Badger Meter Irrigation Sensors - 1/2 and larger User Manual

Series 200

Insertion Style Flow Sensors

This manual contains important information.

872020-EN (August 2012)

Rev. 8

IMPORTANT:

READ AND KEEP FOR REFERENCE.

Installation & Operation Manual

Series 200 Flow Sensors

Contents

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

INSTALLATION FOR 220BR, 220SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Alignment of Flow Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

HOT TAP INSTALLATION FOR 225BR, 226BR, and 226SS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

If the Pipe is Depressurized and Drained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INSTALLATION INTO A PRESSURIZED PIPELINE USING MODEL HTT . . . . . . . . . . . . . . . . . . . . . . . . .5

ELECTRICAL INSTALLATION "STANDARD" SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

ELECTRICAL INSTALLATION "IR" SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

ELECTRICAL INSTALLATION "HIGH TEMPERATURE" SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Calibration Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

IMPELLER ASSEMBLY AND SHAFT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

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Installation & Operation Manual

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 waterborne 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.

MECHANICAL INSTALLATION

General

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, pipe bends, etc. 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, but the following recommendations should be followed to ensure maximum system accuracy:

1. 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.

2. 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.

3. An insertion depth of 1-1/2 inches for pipe sizes

2.5 inches and larger is required for accurate flow rate calibration. Detailed installation instructions for various sensor mounting configurations on the following pages include methods for ensuring correct insertion depth.

4. Alignment of the sensor to ensure that impeller rotation is parallel to flow is important. Alignment instructions are also included on the following pages.

INSTALLATION FOR 220BR, 220SS

Installation Procedure

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 from the inside wall of the pipe. In order 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

2.5 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 hole through a depressurized pipe and then secure the saddle or weld-on fitting to the pipe. (For drilling into a pressurized pipe, see instructions for Series 225 and 226 sensors.) Install the 2 inch NPT adapter provided, using a thread sealant to prevent leakage. Tighten as necessary. Badger Meter insert style sensors are calibrated with the sensor inserted 1-1/2 inches into the pipe flow.

To determine the proper insertion depth, proceed as follows:

1. Apply anti-seize thread lubricant , supplied with the sensor, to the threaded studs of the mounting adaptor.

2. Insert the depth gauge into the mounting adapter and set it against the inside wall of the pipe as shown. Set the top of the upper adjusting nut to 3-3/4 inches as measured. Lock it in place with the bottom nut on the same stud. Repeat for the other adj. nuts.

Note: For Model 220PVS - set nuts 6.5 inches above inside wall of pipe.

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Series 200 Flow Sensors

Adjusting Nuts

3 ¾”

20345

2. As a backup to the flow arrow label, there is a small hole next to the larger sighting hole of the upstream side. With a 3/32 inch Allen wrench, tighten positioning collar set screws.

3. Double check that the sighting holes in the sleeve are parallel down the pipe and that the flow arrow label matches pipe liquid flow direction.

4. Cable routing: The positioning collar is threaded for connection of a standard 1/2 inch electrical conduit (flex cable) or a wire strain relief. Route cable as required. Be sure to leave enough flex in cable or conduit to allow future removal of sensor for service or cleaning if necessary.

Figure 1: Installation for 220BR and 220SS

3. Clean O-rings and flow sensor sleeve, and lightly lubricate O-rings with silicone grease from the packet provided or some other acceptable lubricant. Take care not to get grease on the impeller or bearing.

4. Insert the flow sensor into the 2 inch NPT adapter so that the mounting holes in the positioning collar fit over the studs on the adapter. 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 firmly against the upper adjusting nuts to secure them for future removal of the sensor for inspection or service.

Alignment of Flow Sensor

1. Loosen positioning collar set screws with a 3/32 inch Allen wrench. Place the alignment rod through the sight holes in the flow sensor. Refer to Figure 2. Using the alignment rod as a guide, align the flow sensor so that the flow label arrow matches pipe flow direction and so that the alignment rod is exactly parallel to the pipe. This procedure aligns the impeller directly into the fluid flow.

ALIGNMENT ROD

SET SCREW

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 sensors are designed to be installed either in a depressurized pipe by hand or “Hot Tapped” into a pressurized pipeline. Both installation procedures are listed in this installation and operation manual. If there is the slightest possibility that the pipe could be full or pressurized, FOLLOW THE INSTALLATION FOR

PRESSURIZED PIPE.

Refer to Figure 3 for location or identification of the various parts described in the following procedures.

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 from the inside wall of the pipe. In order 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, weld-o-lets, etc.

