Used in conjunction with any Badger Meter flow monitor or endpoint, Badger Meter non-magnetic Impeller flow sensors
provide an accurate reading of the 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. The impeller bearing assembly, shaft and o-rings are replaceable
in the field.
The Series 735 Impeller flow sensors feature a four-bladed impeller design, using a proprietary, non-magnetic sensing
technology. 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.
ELECTRONIC TYPES
Sensors are normally supplied with two single-conductor 18 AWG solid copper wire leads with U.L. Style 116666 direct burial
insulation. These IR models are used in below grade applications such as irrigation, municipal, and groundwater monitoring.
All Badger Meter Series 735 sensor electrical components are self-contained. Pressure/temperature ratings for the various
models are contained in "SPECIFICATIONS" on page 10. These models can be further described as follows.
IR Sensor
Designed for below grade applications such as irrigation, municipal, and groundwater monitoring where the flow rates are
between 2...20 feet/second and temperatures are below 110° F. IR sensors are supplied with two single conductor, 18 AWG
solid copper wire with U.L. Style 116666 direct burial insulation.
Model 735PV
These models feature a modified PVC tee with solvent weld socket end connections, and a removable PPS sensor insert. Available
sizes include 1/2", 3/4", and 1" BSP threaded adapters also available.
The impeller style flow sensor described in this manual is not intended for use in safety critical applications.
Use of the device in this manner is done at the sole discretion of the customer and/or end user of the device
The impeller style flow sensor described in this manual is not intended for use in systems with flammable liquids or
gases. Additionally, the device is not intended for systems containing hazardous fluids, or fluids other than water.
The impeller style flow sensor described in this manual must be installed in accordance with all local and federal codes
or end use standards as applicable.
If the devices described in this manual are used in a manner not specified by the manufacturer, the protection provided
by the equipment may be impaired.
Page 3 January 2013
Series 735PV Plastic Tee Type Impeller Flow Sensor
MECHANICAL INSTALLATION
Depressurize and vent piping system prior to any installation or maintenance of the flow sensor.
General
The accuracy of flow measurement for all flow measuring devices is highly dependent on proper location of the sensor in the
piping system. Irregular flow velocity profiles caused by valves, fittings, pipe bends, etc. can lead to inaccurate overall flow
rate indications even though local flow velocity measurement may be accurate. A sensor located in the pipe 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, but the following recommendations should be followed to
ensure maximum system accuracy:
• Choose a location along the pipe where ten pipe diameters upstream and five 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 for the sensor 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 dead center. The sensor should never be located at the bottom of the pipe, as sediment may collect there. Locations
off top dead center cause the impeller friction to increase, which may affect performance at low flow rates and increase
wear. Any circumferential location is correct for installation in vertical pipes. Rising flow preferred to reduce effects of any
trapped air.
Page 4January 2013
Installation & Operation Manual
ELECTRICAL INSTALLATION
Disconnect power from flow sensor source and/or receiving device prior to any installation or maintenance
of the system.
Flow sensor source and/or receiving device must provide basic isolation from mains to insure safe operation
of the system.
General
The sensor leads are supplied with watertight caps over the ends.
1. DO NOT remove the plastic caps from the sensor leads until ready to splice. See Application Brief DAB-031 and Technical
Brief DTB-043 at www.badgermeter.com.
2. Use a twisted pair cable suitable for direct burial to connect the sensor to the endpoint, monitor, or controller. Multi-pair
telecommunication cable or direct burial cables may be used.
3. Make a water tight splice. Two part epoxy type waterproof kits are recommended. Be sure the epoxy seals the ends of the
cable jacket.
4. Make sure the epoxy is hardened before inverting the splice or dropping it in standing water.
5. DO NOT make an underground splice unless absolutely necessary.
6. Route the cable from the sensor to a Badger Meter ow monitor/endpoint. The cable may be extended up to 2000 feet,
using 2-conductor shielded 20 AWG or larger stranded copper wire with appropriate ratings. Be sure to leave enough
exibility in the cable or conduit to allow for future service of sensor, if necessary.
7. When connecting to a Badger Meter ow monitor/endpoint, locate the section of terminal strip on the monitor
labeled SENSOR INPUT or SENSOR. Connect the red wire to IN, SIGNAL(+)ORSIGNAL terminal and the black wire
to GND, SIGNAL(–), or COM terminal and the shield drain wire (if applicable) to SLD.
8. When interfacing with other equipment, the signal wave forms and power requirements are as shown in
"SPECIFICATIONS" on page 10. Refer to Technical Brief DTB-058 at www.badgermeter.com.
Page 5 January 2013
Series 735PV Plastic Tee Type Impeller Flow Sensor
INSTALLATION INFORMATION
Depressurize and vent piping system prior to any installation or maintenance of the flow sensor.
