Carlisle Acid Catalyst Meter Owner's manual

Brand: Carlisle

Model: Acid Catalyst Meter

Type: Owner's manual

SERVICE MANUAL

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Standard Flow Meter 310-9000

Acid Catalyst Flow Meter 310-9002

for RM2 and RF2

Scan the related QR code above for other languages

of this ow meter service manual and additional

product information.

RF2 RM2

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EN CONTENTS

CONTENTS

SAFETY 4-8

Safety Precautions ............................................................................................................................................ 4

Hazards/Safeguards ........................................................................................................................................ 5-8

INTRODUCTION 9-10

Standard Flow Meter 310-9000 Introduction ........................................................................................................ 9

Acid Catalyst Flow Meter 310-9002 Introduction ................................................................................................ 10

INSTALLATION 11-12

Flow Meter General Information ........................................................................................................................ 11

Intrinsically Safe Operation ............................................................................................................................... 12

OPERATION 13

Principle of Operation ..................................................................................................................................... 13

Calibration ...................................................................................................................................................... 13

Flow Meter Automatic Clean Procedure ............................................................................................................. 13

MAINTENANCE 14-31

Flow Meter Servicing Overview ......................................................................................................................... 14

Disassembly, Inspection, and Assembly ............................................................................................................. 15

Standard Flow Meter Components..................................................................................................................... 24

Acid Catalyst Flow Meter Components ............................................................................................................... 26

Dual Pickup Sensor Cables ............................................................................................................................... 28

Fiber Optic Pickup Sensor Cables ...................................................................................................................... 30

MANUAL REVISIONS 32

Manual Revisions Summary .............................................................................................................................. 32

WARRANTY 34

Warranty ......................................................................................................................................................... 34

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SAFETY

The hazards shown on the following pages may

occur during the normal use of this equipment.

WARNING!: Indicates a hazardous situation that, if

not avoided, could result in death or serious injury.

Caution!: Indicates a hazardous situation that, if

not avoided, could result in minor or moderate

injury or equipment damage.

Notice: Indicates information considered important

but not hazard related.

SAFETY PRECAUTIONS

Before operating, maintaining or servicing any

electrostatic coating system, read and understand

all of the technical and safety literature for your

products. This manual contains information that

is important for you to know and understand.

This information relates to USER SAFETY and

PREVENTING EQUIPMENT PROBLEMS.

To help you recognize this information, we use the

following symbols. Please pay particular attention to

these sections.

While this manual lists standard specications and

service procedures, some minor deviations may be

found between this literature and your equipment.

Dierences in local codes and plant requirements,

material delivery requirements, etc., make such

variations inevitable. Compare this manual with

your system installation drawings and associated

equipment manuals to reconcile such dierences.

Careful study and continued use of this manual will

provide a better understanding of the equipment

and process, resulting in more ecient operation,

longer trouble-free service and faster, easier

troubleshooting. If you do not have the manuals

and safety literature for your equipment, contact

your local Carlisle Fluid Technologies representative

or Carlisle Fluid Technologies technical support.

SAFETY

Repairs may only be performed by personnel

authorized by Carlisle Fluid Technologies.

The user MUST read and be familiar with the

Safety Section in this manual and the safety

literature therein identied.

This equipment is intended to be used by trained

personnel ONLY.

This manual MUST be read and thoroughly

understood by ALL personnel who operate, clean

or maintain this equipment! Special care should be

taken to ensure that the WARNINGS and safety

requirements for operating and servicing the

equipment are followed.

The user should be aware of and adhere to ALL

local building and re codes and ordinances as

well as NFPA 33 AND EN 16985 SAFETY

STANDARDS, LATEST EDITION, or applicable

country safety standards, prior to installing,

operating, and/or servicing this equipment.

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EN SAFETY

AREA

Tells where hazards

may occur

HAZARDS

Tells what the hazard is

SAFEGUARDS

Tells how to avoid the hazard

Spray Area Fire Hazard

Improper or inadequate

operation and maintenance

procedures will cause a re

hazard.

Protection against

inadvertent arcing that

is capable of causing

re or explosion is lost if

any safety interlocks are

disabled during operation.

Frequent Power Supply

or Controller shutdown

indicates a problem in the

system requiring correction.

