claim
for equipment damaged in transit is the re-
sponsibility of the customer.
Installation of the register in areas of high
temperature or severe vibration should be
avoided. When used on oscillating piston
meters, turbine meters and SOT meters with
flow temperatures over 140?F, use finned
mounting adapter to dissipate heat. Use P/N
31278-1 for oscillating piston meters and P/N
31728 for SOT and turbine meters.
a. MOUNTING THE REGISTER. (See Figure 2-1.) The
register mount will fit a 3/4 inch hood base. The instrument
is mounted with four or two 1/4-20 screws. The mounting
holes on existing meters may have to be drilled to 17/64 inch
dia. to accept the 1 /4 inch screws.
Figure 2-1. Register Mounting
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4
4
RELAY
1 COIL
SIGNAL
SW
.
RELAY CONTAACTS FRT.
~ >~ I
Fx- l L_
RD -h BR HIJ
0
0
0
0 POWER
Figure 2.2. Internal Wiring Diagram - Model AR with
Relay
00000000
1 2 3 4 5 6 7 8
0 0 0 0 0 0 NEW AR
1 2 3 4 5 6
0000
- 0 +Q OLD EA-L (6 to 24V)
0000 NEW SR
1 2 3 4
The basic internal wiring diagrams are shown in Figures
2-2 thru 2-4. If additional information or assistance is
required to make a specific installation, contact Badger
Meter, Inc., Flow Products Division, Industrial Sales
Department, or the local representative. Make sure that all
wiring to the instrument (both power and signal) conforms
with the local electrical code.
Section III
OPERATION
3-1. CONTROLS AND INDICATORS
a. CONTROL KNOB. The single control knob for Register
SR is used to preset the desired flow quantity as indicated by
the pointers. Pushing the knob in and turning
counterclockwise moves the pointers to the desired batch
quantity.The inner pointer moves one graduation for each
O
SIGNAL
SW. FRT.
POWER JL
Figure 2-3. Internal Wiring Diagram - Model AR less
Relay
2.3. PERFORMANCE CHECK
Although the registers are factory adjusted for switch
actuation and pointer alignment, it is advisable to check the
operation of a register before actual use. For AR registers
the reset pointer is set at 50 per cent of the scale. The user
may require a different operating point. Complete
adjustment and test information is given in Section V.
2-4. REGISTER REPLACEMENT
Model AR and SR registers can be used to replace Model
ARC, EA-H and EA-L registers. The necessary wiring
changes are shown in Figure 2-5.
complete revolution of the outer pointer.
b. DIALS. The 5-3/4 inch dial is calibrated in units of
measure marked on the dial face. The small test circle is
marked with 10 divisions. One revolution of the test circle
pointer is equivalent to one digit change on the lowest (right
side) position of the totalizer.
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3-2. OPERATING PROCEDURE - SR REGISTER
At the end of a flow cycle the pointers will both be at zero.
To preset the unit, proceed as follows:
a. Push in the control knob which will engage the
coupling on the preset shaft with the register gear train.
b. Turn the knob counterclockwise to the desired quan-
tity as indicated by the pointers. Release the knob. Spring
tension will return the knob to the out position.
c. The register will start when flow starts and continue to
indicate the remaining quantity until the pointers reach zero
at the end of the cycle. At this time the signal switch opens
or closes to operate external alarms or functions. The
pointers move counterclockwise during operation.
d. After regeneration preset the register as described
above.
3-3. OPERATING PROCEDURE - AR REGISTER
To preset the register, remove housing cover and
proceed as follows:
a. Rotate the reset pointer until it picks up the red
pointer and continue until the switch arm drops into the
notch in the motor cam.
b. Loosen two screws in the reset pointer hub and posi-
tion both pointers to the desired preset quantity. Be sure the
motor cam remains stationary during pointer positioning.
c. Tighten the reset pointer hub screws.
d. Run the register through one cycle to check preset.
The instrument must stop with both pointers at the preset
position.
3-4. OPERATOR EMERGENCY MAINTENANCE
If the register does not start or stops prematurely, check
the power source. If the power source checks out, the regis-
ter may require adjustment. Refer to troubleshooting data
and adjustment procedures in Section V.
If a register fails to stop at zero, turn off the power to the
instrument. Investigate the cause of malfunction (Section V).
Section IV
PRINCIPLES OF OPERATION
4-1. GENERAL
Whenever there is liquid flow, the movement of the
meter's measuring element is coupled to the register and
transferred to the indicating pointers and totalizer through a
gear train. The exact makeup of the gear train is determined
by the dial capacity, unit of measure and meter application.
Each instrument incorporates a set of change gears which
allows some variation in overall gear train ratio to compen-
sate for differences in liquids and conditions.
In an automatic system the end of cycle or zero point
signal is used to start the regeneration cycle. The switch is
cam actuated off the pointer shaft(s). The actuation of the
switch(es) and position of the pointer(s) are adjustable to
permit exact correlation between the pointers and switch
action.
4-2. MODEL SR
A coupling is mounted on the control knob shaft. With the
knob in, the coupling engages the gear train and allows the
pointers to be moved when the knob is rotated.
Initially with the register at zero, the signal switch is on
the low part of the pointer cams. In this position the signal
switch (normally open contacts) is open. When the pointers
are moved off zero to preset, the cams rotate so that the
signal switch is on the high part of the cams and the signal
switch (normally open contacts) is closed. When flow starts,
the register continues to run toward zero until both pointer
cams reach the initial position to reverse the switch mode.
4.3. MODEL AR (See Figure 4.1)
The Model AR employs two tandem cams to actuate the
signal switch and reset motor switch. The front signal cam is
mounted on the delivery (red) pointer shaft; the rear motor
switch on the reset motor-pointer shaft. Both cams contact
the common pivoting switch arm which actuates the
switches. Each switch is mounted independently on
adjustable brackets to allow separate adjustment. The
switch arm is latched or unlatched by a spring-loaded pawl
as controlled by the cams.
