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Badger Meter 220 Operating Manual

Flow Sensors
Insertion Style Flow Sensors
Series 220, 225, 226
SEN-UM-01635-EN-11 (February 2018)
User Manual
Flow Sensors, Insertion Style Flow Sensors
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Certications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation for 220BR, 220SS, 220PV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Alignment of Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hot Tap Installation for 225BR, 226BR, and 226SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Sensor Assembly Depth and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Installation if the Pipe is Depressurized and Drained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation into a Pressurized Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Standard Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
IR Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
High Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electrical Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Description of Calibration Table Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibration Table for Pipe Sizes 3…36 Inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Page ii February 2018SEN-UM-01635-EN-11

Introduction

INTRODUCTION
Used in conjunction with any Badger Meter impeller flow monitor or transmitter, Badger Meter non-magnetic flow sensors provide an accurate rate of liquid flow as well as total accumulated flow. A number of sensor models are offered, which cover applications for a wide range of pipe sizes and pressure/temperature specifications.
The flow sensors generate a frequency which is proportional to flow rate. An internal preamplifier allows the pulse signal to travel up to 2000 feet without further amplification. Power to operate the sensor is provided by the flow monitor. The impeller bearing assembly, shaft and O-rings are replaceable in the field.
Badger Meter flow sensors feature a closed, six-bladed impeller design, using a proprietary, non-magnetic sensing technology. The forward-swept impeller shape provides higher, more constant torque than four-bladed impeller designs, and is less prone to fouling by water-borne debris. The forward-curved shape, coupled with the absence of magnetic drag, provides improved operation and repeatability, even at lower flow rates. As the liquid flow turns the impeller, a low impedance signal is transmitted with a frequency proportional to the flow rate.
Sensors of similar type are interchangeable, so there is no need for recalibration after servicing or replacement.
This manual provides instructions for the following insertion style flow sensors, as indicated:
220BR; 220SS; 220PV; 225BR; 226BR; 226SS
CERTIFICATION

MECHANICAL INSTALLATION

Flow measurement accuracy for all flow measuring devices is highly dependent on proper location in the piping system. Irregular flow velocity profiles caused by valves, fittings, and pipe bends can lead to inaccurate overall flow rate indications although local flow velocity measurement may be accurate. A sensor located where it can be affected by air bubbles, floating debris, or sediment may not achieve full accuracy and could be damaged. Badger Meter flow sensors are designed to operate reliably under adverse conditions. Follow these recommendations to provide maximum system accuracy:
• Choose a location along the pipe where 10 pipe diameters upstream and 5 pipe diameters downstream of the sensor provide no flow disturbance. Pipe bends, valves, other fittings, pipe enlargements and reductions should not be present in this length of pipe.
• The preferred location around the circumference of a horizontal pipe is on top. If trapped air or debris will interfere, then the sensor should be located further around the pipe from the top but not more than 45 degrees from top center. The sensor should never be located at the bottom of the pipe, as sediment may collect there. Locations off top center cause the impeller friction to increase, which may affect performance at low flow rates. Any circumferential location is correct for installation in vertical pipes.
• Allow an insertion depth of 1-1/2 inches (38 mm) for pipe sizes 2-1/2 inches and larger for accurate flow rate calibration. Detailed installation instructions for various sensor mounting configurations on the following pages include methods for providing correct insertion depth.
• Align the sensor so that the impeller rotation is parallel to flow. Alignment instructions are included on the following pages.
Page 3 February 2018 SEN-UM-01635-EN-11

Installation for 220BR, 220SS, 220PV

INSTALLATION FOR 220BR, 220SS, 220PV

Installation Procedure

The insertion depth and alignment of the flow sensor assembly are critical to the accuracy of the flow measurement. The flat end of the sensor sleeve assembly MUST BE INSTALLED 1-1/2 inches (38 mm) from the inside wall of the pipe. To allow for variations in wall thickness, lining, or coatings, the depth adjustment is controlled by the position of the hex nuts on the three threaded studs of the hex mounting adapter. The hex mounting adapter is provided with a 2 inch male NPT connection.
There are two methods of mounting these sensors in a 2-1/2 inch or larger pipe. One is with a 2 inch NPT threaded pipe saddle. The other is with a welded-on fitting such as a Thredolet®, also tapped for a 2 inch NPT connection. In either case, cut a 2 inch (51 mm) hole through a depressurized pipe and then secure the saddle or weld-on fitting to the pipe. (For drilling into a pressurized pipe, see "Installation into a Pressurized Pipeline" on page 7.) Install the 2 inch NPT adapter provided, using a thread sealant to prevent leakage. Tighten as necessary. Badger Meter insert style flow sensors are calibrated with the sensor inserted 1-1/2 inches (38 mm) into the pipe flow.
To determine the proper insertion depth, follow these steps:
1. Apply anti-seize thread lubricant (supplied with the sensor) to the threaded studs of the mounting adapter.
2. Insert the depth gauge into the mounting adapter and set it against the inside wall of the pipe as shown in Figure 1. Set the top of the upper adjusting nut to 3-3/4 inches (95 mm) as measured. Lock it in place with the bottom nut on the same stud. Repeat for the other adjusting nuts.
OTE:N For Model 220PVS, set the nuts 6-1/2 inches (165 mm) above the inside wall of the pipe.
Adjusting Nuts
20345
3 ¾”
Figure 1: Installation for 220BR and 220SS
3. Clean the O-rings and the ow sensor sleeve, and lightly lubricate the O-rings with silicone grease from the packet provided (or another acceptable lubricant). Take care not to get grease on the impeller or bearing.
4. Insert the ow sensor into the 2 inch NPT adapter so that the mounting holes in the positioning collar t over the studs on the adapter.
5. Lower the sensor onto the previously adjusted nuts. Install the lock nuts on top of the positioning collar and tighten. Now tighten the lower jam nuts rmly against the upper adjusting nuts to secure them for future removal of the sensor for inspection or service.
Page 4 February 2018SEN-UM-01635-EN-11
SET SCREW
ALIGNMENT ROD
ALIGNMENT ROD
C
C
Hot Tap Installation for 225BR, 226BR, and 226SS

