Veris SDI Installation Instructions

SDI Series

Insert Style Flow Sensors

Installation &

Operation Manual

BadgerMeter, Inc.

PN# 72034

1-09 Rev B8

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Introduction

The Data Industrial SDI Series impeller ow sensor offers unparalleled performance for liquid ow measurement in closed pipe systems in an easy to install economical package. Impeller sensors offer a quick response to changes in ow rate and are well suited to ow control and batch type applications in addition to ow 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 ows 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 ow rate that may be transmitted up to 2000 feet without amplication. Models are available to measure ow in one or both directions.

All SDI insert sensors are mounted on the pipe using a 1” tap. As with any insert sensor, a pipe saddle or weld-on tting is preferred over a service tee because it causes fewer disturbances to the ow.

Models Available

Direct insert sensor models are installed in piping congurations

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 difcult 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 tting 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” 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 ow.

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 rmly in place at the

correct depth and alignment.

SDI Series Hot Tap Ordering Matrix

SDI 0 H1 N 0 0 - 0 2 0 0

Material

Stainless Steel/PPS Tip 0 Stainless Steel/PEEK Tip 2

Type

Hot Tap for Pipe 1-1/2" thru 10" * H1 Hot Tap for Pipe 12" thru 36" * H2 Hot Tap for Pipe 36" and UP* H3

Electronic Housing

NEMA 4X N

Output

Standard Frequency Pulse 0 Analog 4-20mA 1 Scaled Pulse 2 Bi-Directional, 4-20mA + Direction [PPS tip Only] 5 Bi-Directional, Scaled Pulse [PPS tip Only] 6

Display

No Display 0 LCD Option [not available with output option 0] 1

O-Ring

Viton

Shaft

Tungsten Carbide [Standard] 2 Hastelloy

C-276 [optional - consult factory] 1

Zirconia Ceramic [optional - consult factory] 0

Impeller

Stainless Steel 0

Bearing

Torlon

*Pipe size for reference only-Depending on pipe material, tapping saddle, or existing

hardware, longer sensor length may be required. Consult Factory

SDI Series Direct Insert Ordering Matrix

SDI 0 D1 N 0 0 - 0 2 0 0

Material

Stainless Steel/PPS Tip 0 Brass/PPS Tip 1 Stainless Steel/PEEK Tip 2

Type

Direct Insert for Pipe 1-1/2" thru 10" * D1 Direct Insert for Pipe 12" thru 36" * D2 Direct Insert 36" and UP* D3

Electronic Housing

NEMA 4X N

Output

Standard Frequency Pulse 0 Analog 4-20mA 1 Scaled Pulse 2

Display

No Display 0 LCD Option [not available with output option 0] 1

O-Ring

Viton

Shaft

Tungsten Carbide [Standard] 2 Hastelloy

C-276 [optional - consult factory] 1

Zirconia Ceramic [optional - consult factory] 0

Impeller

Stainless Steel 0

Bearing

Torlon

*Pipe size for reference only-Depending on pipe material, tapping saddle, or existing

hardware, longer sensor length may be required. Consult Factory

Electronic Outputs

Standard Frequency

Sensor output is a pulse proportional to ow. The signal is similar to all 200 Series Data Industrial ow sensors and will interface with all existing Data Industrial transmitters and monitors. The power supply to the sensor and the output signal from the sensor is 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 a Data Industrial A-301 connection cable. Units may be pre-programmed at the factory or eld programmed. All information is stored in non-volatile memory in the ow 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 pre-programmed at the factory or eld programmed using a Data Industrial A-301 connection cable and a Windows based software program. All information is stored in non-volatile memory in the ow sensor. This is a four-wire option.

Bi-directional Flow- Analog Output

This option provides a programmable 4-20 mA signal proportional to ow rate and a contact closure to indicate the direction of ow. All programming is accomplished as previously mentioned. The user can program the unit for pipe size, ow scale and the direction of ow. This is a six-wire option.

Bi-directional 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 ow 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 ow by the user are also accomplished by using a PC with Data Industrial software and A-301 connection cable. This option

Display Options-

5 x Pipe Dia

DATA INDUSTRIAL SDI Series Sensor

10 x Pipe Dia

FLOW

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 ow, ow total or toggle between the two. Bidirectional models also show ow direction.