Figure 4.1. Model AR Switch Mechanism
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At the end of the preset cycle, the switch arm is at rest in
the notch or low point of the motor cam. Both the reset
motor switch and signal switch are open. The pawl is con-
tacting the outer edge of the switch arm as shown in
Figure 4-1.
When flow starts, the red pointer and signal cam are
driven around until the high point of the signal cam moves
the switch arm to close the switches at zero. This allows the
pawl to engage the notch in the switch arm to lock the
switches in close position. The reset motor is energized
through the motor switch and drives the reset pointer and
reset motor cam. The signal switch closure is used to start
the regeneration cycle either directly or through a relay and
external circuitry provided by the water conditioning equip-
ment manufacturer.
The motor cam continues to rotate and the reset pointer
picks up the red delivery pointer to return to the preset
position. As the cam nears the end of its full revolution, the
pin on the motor cam pushes the pawl out to unlatch the
switch arm but the switch arm is on the high part of the
motor cam so the switches remain closed.
When the notch in the motor cam reaches the switch
arm, the arm drops into the notch and opens the switches.
This stops the reset motor and interrupts the regeneration
signal. The register is now ready for another cycle.
Section V
MAINTENANCE
A
5.1. GENERAL
This section of the manual provides information
pertaining to maintenance of the registers. The information
consists of preventive maintenance, troubleshooting and
corrective maintenance procedures.
NOTE
Maintenance of the registers requires ade-
quate test equipment as well as personnel
experienced in the checkout and repair of
electro-mechanical equipment.
5.2. MAINTENANCE EQUIPMENT
The test equipment and tools required for checkout and
maintenance of the registers are listed below. Besides those
items listed, the only other maintenance equipment required
is the usual complement of hand tools used by service
technicians.
5-3. PREVENTIVE MAINTENANCE
The purpose of preventive maintenance for the registers
is to ensure efficient, trouble-free operation and to discover
and correct conditions that can result in damage or
instrument failure. Perform the following preventive mainte-
nance procedures on a routine basis.
a. CLEANING. Clean all dust, dirt, moisture or grease
from the front panel and housing of the instrument. Use a
clean cloth dampened with detergent and water. Wipe dry
with a clean cloth.
b. INSPECTION. Visually inspect the instrument for
breaks, cuts, wear or deterioration in the power intercon-
necting wiring and signal wiring. Replace any defective
wiring.
NOTE
The operator should always note any erratic
indications and unusual noises. These are
cause for instrument checkout.
c. LUBRICATION. Apply a soft grease such as Lubriplate
sparingly to the following points every 6 months.
1. Drive bevel gears.
2. Reset shaft (SR only).
5-4. TROUBLESHOOTING
Should a register fail to operate properly, the first step in
troubleshooting the instrument is to try to localize the mal-
function to a component. The trouble symptoms listed in the
troubleshooting chart, Tables 5-1 and 5-2, will aid in deter-
mining and locating the difficulty. The chart lists possible
troubles, probable causes and remedies. Use the wiring
diagrams in Section II as a further aid in isolating the fault.
5.5. ADJUSTMENTS - MODEL SR
a. SIGNAL SWITCH, SECOND STAGE
Use a test light or an ohmmeter with the power off. Connect
to the common and normally-open signal switch terminals.
See Figure 5-1.
1. Loosen the switch bracket locking screw slightly
with an offset screwdriver.
2. With an Allen wrench, loosen the setscrew in the
high-speed cam.
3. By hand, rotate the high-speed cam to position the
switch roller in the drop-off zone of the cam.
4. Rotate the low-speed cam (by hand) to position the
switch roller in the center of the drop-off zone of this cam.
5. Rotate the high-speed cam until the switch roller
is on the drop-off point of the cam. Tighten the setscrew in
the high-speed cam.
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9. Recheck operation.
b. POINTER POSITION. At the end of a metering cycle
with the signal switch closed, the red pointer must be on
zero. If necessary, loosen the screw on the hub and reposi-
tion pointer. Tighten screw after adjustment.
5.6. ADJUSTMENTS - MODEL AR
a. SWITCH ARM PAWL. The pawl may require adjust-
ment if the switch arm does not latch.
1. Set the pawl spring tension as shown in Figure
5-2, View A.
2. Bend the pawl tab to obtain latch clearance as
shown in Figure 5-2, Views B and C.
3. Rotate the reset pointer so it picks up the red
pointer and continues until the switch arm drops into the
notch in the motor (rear) cam.
4. Rotate the red pointer (and cam) and observe
latching of the switch arm by the pawl. As the high point of
the signal cam passes the switch arm, the pawl must
engage the notch of the switch arm and latch the arm. (See
Figure 5-2, View B.) The switch arm must remain latched
when the high point of signal cam is past the switch arm.
b. SIGNAL AND MOTOR SWITCHES. (See Figure 5-3.)
1. Slightly loosen three switch mounting arm locking
screws.
2. Rotate the register drive if necessary to set the
high part of the motor cam (rear) on the switch arm.
3. Back off both adjusting screws so that the signal
and motor switches are open (normally-open contacts).
4. Advance the motor switch (rear) adjusting screw
until the motor switch closes. Then advance the adjusting
screw 1-1/3 turns for proper overtravel.
5. Advance the signal switch (front) adjusting screw
until the signal switch closes. Then advance the adjusting
screw 1 turn for proper overtravel.
6. Tighten the switch mounting bracket locking
screws.
.005 MIN. WHEN
CAM IS AT ITS
HIGHEST POINT
.025 (ABOUT HALF
THE THICKNESS OF
THE TAB)
Figure 5.1. Signal Switch Adjustment
(Positioning Roller on Cams)
6. Slowly advance the adjusting screw while slowly
turning the register's reset knob to rotate the high-speed
cam until only one signal is received during two revolutions
of the high-speed cam past the trip point.
NOTE
To obtain proper cam adjustment, carefully
observe the movement of the switch roller.
When the high-speed cam completes one
revolution before shut-off, the switch roller
must lower into the drop-off zone of the low-
speed cam to activate an electrical signal.
7. Tighten the switch bracket locking screw.
8. Recheck cam adjustments by rotating the cams
(turn the reset knob) until drop-off points are aligned. The
switch roller must be positioned in the center of the low-
speed drop-off zone.
