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Installation and Operation Manual

Oval Gear MeterModel 9400

Engineering the Future

TM

X-9400Revision 01

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Essential InstructionsBrodie Meter Co., LLC designs, manufactures and tests its products to meet many national andinternational standards. Because these instruments are sophisticated technical products, you mustproperly install, use and maintain them to ensure they continue to operate within their normalspecifications. The following instructions must be adhered to and integrated into your safety programwhen installing, using and maintaining Brodie Meter Co., LLC products.• Read all instructions prior to installing, operating, and servicing the product. If this instruction

manual is not the correct manual, telephone 1-912-489-0200 and the requested manual will beprovided. Save this instruction manual for future reference.

• If you do not understand any of the instructions, contact your Brodie representative for clarification.• Follow all warnings, cautions, and instructions marked on and supplied with the product.• Inform and educate your personnel in the proper installation, operation, and maintenance of the

product.• Install your equipment as specified in the installation instructions of the appropriate instruction

manual and per applicable local and national codes. Connect all products to the proper electricaland pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program, andmaintain the product.

• When replacement parts are required, ensure that qualified people use replacement partsspecified by the manufacturer. Unauthorized parts and procedures can affect the product’sperformance and place the safe operation of your process at risk. Look-alike substitutions mayresult in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except whenmaintenance is being performed by qualified persons, to prevent electrical shock and personalinjury.

• Before opening the flameproof enclosure in a flammable atmosphere, the electrical circuits must beinterrupted.

• The ATEX approval applies to equipment without cable glands. When mounting the flameproofenclosure in a hazardous area, only flameproof cable glands certified to EN 50018 must be used.

• If replacement of screws that secure the gear housing, sensor housing, UMB, cover, or electricregister is necessary, they must be replaced with M6-1 X 16 mm hex socket head cap screws.The screws must be made of 304 stainless steel and have a minimum tensile strength of 125 KSI.

• When installing this equipment, bolting must conform to the requirements of ASME B16.5paragraph 5.3 and to the material requirements of ASME B16.5 Table 1B. Gaskets must conformto the requirements of ASME B16.20.

• It is the customer’s responsibility to ensure that piping or other attachments connected to theBiRotor Meter do not place adverse stresses on the BiRotor Meter. The design of the BiRotorMeter has not been assessed for the effects of traffic, wind or earthquake loading.

• It is the customer’s responsibility to provide fire prevention measures and equipment per localregulations.

• The Oval Meter has been designed without allowance for corrosion. The customer shouldimplement a periodic inspection and maintenance program to ensure that no part of the OvalMeter’s pressure-retaining components has been subjected to corrosion.

• Use of this equipment for any purpose other than its intended purpose may result in propertydamage and/or serious personal injury or death.

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WarningDo not exceed the maximum working pressure of equpment as stamped on the

nameplates. It is the customer’s responsibility to install this equipment in a system that provides adequate over-pressure protection.

NOTICELines should be flushed thoroughly to rid piping of potentially damaging foreign material

such as welding bead, pipe scale, etc. before the equipment is placed in service. A strainer of proper size should be installed upstream of the valve to protect it from the introduction

of foreign material.

Notice

Brodie Meter Co., LLC (“Brodie”) shall not be liable for technical or editorial errors in this manual or omissions from thismanual. Brodie makes no warranties, express or implied, including the implied warranties of merchantabilityand fitness for a particular purpose with respect to this manual and, in no event, shall Brodie be liable for anyspecial or consequential damages including, but not limited to, loss of production, loss of profits, etc.

Product names used herein are for manufacturer or supplier identification only and may be trademarks/registered trademarks of these companies.

The contents of this publication are presented for informational purposes only, and while every effort has been made toensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, regarding theproducts or services described herein or their use or applicability. We reserve the right to modify or improve thedesigns or specifications of such products at any time.

Brodie does not assume responsibility for the selection, use or maintenance of any product. Responsibility for properselection, use and maintenance of any Brodie product remains solely with the purchaser and end-user.

Brodie Meter Co., LLCStatesboro, Georgia, USA

All rights reserved. No part of this work may be reproduced or copied in any form or by any means - graphic,electronic or mechanical - without first receiving the written permission of Brodie Meter Co., LLC.,Statesboro, Georgia, U.S.A.

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Warranty1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except asotherwise expressly provided herein, Brodie Meter Co., LLC (“Brodie”) warrants that the firmwarewill execute the programming instructions provided by Brodie, and that the Goods-manufactured orServices provided by Brodie will be free from defects in materials or workmanship under normal useand care until the expiration of the applicable warranty period. Goods are warranted for twelve (12)months from the date of initial installation or eighteen (18) months from the date of shipment byBrodie, whichever period expires first. Consumables and Services are warranted for a period of 90days from the date of shipment or completion of the Services. Products purchased by Brodie from athird party for resale to Buyer (“Resale Products”) shall carry only the warranty extended by theoriginal manufacturer. Buyer agrees that Brodie has no liability for Resale Products beyond makinga reasonable commercial effort to arrange for procurement and shipping of the Resale Products. IfBuyer discovers any warranty defects and notifies Brodie thereof in writing during the applicablewarranty period, Brodie shall, at its option, promptly correct any errors that are found by Brodie inthe firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the Goodsor firmware found by Brodie to be defective, or refund the purchase price of the defective portion ofthe Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normalwear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse,improper installation, modification, repair, storage or handling, or any other cause not the fault ofBrodie are not covered by this limited warranty, and shall be at Buyer’s expense. Brodie shall not beobligated to pay any costs or charges incurred by Buyer or any other party except as may be agreedupon in writing in advance by an authorized Brodie representative. All costs of dismantling,reinstallation and freight and the time and expenses of Brodie’s personnel for site travel anddiagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Brodie.Goods repaired and parts replaced during the warranty period shall be in warranty for the remainderof the original warranty period or ninety (90) days, whichever is longer. This limited warranty is theonly warranty made by Brodie and can be amended only in a writing signed by an authorizedrepresentative of Brodie. Except as otherwise expressly provided in the Agreement, THERE ARENO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TOMERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER MATTER WITHRESPECT TO ANY OF THE GOODS OR SERVICES. It is understood that - corrosion orerosion of materials is not covered by our guarantee.