Fire extinguishing equipment must be present in

the spray area and tested periodically.

Spray areas must be kept clean to prevent the

accumulation of combustible residues.

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must

be turned o prior to cleaning, ushing, or

maintenance.

Spray booth ventilation must be kept at the rates

required by NFPA 33, EN 16985, country, and

local codes. In addition, ventilation must be

maintained during cleaning operations using

ammable or combustible solvents.

Electrostatic arcing must be prevented. Safe

sparking distance must be maintained between the

parts being coated and the applicator. A distance of

1 inch (25mm) for every 10KV of output voltage is

required at all times.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but only

as instructed.

Non-factory replacement parts or unauthorized

equipment modications may cause re or injury.

If used, the key switch bypass is intended for use

only during setup operations. Production should

never be done with safety interlocks disabled.

The paint process and equipment should be set up

and operated in accordance with NFPA 33, NEC,

OSHA, local, country, and European Health and

Safety Norms.

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SAFETY

AREA

Tells where the

hazard may occur

HAZARD

Tells what the hazard is

SAFEGUARDS

Tells how to avoid the hazard

Spray Area Explosion Hazard

Improper or inadequate

operation and maintenance

procedures will cause a re

hazard.

Protection against

inadvertent arcing that

is capable of causing

re or explosion is lost if

any safety interlocks are

disabled during operation.

Frequent Power Supply

or Controller shutdown

indicates a problem in the

system requiring correction.

Electrostatic arcing must be prevented. Safe

sparking distance must be maintained between the

parts being coated and the applicator. A distance of

1 inch (25mm) for every 10KV of output voltage is

required at all times.

Unless specically approved for use in hazardous

locations, all electrical equipment must be located

outside or applicable county code hazardous areas,

in accordance with NFPA 33.

Test only in areas free of ammable or combustible

materials.

The current overload sensitivity (if equipped) MUST

be set as described in the related section of the

equipment manual. Protection against inadvertent

arcing that is capable of causing re or explosion

is lost if the current overload sensitivity is not

properly set. Frequent power supply shutdown

indicates a problem in the system which requires

correction.

Always turn the control panel power o prior to

ushing, cleaning, or working on spray system

equipment.

Before turning high voltage on, make sure no

objects are within the safe sparking distance.

Ensure that the control panel is interlocked with the

ventilation system and conveyor in accordance with

NFPA-33, EN 16985.

Have re extinguishing equipment readily available

and tested periodically.

General Use and

Maintenance Improper operation or

maintenance may create a

hazard.

Personnel must be properly

trained in the use of this

equipment.

Personnel must be given training in accordance with

the requirements of NFPA 33.

Instructions and safety precautions must be read

and understood prior to using this equipment.

Comply with appropriate local, state, and national

codes governing ventilation, re protection,

operation maintenance, and housekeeping.

Reference OSHA, NFPA 33, EN Norms and your

insurance company requirements.v

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EN SAFETY

AREA

Tells where the

hazard may occur

HAZARD

Tells what the hazard is

SAFEGUARDS

Tells how to avoid the hazard

Spray Area /

High Voltage

Equipment

Electrical Discharge

There is a high voltage

device that can induce

an electrical charge on

ungrounded objects which

is capable of igniting

coating materials.

Inadequate grounding

will cause a spark hazard.

A spark can ignite many

coating materials and cause

a re or explosion.

Parts being sprayed and operators in the spray area

must be properly grounded.

Parts being sprayed must be supported on

conveyors or hangers that are properly grounded.

The resistance between the part and earth ground

must not exceed 1 Meg Ohm. (Refer to NFPA 33,

EN 16985.)

Operators must be grounded. Grounding straps

on wrists or legs may be used to assure adequate

ground contact.

Footware to be used by operator shall comply with

EN ISO 20344, resistance not to exceed 100 Meg

Ohm. Protective clothing including gloves should

comply with EN 1149-5, resistance not to exceed

100 Meg Ohm.

Operators must not be wearing or carrying any

ungrounded metal objects.

When using an electrostatic handgun, operators

must assure contact with the handle of the

applicator via conductive gloves or gloves with the

palm section cut out.