Depth setting is accomplished by positioning the hex nuts 14-7/8 inches 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 hole was cut into the pipe. If the pipe was 1/8 inch thick, subtract 1/8 inch from 14-7/8 inch, or position the nuts 14-3/4 inch from the outside diameter of the pipe. This will allow the 16-3/8 inch sensor to protrude 1-1/2 inch into the pipe.

Apply anti-seize thread lubricant, supplied with the sensor, to the threaded studs of the mounting adaptor.

Figure 2: Alignment of Flow Sensor in 220BR and

220SS

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Installation & Operation Manual

BLEED VALVE

HEX NUT

JAM NUT

The alignment of the impeller with the flow in the pipe is accomplished by aligning 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. To adjust, loosen the two set screws in the positioning collar with a 3/32 inch Allen wrench provided in the Series 200 hot tap installation kit. Slip one end of the 1/4 inch x 18 inch steel rod (also supplied in the installation kit) through the holes in the sensor tube. Rotate the sensor tube until the rod is centered on the pipe. Ensure the flow label “Arrow” on the sensor matches the liquid flow direction. Tighten the positioning collar Allen screws to lock the sensor tube assembly in position. Note: As a backup to the flow direction arrow label on the tube assembly, there is a smaller hole located beside one of the sighting holes in the tube, to also indicate the upstream side of the tube assembly.

If the Pipe is Depressurized and Drained

1. Drill or cut a 1-7/8 inch hole in the pipe with a drill

or hole saw. Note the pipe wall thickness for use in calculating sensor assembly depth. A location on the top of the pipe is best for overall performance and service life; however, any radial location on the top half of the pipe is acceptable. Allow a minimum of ten pipe diameters upstream and five downstream from the sensor of straight unobstructed pipe to allow full development of the flow profile.

2. Install either a service saddle or welded pipe fitting (2

inch female NPT) on the outside diameter of the pipe over the 1-7/8 inch hole.

3. Install the Badger Meter isolation valve and nipple

onto the fitting using pipe thread sealant or Teflon® tape on all threads.

4. Install the Badger Meter hex mounting adapter onto

the valve assembly. Use pipe thread sealant on the adapter. Tighten the hex adapter so that no stud is aligned with the center-line of the pipe. This could interfere with final sensor alignment. Measure depth and set the height of the nuts of the hex mounting adapter.

5. Open the bleed petcock valve on the hex adapter to

relieve the pressure as the sensor tube is installed. Carefully hand insert the Badger Meter hot tap flow sensor tube into the hex mounting adapter. The sleeve should be inserted past the top two O-rings in the adapter (approx. 1 to 1-1/4 inches). Take care not

to push the tube in too far as the impeller could be damaged if it strikes the closed valve.

6. Even if the sensor is installed with system drained,

Badger Meter recommends that a HTT, hot tap insertion/removal tool be purchased for future service. This tools allows the sensor tube assembly to be removed from the pipe line without draining the entire loop where the sensor is mounted.

7. In a fully depressurized and drained pipe, the sensor tube assembly may be installed by hand. Carefully and very slowly open the isolation valve to relieve any pressure that may have built up. Fully open the isolation valve. Push the sensor tube into the pipe with a slight twisting motion. Guide the sensor collar holes over the three hex adapter studs until the collar rests on the nuts. Hex nuts should have been previously set to the correct height. Install the three lock nuts onto these studs at the top of the positioning collar and securely tighten.

8. Loosen the two set screws in the positioning collar with a 3/32 inch Allen wrench. Align the sensor sight holes along the pipe axis using the alignment rod provided in the installation kit supplied with the sensor. Ensure that the flow label arrow on the sensor matches the liquid flow direction inside the pipe. Tighten the positioning collar set screws. Note: As a backup to the flow label arrow, there is a small hole located beside one of the sighting holes to also indicate the upstream side of the sensor.

INSTALLATION INTO A PRESSURIZED PIPELINE USING MODEL HTT

For information on installing hot tap sensor with older 225H consult technical bulletin DID-001.

For pipe sizes 2½” and above; all Badger Meter sensors are inserted 1 1/2” from the inside wall of the pipe. The insertion depth is controlled by the position of the hex nuts on the three threaded rods. The formula below defines the distance between the top of the sensor hex mounting adaptor and the bottom of the positioning collar (the top of the hex nut). Reference Figure 3.

D = 16 3/8” - ( H + Pipe Wall Thickness + 1.5 “ )

Example: If sensor is installed in a 8 inch Sch 80 pipe with a pipe wall thickness of 1/2 inch and the “H” dimension is 10 inches then the calculation would be as below:

D = 16 3/8 - ( 10 inches + 0.5 inches + 1.5 inches)

D = 4 3/8”

Figure 3:

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