2. Limitation Of Remedy And Liability: Brodie Shall Not Be Liable For Damages Caused By DelayIn Performance. The Sole And Exclusive Remedy For Breach Of Warranty Hereunder Shall BeLimited To Repair, Correction, Replacement Or Refund Of Purchase Price Under The LimitedWarranty Clause In Section 1 Herein. In No Event, Regardless Of The Form Of The Claim Or CauseOf Action (Whether Based In Contract, Infringement, Negligence, Strict Liability, Other Tort OrOtherwise), Shall Brodie’s Liability To Buyer And/Or Its Customers Exceed The Price To Buyer OfThe Specific Goods Manufactured Or Services Provided By Brodie Giving Rise To The Claim OrCause Of Action. Buyer Agrees That In No Event Shall Brodie’s Liability To Buyer And/Or ItsCustomers Extend To Include Incidental, Consequential Or Punitive Damages. The Term“Consequential Damages” Shall Include, But Not Be Limited To, Loss Of Anticipated Profits, Loss OfUse, Loss Of Revenue And Cost Of Capital.

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9400CODE

25355565759

CODEF

CODEBDH

CODE7

CODECDF

CODE145

BEARING MAGNET SHAFTSA Carbon Ceramic Stn. S tl.B Carbon Ceramic Stn. S tI.C Carbon Ceramic EncaStn. S ti.L Carbon Ceramic Stn. S tI.M Carbon Ceramic Stn. S tI.R W aukesha Ceramic Chrom. PIt.T W aukesha Ceramic Chrom. Pit.

CODE2378

CODEABEFR

BASIC MODEL NUMBER

CODE

BASE METER BY SIZE: Includes register adaptor & gear box w ith fixed adjustor

150 lb. ANSI RF Carbon Steel Flanges (Std.); Max. W orking Pressure 285 psi at 100 F

HOUSING and COVER MATERIAL

1/2"1''1''1- 1/2"2"3"REVISION LEVELThree Piece ConstructionCONNECTION TYPE

High Temperature to 4001F (204C), Class "C"Thermonized Class "A", to 230OF (115F)Thermonized Class "C", to 400OF (204C)Dual Magnets in Rotor and on Following Shaft

Silicon (FDA approved for clean-in-place service)EPRVARIATIONSNone

(2) High Viscosity for products above 300 centipoise

VitonTeflon

O-RINGSIf not noted, gears are Class "A" for process temperatures to 2301F (115C)

High Viscosity (2) Class "C"Std. Viscosity 0)Hiqh Viscosity (2)

(1) Standard V iscosity for products up to 300 centipoise.

Alloy 20 (For 20 Housing and Cover only.)GEAR ASSEMBLY CONSTRUCTION

Std. Viscosity (1)TYPE

316 Stainless Steel

Gears noted Class "C" are for process temperatures to 400F (204C).

Carbon SteelAlloy 20GEAR MATERIAL.316 Stainless Steel (Not for use with Alloy 20 Housing and Cover)

Std. Viscosity (')Class "C"Std. Viscosity (1)High Viscosity (2)

316 Stainless Steel (Voidless for Clean-in-place - For Stainless S teel Housing

300 lb. ANSI RF Carbon Steel Flanges (Std.); Max. W orking Pressure 740 psi at 150 lb. Tri-c lover with 125 reamed inlet and outlet - for CIP (Clean-in-place) food COUPLINGMagnetic Type 7

Brodie Meter Three-Piece Oval Flowmeter Model Number System

The model number consists of 12 numbers as designated in the table below. EX: 94 57 F B 7 C 1 A 3 A

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1.0 Oval Flowmeter Series 94001.1 Purpose

Brodie Flowmeters, hereafter called flowmetersare positive displacement meters that accuratelymeasure liquid flow. Total flow is indicated on atotalizing type register and, through the use ofaccessories, provides pulse and rate outputs.

1.2 Description

Flowmeters are of simple and ruggedconstruction. Precision machined oval-shapedrotors are used as metering elements whichensure minimum slippage, high accuracy andvirtual immunity to changes in viscosity.

1.3 Specifications

The following specifications apply to allFlowmeters. Where there is a differencebetween models, it will be so noted.

Pressure Ratings: See Table 1.2

WarningDo not use this meter in excess of these

specified values. Failure to stay within values may result in personal injury and/or damage to

the equipment.

1.4 Materials of Construction

See Table 1.1

Maximum Safe Working Temperature

For standard “Class A” construction 230°F(110°C) For higher temperatures, specialclearance rotors, high temperature magneticfollower and register extension are required.Meters are available with optional hightemperature trim for ”Class C” construction 230°to 392°F (110° to 200° C). For high temperaturetrim, use all stainless steel meters.