TO INSURE PROPER
SPRING FORCE, PUSH
BEND THIS TAB PAWL ASSEMBLY
TO MAKE /~UNTIL IT TOUCHES
ADJUSTMENTS \~(!/ POST, THEN RELEASE
AS SHOWN R \\
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A
c. DELIVERY POINTER (RED).
1. Rotate the reset pointer counterclockwise until
the switch arm drops into the notch in the motor cam.
2. Rotate the red delivery pointer counterclockwise
until the motor (rear) switch closes. With this cam position
the red pointer should be at zero on the dial. If it is not,
remove reset pointer and hub. Loosen the pointer lock
screw, set the pointer on zero and tighten the lock screw.
Do not move the signal cam during pointer position adjust-
ment. Replace reset pointer and adjust to preset position.
d. PRESETTING. Refer to paragraph 3-3.
5-7. CHANGE GEARS
Due to differences in fluid viscosity, specific gravity,
temperature, et cetera, the register may not be indicating
the correct flow quantity. If this occurs, proceed as follows:
a. Determine the exact register reading for the corres-
ponding quantity of product delivered. Measure quantity
exactly.
b. Check the number of teeth on the driven and driver
change gears on the rear of the gear plate (See Figure 5-4).
The gears are stamped with the number of teeth.
Figure 5-4. Change Gears
c. Notify the Flow Products Division of Badger Meter of
the data in a and b above. Badger Meter engineering will
advise you of required changes to be made.
d. To adjust or interchange the gears, loosen the lock
screw and pivot the driven gear away. Replace the change
gears if required. Align the gear teeth and setscrews. Swing
the driven gear until it meshes with the driver gear and
tighten the lock screw.
NOTE
Be sure gear teeth mesh fully without any
tightness.
5-8. PERFORMANCE CHECK - MODEL AR
To test for proper actuation and relay operation (if so
equipped), perform an operational performance check. A
set of test lights should be used. Different color lamps with
corresponding color test leads are suggested for simplicity.
Connect the power source per unit rating with an external
switch to the terminals as shown on the applicable wiring
diagram in Section II. The external power switch must be
open.
a. MODEL AR WITH RELAY (Normally-Open)
1. Connect test lights to the terminal strip as follows:
Test Light No. 1 - to terminals 2 and 3
Test Light No. 2 - to terminals 4 and 6
Test Light No. 3 - to terminals 5 and 6
Test Light No. 4 - to terminal 3 and the normally-
closed terminal of the reset motor switch (rear
switch - unconnected terminal).
2. Rotate the pointers to the preset position where
the switch arm drops into the notch of motor cam.
3. Turn on the power. As the power is turned on the
test lights No. 3 and No. 4 must light up.
4. Turn the red pointer counterclockwise to a posi-
tion close to zero on the dial.
5. Slowly advance the red pointer further by rotating
the register drive shaft. As the red pointer reaches zero the
test light No. 4 will go out and the reset motor will start. Do
not rotate any further.
6. The motor will turn the motor cam and raise the
switch arm until it rides on the O.D. of the motor cam. This
will close the front or signal switch and energize the relay.
Test light No. 3 will go out and test lights No. 1 and No. 2 will
light simultaneously.
Test light No. 4 must go out when the red
pointer indicates zero on the dial and before
test light No. 3 goes out.
7. The reset pointer (nickel-plated) will pick up the
delivery pointer (red) and reset it to the preset position and
turn the motor off. This completes the cycle and the test.
b. MODEL AR LESS RELAY (Normally-Open Signal
Switch).
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1. Connect test lights to the terminal strip as follows:
Test Light No. 1 - to terminals 1 and 2
Test Light No. 2 - to terminal 1 and the normally-
closed terminal of the reset motor switch (rear
switch - unconnected terminal).
2. Rotate the pointers to the preset position where
the switch arm drops into the notch of motor cam.
3. Turn on the power. As the power is turned on the
test light No. 2 must light up.
4. Turn the red pointer counterclockwise to a
position close to zero on the dial.
5. Slowly advance the red pointer further by rotating
the register drive shaft. As the red pointer reaches zero the
test light No. 2 will go out and the reset motor will start. Do
not rotate any further.
6. The motor will turn the motor cam and raise the
switch arm until it rides on the O.D. of the switch cam. This
will close the front or signal switch and test light No. 1 will
light up.
Test light No. 2 must go out when the red
pointer indicates zero on the dial and before
the test light No. 1 lights up.
7. The reset pointer (nickel-plated) will pick up the
delivery pointer (red) and reset it to the preset position and
turn the motor off. This completes the cycle and the test.
5.9. PARTS REPLACEMENT
Normal parts replacement includes the microswitches,
relay, and possibly gears or cams which are worn. Mounting
of these parts is shown in the exploded views in Section VI.
Refer to Section VI for parts replacement listings and
ordering information.
Table 5-1. Model AR Troubleshooting Chart
Since the AR register is usually a part of a larger control system not supplied by Badger Meter, Inc., it is necessary that
the system is checked to be sure it is installed properly and wired in accordance with the manufacturer's
recommendations before changing any adjustments or troubleshooting is done on the AR register.
POSSIBLE TROUBLE
PROBABLE CAUSE
REMEDY
Pointers do not return to proper
1.
Loose reset pointer screws.
1.
Re-adjust preset and tighten
preset.
screws.
2.
Malfunctioning or faulty motor
2.
Check switch actuation and
switch.
mounting. Adjust if required.
Replace if defective.
Register does not stop at zero.
1.
Loose delivery pointer screw.
1.
Re-adjust position of pointer.
Register does not stop.
1.
Malfunctioning or faulty signal
1.
Check switch actuation and
switch.
mounting. Adjust if required.
Refer to para. 5-6 a.
Register does not reset.
1.
Malfunctioning motor switch.
1.
Check switch actuation. Re-
adjust if required. Refer to
para. 5-6 a.
2.
Faulty motor switch.
2.
Check operation of switch.
Replace if defective.
3.
Loose motor cam.
3.
Secure motor cam. Re-adjust.
