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SDI
Operating Manual
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Operating Manual
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Badger Meter SDI Operating Manual

SDI Series
Insert Style Flow Sensors
SEN-UM-00215-EN-10 (April 2019)
User Manual
SDI Series, Insert Style Flow Sensors
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models Available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electronic Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Scaled Pulse Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bidirectional Flow – Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bidirectional Flow – Scaled Pulse Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Display Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation for Direct Insert Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation for Hot Tap Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Customer Reference Number Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
K and Oset Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Page 2 April 2019

Introduction

INTRODUCTION
The Badger Meter SDI Series impeller flow sensor offers unparalleled performance for liquid flow measurement in closed pipe systems in an easy to install economical package. Impeller sensors offer a quick response to changes in flow rate and are well suited to flow control and batch type applications in addition to flow monitoring. The new four-bladed impeller design is rugged, non-fouling and does not require custom calibration.
Coupled with the proprietary patented digital detection circuit, the sensor measures flows from under 0.3 feet per second to over 20 fps regardless of the conductivity or turbidity of the liquid. The standard frequency output produces a low impedance square wave signal proportional to flow rate that may be transmitted up to 2000 feet without amplification. Models are available to measure flow in one or both directions.
All SDI insert sensors are mounted on the pipe using a 1 in. tap. As with any insert sensor, a pipe saddle or weld-on fitting is preferred over a service tee because it causes fewer disturbances to the flow.

MODELS AVAILABLE

Direct insert sensor models are installed in piping configurations that are not in service or under pressure.
Hot tap insert sensor models feature isolation valves and mounting hardware to install or remove the sensor from a pipeline
that would be difficult to shut down or drain. In a true hot tap installation the sensor is mounted in the pipe under pressure by attaching a service saddle or weld-on fitting to the pipe and mounting the isolating valve and nipple to the threaded connection. A hole is then cut in the wall of the pipe through the valve using a commercial tapping machine with a 1 in. size cutter. Once the hole is cut, the tapping machine is removed and the valve is shut. Then the sensor assembly is mounted to the isolation valve and extended into the pipeline to measure flow.
Even in new construction a hot tap sensor may be appropriate for service considerations.
The small stem diameter allows the sensor to be inserted into the pressurized pipeline by hand without the need for an installation tool. The mounting hardware holds the sensor firmly in place at the correct depth and alignment.

ELECTRONIC OUTPUTS

Standard Frequency

Sensor output is a pulse proportional to flow. The signal is similar to all 200 Series Badger Meter impeller flow sensors and will interface with all existing Badger Meter transmitters and monitors. The power supply to the sensor and the output signal from the sensor are carried on the same two wires. Wire connections are made at screw terminals on removable headers inside the NEMA 4X housing.

Analog Output

The sensor is also available with a two-wire loop powered 4…20 mA output. The analog output is produced by an on-board micro-controller for precise, drift-free signals. The unit is programmed from a computer using Windows® based software and an A-301 connection cable. Units may be pre-programmed at the factory or field programmed. All information is stored in non-volatile memory in the flow sensor.

Scaled Pulse Output

The scaled pulse is produced by an on-board micro-controller for precise, accurate outputs. This option may be programmed to produce an isolated dry contact closure scaled to any number of engineering units of measure. Sensors may be pre­programmed at the factory or field programmed using an A-301 connection cable and a Windows based software program. All information is stored in non-volatile memory in the flow sensor. This is a four-wire option.
Bidirectional Flow, Analog Output
This option provides a programmable 4…20 mA signal proportional to flow rate and a contact closure to indicate the direction of flow. All programming is accomplished as previously mentioned. The user can program the unit for pipe size, flow scale and the direction of flow. This is a six-wire option.
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Mechanical Installation

Bidirectional Flow, Scaled Pulse Output
This option provides the user with a choice of outputs. In one case the sensor provides an output scaled to the required number of engineering units on one set of terminals and a contact closure to indicate the direction of flow on another. The other choice provides two isolated scaled pulse outputs, one for each direction. Programming the output choice, pipe size, output scale and direction of flow by the user are also accomplished by using a PC with Badger Meter software and A-301 connection cable. This option also requires six wires.
* = Combination for >180° F Service
Figure 1: SDI series direct insert ordering matrix Figure 2: SDI series hot tap ordering matrix