Disconnect power from flow sensor source and/or receiving device prior to any installation or maintenance
of the system.
1. Remove the sensor assembly and the nut from the tee.
2. Deburr pipe ends and remove dirt and loose debris from pipe and tee sockets.
3. Glue the line pipe into the tee, using an appropriate primer and cement, according to the manufacturer's instructions.
DO NOT use or leave excess glue. Glue build-up in the tee can affect the measurement performance of the unit and/or
prevent the impeller from turning. DO NOT let glue or primer contact the bore where the o-rings seal.
Page 6January 2013
Installation & Operation Manual
4. Insert the sensor into the tee, carefully lining up the locating hole in the sensor with the locating pin in the tee.
5. Install and HAND TIGHTEN the retaining nut.
Complete the wiring connections. Note that the red wire corresponds to the positive connection and the black wire
corresponds to the negative connection. See "Electrical Installation" on page 5 for details.
Additional Information
• The unit functions best with schedule 40 or a pipe wall thinner than schedule 40.
• Keep all parts as clean as possible. DO NOT let glue or primer contact the surfaces where the o-rings make their seal.
• Although the meter can measure at velocities up to 20 ft/sec, most irrigation companies do not recommend working
velocities above 7.5 ft/sec, and not to exceed 10 ft/sec, due to potential damage from pressure and/or water hammer.
Page 7 January 2013
Freq=
Gpm
K
- offse
t
Series 735PV Plastic Tee Type Impeller Flow Sensor
CALIBRATION
Badger Meter Impeller sensors use unique K and offset numbers for calibration. These numbers are derived from calibration
runs using NIST traceable instruments. Using both a K and an offset number provides higher accuracy than using a K factor
alone. The K and offset numbers for each tee configuration are listed in the "Calibration Table" below.
Calibration Table Columns
The table below provides calibration and operation data for Badger Meter Plastic Tee Sensors 1-1/2" to 4".
Column 1Sensor Model Number
Columns 2 and 3The K value and Offset values to use in our frequency equation:
This equation describes the frequency of the output signal of all Badger Meter flow sensors. By
substituting the appropriate K and Offset values from the table, the sensor’s output frequency can be
calculated for each pipe size. This information is required when calibrating an output board or when
using the raw sensor data as direct output to interface with a device that is not a Badger Meter product.
Calibration Table
Size/ScheduleKOffset
1/2" S400.0780000.9
1/2" SDR 13.50.1201190.1
3/4" S400.1563000.9
3/4" SDR 210.197000–0.6
1" S400.2611191.2
1" SDR 210.3217390.6
Page 8January 2013
DIMENSIONS
Installation & Operation Manual
A
Soc Size, NPS
1/2" [Ø.840"]3.85"3.06"6.086"
3/4" [Ø1.050"]3.85"3.31"6.775"
1" [Ø1.315"]3.94"3.50"6.775"
B
C/L to Top
LL
BSP
Page 9 January 2013
Series 735PV Plastic Tee Type Impeller Flow Sensor
SPECIFICATIONS
Wetted Materials (except tees)See "Ordering Matrix" in Technical Brief for material specifications.
Materials
TeePVC Type 1, white
AdapterPVC Type 1, gray
BSP FittingPVC Type 1
Sensor HousingPPS
Retaining NutAcetal copolymer, black
Locating Pin300SST
Impeller300SST
ShaftTungsten Carbide
BearingUHMWPE
O-RingsEPDM
Wires18 AWG Irrigation Wire (solid copper)
Pressure/Temperature
Ratings
(DO NOT EXCEED)
Rated Temperature
(DO NOT EXCEED)
Recommended Design Flow
Range
Accuracy± 3.0% of full scale over recommended design flow range
Repeatability± 1.5% of full scale over recommended design flow range
Linearity± 1.5% of full scale over recommended design flow range
Transducer Excitation• 8…35V DC max. input, source limited to 100 mA
Output Frequency3.2…200 Hz
Output Pulse Width5 msec ±25%
Environmental• IP 68 / NEMA 4X
Electrical Cable for IR Sensor
Electronics
150 psig @ 73° F
75 psig @ 110° F
Operating: 35…110° F
Storage 14…110° F
2…20 ft/sec
• Quiescent current 600 uA @ 8…35V DC max.
• Quiescent voltage (Vhigh=Supply Voltage–(600 uA*Supply impedance))
• ON State (Vlow) Max. 1.2V DC @ 40 mA current limit (15 Ω + 0.7V DC)
• Suitable for pollution degree 4 environments
• Suitable for outdoor use above or below grade
• Suitable for use in 100% humidity
UL Style 116666 copper solid AWG 18 wire w/direct burial insulation. Rated to 105° C.