4.
Broken pawl spring.
4.
Replace spring and adjust
pawl.
5.
Faulty reset motor.
5.
Replace motor.
Delivery pointer does not
1.
Loose gear.
1.
Check setscrews in gears for
move.
looseness. Tighten.
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Table 5-2. Model SR Troubleshooting Chart
I
POSSIBLE TROUBLE
PROBABLE CAUSE
REMEDY
Switch does not close or open.
1. Malfunctioning or faulty signal
1. Check switch actuation and
switch.
mounting. Adjust if required. Re-
place if defective.
Register pointer(s) do not move.
1. Loose gear.
1. Check setscrews on gears for
looseness. Tighten.
For other malfunctions of the system check external equipment as recommended by the manufacturer.
Section VI
ILLUSTRATED PARTS LIST
j
6.1. PART LOCATION ILLUSTRATIONS
The location and identification of the assemblies and
parts comprising Models AR and SR are shown on the
exploded view illustrations. Each assembly or part shown on
the illustrations is identified by an index number that is
cross-referenced to an associated parts list.
6-2. PARTS LISTS
6-3. ORDERING INFORMATION
Order replaceable parts for applicable register through
the local Badger Meter Sales Representative or directly
from the Industrial Sales Department, Flow Products
Division of Badger Meter, Inc. (address on title page). When
placing an order, provide the following information:
a. Complete name plate data.
b. Dial capacity and number of fixed digits behind the
totalizer.
The parts lists consist of columnar lists of the assemblies c. Complete description of the assembly or parts
and parts that are shown in the part location illustrations and
required.
provide the following information for each item listed. d.
Part number of the item as indicated in the parts list
a.
b.
FIGURE AND INDEX NUMBER.
PART NUMBER.
e.
f.
.
Quantity of parts required.
A purchase order number and exact return and billing
c. DESCRIPTION.
Model
Part No.
Manufactured by
Badger Meter, Inc.
Milwaukee,Wisconsin
address.
Spec. data
Model
Part No.
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10
7 13
12 /
11
/ 14 // 17
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FIG. 6.1
ITEM NO.
PART NO.
DESCRIPTION
1
56599-00300
Dial - 100 Gal. Capacity
1
56599-00400
Dial - 200 Gal. Capacity
1
56599-00500
Dial - 500 Gal. Capacity
2
56948-00100
Delivery Pointer Hub Assy.
3
24349-00000
Delivery Pointer
4
20454-00000
Lockwasher#3
5
55090-08600
Pan Head Screw - 3-48 x 3116
6
56949-00100
Preset Pointer Assembly
7
21451-00000
Set Screw - 4-48 x 1 /8
8
30089-00000
Preset Pointer Hub
9
30090-00000
Pointer Retainer Plate
10
33319-00000
Pointer
11
31820-00000
Pan Head Screw - 2-32 x 5/16
12
55293-00300
Lockwasher
13
21700-00000
Spacer Post
14
56678-00300
Front Plate Assembly
15
55109-16700
Round Head Screw - 6-32 x 3
16
55294-00700
Lockwasher#6
17
31820-00400
Flat Head Screw - 2-32 x 3/8
18
56664-00100
Terminal Mounting Bracket
19
31898-00800
Marker Strip, 8-Term. AR wlRelay
19
31898-00900
Marker Strip, 6-Term. AR less/Relay
20
22800-01800
Terminal Strip, 8-Term. AR w/Relay
20
22800-01700
Terminal Strip, 6-Term. AR less/Relay
21
55090-17200
Pan Head Screw - 6-32 x 1/2
22
56630-00100
Spindle and Cam Assembly
23
56950-00100
Totalizer Assembly
24
56600-00500
1000 Capacity Label x 10
24
56600-00500
2000 Capacity Label x 10
24
56600-00500
5000 Capacity Label x 10
24
56600-00600
10M Capacity Label x 100
24
56600-00600
20M Capacity Label x 100
24
56600-00600
50M Capacity Label x 100
24
56600-00700
100M Capacity Label x 1000
24
56600-00700
200M Capacity Label x 1000
24
56600-00700
300M Capacity Label x 1000
24
56600-00800
100OM Capacity Label x 10,000
24
56600-00800
2000M Capacity Label x 10,000
24
56600-00800
5000M Capacity Label x 10,000
24
56600-00900
10,000M Capacity Label x 100M
25
56600-00200
Label - Liters
25
56600-00300
Label - M3
25
56600-01400
Label - Imp. Gallons
25
56600-01000
100 Test Circle Label - 00
25
56600-01100
1000 Test Circle Label - 000
26
56600-01500
.1 Test Circle Label - x .1
26
56600-01600
Blank Label
27
55109-08600
Round Head Screw - 3-48 x 3/16
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 nn '39 I R
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
33
4 13
22 12
24 \\ \ A I / 7 in
11. ~m G
11 JK-J-1 1 z 1 8 - \
m
32 V
/
97 6
(Gearing Details Shown on Page 14)
30\
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
FIG. 6.2
ITEM NO.
PART NO.
DESCRIPTION
FIG. 6.2
ITEM NO.
PART NO.