Display Options

All models except the standard frequency output version may also be equipped with a display. Integrated into the NEMA 4 housing, the 8 digit LCD may be programmed to show rate of flow, flow total or toggle between the two. Bidirectional models also show flow direction.
MECHANICAL INSTALLATION
The accuracy of flow measurement for all insert type flow measuring devices is highly dependent on proper location of the sensor in the piping system. Irregular flow velocity profiles caused by valves, fittings and pipe bends can lead to inaccurate overall flow rate indications even though local flow velocity measurement may be accurate. A sensor located in the pipe that is partially full or where it can be affected by air bubbles, floating debris or sediment may not achieve full accuracy and could be damaged.
Badger Meter impeller flow sensors are designed to operate reliably under adverse conditions, but the following recommendations should be followed to provide maximum system accuracy.
Badger Meter
SDI Series Sensor
10 x Pipe Dia
5 x Pipe Dia
FLOW
Figure 3: Minimum recommended straight run distance
Page 4 April 2019SEN-UM-00215-EN-10
Mechanical Installation
• Choose a location along the pipe where there is straight pipe for a distance of 10 pipe diameters upstream and 5 pipe diameters downstream of the sensor. Pipe bends, valves, other fittings, pipe enlargements and reductions or anything else that would cause a flow disturbance should not be present in this length of pipe.
• The recommended tap location around the circumference of a horizontal pipe is on top. If trapped air or debris will interfere, then the sensor should be located around the pipe from the top preferably 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. Any circumferential location is correct for installation in vertical pipes. Insertion depth is critical to accuracy. The algorithm used to convert impeller motion into flow was developed through flow tests in an independent calibration laboratory. The impeller must be located in the same position in the pipe as it was in the calibration test for the impeller frequency to accurately describe the same liquid velocity. Detailed installation instructions on the following pages include methods for correct insertion depth.
• Alignment of the sensor is also important. The
15 3/4 in. *
impeller shaft must be perpendicular to the flow for accuracy. Alignment instructions are also included on the following pages.
* Pipe Sizes for reference only. Depending on pipe material, tapping saddle or existing hardware longer sensor length may be required. Contact factory for more information.
Figure 4: Direct insertion sensor dimensions
4.23 in.
0.660 in. Handtight Engagement + Wrench Makeup Per ANSI/ASME B1.20.1-1993, R1992

Installation for Direct Insert Models

These instructions are for the installation of flow sensors into piping systems that are not under pressure at the time of installation. If the line must be tapped under pressure, a hot tap style sensor must be used. See “Installation for Hot Tap
Models” on page 7 for hot tap installation instructions.
The insertion depth and alignment of the sensor are critical to the accuracy of the flow measurement. The impeller must be at the same location in the pipe as it was during calibration. Badger Meter provides sensors with different stem lengths. Longer stems are intended for use in larger diameter pipes and shorter stems for use in smaller pipelines. However stem length has no affect on the operation of the sensor provided that the impeller is positioned correctly in the pipe.
Direct insert models are available in one stem length designated D1. They are intended for nominal pipe diameters from 1-1/2…10 in. However, pipe with extra thick walls, existing linings, or unusual tapping hardware may require longer length sensors - Consult factory. For larger pipe sizes hot tap style sensors equipped with isolation valves are recommended.
The preferred method of installation is by means of a saddle with a 1in. NPT outlet. On steel pipelines a weld-on type fitting may be substituted.
Page 5 April 2019 SEN-UM-00215-EN-10
Mechanical Installation
Mounting
Adapter
Pipe Saddle
(ref)
Hex Cap
Stem Collar
Cover
Mounting Adapter
Pipe Saddle
(ref)
Gasket
(ref)
Figure 5: Dimension B
Gasket
(ref)
Stem
1. Attach the saddle to a section of pipe that has at least 10 diameters of straight pipe ahead and ve diameters of straight pipe behind the saddle. Drill a minimum 1-1/8 in.
B
diameter hole in the pipe.
2. Remove the sensor assembly from the mounting hardware by loosening the hex cap over the stem collar and the cover to the mounting adapter and detaching the assembly. Set aside taking care not to damage impeller/shaft assembly.
3. Attach the pipe thread end of the mounting adapter to the saddle or weld-o-let using a pipe joint compound and tighten the joint. Do not apply sealing compound to the top thread of the mounting adapter. It is sealed with an O-ring.
4. The sensor rotor assembly is to be located a xed distance from the center of the pipe. To position the impeller at this depth, use a reference measurement for the pipe size and schedule.
a. Look up the pipe size and schedule number in the “Customer Reference Number
Tables” on page 14 and note the Customer Reference Number (Customer Ref #)
OTE:N The Customer Reference Number has been calculated using the
following formula: Ref # = Insertion Depth + Wall Thickness + Cover Thickness
b. Next, measure from the outside wall of the pipe to the top of the installed
mounting adapter, this is dimension B in Figure 5.
c. Add this number to the reference measurement. The resulting number is
dimension C in Figure 6 Dimension C = Customer Ref # + Dimension B
d. Dimension C is the distance from the recess of the sensor tip to the bottom of the
stem collar. Insert the metal tab of a tape measure into the recess of the flow sensor tip. Extend the tape up the stem and mark the shaft with a pencil.
e. Slide the collar along the shaft until its bottom surface is at the mark on the stem.
Tighten the cap screw on the collar. When the sensor is reassembled, this will set the insertion depth of the sensor.
5. Attach the sensor to the mounting adapter by gently pushing the ow sensor into the
C
mounting adapter until the cover touches the mounting adapter. Tighten the cover against the O-ring seal. This will seal the sensor assembly.
6. Continue to insert the ow sensor stem until the stem collar meets the cover. Thread the hex cap onto the mounting adapter but do not tighten. Align the ow sensor with the pipe by using the at cover on the electronics housing as a guide. Place a straightedge along the cover and rotate the sensor until the straightedge is parallel
with the pipe as shown in Figure 7. Tighten the hex cap over the collar approximately 10 ft-lb. The hex cap holds the sensor alignment but performs no sealing functions. DO NOT OVER TIGHTEN .
7. Pressurize pipeline and check for leaks.
Figure 6: Dimension C
Pipe Pipe
Straight Edge Parallel to Pipe
Figure 7: Align the flow sensor with the pipe
SDI
Flow Sensor
Page 6 April 2019SEN-UM-00215-EN-10
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