Minimum Operating Temperature

0°F. (-18°C.). Lower temperature is possible.Consult factory.

Performance

Accuracy: ± 0.5% on viscosities from 0.2 to 5centipoise and Class C.

± 0.25% for viscosities of 5 centipoise and aboveRepeatability: ±0.05%

Accuracy and Pressure Drop Curves: See Fig.1-1 Capacities: See Table 1-4

Dimensions: See Figure 1.2

Strainer Specifications: See Table 1.3

Materials of ANSI Conn.Construction Flange

Steel 150 RF 285 1965Steel 300 RF 740 5102

316 Stn. Steel 150 RF 275 1895316 Stn. Steel 300 RF 720 4960

at 100°F (38°C.)Pressure Rating

Connection ModelSize Number

1"& 1-1/2" 9455 & 9456 60 2502" & 3" 9457 & 9459 40 350

1/2" & 1 " 9402 & 9453 80 150

MicronsMesh

Table 1.3 Strainer Specifications

Table 1.2 Pressure Ratings

Note: Available for Models 9402, 9453, 9455 and 9456only. (316 Stainless Steel is alloy CF-8M Stainless Steel)

Table 1.1 Materials of Construction

Housing Rotors Shafts Bushings O-rings316 316 316 Hard

Stn. Stl. Stn. Stl. Stn. Stl. Carbon Viton

4444444

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Conn.Size(in.) No. Water 140-230T. 0.2 cP 0.3-0.7 cP 0.7-1.8 cP 2-4 cP 5-300 cP1/2 9402 1.3-6.6 1.8-4.4 3.1-7.9 1.8-7.9 1.3-7.9 0.7-8.8 0.4-8.81 9453 2.7-13.2 3.1-8.8 4.8-15.9 3.1-15.9 2.4-15.9 1.2-17.6 0.7-17.61 9455 4.4-30.8 5.3-22 7.9-37.4 5.3-37.4 4.4-37.4 1.8-44 1.1-44

1 1/2 9456 8.8-61.6 11-44 15.4-74.9 11-74.9 8.8-74.9 4-88.1 2.6-88.12 9457 17.7-132.1 22-88.1 35.2-154.1 22-154.1 17.6-154.1 8.8-176.1 5.3-176.13 9459 35.2-264.2 44-176.1 66-308.2 11-308.2 35.2-308.2 26.4-396.3 17.6-396.3

Gasoline Kerosene Light Oil Heavy OilModel Cold Hot Water LPG

Table 1.4 Flowrange

Capacities (USGPM) Refer to Tech Bulletin T-067 for comprehensive flow data

Note: Intermittent Service, eight to ten hours per day. For continuous service on non-lubricatingproducts, multiply maximum flow by 0.67. Capacities (Liters/Minute)

Conn.Size(in.) No. Water 140-230T. 0.2 cP 0.3-0.7 cP 0.7-1.8 cP 2-4 cP 5-300 cP1/2 9402 5-25 6.7-16.7 11.7-30 6.7-30 5-30 2.6-33.3 1.5-33.3

1 9453 9.2-50 11.7-33.3 18.3-60 11.7-60 9.2-60 4.5-66.7 2.6-66.71 9455 16.7-116.7 20-83.3 30-141.7 20-141.7 16.7-141.7 6.7-166.7 4.3-166.71-1/2 9456 33.3-233.3 41.7-167 58.3-283.3 41.7-283.3 33.3-283.3 15-33.3 10-333.32 9457 66.7-500 83.3-333.3 133.3-583.3 83.3-583.3 66.7-583.3 33.3-66.7 20-666.73 9459 133.3-1000 166.7-666.7 250-1166.7 166.7-1166.7 133.3-1166.7 100-1500 66.7-1500

Model Cold Hot Water LPG Gasoline Kerosene Light Oil Heavy Oil

Capacities (Liters/Minute)

Figure 1.1 Characteristics Accuracy and Pressure Drop Curves

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Mesh MicronsInches mm Inches mm Inches mm Inches mm Size Approx. lbs. kilo. Ft3 M3

9402 12-1/16 307 1-1/4 31 4-13/16 222 4-13/16 122 80 150 33 14.97 1.58 0.0459453 13 330 1-11/16 43 4-13/16 222 4-13/16 122 80 150 48 21.77 1.81 0.0519455 13-5/8 347 2 51 6 222 6 152 60 250 64 29.03 1.93 0.0549456 14-7/8 378 2-9/16 65 7-1/8 254 7-1/8 181 60 250 79 35.83 2.19 0.0629457 16-1/4 413 3-1/2 89 9-15/16 349 9-15/16 252 40 350 159 72.12 2.99 0.0859459 19-1/8 486 4-3/4 121 13-3/4 441 13-3/4 349 40 350 259 117.48 4.84 0.137

MODELDIMENSIONS STRAINER

A B C DSHIPPING WEIGHT

SHIPPINGCUBE

Table 1.5 Dimensions

(For Certified Dimension Prints, consult factory)

Figure 1.2 Dimensions for 9400 Models

6666666

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2.0 Installation2.1 General

This section contains the procedures for thereceipt and installation of the flowmeter.