DESCRIPTION
1
56679-00300
Back Plate Assembly
32
22562-01300
Flat Washer
2
20454-00000
Lockwasher No. 3
33
55292-00500
Lock Washer No. 4 Int. Teeth
3
55090-08600
Rd. Head Screw - 3-48 x 3/16
34
56656-00100
Post, Pivot Switch Arm
4
24579-00100
Insulation
35
24580-00100
Switch Arm
5
55089-12600
Pan Head Screw - 4-40 x 1-318
36
55230-16500
Set Screw No. 6-32 x 1/8
6
55089-12200
Pan Head Screw - 4-40 x 7/8
37
24336-00000
Motor Cam Assembly
7
56639-00100
Switch Retaining Plate
38
56660-00100
Clutch and Gear Assembly
8
55283-00700
Lockwasher No. 6
39
56648-00100
Shaft, Delivery Pointer
9
55002-03400
Hex Nut No. 6
40
56652-00100
Spindle No. 7 - Preset Pointer
10
23983-02800
Spacer
41
20398-00000
Miter Gear
11
55270-00500
Lockwasher
42
56634-00100
Drive Spindle
12
55046-11400
Pan Head Screw- 4-40 x 1/4
43
55230-16500
Set Screw No. 6-32 x 1/8
13
24335-00000
Motor - 110 V, 60 Hz., 20 rph
44
56649-00100
Input Spindle
13
24335-00100
Motor - 24 V, 60 Hz., 20 rph
45
56670-00100
Gear and Pinion Assy. Style A & B
13
24335-00200
Motor - 220 V. 50 Hz., 20 rph
46
56960-00400
Gear & Spindle Assy. Style A,B,C, & D
13
24335-00300
Motor - 110 V. 60 Hz., 4 rph
47
56959-00500
Gear & Spindle Assy. Style A
14
55109-11300
Rd. Head Screw - 4-40 x 3/16
48
56670-00500
Style A Gear and Hub Assembly
*15
1065-00000
Set Screw
49
56676-00100
Style A Gear and Pinion Assy.
*16
32652-00000
Change Gear - Spec. No. Teeth
50
56955-00100
Style A Gear & Spindle Assy.
*17
56966-00100
AR Relay w/Wire Harness, 110 V
51
22562-01200
Flat Washer
17
56966-00200
AR Relay w/Wire Harness, 220 V
52
34780-00100
Gear - 20 Teeth
17
56966-00300
AR Relay w/Wire Harness, 24 V
53
55230-11300
Set Screw - 4-40 x 3/16
17
513841-00100
Wire Harness, AR less Relay
54
56564-00100
Housing
18
56867-00100
Adjusting Plate
55
22559-01600
Tetraseal
19
56673-00100
Change Gear Spindle Assy.
56
56563-00100
Lens and Bezel
20
31239-00100
Spacer - .109 Long
57
55068-27400
Flat Head Screw - 114-20 x 3/8
*21
24574-00100
Switch
58
22559-04200
Tetraseal
22
56654-00100
Switch Adj. Bracket - Short
59
56750-00100
Base
23
56655-00100
Switch Adj. Bracket - Long
60
55030-11800
Hex Capscrew - 1/4-20 x 1-3/4
24
55046-12300
Fil. Head Screw - 4-40 x 5/8
61
55109-19700
Round Head Screw - 8-32 x 3/8
25
55002-03200
Hex Nut - 4-40
62
55294-00800
Lockwasher No. 8
26
55089-11800
Pan Head Screw - 4-40 x 1/2
63
56646-00200
Coupling - Upper
27
22602-00900
Spring
64
56646-00300
OP Meters Coupling - Lower
28
56736-00100
Switch Adjustment Bracket
64
56646-00100
Other Meters Coupling - Lower
29
24334-00000
Spring
65
21451-00000
Set Screw - 4-48 x 1/8
30
24333-00000
Pawl Pivot Post
66
22562-00900
Flat Washer (Gear Spacer)
31
24330-00000
Pawl and Hub Assembly
67
56691-00100
Bushing
It
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
For gear reductions, see table 6-1
66
Style B
22000:1 or
11000:1
Style H 11:1
Style E
220:1 or
110:1
Figure 6.2. (Continued) Model AR Gearing
Style G 22:1 ( 3 ) _ `50
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
l14
FIG. 6.2
ITEM NO
.
PART NO.
DESCRIPTION
45
56670-00100
Style A & B Gear & Pinion Assy.
45
56670-00100
Style C Gear & Pinion Assy. (5500:1)
45
56670-00700
Style C Gear & Pinion Assy. (2200:1)
45
56670-00700
Style D Gear & Pinion Assembly
46
56960-00400
Style A,B,C, & D Gear & Spindle Assy.
46
56960-00600
Style E & F Gear and Spindle Assembly
46
56960-00300
Style G & H Gear and Spindle Assembly
47
56959-00500
Style A Gear and Spindle Assembly
47
56960-00100
Style B Gear and Spindle Assembly
47
56957-00400
Style C Gear & Spindle Assy. (5500:1)
47
56957-00500
Style C Gear & Spindle Assy. (2200:1)
47
56958-00100
Style D Gear & Spindle Assy. (1100:1)
47
56958-00200
Style D Gear & Spindle Assy. (550:1)
47
56957-00100
Style E Gear and Spindle Assembly
47
56958-00600
Style F Gear and Spindle Assembly
47
56960-00200
Style G Gear and Spindle Assembly
47
56957-00200
Style H Gear and Spindle Assembly
48
56670-00500
Style A Gear and Hub Assembly
49
56676-00100
Style A Gear and Pinion Assembly
49
56670-00100
Style B Gear Pinion Assy. (22000:1)
49
56670-00400
Style B Gear & Pinion Assy. (11000:1)
49
56670-00600
Style C Gear & Pinion Assy. (5500:1)
49
56676-00100
Style C Gear & Pinion Assy. (2200:1)
49
56670-00600
Style E Gear & Pinion Assy. (220:1)
49
56676-00100
Style E Gear & Pinion Assy. (110:1)
49
56670-00400
Style G Gear and Pinion Assembly
49
56670-00600
Style H Gear and Pinion Assembly
50
56955-00100
Style A Gear & Spindle Assembly
50
56956-00200
Style B Gear & Spindle Assy. (22000:1)
50
56956-00300
Style B Gear & Spindle Assy. (11000:1)
50
56955-00200
Style C Gear & Spindle Assy. (5500:1)
50
56955-00300
Style C Gear & Spindle Assy. (2200:1)
50
56956-00400
Style D Gear & Spindle Assy. (1100:1)
50
56956-00500
Style D Gear & Spindle Assy. (550:1)
50
56955-00400
Style E Gear & Spindle Assy. (220:1)
50
56955-00500
Style E Gear & Spindle Assy. (110:1)
50
56956-00400
Style F Gear and Spindle Assembly
50
56956-00100
Style G Gear and Spindle Assembly
50
56955-00600
Style H Gear and Spindle Assembly
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
21
---A
22/"'3T
X36
a
6--16
.z 24 / "1 z
/ Z W-29
7 ~7 / x--26
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
it
4
FIG. 6.3
ITEM NO.