NOTE: REFER TO NFPA 33, EN 16985 OR SPECIFIC

COUNTRY SAFETY CODES REGARDING PROPER

OPERATOR GROUNDING.

All electrically conductive objects in the spray area,

with the exception of those objects required by the

process to be at high voltage, must be grounded.

Grounded conductive ooring must be provided in

the spray area.

Always turn o the power supply prior to ushing,

cleaning, or working on spray system equipment or

applicable county code.

Unless specically approved for use in hazardous

locations, all electrical equipment must be located

outside or applicable country code, hazardous

areas, in accordance with NFPA 33.

Avoid installing an applicator into a uid system

where the solvent supply is ungrounded.

Do not touch the applicator electrode while it is

energized.

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SAFETY

AREA

Tells where the

hazard may occur

HAZARD

Tells what the hazard is

SAFEGUARDS

Tells how to avoid the hazard

Electrical

Equipment Electrical Discharge

High voltage equipment

is utilized in the process.

Arcing in the vicinity of

ammable or combustible

materials may occur.

Personnel are exposed

to high voltage during

operation and maintenance.

Protection against

inadvertent arcing that may

cause a re or explosion

is lost if safety circuits are

disabled during operation.

Frequent power supply

shut-down indicates a

problem in the system

which requires correction.

An electrical arc can ignite

coating materials and cause

a re or explosion.

Unless specically approved for use in hazardous

locations, the power supply, control cabinet, and all

other electrical equipment must be located outside

or applicable country codes, hazardous areas in

accordance with NFPA 33 and EN 16985.

Turn the power supply OFF before working on

the equipment.

Test only in areas free of ammable or combustible

material.

Testing may require high voltage to be on, but only

as instructed.

Production should never be done with the safety

circuits disabled.

Before turning the high voltage on, make sure no

objects are within the sparking distance.

Toxic Substances Chemical Hazard

Certain materials may be

harmful if inhaled, or if

there is contact with the

skin.

Follow the requirements of the Safety Data Sheet

supplied by coating material manufacturer.

Adequate exhaust must be provided to keep the air

free of accumulations of toxic materials. Reference

EN 12215 or applicable code.

Use a mask or respirator whenever there is a

chance of inhaling sprayed materials. The mask

must be compatible with the material being

sprayed and its concentration. Equipment must be

as prescribed by an industrial hygienist or safety

expert, and be NIOSH approved.

Spray Area Explosion Hazard -

Incompatible Materials

Halogenated hydrocarbon

solvents for example:

Methylene chloride and

1,1,1, - Trichloroethane are

not chemically compatible

with the aluminum that

might be used in many

system components. The

chemical reaction caused

by these solvents reacting

with aluminum can become

violent and lead to an

equipment explosion.

Spray applicators require that aluminum inlet

ttings be replaced with stainless steel.

Aluminum is widely used in other spray application

equipment - such as material pumps, regulators,

triggering valves, etc. Halogenated hydrocarbon

solvents must never be used with aluminum

equipment during spraying, ushing, or cleaning.

Read the label or data sheet for the material you

intend to spray. If in doubt as to whether or not a

coating or cleaning material is compatible, contact

your coating supplier. Any other type of solvent may

be used with aluminum equipment.

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EN INTRODUCTION

INTRODUCTION

310-9000 DESCRIPTION

The Ransburg 310-9000 ow meter is developed to precisely meter and monitor uid ows. This ow meter,

in many cases, surpasses the performance of other types of meters currently used.

FLOW RATE ACCURACY

A ow rate accuracy of 0.5% is typical with many uids if the ow meter is calibrated at or near the

expected ow rates. Even with wide ow rate swings (such as when used with robots under analog control),

an accuracy of ± 2% is possible.

REVERSE FLOW DETECTION

The sensors (pickups) are available in single or dual-sensor versions. The dual sensor version outputs two

square waves in quadrature mode so that sensing circuitry can determine ow rate and direction. If it is

necessary to sense the reverse ow of the material, the dual-sensor version should be used.

FLUID PASSAGES

The ow meter requires 3/8” AN male ttings. This tting style eliminates ow “dead space” and removes

the need for specially designed ttings or TFE inserts. When a streamlined uid passage is made, the color

change time of the meter is improved.