2.2 Receipt of Equipment

When you receive your meter, inspect theoutside of the packing case for damage whichmay have been incurred during shipping.Damage incurred during shipment is theresponsibility of the carrier and is not part of thefactory warranty. If the package is in goodcondition, remove the envelope containing thepacking list and carefully remove the meter, andall components included in the shipment, fromthe packing case. Inspect for damaged ormissing parts, referring to the packing list, priorto discarding the packing material. If items aremissing from your shipment, contact your salesrepresentative. Your sales order number will berequired.

if the packing case is damaged, notify the localcarrier immediately. If the meter must bereturned to the factory for repair or replacement,a Returned Materials Report (RMR) must beincluded with the meter or components. RMRforms may be obtained from your salesDepartment. In addition to the RMR, a MaterialSafety Data Sheet and a DecontaminationStatement must be included with items beingreturned to the factory.

A Decontamination Statement is included in theback of this manual for your convenience.

2.3 Return Shipment

To be able to process return goods quickly andefficiently, it is IMPORTANT that you provideessential information. Do not return anyassembly or part without an “R.M.R.”(RetumedMaterials Report), or a letter which describes theproblem, correction action, if any, to be taken,and the work that is to be performed at thefactory. R.M.R. forms can be obtained fromBrodie Sales Offices or the Service Department,Brodie Meter Co., LLC, P.O. Box 450, Highway301 N., Statesboro, Georgia, 30459.

Place a copy of either of the above inside theshipping container and attach it physically to thematerial being returned. A copy of your packinglist should be placed inside an envelope andattached to the outside of the shipping container,or placed inside the container.

Equipment returned to the factory without properdocumentation will be returned to sender at theirexpense.

Ship the container to:Brodie Meter Co., LLCProduct Service Department19267 Hwy. 301 NorthStatesboro, GA 30458Telephone: 1 912 489 0200Fax: 912 489 0435

2.4 Recommended Procedures

Prior installation of the meter, the following itemsof general information and recommendationsshould be considered:

1. On new installations, the lines should beflushed thoroughly to rid the pipe of weldingbead, pipe scale, etc., before the meter isplaced in service. This can be done by using aspool piece in place of the meter.

2. The flowmeter must be installed sothe shaftsof the rotors are horizontal, never vertical or“on end.” (See Figures 2.1, and 3.2.) Severedamage to components may be the result.

3. A strainer should be installed upstream andadjacent to the flowmeter to protect it fromforeign matter such as dirt, pipe scale orwelding splatter. Refer to Table 1.3 for strainerdata.

4. Valves should be installed to facilitate removalof the flowmeter and strainer.

5. Install flowmeter on the discharge side of apump wherever possible.

6. Remove the protective covering from theflowmeter flanges before installation.

7. LDR counters can be rotated and secured inany of eight positions.

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8. The flowmeter should be installed in an areathat has a clean, dry atmosphere and isrelatively free from excessive vibration.

Figure 2.1 Horizontal and Vertical Installations

2.5 Horizontal Installation

(See Figure 2.1)

When the flowmeter is installed in the main flowline it is recommended that a by-pass line andthree valves be provided as shown in Figure 2 1.The by pass permits removal of the flowmeterand cleaning of the strainer without shutting downthe system. Three valves are required as shownin Figure 2 1. The valves permit system start upwhen the flowmeter is used with hightemperature liquids. The valves also controlinitial flow surges that could damage flowmetercomponents.This is especially important duringstart up when the lines are filled with air. Overspeeding and/or running the flowmeter withoutliquid lubrication will damage flowmetercomponents.

2.6 Vertical Installation

(See Figure 2.1)

When the flowmeter is installed in a verticalpipeline, itis recommended that a by pass lineand three valves be provided as shown in Figure2 1.

The vertical installation has the advantage ofreducing the amount of pipe scale or foreignmatter than could pass through the flowmeter.

The valves permit system start up when theflowmeter is used with high temperature liquids.The valves also protect the flow meter frorn initialflow surges that could damage flowmetercomponents from thermal shock.

3.0 Operation3.1 General

The flowmeter has been completely assembled,checked and calibrated at the factory. Undernormal circumstances, no adjustments shouldbe required. Since the flowmeter is calibrated asa complete unit, it is normal for the register toindicate other than zero. Do not attempt to startthe system until the flowmeter has beenpermanently installed. It is extremely importantthat the start up procedures be followed in theexact sequence presented. Permanent damageto the flowmeter components may result unlessthe procedures are followed.

3.2 Principle of Operation

See Figure 3.1 and 3.2

The Oval Flowmeter accurately measures liquidflow by using a slight pressure differential torotate a pair of oval gears. The meshed gearsseal the inlet from he outlet flow, developing thepressure differential. When in the position shownin Figure 3 1, Diagram 1, all of the driving torqueresulting from the differential pressure is appliedto Gear A. Gear B has zero driving torque sinceequal areas of gear surface on opposite sides ofthe axis of rotation are exposed to the higher inletpressure. As the gears begin to rotate (seeDiagram 2), the torque applied to Gear Adecreases, but Gear B now has driving torque,

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due to the increased area exposed to the highpressure. At the position shown in Diagram 3, allof the driving torque is exerted on Gear B andGear A has decreased to zero. This alternatedriving action provides a smooth rotation ofalmost constant torque without dead spots.Diagrams 4 through 9 illustrate this principlethrough a complete cycle bringing Gear A backto its original position.

As the gears rotate, they trap precise quantitiesof liquid in the crescent shaped gaps of themeasuring chamber. The total quantity of flow forone rotation of the pair of oval gears is four timesthat of the crescent shaped gap. The rate of flowis proportional to the rotational speed of thegears. Because the amount of slippage betweenthe oval gears and the measuring chamber wallis minimal, the meter is essentially unaffected bychanges in viscosity and lubricity of the liquids.