PART NO.
DESCRIPTION
1
55090-08600
Pan Head Screw - 3-48 x 3/16
2
20454-00000
Lockwasher No. 3
3
22859-00000
Outer Pointer
4
21451-00000
Set Screw - 4-48 x 1 /8
5
22860-00000
Outer Pointer Hub
6
22859-00100
Inner Pointer
7
56962-00100
Inner Pointer Hub Assembly
8
33319-00000
Test Circle Pointer
9
31820-00000
Pan Head Screw - 2-32 x 5/16
10
55293-00300
Lockwasher No. 2
11
56599-00100
Dial
12
56600-00500
30,000 Capacity Label x 10
12
56600-00600
300,000 Capacity Label x 100
12
56600-00700
3,000,000 Cap. Label x 1000
13
56600-00200
Label - Liters
13
56600-01400
Label - Imp. Gallons
13
56600-00300
Label - M3
14
56600-01000
100 Test Circle Label - 00
14
56600-01100
1000 Test Circle Label - 000
14
56600-01500
.1 Test Circle Label - x .1
14
56600-01600
Blank Label
15
55090-11500
Pan Head Screw - 4-40 x 5/16
16
56844-00100
Wiring Harness
17
55109-17500
Round Head Screw - 6-32 x 3/4
18
55002-03400
Hex Nut - 6-32
19
55294-00700
Lockwasher No. 6
*20
24574-00500
Signal Switch
21
56872-00100
Insulation
22
55046-12300
Fil. Head Screw - 4-40 x 5/8
23
56734-00100
Switch Adjusting Bracket
24
22562-00100
Flat Washer
25
21700-00000
Spacer Poe t
26
22602-02500
Spring
27
55002-03200
Hex Nut - 4-40
28
55291-00500
Lockwasher No. 4
29
56736-00100
Switch Adjusting Bracket
30
56664-00100
Terminal Mounting Bracket
31
22800-01400
Terminal Strip - 4 Term.
32
31898-01000
Marker Strip - 4 Term.
33
55090-17200
Pan Head Screw - 6-32 x 1/2
34
56678-00100
Front Plate Assembly
35
55109-17700
Round Head Screw - 6-32 x 1
36
55291-00500
Lockwasher No. 4
37
55089-11400
Pan Head Screw - 4-40 x 1 /4
38
55109-16700
Round Head Screw - 6-32 x 3/16
39
56630-00100
Cam Spindle Assembly
40
56950-00100
Totalizer Assembly
41
34780-00100
Gear - 20 Teeth
42
55230-11300
Set Screw - 4-40 x 3/16
43
31820-00400
Flat Head Screw - 2-32 x 3/8
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
For gear reductions,
see table 6-1
1000:1
Style A
20 r-, . I , \ 10
21 ( " 15 , " - 13
9
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
FIG. 6.4
ITEM NO.
PART NO.
DESCRIPTION
1
56679-00100
Back Plate Assembly
*2
1065-00000
Set Screw - 4-48
3
32652-00000
Change Gear - Spec. No. Teeth
4
55109-11300
Round Head Screw - 4-40 x 3/16
5
55283-00500
Lockwasher No. 4
6
56867-00100
Adjusting Plate Assembly
7
22570-00300
"E" Ring
8
56673-00100
Change Gear Spindle Assembly
9
26459-03000
Drive Pinion - 30 Teeth
10
55230-11300
Set Screw -4-40 x 3/16
11
56708-00100
Spacer
12
56720-00100
Gear Cluster - 50 Teeth
13
56711-00100
Spindle
14
56955-00700
Style A Gear & Spindle Assy.
14
56956-00400
Style B Gear & Spindle Assy.
14
56956-00600
Style C Gear & Spindle Assy.
14
56955-00800
Style D Gear & Spindle Assy.
15
56960-00500
Style A Gear & Spindle Assy.
15
56958-00400
Style B Gear & Spindle Assy.
15
56958-00500
Style C Gear & Spindle Assy.
15
56959-00100
Style D Gear & Spindle Assy.
16
56959-00300
Style A Gear & Spindle Assy.
16
56959-00300
Style B Gear & Spindle Assy.
16
56959-00400
Style C Gear & Spindle Assy.
16
56959-00200
Style D Gear & Spindle Assy.
