Veris Badger228 Installation Instructions
Badger® Series
250 & 228
Flow Sensors
Metal Tee Type
Impeller Flow Sensors
Installation &
Operation Manual
BadgerMeter, Inc.
872021
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, sixbladed 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.
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 deg. 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 selfcontained. Pressure/temperature ratings for the various
models are contained in the Specifications section of this
manual. 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 0.5-30 feet/second and temperatures
are below 180 deg. F. IR sensors are supplied with two
single conductor, 18 AWG solid copper wire leads 48
inches in length with U.L. Style 116666 direct burial insulation.
"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 deg.
C cable. These sensors must be used with an approved
safety barrier.
Models 228BR, 228CB, 228SS, and 228CS
Sizes of 2” and 2 1/2” are available in this series.
Model 228BR
This model consists of a Model 220BR sleeve and hex
mounting adapter assembly inserted in a 2" or 2 1/2"
bronze tee and preset to a specific height. The 2" size
includes copper solder adapters for mating to copper tubing.
Model 228CB
This model consists of a Model 220BR sleeve and hex
mounting adapter assembly inserted in a 2" or 2 1/2"
Class 150 cast iron tee and preset to a specific height.
Model 228CS
This model consists of a Model 220SS sleeve and hex
mounting adapter assembly inserted in a 2" or 2 1/2"
Class 150 cast iron tee and preset to a specific height.
Model 228SS
This model consists of a Model 220SS sleeve and hex
mounting adapter assembly inserted in a 2" 316 stainless
steel tee and preset to a specific height.
"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 deg. F. Standard sensors
are supplied with 20 feet of 2-conductor 20 AWG shielded
U.L. type PTLC 105 deg. C cable.
2
Model 250BR
These models combine a PPS electronics package
inserted in a 1/2”, 3/4", 1”, 1 1/4”, and 1 1/2” proprietary
cast bronze pipe tee with threaded NPT connections.
200 Series Metal Tee Sensors Matrix (½" to 2½")
Example: 2xxxxx-xxxx
STYLE
Tee Mounted Insert Sensor ( 2" and 2.5" only)28
Cast Bronze Tee (1/2" to 1.5"only)50
MATERIAL
Brass/BronzeBR
Stainless Steel ( 2" and 2.5" only)SS
Tee - Carbon Steel Sensor BrassCB
Tee - Carbon Steel Sensor Stainless Steel CS
Size
0.5" 05
0.75" 07
1" 10
1.25" 12
1.5" 15
2" 20
2.5" 25
Electronics Housing
PPS 0
ELECTRONICS
Magnetic2
FM/CSA Approved 4
Standard5
IR-Irrigation6
High Temperature8
O-RING
Viton 0
EPDM1
Buna N8
SHAFT
Zirconia Ceramic0
Hastalloy C1
Tungsten Carbide2
Titanium 3
Monel 5
316 Stainless Steel 6
Tantalum 7
IMPELLER
Nylon 1
Tefzel 2
BEARING
Pennlon 1
Tefzel 2
Teflon
3
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. Rising flow
preferred to reduce effects of any trapped air.
Mechanical Installation for 228BR, 228CB,
228CS, and 228SS
These tee-type sensors have a factory set insertion depth and alignment.
Warning: do not disturb the position of
thread hex adapter or the lower two nuts on
the threaded rods of the hex
adapter. This could lead to inaccurate calibration and faulty reading of the flow rate.
Remove sleeve assembly by removing the top
7/16" nuts only. Pull the sleeve assembly straight
out of the mounting adaptor.
To install the sensor tee
1) There must be free, unrestricted pipe for
at least 10 diameters upstream and 5 diameters
downstream of the tee. note: If soldering of
threaded adapters is to be done near the assembly, remove the sensor sleeve to prevent
heat damage to O-rings and plastic parts.
2) Apply pipe compound over the first 3 or 4
threads of the mating pipe.
3) Thread the pipe into the sensor tee until
hand tight.
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.
2) 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
To install sensor in tee
1) Apply a small amount of silicone grease to O-rings on
2) Align flow arrow on sensor with direction of flow.
3) Carefully press sleeve straight into hex mounting
4) Install 7/16 lock nuts on threaded rod, tighten, do not
5) Before pressurizing pipe, verify that:
• All threaded connections are tight.
• The ow direction arrow on sensor is aligned with ow
• The 7/16 nuts are re-installed on the threaded rods
Mechanical Installation for 250BR
Install with flow label pointing in the direction of flow
(downstream).