An output shaft is rotated in direct proportion tothe oval gears by means of a powerful magneticcoupling. The output shaft drives a gear trainthat provides meter registration in engineeringunits of gallons, liters, pounds, etc.

3.3 Pre Operation Procedure

After the flowmeter has* been installed asdescribed in Section 2, slowly allow the liquid toflow in the by pass section of a horizontalinstallation or the main line of a verticalinstallation. This will clear the line of any foreignparticles.

Caution must be taken so that flow rate,pressure and temperature are withinrecommended specifications. When theflowmeter is used with high temperature liquids,refer to special start up procedures in Paragraph3 5. No other special operating procedures needto be observed, except to insure the meteredliquid is clear of foreign particles which maydamage the flowmeter.

3.4 Normal Start Up Procedure

After the lines have been cleared, proceed asfollows:a. SLOWLY open the inlet valve.b. SLOWLY open the outlet valve.c. Completely close the by pass valve.d. Make sure that temperature, pressure and

flow rate are within the recommendedspecifications.

3.5 Higher Temperature Start Up Procedure

On temperature service above 1500F. (based onambient temperature of 700F.), special start upprocedures are required to prevent permanentdamage to flowmeter components. The followingequation may be used to determine theapproximate flowmeter warm up time. A similarprocedure should be followed on any thermalshock in excess of 80F.

Warm Up Time (Hrs.) = Nom.Conn.Size x (Oper. Temp. 0F. 150)100

Figure 3.2Oval Gear Flowmeter, Pictorial Diagram

Figure 3.1 Principle of Operation

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a. Valve No. 1 and Valve No. 2 must be tightlyclosed.

b. Valve No. 3 should be opened in gradualsteps until by-pass piping is stabilized atoperating temperature and valve is fully open.

c. With Valve No. 3 open and Valve No. 2 closed,very a slightly open Valve No. 1. Allowtemperature to stabilize around the flowmeter.Open Valve No. 1.

d. Open Valve No. 2 approximately 5%, justslightly admitting flow through the flowmeter.

e. With the flowmeter rotors operating normally,gradually open Valve No. 2 in smallincrements until the valve is fully open.

f. Gradually close Valve No. 3.

NOTE: The above procedure must befollowed each time the flowmeter is startedfrom ambient to operating temperaturesabove 1500F.

3.6 Flowrate Determination

The flowrate may be determined without the useof test equipment. A stopwatch is the only aidrequired. The stopwatch is used to determinethe elapsed time of a predetermined number ofregister pointer revolutions. The elapsed timeshould be sixty (60) seconds or more and theminimum number of register pointer revolutionsshould be three (3). A minimum of three runsshould be made for greater accuracy. Using thefollowing information as an example, solve theequation to derive actual flowrate.

Caution

If flowmeter rotors bind or make excessive noise at this time, DO NOT change valve

positions. When temperature has fully stabilized within the flowmeter, normal operation will

occur. Do not open Valve No.2 any further until flowmeter rotors are turning freely.

a. Flowmeter maximum flowrate = 32 gpm

b. Register pointer revolutions = 3

c. Register Graduations = 1 revolution equals tengallons

d. Indicated Volume = 30 gallons

e. Elapsed Time = 81.8 seconds

IF: Flowrate (Gal./Min.) =

Indicated Volume (Gal.) x 60 Sec./MinElapsed Time (Sec.)

THEN: Flowrate (Gal./Min.) =

30 Gallons x 60 (Sec./Min.) 81.8 (Sec.)

OR: Flowrate = 22 gpm

3.7 Accuracy Adjustor

Accuracy adjustment can be accomplished byusing one of two methods. The standardaccuracy adjustor is a fixed gear train in the newgear box. For calibration purposes, the fixed geartrain can be easily removed for substitution of adifferent fixed gear train. In addition to thestandard adjustor, an optional Model 4200Adjustor is necessary for applications wherevarious viscosity products will be measuredthrough one meter or for fine adjustment.

3.8 Accessories

The Oval Meter may be mounted to the completeBrodie Meter line of accessories with the designof the new oval gear box. Reference Page 18 forthe typical accessory combinations that may beapplicable to your meter.

Figure 3.3 High Temperature Installation

10101010101010

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4.0 Maintenance4.1 General

No routine maintenance, cleaning or lubricationis required on the flowmeter. The user shouldestablish a schedule for periodic checking andcleaning of the strainer.

4.2 Manufacturer’s MaintenanceRecommendations

The following items apply to all flowmeters.Users must give careful consideration to theconsequences that may be the result of failure tofollow manufacturer’s recommendations.

a. No attempt should be made by the user toalter any physical dimension of the flowmeteror component part.

b. Do not use force to assemble or disassembleany component of the flowmeter. Allcomponents are machined to exacttolerances.

c. When an unserviceable flowmeter has beenreturned to the factory for rework, it must beunder-stood that in extreme cases it may beeconomically impractical to repair theflowmeter.

d. No attempt should be made by the user toreplace the rotor bearings. Rotors andbearings are manufactured as asubassembly and are available asreplacement or spare parts.

4.3 Disassembly

WarningIt is not necessary to remove the flow meter from the pipeline for disassembly. Read the ENTIRE procedure for disassembly before

making ANY attempt to disassemble the meter. Serious personal injury or damage to the meter

can result if it is improperly handled.