SPECIFICATIONS

310-9000 Ransburg Flow Meter Operation Specications

Flow Rate: 10–3,000 cc/min (material dependent)

Accuracy: ± 0.5%

Max Working Pressure: 6,000 psi (413.69 bar/41369 kPa) @ 100 °F (37.77 °C)

Temperature: -40–140 °F (-40 °C to 60 °C)

Signal Output: 2 Channel Quadrature, 56,000 pulses per liter

Power: 10–30 VDC

310-9000 Ransburg Flow Meter Materials Specications

Body: 303 Stainless Steel / DIN 1.4305

Gears: DIN 1.4122

Sleeve Bearings: Tungsten Carbide

Shafts: Tungsten Carbide

Seal: PTFE

Filtration Required: 120 Microns

Connections: 9/16-18G (JIC 37) ports

Weight: 3.6 lbs (1.6 Kg)

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INTRODUCTION

310-9002 DESCRIPTION

The Ransburg 310-9002 acid catalyst ow meter is developed to precisely meter and monitor uid ows.

This ow meter, in many cases, surpasses the performance of other types of meters currently used.

FLOW RATE ACCURACY

A ow rate accuracy of 0.5% is typical with many uids if the ow meter is calibrated at or near the

expected ow rates. Even with wide ow rate swings (such as when used with robots under analog control),

an accuracy of ± 2% is possible.

REVERSE FLOW DETECTION

The sensor (pickups) is a dual-probe version. The dual sensor version outputs two square waves in

quadrature mode so that sensing circuitry can determine ow rate and direction. If it is necessary to sense

the reverse ow of the material, the dual-sensor version should be used.

FLUID PASSAGES

The ow meter requires 3/8” AN male ttings. This tting style eliminates ow “dead space” and removes

the need for specially designed ttings or TFE inserts. When a streamlined uid passage is made, the color

change time of the meter is improved.

SPECIFICATIONS

310-9002 Ransburg Flow Meter Operation Specications

Flow Rate: 4–1893 cc/min (material dependent)

Accuracy: ± 0.5%

Max Working Pressure: 6,000 psi (413.69 bar/41369 kPa) @ 100 °F (37.77 °C)

Temperature: -40–140 °F (-40 °C to 60 °C)

Signal Output: 2 Channel Quadrature, 56,000 pulses per liter

Power: 10–30 VDC

310-9002 Ransburg Flow Meter Materials Specications

Body: 316 Stainless Steel / DIN 1.4404

Gears: DIN 1.4122

Sleeve Bearings: Tungsten Carbide

Shafts: Tungsten Carbide

Seal: PTFE

Filtration Required: 120 Microns

Connections: 9/16-18G (JIC 37) ports

Weight: 3.6 lbs (1.6 Kg)

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EN INSTALLATION

GENERAL INFORMATION

The unit can be mounted with the bolt pattern shown below. Mount the ow meter vertically so the gear

faces are perpendicular to the earth’s horizon. This mount position minimizes the eect of gravity on the

gears. The ow direction must be plumbed as marked on the side label of the meter. The uid inlet is

opposite the sensor connection. Two (2) 1/4-20 screws must be used.

ELECTRICAL NOISE

Although not required, the meter can be plumbed so the ow enters at the bottom of the meter and exits at

the top. This type of plumbing eliminates the possibility of air entrapment in the meter.

Make sure that the ow meter cables are not put closer than 12” to noise generation devices. For example,

large electric motors, uorescent lighting, transformers, ballasts, etc.

INSTALLATION

This ow meter can be installed in Class I, Division I, and Group D locations when used with the correct

Zener Barrier. Refer to pages 14-17 for more details.

OUTLET PORT

Ø 3.30” (Ø 84 mm)

INLET PORT

1.730”

(196.35 mm)

M6 x 20 mm THD

x 12 mm DEEP

(2 PLACES)

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The ow meter can be operated in hazardous areas (Class I, Division I, Group D locations). It is necessary to

route the power to the ow meter and the signal (or signals) that return from the ow meter sensor through

an approved Zener barrier.