4) Tighten the pipe, using a wrench, an ad-
ditional 1 1/2 turns.
sensor sleeve assembly and chamfer on inside lip of
tee. Clean off any grease which could be deposited
on the impeller.
adaptor.
move bottom nuts as they set sensor depth.
direction.
above the metal collar.
3
To install the sensor tee
1) Note intended direction of flow as indicated by
arrows on the cast bronze tee. There must be free,
unrestricted pipe for at least 10 diameters upstream
and 5 diameters downstream of the tee.
2) Apply pipe compound over the first 3 or 4 threads of
the mating pipe.
3) Thread the pipe into the sensor tee until hand tight.
4) Tighten the pipe, using a wrench, an additional 1 1/2
turns.
To install sensor in tee
1) Apply a small amount of silicone grease to O-rings on
sensor insert and chamfer on inside lip of tee. Clean
off any grease which could be deposited on the
impeller.
2) Align flow arrow on sensor with direction of flow.
3) Carefully press sensor straight into tee. Caution:
Impeller may strike sides of venturi cavity in tee if
misaligned, causing damage to impeller or shaft.
4) Install clevis pin through the tee, sensor, and conduit
cap, and install split ring.
5) Before pressurizing pipe, verify that:
a) All threaded connections are tight.
b) The flow direction arrows on the tee and
sensor are aligned with the flow direction.
c) The clevis pin and cotter ring are installed.
Electrical Installation "Standard" Sensors
1) The metal collar on the top of the Series 220 sensors
or an optional conduit cap on the Series 250 sensors
will accept 1/2" threaded conduit fittings.
2) Route the cable from the sensor to a Badger Meter
flow monitor/transmitter. The cable may be extended
up to 2000 feet, using 2-conductor shielded 20 AWG
or larger stranded copper wire. Be sure to leave
enough flexibility in the cable or conduit to allow for
future service of sensor, if necessary.
3) When connecting to a Badger Meter flow monitor/
transmitter, locate the section of terminal strip on the
monitor labeled “SEnSOR InPuT” or “SEnSOR”.
Connect the red wire to “ In”, "SIGnAL(+)" or
"SIGnAL" terminal and the black wire to “Gnd",
"SIGnAL(-)”, or "COM" terminal and the shield drain
wire (if applicable) to “SLd”.
4) When interfacing with other equipment consult manufacture for input designations. The signal wave forms
and power requirements are as shown in the Specifications section. Refer to Technical Bulletin DTB-058
at www.badgermeter.com.
1) dO nOT remove the plastic caps from the sensor
leads until ready to splice.
2) Use a twisted pair cable suitable for direct burial to
connect the sensor to the transmitter, 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
flow monitor/transmitter. 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 flexibility in the cable or
conduit to allow for future service of sensor, if necessary.
7) When connecting to a Badger Meter flow monitor/
transmitter, locate the section of terminal strip on the
monitor labeled “SEnSOR InPuT” or “SEnSOR”.
Connect the red wire to “ In”, "SIGnAL(+)" or
"SIGnAL" 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
the Specifications section. Refer to Technical Bulletin
DTB-058 at www.badgermeter.com.
Electrical Installation "High Temperature" sensors
1) Route a cable from the sensor to a Badger Meter flow
monitor/transmitter. The cable may be run up to 2000
feet, using 2-conductor shielded 20 AWG or larger
stranded copper wire. Be sure to leave enough flexibility in the cable or conduit to allow for future service
of sensor, if necessary.
2) Connect to cable inside sensor electronic housing
and connect with standard wire nuts.
3) When connecting to a Badger Meter flow monitor or
transmitter, locate the section of terminal strip on the
monitor labeled “SEnSOR InPuT” or “SEnSOR”.
Connect the red wire to “ In”, "SIGnAL(+)" or
"SIGnAL" terminal and the black wire to “Gnd",
"SIGnAL(-)”, or "COM" terminal and the shield drain
wire (if applicable) to “SLd”.
4) When interfacing with other equipment, the signal
wave forms and power requirements are as shown in
the specifications section.
Electrical Installation "IR" sensors
The sensor leads are supplied with watertight caps over
the ends. See Application Note DAB-031 and Technical
Bulletin DTB-043 at www.badgermeter.com.
4
Electrical Installation "Magnetic" sensors
The magnetic sensor has a custom wire connec-
tor that connects to the series 1400 monitor only.
The cable may be extended up to 100 feet from the
sensor. If extension cables are needed they may be
ordered from Badger Meter.
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