Before proceeding with any disassembly, becertain to:

1. Close all valves and isolate the meter fromline pressure or back pressure.

2. If used at elevated temperatures, reduce thetemperature of the meter, including internals, toambient.

3. Disconnect all electrical lines to or from themeter.

4. CAUTION: If the meter has been used forcorrosive, toxic or other dangerousliquids, follow the procedures outlined inSubpart l, Sections 1910.132 through1910.140 of the Occupational Safety andHealth Standards, Federal Register No.202-Pt II-1, or subsequent changesthereto.

5. Reduce the pressure inside the meter to zeroby completely draining that part of the processline which is isolated with the meter. It isrecommended that product be removedthrough the strainer, drain plug or device otherthan the meter for this purpose. If pressuremust be reduced through the flowmeter, veryslowly and carefully loosen the hex screws ofthe bottom flange (Figure 6-2, Items 6 and 9)until the meter begins to drain and pressure isreduced to zero. Refer to CAUTION inItem 4 above.

6. Drain the flowmeter completely by removingthe bottom flange (Item 6). CAUTION:

Figure 4.2Oval Gear Flowmeter With Both Rotors Installed

Figure 4.1Oval Gear Flowmeter With One Rotor Installed

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Extreme care should be taken as thecrescent shaped pockets of the measuringchamber may still contain liquid.

7. Disconnect all tubing and/or wiring from themeter mounted accessories.

4.4 Procedure

CautionNever use any gripping tool or any internal

component of the meter assembly. Do not drop any part of the meter as damage may occur.

The meter is made up of sub-assemblies which can be serviced independent of the meter.

When disassembling the gear box or removingthe register, avoid breaking the meter apart at themeter body and register adaptor, as reassemblyrequires the gear box to be separated from theregister adaptor and an involved meshing of theidler gear with the output gear. Changing theregister DOES NOT require the meter to bedisassembled.

The meter can be disassembled in the line as

from their shafts unless necessary asplacement is critical to timing. If removal orreplacement is required, note timing marks onthe face of each rotor and mark clearly.

5. For complete measuring unit disassembly,re-move thrust washers (Item 35), oval gears(Item 5) and rotor shafts (Item 32) using agentle rocking motion.

CautionNever use gripping tools on internal components of the measuring unit.

6. Inspect all internal parts for damage and wear.

For service or replacement of parts from theregister adaptor side of the meter or todisassemble or disengage the register andregister adaptor from the meter body (ReferenceFigure 6-2):

1. Loosen the three setscrews (Item 26) of theregister adaptor assembly and lift straight outto disengage gearing. (Models 9453, 9455,9456, 9457 and 9459.

2. Proceed to the meter for disassembly.

3. Remove cap screws (Item 10) from thedriving rotor flange (Item 12). Remove andinspect O-Ring (Item 11).

4. The follower magnet shaft (Item 8) may beremoved at this time.

5. Remove hex screws (Item 9) from the top/front flange (Item 31). Using jack screws orprying tool (when the meter body is recessedfor flange removal), alternate sides and lift theend flange away from the meter body.(Reference Step 2, “Access Through BottomFlange.”)

6. For complete measuring unit disassembly,locate and clearly mark timing marks of theoval gears. Remove thrust washers (Item 35),oval gears (Item 5) and rotor shafts (Item 32)using a gentle rocking motion.

7. Inspect all internal parts for damage or wear.

Register Adaptor Disassembly

well as removed from the line with access to thebottom flange (Item 6). Utilizing the two jackscrew locations on the face of the flange, insertcap screws finger tight and turn alternately one-half turn to lift the flange from the meter body.

Note: Some models may have slotteddepressions for the flange removal. In such acase, gently pry the flange from the face of themeter body using an appropriate prying tool.

CautionWhen utilizing the prying method, care should be taken not to score the face of the flange or

meter or to damage the sealing O-Ring.

3. Normally, upon removal of the bottom flange,the dowel pins (Item 4) and rotor shafts (Item32) will remain intact with the meter body.Note position of all components.

4. DO NOT remove Oval Gear Rotors (Item 5)

12121212121212

12

12

1. Remove hex screws from gear box assemblyand lift straight out to disengage adaptorcoupling (Item 21).

2. Remove roll pin (Item 20, coupling (Item 21)and crescent snap ring (Item 22) to dislodgetransmission shaft assembly (item 24) fromadaptor housing (Item 18).

3. To replace idle gear assembly (Item 25),remove self-locking nut (Item 19), washer(Item 17), idle shaft spacer (Item 16) and snapring (Item 19).

4.5 Reassembly

It is recommended that new O-Rings be installedfollowing each disassembly to protect integrity ofthe meter seal.1. Orient the meter in such a way as to have the

measuring cavity facing up and out.

2. Press the rotor shafts (Item 32) into the boresprovided in the meter body using a lock-tightsecuring compound. Reference Figure 4-3 forproper Installation of the hollow rotor shaft andmagnetic rotor. The flow arrow indicates theproper orientation. The open end of the hollowshaft is to face toward the register output shaft.

3. Install one thrust washer (Item 35) on eachshaft.

4. Place the rotor (Item 5) with two timing marksfacing out, on the solid rotor shaft (Item 32) ina vertical position (12 o’clock).

5. Place the remaining rotor, having an internalmagnet and one timing mark, on the hollowrotor shaft with the timing mark facing out in ahorizontal (6 o’clock) position as shown inFigure 4-2 and 4-3. Check for proper rotormesh by turning the rotors one or morecomplete revolutions. If the mesh is notproper, disengage one of the two oval rotors,rotate one tooth in either direction, re-engageand check for proper mesh. Continue thisprocedure until a proper mesh is establishedallowing free-turning rotors for one or morerevolutions.