The ow meter with the dual-probe pickup sensor (PN 310-9011) is included with the Remote Fluid Panel

Kit, Barrier & F.O. Transceiver Box kits 310-8020 and 310-8021. For installation information, see Installation

Manual 77-3155.

The ow meter with the ber optic pickup sensor (PN 310-9012) is included with the In-Booth Remote Fluid

Panel kits 310-8022 and 310-8023. For installation information, see Installation Manual 77-3155.

OPERATION-INTRINSICALLY SAFE

INTRINSICALLY SAFE OPERATION

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OPERATION

PRINCIPLE OF OPERATION

Gear-type ow meters work on the principle that a small material is trapped between each gear’s teeth.

One to two proximity sensors detect each gear tooth rotation as the gears rotate. When a gear tooth passes

a proximity sensor, the sensor sends a square wave pulse back to the controller to indicate one of those

material cavities has passed through the meter.

Flow Meters are typically calibrated by the pulse count occurrences when one liter of material has passed

through the meter. That value is generally called the calibration value or calibration factor and is expressed

in pulses per liter (ppl). Although this value would stay the same from material to material, it is dierent

because it varies based on several factors. These factors include (but are not necessarily limited to) viscosity,

ow rate, material temperature, percent of solids, the lubricity of the material, solvent vs. water-based, and

whether or not the material is thixotropic. As a result, gear-type ow meters must be calibrated with the

material used during production and at the expected ow rates.

CALIBRATION

The ow meter must be calibrated periodically as the calibration value (in pulses per liter or PPL) will vary

based on viscosity, ow rate, temperature, wear, and other factors. Refer to the appropriate associated

equipment documentation for the proper calibration procedure.

PROCEDURE TO AUTOMATICALLY CLEAN THE FLOW METER

Fluid Line Air Purges

Air purges are used in automatic coating operations for rapid color changes and to minimize the solvent

required to ush out the old color. Special considerations must be made when air purges through the ow

meter are used.

1. Long air purges do not provide the lubrication the ow meter gears require. The metered uid or

solvent typically delivers this lubrication.

2. Air purges can cause coating materials to thicken or dry on the ow meter shafts and gears. Such

materials will aect the performance characteristics of the ow meter, primarily when water-based

materials are used.

3. Long air purges will cause premature gear and shaft failure.

4. All clean cycles must start with a solvent push to prevent dried coating materials on ow meter parts.

5. Solvent and air “chop” cycles are recommended as the most satisfactory method to ush ow meters.

6. On plural-component materials or other materials that cause a ’skinning’ eect on the inside of the uid

lines, it is recommended that they be lled with non-pressurized solvent during idle times. The system

must be ushed before the next spray cycle load.

7. Air purges are not recommended for water-based applications.

OPERATION

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FLOW METER SERVICING OVERVIEW

Flow Meter problems can be caused by incorrectly ltered uid.

Particulates in the uid can cause the gears

to bind, and the results are incorrect signals for the actual ow rate. Refer to the instructions from the lter

manufacturer to maintain the uid lters. If the disassembly and clean procedures are needed again and

again to remove solids and particulates, examine the full uid supply system and make an analysis of the

system’s automatic clean procedure cycle.

Fluid backup (reverse ow) can cause reacted or catalyzed material to enter the ow meter. The 2K controls

will sense the reverse ow, and the system will shut down. Immediately clean the ow meter before the

uid sets up. During regular operation, the magnetic sensors or electrical connections will not need to be

replaced.

BOTTOM BODY (EXTERNAL) TORQUE SEQUENCE (EXTERNAL)

BOTTOM BODY (INTERNAL) TOP BODY (INTERNAL)

2 7

9 5

8 1

6 10

4 3

3.30”

(84 mm)

1.730”

(196.35 mm)

5 mm Socket

Head Cap Screw

Fluid Outlet

Fluid InletAlignment

Pins (two)

FLUID FLOW

DIRECTION

M6 x 20 mm THD

x 12 mm DEEP

(2 PLACES)

MAINTENANCE

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EN MAINTENANCE

DISASSEMBLY

These instructions are only applicable after the

upper and lower material lines are disconnected,

and the ow meter assembly with attached bracket

is removed from the uid panel for servicing.

Dual Probe Pickup Sensor Removal

1. Disconnect the ow meter cable (a) from the

dual probe pickup sensor (b).

