Veris Badger200 Installation Instructions
Badger® 200 Series
Insert Style Flow Sensors
Installation &
Operation Manual
BadgerMeter, Inc.
872020
Rev. 6
4-09
INTRODUCTION
Used in conjunction with any Badger Meter Impeller flow
monitor or transmitter, Badger Meter non-magnetic 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. 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.
ELECTRONIC TYPES
Badger Meter provides several basic sensor configurations
using the same impeller element. This allows for a wide
range of applications and pipe sizes. Sensors are normally
supplied with 20 feet of 2-conductor 20 AWG shielded U.L.
type PTLC 105°C cable. Optional sensors designated with
the prefix "IR" feature two single conductor 18 AWG solid
copper wire leads 48 inches in length 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 Series 200 sensor electrical components are self-contained. Pressure/temperature ratings for
the various models are contained in the Specifications section of this manual. These models can be further described
as follows:
"Standard" Sensor
Designed for indoor or protected area applications such
as HVAC, pump control, and industrial process monitoring
where the flow rates are between 0.5-30 feet/second and
temperatures are below 221°F. Standard sensors are supplied with 20 feet of 2-conductor 20 AWG shielded U.L. type
PTLC 105°C cable.
"IR" Sensor
Designed for below grade applications such as irrigation,
municipal, and groundwater monitoring where the flow rates
are between 0.5-30 feet/second and temperatures are below
180°F. IR sensors are supplied with two single conductors,
18 AWG solid copper wire leads 48 inches in length with U.L.
Style 116666 direct burial insulation.
*
* *
"High Temperature" Sensor
Designed for indoor or protected area applications such as
hydronic heating loops, boiler feed, and condensate return
line monitoring where the flow rates are between 0.5-30 feet/
second and temperatures may be up to 285 deg. F. High
temperature Series 228 and 250 sensors are supplied with
12 inches of 2-conductor 20 AWG shielded U.L. type PTLC
105°C cable inside the electronics housing.
"FM/CSA" Sensor
Designed for indoor or protected area applications where
intrinsic safety is required and the flow rates are between
0.5-30 feet/second and temperatures are below 221 deg. F.
FM/CSA sensors are supplied with 20 feet of 2-conductor 20
AWG shielded U.L. type PTLC 105°C cable. These sensors
must be used with an approved safety barrier.
"Magnetic" Sensor
Designed for use with the Badger® Series 1400 battery
powered flow monitor in above or below or grade applications such as irrigation, municipal, and groundwater monitoring where the flow rates are between 1-30 feet/second and
temperatures are below 221 deg. F.
Models 220BR, 220PVS, 225BR, 226BR, 220SS and
226SS
Model 220BR
This insert style sensor has a 5 1/4 inch long sleeve length,
and uses brass and bronze hardware. It is used in all pipe
sizes from 2.5 inch to 40.0 inch in diameter. A bronze 2
inch NPT externally threaded hex adapter is provided. The
adapter may be mounted to the pipe using a welded-on
threaded fitting such as a Thredolet® or pipe saddle.
Model 220PVS
This insert style sensor has an 8 inch long sleeve length,
and uses PVC and stainless steel hardware. It is used in all
pipe sizes from 2.5 inch to 40.0 inch in diameter. A PVC 2
inch NPT externally threaded hex adapter is provided. The
adapter may be mounted to the pipe using a pipe saddle.
Model 220SS
This is the same as Model 220BR, except that the sensor,
sleeve and hex adapter are made of Series 300 stainless
steel.
Models 225BR
This insert style sensor has a 16 3/8 inch long sleeve length,
and uses brass and bronze hardware for hot tap installations.
It has a bronze isolation gate valve for applications where the
pipe is drained for initial installation but cannot be drained for
service.
Models 226BR
This is the same as Model 225BR, except that it has a ball
type isolation valve. The ball valve allows for higher pressure
use. We recommend this sensor when installation is to be
made under pressure, in a true “hot tap” installation. The ball
valve cannot be fouled by the tailings from the cutting operation.
* These items must be special ordered
2
200 Series Insert Style Matrix (sizes 2½" and up)
Example: 2 x x x x x - x x x x
STYLE
Short Insert 20
Hot Tap Insert-Gate Valve 25
Hot Tap Insert-Ball Valve 26
MATERIAL
Brass BR
Stainless Steel SS
PVC Sleeve w/Stainless Steel Trim PVS
Size
Insert Style 00
Electronics Housing
PPS 0
ELECTRONICS
Magnetic 2
FM/CSA Approved 4
Standard 5
IR-Irrigation 6
High Temperature 8
O-RING
Viton® 0
EPDM 1
Kalrez® 2
Food Grade Silicon 3
Neoprene 4
Chemraz® 5
Teflon Encapsulated Viton 6
Teflon Encapsulated Silicone 7
Buna N 8
SHAFT
Zirconia Ceramic 0
Hastalloy® C 1
Tungsten Carbide 2
Titanium 3
Monel® 5
316 Stainless Steel 6
Tantalum 7
IMPELLER
Nylon 1
Tefzel® 2
BEARING
Pennlon® 1
Tefzel 2
Teflon®
3
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 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.
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 (3) threaded studs of the hex mounting adapter.
The hex mounting adapter is provided with a 2 inch male
NPT connection.
Models 226SS, IR226SS
This is the same as Model 226BR respectively, except that
the hot tap hardware, ball valve, and sensor sleeve are made
of Series 300 stainless steel.
Model HTT
This is the insertion tool for use with any of the hot tap sensor units. It is used to insert and remove the sensor while
under pressure. Generally, only one HTT tool is needed on
each job site.
MECHANICAL INSTALLATION
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:
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.
There are two methods of mounting these Badger Meter
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 3¾ 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.
3
3 ¾”
20 3 4 5
Adjusting Nuts
2) As a backup to the flow arrow label, there is a small hole
SET SCREW
ALIGNMENT ROD
ALIGNMENT ROD
C
C
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.
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 Badger® 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.
Figure 2
Alignment of Flow Sensor in 220BR and 220SS
4
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.
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
BLEED VALV E
HEX NUT
JAM NUT
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.
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”
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 - 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.
Figure 3
5
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