6. Install the two remaining thrust washers (Item35), one on each shaft.

7. Place O-Ring (Item 34) into the bottom flange(Item 6). Lightly lubricate the O-Ring to assistin assembly.

8. Carefully line up blind holes in the flange facewith the dowel pins in the meter body. Inserthex screws (Item 9) and alternately draw thebottom flange onto the dowel pins and flushwith the meter body.

Figure 4.4 Rotor Position Check

(view from register)

Figure 4.3 Timing Flowmeter Rotors

(view from bottom flange)

13

13

Model Torque Value9402 23.4 ft.-Ibs.9453 24 ft.-Ibs.9455 24 ft.-Ibs.9456 35 ft.-Ibs.9457 104 ft.-Ibs.9459 174 ft.-Ibs.

Continue for Reassembly of Meter/RegisterAdaptor

9. Return the following magnet shaft (Item 8) toits original position.

10. Replace O-Ring (Item 11).11. Secure driving rotor flanges (Item 12) to the

face of the top flange using cap screws (Item10) and replace the output gear assembly(Item 13) if originally removed.

12. Reassemble register adaptor, as required, byreferencing Items 3, 2 and 1 of the Register/Adaptor Disassembly procedure outlinedabove. Assure that all mechanical connectionsare fastened securely.

13. Align gearing to register adaptor and re-engage meter body. Secure in place using setscrews (Item 26).

NOTE: All gear meshes should be lubricatedusing a silicone base lubricating grease.

Figure 4.5 Register Adaptor Installation

Table 4.1 Torque Value for End Flanges

14141414141414

14

14

6.0 Parts List6.1 General

This section contains the necessary partsrequired to make up any standard unit that iscovered in this instruction manual. Each partslist also contains the recommended spare andreplacement parts denoted by an asterisk. Foritems that are not listed or require additionalinformation, consult the factory. When or-dering,the following information must be furnished:

a. Part number and descriptionb. Model number of flowmeterc. Serial number of flowmeterd. Quantity required

When ordering items of a material orspecialconstruc-tion not indicated in the Parts List,furnish the following information so that the partnumber of the item can be determined.

a. Item number and descriptionb. Specific material of itemc. Model number of flowmeterd. Serial number of flowmetere. Quantity required

Table 5.1Troubleshooting

5.0 Troubleshooting5.1 General

The troubleshooting table is presented as an aidin locating and correcting operational problemsin the meter. The user must understand thatevery possible problem could not be listed.However, the table will provide adequateinformation for general field repairs.

5.2 Metering Error

The actual volumetric flowrate of the flowmetermay be determined in the field by the user. Itmust be noted that the accuracy depends on thetype of test equipment and the method ofperforming the operation. If an error is noted, thefollowing conditions may exist:a. Errors of measurement may be attributed to

air in a pipeline before the flowmeter orevaporation of highly volatile liquid in thepipeline. Piping should be evaluated andredesigned if necessary.

b. Errors in flow measurements caused bytemperature differences between the liquid inthe flowmeter and liquid in the prover. If thereis any difference, it must be converted to abase temperature.

c. When oil or caustic soda is measured, caremust be exercised in weight conversion ortemperature compensation.

Symptom Possible Cause Service RequiredNo Flow through flowmeter or 1. Foreign particles or solidified matter in measuring chamber. 1. Flush chambers with suitable solvent.high pressure drop is noted. 2. Inoperative rotors. 2. Replace rotors.

1. Inoperative gear box. 1. Replace gear box.2. Inoperative accuracy adjustor. 2. Replace accuracy adjustor.3. Inoperative register drive assembly. 3. Replace register drive assembly.1. Leaky by-pass valve. 1. Repair or replace defective valve.

Flowmeter indicates low 2. Worn, chipped or corroded rotors or case. 2. Repair or replace rotors or case.compared to actual flow. 3. Flow is below specified rate. 3. Increase flow rate.

4. Magnetic coupling shaft assembly slipping or gear train 4. Repair or replace magnetic coupling intermittently binding. shaft assembly, rotors shafts.1. Air in line or in liquid. 1. Purge all air from line or liquid.

Flowmeter indicates high 2. Pulsating flow rate causes erratic electrical pulse outut and 2. Reduce or eliminate pulsating flows.compared to actual flow. indicates high. 3. Check zero and span adjustment.

3. Remote rate indicator defective. 4. Check transmitter.

Flow but no indication.

15

15

6.2 Basic Mechanical Registration

Standard accuracy adjustment is accomplishedthrough the use of the fixed geartrain in the gearbox. The fixed gear train can be easily removedand an adjustment in accuracy made bysubstitution of a different fixed geartrain. In

addition to this, an optional externally-mountedModel 4200 Adjustor is available for applicationswhere products of varying viscosity will bemeasured through the meter or wherever fineadjustment of accuracy is desired. See Bulletin(S) X-4200 for instructions on the Model 4200Adjustor.