Loosen the two hex head cap screws (c) marked

in red. These are captive screws and will remain

with the pickup sensor when removed from the

ow meter body.

DISASSEMBLY, INSPECTION, AND ASSEMBLY

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3. Carefully

pull the pickup sensor (b) straight

out and away from the ow meter body.

Move the pickup sensor to a clean, safe area to

prevent damage. Do not drop the pickup.

The dual probe pickup sensor is a sensitive device.

If dropped, damage can occur and cause unstable

or incorrect ow indications.

Go to page 18 to continue the ow meter

disassembly procedure.

MAINTENANCE

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EN MAINTENANCE

Fiber Optic Pickup Sensor Removal

1. Disconnect the ow meter ber optic cable

(d) from the ber optic pickup sensor (e).

2. Loosen the jam nut (f) on the pickup sensor

where it touches the ow meter’s front face.

3. Turn the pickup sensor (e) counterclockwise to

remove it from the ow meter body. Move the

pickup sensor to a clean, safe area to prevent

damage. Do not drop the pickup.

The ber optic pickup sensor is a sensitive device.

If dropped, damage can occur and cause unstable

or incorrect ow indications.

Go to page 18 to continue the ow meter

disassembly procedure.

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MAINTENANCE

4. Remove two each of the hex head cap screws

(g), external tooth lock washers (h), and at

washers (i) from the back of the bottom ow

meter body.

Put the mounting bracket (j) and all fastener

hardware in a safe area.

5. Remove the upper and lower hose adapters (k)

from the bottom ow meter body (m).

6. Clean the remaining thread tape or sealant from

the adapters and threaded holes (l) in the bottom

body.

7. If the decals are missing, put a mark across the

halves before separation to later identify their

related positions for reassembly.

8. Use a 5mm hex key wrench and remove the ten

(n) socket head cap screws.

The ow meter body halves are labeled with decals

on the same side to help with reassembly.

The ow meter servicing procedures are identical

for the standard and acid catalyst ow meters.

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EN MAINTENANCE

Divide the top (o) and bottom (m) ow meter

body halves. Put the ow meter body halves in a

clean work area with the mating surfaces pointed

up. Do not let these surfaces get damaged,

especially where the o-ring gasket is set.

If separation of the halves is not easy, do not pry

apart the body halves with a screwdriver or other

such tool. Damage to the mating surfaces, gear

shafts, or shaft bearings can occur.

An alternative method of separation is to:

a) Put two socket head cap screws (n) through

opposite sides of the ow meter and give the

screws a few turns each.

b) Tightly hold the top body, then tap the screw

heads with a soft mallet until separation is

complete.

10. Remove and discard the o-ring gasket (p).

11. Remove the gears (q) and shafts (r) from the

shaft bores in the measuring chamber.

Discard the used o-ring gasket. O-ring gaskets

cannot be reused, but must always be replaced

with new ones during ow meter body servicing.

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MAINTENANCE

INSPECTION

Use an applicable solvent and clean the remaining

material from all ow meter parts.

Examine all following parts for wear and damage:

1. The gear shafts (r) must measure the same

diameter at the ends and center. Replace the

gear shaft set if a shaft does not measure the

same at the three locations or if there are scores,

scratches, or damage to the shaft.

2. The gear teeth (q) must not be worn, chipped,

pitted, broken, or missing. Replace the gear set if

there is damage to a gear.

3. The gear shaft bearing(s) must not be worn,

pitted, or have scores or scratches. Replace the

gear set if a bearing has damage or the gears

wobble on the shafts.

4. The shaft bearings (u) in the top ow meter body

(o) must not be worn, pitted, or have scores or

scratches.

Put the gear shafts into the top body bearings

and try to wobble them. Replace the top body if a

bearing has damage or the gear shafts wobble in

the bearings.

5. The ow meter top’s mating face (t) must not be

gouged, scored, scratched, or pitted. Replace the

top body if there is damage.

t u

MUST BE THE SAME DIAMETER

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Carlisle Acid Catalyst Meter Owner's manual

Carlisle Acid Catalyst Meter Owner's manual

Carlisle Acid Catalyst Meter Owner's manual

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