Alignment of Flow Sensor

1. Loosen the positioning collar set screws with a 3/32 inch Allen wrench. Place the alignment rod through the sight holes in the ow sensor. See Figure 2. Using the alignment rod as a guide, align the ow sensor so the ow label arrow matches the pipe ow direction and the alignment rod is exactly parallel to the pipe. This procedure aligns the impeller directly into the uid ow.
Figure 2: Alignment of Flow Sensor 220BR and 220SS
2. As a backup to the ow arrow label, there is a small hole next to the larger sight hole of the upstream side. With a 3/32 inch Allen wrench, tighten the positioning collar set screws.
3. Double check that the sight holes in the sleeve are parallel down the pipe and the ow arrow label matches the pipe liquid ow direction.
4. Cable routing: The positioning collar is threaded for connection of a standard 1/2 inch electrical conduit (ex cable) or a wire strain relief. Route the cable as required. Be sure to leave enough ex in the cable or conduit to allow future removal of the sensor for service or cleaning.
Page 5 February 2018 SEN-UM-01635-EN-11

Hot Tap Installation for 225BR, 226BR, and 226SS

HOT TAP INSTALLATION FOR 225BR, 226BR, AND 226SS
Badger Meter Series 200 hot tap style liquid flow sensors are designed for use in cases where pipelines will be in continuous service, and depressurizing or draining the system for installation or service is not practical.
The Series 200 hot tap flow sensors are designed to be installed either in a depressurized pipe by hand, or “hot tapped” into a pressurized pipeline. Both installation procedures are in this manual. If there is the slightest possibility the pipe could be full or pressurized, follow the installation for a pressurized pipe. See "Installation into a Pressurized Pipeline" on page 7.
See Figure 4 for the location or identification of the various parts described in the following procedures.

Sensor Assembly Depth and Alignment

The insertion depth and alignment of the sensor assembly are critical to the accuracy of the flow measurement. The flat end of the sensor tube assembly must be installed 1-1/2 inches (38 mm) from the inside wall of the pipe. To allow for variations in wall thickness, lining or coatings, the depth adjustment is controlled by the position of the hex nuts on the three threaded studs of the hex mounting adapter. The hex mounting adapter is provided with a 2 inch male NPT connection. Both gate and ball valve units are provided with 2 inch nipples for mounting onto saddles and weld-o-lets.
Setting the Depth
1. Position the hex nuts 14-7/8 inches (378 mm), minus the thickness of the pipe, from the outside diameter of the pipe. For example, measure the wall thickness of the pipe from the coupon removed when the 1-7/8 inch (48 mm) hole was cut into the pipe. If the pipe was 1/8 inch (3 mm) thick, subtract 1/8 inch (3 mm) from 14-7/8 inches (378 mm), or position the nuts 14-3/4 inches (375 mm) from the outside diameter of the pipe. This will allow the 16-3/8 inch (416 mm) sensor to protrude 1-1/2 inches (38 mm) into the pipe.
2. Apply anti-seize thread lubricant, supplied with the sensor, to the threaded studs of the mounting adaptor.
Aligning the Impeller with the Flow
1. To align the impeller with the ow in the pipe, align the two sight holes at the top of the sensor tube assembly with the center line of the pipe. Make sure the alignment is made to the pipe, and not to a wall or surface near the sensor.
2. To adjust, loosen the two set screws in the positioning collar with the 3/32 inch Allen wrench (supplied in the installation kit).
3. Slip one end of the 1/4 inch x 18 inch steel rod (supplied in the installation kit) through the holes in the sensor tube.
4. Rotate the sensor tube until the rod is centered on the pipe. Make sure the ow label arrow on the sensor matches the liquid ow direction.
5. Tighten the positioning collar Allen screws to lock the sensor sleeve assembly in position.
OTE:N As a backup to the flow label arrow, there is a small hole located beside one of the sight holes to also indicate the
upstream side of the sensor.
Page 6 February 2018SEN-UM-01635-EN-11
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