17
56710-00100
Gear & Hub Assy. - 60 Teeth
18
56649-00100
Input Spindle
19
55230-16500
Set Screw -6-32 x 1 /8
20
20398-00000
Miter Gear
21
56634-00100
Drive Spindle
22
56706-00200
Gear & Cam Assy. - 77 Teeth
23
56705-00600
Clutch Spindle Assy., Style A, B & C
23
56705-00700
Clutch Spindle Assy., Style D
24
56957-00300
Spindle Assembly
25
56958-00300
Spindle Assembly
26
55234-11100
Set Screw-4-48 x 1 /8
27
56961-00100
Reset Spindle
28
56787-00100
Reset Knob Spindle Assembly
29
22877-00400
"V" Ring
*30
22562-02300
Flat Washer
31
56751-00100
Retaining Ring
32
22602-02400
Spring
*33
55230-19400
Set Screw-8-32 x 3/16
*34
24399-00000
Control (Preset) Knob
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
Table 6-1. Gear Reduction Versus Dial Capacities
METER
REGISTER
DIAL
REDUCTION
SIZE
TEST CIRCLE
CAPACITY
RATIO
10
100
11:1
10
200
22:1
10
500
55:1
5/8"
10
1,000
110:1
10
2,000
220:1
Through
10
5,000
550:1
10
10,000
1,100:1
1 "
10
20,000
2,200:1
10
50,000
5,500:1
10
100,000
11,000:1
10
200,000
22,000:1
10
500,000
55,000:1
100
1,000
11:1
100
2,000
22:1
100
5,000
55:1
1-1/2"
100
10,000
110:1
100
20,000
220:1
Through
100
50,000
550:1
100
100,000
1,100:1
3"
100
200,000
2,200:1
100
500,000
5,500:1
100
1,000,000
11,000:1
100
2,000,000
22,000:1
100
5,000,000
55,000:1
1,000
50,000
55:1
1,000
100,000
110:1
4"
1,000
200,000
220:1
1,000
500,000
550:1
and
1,000
1,000,000
1,100:1
1,000
2,000,000
2,200:1
Over
1,000
5,000,000
5,500:1
1,000
10,000,000
11,000:1
METER
REGISTER
OUTER
INNER
REDUCTION
SIZE
TEST CIRCLE
CIRCLE
CIRCLE
RATIO
5/8"
10
100
3,000
10:1
Through
10
1,000
30,000
100:1
1 "
10
10,000
300,000
1,000:1
1-112"
100
100
3,000
1:1
Through
100
1,000
30,000
10:1
3"
100
10,000
300,000
100:1
100
100,000
3,000,000
1,000:1
4"
1,000
1,000
30,000
1:1
and
1,000
10,000
300,000
10:1
Above
1,000
100,000
3,000,000
100:1
20
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
is
WARRANTY
I
4
Badger warrants meters and parts manufactured by it and supplied hereunder to be free from defects
in materials and workmanship for a period of 18 months from date of shipment or 12 months from
date of installation, whichever period shall be shorter. If within such period any meters or parts shall
be proved to Seller's satisfaction to be defective, such meters or parts shall be repaired or replaced
at Seller's option. Seller's obligation hereunder shall be limited to such repair and replacement and
shall be conditioned upon Seller's receiving written notice of any alleged defect within 10 days after
its discovery and, at Seller's option, return of such meters or parts to Seller f.o.b. its factory. THE
FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED
WARRANTIES WHATSOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EXCEPT
OF TITLE) OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Badger shall not
be liable for any defects attributable to acts or omissions of others after shipment, nor any conse-
quential, incidental or contingent damage whatsoever.
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 I
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5 711K1020-C
Revision 2
INSTRUCTION BULLETIN
for
SERIES 71 K1020 FLOW INDICATORS
Design Level C
4
Mog"""""""'" Declassified 'and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
It is imperative that the following precau-
tionary measures be observed in order to
minimize, arid hopefully eliminate, the pos-
sibility of operator injury.
1 Glass meter tubes have been designed to
operate up to maximum design working pressures
listed herein. This is not to be construed as a certifi-
cation that the tubes will not break at any pressure.
Inherent material limitations can result in tube
breakage due to conditions beyond our control.
Fur exarnpi ,; glass is a brittle material which may
break upon impact or if subjected to thermal shock;
glass is notch sensitive- in that scratches, nicks or
cranks may result in breakuco, when pressurized;
ncorrect installation or faulty operating methods
can cause tube breakaype regardless of operating]
pressure.
2) Glass meter tubes are, riot recommended fur
either hot or strong alkalies, fluorine, hydroflounc
acid steam or water ovt'r 200?F (93`C). Glass meter
tubs-,s should i ,t: periodically inspected for signs of
wear. Erosion, stress cracks, nicks or deep scratches
provide early warning for tube replacement. With
certain fluids, the glass may erode evenly so wear is
not visibly noticeablta. If wear is suspected, the tube
should be replaced iris order to eliminate this potential
cause of meter tubs; break(ige.
3) It is important that all materials of construe icon
be compatible with the service to which the meter is
applied. It is especially important that "0" ring ina-
terial be compatible with the process fluid. Glass
meter tube breakage can occur in those meters using
an "O" ring as an internal seal if the improper mate
rial is used. Refer to F&P Co. Catalog 10A102 s,
Rota meter Selection Guide, material selection.
4) The Meter should never be subjected to excces
sive vibration.
5) Remove pressure from the Flow Indicator I.,-_-
fore attempting to remove the meter tube.
6) Be sure the set screws that serve to lock the
meter end fittings in place are secure. This stroui i no
checked before the Flow Indicator is put into se:r:: o-'
or returned to service after maintenance. Loose "r:rf
fittings may result in glass meter tube br(-akage.
7) The glass meter tube should be periodically
inspected and replaced if cracked, ni(,ked, scratched
or worn.
8) Do not operate the Flow Indicator without the
operator protection shield in place. To do so may
result in operator bodily injury.
MODEL NUMBERING
Refer to the F&P data sheet or the meter data tag for the model A = Buna N
number of the equipment furnished. The model number breakdown B = Butyl
is as follows: C = Viton
r
f
t
letter
si
d b
l
L
tt
71
Engineering File Reference; T
K 10
2 0
A A
y;
gne
y
ac
o
er as
:
e
Design Leve
XX
changes when some part is no longer interchangeable.
i
i
l D
Chemical Dispenser Auxiliary Equipment
Inpact Type
Flowrate Indicator
9
E
gn
es
? A = Orig
na
? B = Ball Float changed to Black Glass,
Range Orifice changed to accommodate
,
Momentary Reading
nation: Fixed Data
n Desi
i
D
G
float.
? C = Added Operator Protection Shield,
"
Discussed
g
es
g
Bushing mount option and 10
in this
t
i
i
es
h
16"
Bulletin
Capacity
pe s
.
p
z
ru
t
e
FP,
Note
Pipe Size
inche
s
1.1/2
8
80
Return tube has four
2
10
135
scales. Purchase a
Service
Pipe
15
195
-1
service clamp or
Clamp
Bushing
197
er the
i
e bushin
30
,
g p
p
p
4
520
actual pipe size. Pipe
5
820
bushing cannot be
_
6
1200
used for 1-1/2"
T
2100
pipe.
3300
4600
t
d
C
on
inue
14
5600
N
t
ex
16
Column
71 K 102 A A XX
F--"0" Ring Material T f
I
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
4
GENERAL
The Fischer & Porter Series 71K1020 Fl"w Indi-
cator is an impact type meter that requires -.rely one
connection to the pipe line. As shown on the cover,
the meter may be attached to the pipe line by way of
a service clamp or a bushing that is welded into the
line. The pipe line may be horizontal, vertical or
sloped; however, the meter must be in a true vertical
postion as illustrated. The liquid flow may be from
either direction; a single adjustment makes the meter
compatible with the direction of flow. Flow through
the meter is normally shut-off as continuous indica-
tion of flow is not required.