Figure 6.1 “New Gear Box” Conversion

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16

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18181818181818

18

18

Figure 6.3 Gear Box Assembley

Item Description 9402 9453 9455 9456 9457 94591 Gear Box Assembly

1 U.S.Gallon CS-381Z-399-AAA CS-381Z-409-AAA CS-381Z-345-AAA CS-381Z-369-AAA NIA NIA10 U:S. Gallons NIA GS-3812-379-AAA CS-381L285-AAA- CS-3812.3.10-AAA CS-384Z-328-AAA. CS-3812-355-AAA

1000 U.S. Gallons NIA NIA NIA NIA CS-381Z-270-AAA CS-381Z-295-AAA1 Imperial Gallon CS-381Z-394-AAA CS-381Z-404-AAA CS-381Z-340-AAA CS-381Z-360-AAA NIA NIA

10 Imperial Gallons NIA CS-381Z-374-AAA CS-381Z-280-AAA CS-381Z-300-AAA CS-381Z-320-AAA CS-381Z-350-AAA100 Imperial Gallons NIA N/A NIA NIA CS-381Z-263-AAA CS-381Z-290-AAA

10 Liters CS-381Z-384-AAA CS-381Z-389-AAA CS-381Z-315-AAA CS-381Z-335-AAA CS-381Z-365-AAA N/A100 Liters N/A NIA CS-381Z-258-AAA CS-381Z-275-AAA CS-381Z-305-AAA CS-381Z-325-AAA1000 Liters NIA N/A NIA NIA N/A CS-381Z-269-AAA

A Gear Box Housing CD-441C-291-FD3 CD-441C-291-FD3 CD-441C-291-FD3 CD-441C-291-FD3 CD-441C-291-FD3 CD-441 C-291-FD3B Gear Train

1 U.S.Gallon CS-381A-502-AAA CS-381A-512-AAA CS-381A-448-AAA CS-381A-472-AAA NIA NIA10 U.S. Gallons N/A CS-381A-482-AAA CS-381A-388-AAA CS-381A-413-AAA CS-381A-431-AAA CS-381A-458-AAA

100 U.S. Gallons _NIA NIA N/A NIA CS-381A-373-AAA CS-381A-398-AAA1 Imperial Gallon CS-381A-497-AAA CS-381A-507-AAA CS-381A-443-AAA CS-381A-463-AAA NIA NIA

10 Imperial Gallons NIA CS-381A-477-AAA CS-381A-383-AAA CS-381A-403-AAA CS-381A-423-AAA CS-381A-453-AAA100 ImperialGallons NIA_ N/A NIA_ N/A CS-381A-366-AAA CS-381A-393-AAA

10 Liters CS-381A-487-AAA CS-381A-492-AAA CS-381A-418-AAA CS-381A-438-AAA CS-381A-468-AAA NIA100 Liters N/A N/A CS-381A-361-AAA CS-381A-378-AAA CS-381A-408-AAA CS-381A-428-AAA1000 Liters NIA NIA NIA NIA NIA CS-381A-372-AAA

C Screw (3) 150632 _150632 150632 150632 150632 0.15D Cover Plate (1) CA-219Z-146-ENG CA-219Z-146-ENG CA-219Z-146-ENG CA-219Z-146-ENG CA-219Z-146-ENG CA-219Z-146-ENGE Screw (2) 150529-419 150529-419 150529-419 150529-419 150529-419 150529-419F Set of 4 Calibration Gears '575-06-3XX-XX '575-06-3XX-XX '575-06-3XX-XX '575-06-3XX-XX '575-06-3XX-XX '575-06-3XX-XX

Table 6.2 Gear box and Register Adaptor Assembly - Parts List

*Calibration gears vary with individual meters and are installed based upon calibration of the meter. Must substitute “X’s” with part numbers.

19

19

Figure 6.4 Typical Accessory Schematic

Typical Accessory Schematic for Brodie Three-Piece Oval Flowmeters with the new gear boxpart Number 381Z-XXX-AAA. All of theseaccesories will mount to Brodie Three-PieceOval Flowmeters furnished with the new designOval Regster/Gear Box.

Notes:

1. Consult factory for torque capability when more thanthree accessories are required.

2. When mechanical preset is specified, the quantitycontrol valve must also be specified.

20202020202020

20

20

Figure 6.5 Output Gearing

Brodie-Oval Meter Registration

Standard-U.S. Gallons

Opional: metric, Pounds, & Barrels

Refer to Tables below for volume per Revolutionof Output shafts, “b” and “C”

(NA=Not Available)

The output “B” is exactly one quarter that of output“A” (the oval gear metering element). Output “C”is adjusted output that drives the registers inEngineering Units 1, 10, 100, or 1,000. Due to highration, in some models, refer to the chart belowfor the volume per revolution pf the output shaft oneach meter model. The gear box can be rotatedfor use on meters modified vertically, horizontally,or diagonally, if the meter rotors remain inhorizontal position.

Standard Optional Standard Optional Standard Optional Standard Optional9402 1/2" 1 10 10 100 10 100 0.1 NA9453 1" 1 10 10 100 10 100 0.1 NA9455 1" 1 10 10 100 10 100 0.1 NA9456 1-1/2" 1 10 10 100 10 100 0.1 19457 2" 10 100 100 NA 100 1000 1 NA9459 3" 10 100 100 1000 100 1000 1 10

Model # Meter SizeOutput "C" (Units per Revolution)

U.S. Gallons Liters Pounds Barrels

9402 48.759453 27.209455 6.7759456 3.1759457 1.1959459 0.4525

Model # Output "B" Revolutions/Gal.

21

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The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Brodie Meter

Co., LLC reserves the right to modify or improve the designs or specifi cations of such products at any time without notice.

Brodie International19267 Highway 301 North • Statesboro, GA 30461

Phone: 001.912.489.0200 • Fax: 001.912.489.0294A Brodie Meter Co., LLC Company

www.brodieintl.com

Engineering the Future

TM