The flow of liquid through the meter is controlled
by a spring loaded shut-off valve. When the knob on
the front of the meter is pushed in, the meter is in
service and the flow rate of liquid flowing through
the pipe line can be read. To read the meter, observe
the horizontal center line of the ball float on the tube
scale. Upon release of the knob, the fluid flow is
shut-off to maintain meter cleanliness. With the flow
shut-off, the meter can be partially disassembled to
clean the meter and scale tubes as well as the range
orifice.
NOTES:
1. DIMENSIONS ARE PROVIDED FOR REFERENCE ONLY.
tj 2. DIMENSIONS ARE IN INCHES AND (mm).
3. ALL DIMENSIONS SUBJECT TO MANUFACTURING
TOLERANCE OF ?1/8(3) UNLESS OTHERWISE
SPECIFIED.
4. MOUNT METER ON HORIZONTAL,VERTICAL OR
SLOPED RUN OF PIPE. CAN BE ADJUSTED FCR
FLOA NEITHER DIRECTION.METER MUST BE
VERTICAL.
SERVICE CLAMP
FURNISHED BY CUSTOMER UNLESS
OTHERWISE SPECIFIED. MUST
MEASURE I-7/16(36)FROM SADDLE
NOMINAL - 1 ;I
THD. 13) f%f
4
FRONT
VIEW
116
(40)
I/2NPT---- '' i
2.1
4
(70)
Do not operate the flow indicator without -
the operator protection shield in place. Op-
eration of the meter without the operator
protection shield may result in operator
bodily injury.
When the knob is pushed in, the flow of liquid tc
be measured enters the hole in the impact tube and
flows through the tube towards the meter. As the
liquid enters the meter it flows upwards throuchh, a
range orifice into a Tri-Flat'" variable area flown eter
tube where it positions a ball float to indicate the
flow rate. The liquid spills over the top of the meter
tube into a return flow path enclosed by the scale
tube. The downward flow is then directed thrcuc,ii
passages in the inlet and shut-off valve assernh!y
and returned to the pipe line.
INSTALLATION
1. General
The Flow Indicator is designed for a -Maximum
working pressure of 175 psig (1.21 MPa). Meter
scales and range orifices are sized for use with nom-
inal size schedule 40 ANSI pipe, unless oth,erwi,
specified. Select a mounting location in the pipe. ltr:/
BUSHING
FURNISHED BY CUSTOMER
UNLESS OTHERWISE SPECIFIED.
DISTANCE FROM TA-,E OF
BUSHING TO PIPE 00 MUST
BE AS INDICATED
1-1/2' PIPE=I.7/16' (36)
12' THRU 16' PIPE=1' (25)
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
where at least 10 straight pipe diameters uptrearrl
of the meter are available if at all possible; for an in
sialiation in 1-1/2" pipe, 20 pipe diameters is pre
ferred. Items that create flow pattern disturbance,
such as valves and elbows, should be avoided.
The installation may be made in a vertical, hori-
zontal or sloped run of pipe; however, the meter
must be vertical and plumb. Flow may be in either
direction through the pipe.
When the main pipeline is drained, liquid is
trapped in the Flow Indicator. If subject to
freezing temperature, the meter tube can be
broken. Drain the liquid from the meter tube
by removing the drain and vent screws and
pushing in the reading knob.
II. Service Clamp Mounted
Drill a 1/2" (13rnm) hole horizontally through the
center of the pipe, as indicated in Figure 1. Attach
the eervice clamp (opti(nal accessory, Lt extra cost)
to the pipe line, being certain that the tapped hole in
t'ie clamp is centered over the hole in the pipe. As
shown in Figure 2, the -lamp has a gasket that most
be included between the pipe and the clamp.
After the service clamp is attached to the pipe line,
back off the meter gland nut and remove the adaptor
hushing from the impact tube. Assemble the adaptor
bushing to the service clamp using pipe dope or,i
sealing tape on this joint to prevent leakage. Mount
the meter and while holding it in a vertical positiot
tighten the gland nut securely.
Make certain that the impact tube is not being
forced against the edge of the hole that was
drilled into the pipe.
FIGURE 2 METHOD OF MOUNTING
WITH SERVICE CLAMP
FIGURE 3 METHOD OF MOUNTING
WITH BUSHING
III. Bushing Mounted
Drill a hole horizontally in the pipe line to suit the
bushing as indicated in Figure 1. Position the bush-
ing (optional accessory, at extra cost) over the drilled
hole and weld in place as shown in Figure 3. It is sug-
gested that a piece of 1/2" pipe be threaded into the
bushing while it is being welded so that the horizontal
alignment can be checked. Check that the dimension
given from the face of the bushing '-o the pipe OD is
correct.
After the bushing is in place, back off the meter
gland nut and remove the adaptor bushing from the
impact tube. Assembly the adaptor bushing to the
bushing using pipe dope or a sealing tape on this
joint to prevent leakage. Mount the meter and while
holding it in a vertical position, tighten the gland nut
securely.
PLACING IN OPERATION
During the following procedure, the scale
tube will be turned to the scale that matches
the pipe size. The polycarbonate operator
protection shield should not be removed
for this procedure.
Each meter can be used on four pipe line sizes.
The meter has a scale tube (with four separate
scales) which surrounds the metering tube. This
scale tube must be turned to the proper position
either before or after the meter is installed.
To adjust the position of the scale tube a 3/32" hex
key wrench and a 3/8" open end wrench are used.
The insert on Figure 5 shows the location and
procedure for turning the scale tube.
Adjust the impact tube as discussed in the follow-
ing steps.
INTO PIP? L!ME-
GASKET
VERVICE CLAMP WITH
I/2 NPT TAPPING
Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
 Declassified and Approved For Release 2012/05/04: CIA-RDP02-06298R000900070003-5
4
1) Using the 1/16" hex key wrench t.ruvid"d,
loosen the set screw in the 'Push to R