Mechanical Installation

The accuracy of ow measurement for all insert type ow measuring devices is highly dependent on proper location of the sensor in the piping system. Irregular ow velocity proles caused by valves, ttings, pipe bends, etc. can lead to inaccurate overall ow rate indications even though local ow velocity measurement may be accurate. A sensor located in the pipe that is partially full or where it can be affected by air bubbles, oating debris, or sediment may not achieve full accuracy and could be damaged.

Data Industrial ow 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 there is straight pipe for a distance of 10 pipe diameters upstream and 5 pipe diameters downstream of the sensor. Pipe bends, valves, other ttings, pipe enlargements and reductions or anything else that would cause a ow disturbance should not be present in this length of pipe.

2) 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 ow rates. Any circumferential location is correct for installation in vertical pipes.

Pipe Saddle

(ref.)

Mounting Adapter

Gasket

(ref)

15 3/4” *

4.23”

0.660”

Handtight Engagement + Wrench Makeup Per ANSI/ASME B1.20.1-1993, R1992

* Pipe Sizes for reference only - Depending on pipe material, tapping saddle, or existing hardware longer sensor length may be required Contact Factory.

3) Insertion depth is critical to accuracy. The algorithm used to convert impeller motion into ow was developed through ow 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 ensuring correct insertion depth.

4) Alignment of the sensor is also important. The impeller shaft must be perpendicular to the ow for accuracy. Alignment instructions are also included on the following pages.

also requires six wires.

Installation for Direct insert models

These instructions are for the installation of ow 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 following section

for hot tap installation instructions.

The insertion depth and alignment of the sensor are critical to the accuracy of the ow measurement. The impeller must be at the same location in the pipe as it was during calibration. Data Industrial 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” to 10”. 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 an isolation valves are recommended.

The preferred method of installation is by means of a saddle with 1” NPT outlet. On steel pipelines a weld-on type tting may be substituted.

Pipe Saddle

(ref.)

Mounting Adapter

Gasket

(ref)

Stem

Stem Collar

Hex Cap

Cover

1. Attach the saddle to a section of pipe that has at least 10 diameters

Straight Edge Parallel to Pipe

Pipe Pipe

SDI

Flow Sensor

of straight pipe ahead and ve diameters of straight pipe behind the saddle. Drill a minimum 1 1/8” 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/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, a reference measurement for the pipe size and schedule is used. Look up the pipe size and schedule number in Table A and note the reference number. Next, measure from the outside wall of the pipe to the top of the installed mounting adapter “B” in Figure 3. Add this number to the reference measurement.

The resulting number, “C” in Figure 4 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 ow sensor tip. Extend the tape up the stem and mark the shaft with a pencil. 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 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 mount-

ing adapter but don’t 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. Tighten the hex cap over the collar approximately 10 foot pounds. The hex cap holds the sensor alignment but performs no sealing functions. DO NOT OVERTIGHTEN.

7. Pressurize pipeline and check for leaks.

H1=19” * H2=21½” * H3=27½” *

7.85”

7 ¾”

2 27/32”

4 11/32”

* Pipe Sizes for reference only - Depending on pipe material, tapping saddle, or existing hardware longer sensor length may be required Contact Factory.

Installation for Hot tap models

Ball Valve

Stem Collar

Bottom of Housing

Stem

Hex Cap

Cover

Measure Insertion Depth From Here

The insertion depth and alignment of the sensor are critical to the accuracy of the ow measurement. The impeller must be at the same location in the pipe as it was during calibration. Data Industrial provides sensors with three 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 center of the pipe.

Stem length H1 is intended for use in nominal pipe diameters from 1 1/2” to 10”, H2 is for nominal pipe diameters from 12” to 36”, and stem length H3 is for nominal pipe diameters from 36” and up. However, pipe with extra thick walls, existing linings, or unusual tapping hardware may require longer length sensors - Consult factory.

The preferred method of installation is by means of a saddle with 1” NPT out-

Pipe Saddle

(ref.)

Gasket

(ref)

Ball Valve

Stem Colla

Stem

Hex Cap

Cover

Pipe Saddle

(ref.)

Gasket

(ref)

Ball Valve

let. On steel pipelines a weld-on type tting may be substituted.

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.

2. Remove the sensor assembly from the mounting/isolation valve by

loosening the hex cap over the stem collar and the cover to the mounting/ isolation valve and detaching the assembly. Set aside taking care not to damage impeller/shaft assembly.

3. Attach the pipe thread end of the valve to the saddle using a pipe joint

compound and tighten the joint. Do not apply sealing compound to the top

thread of the valve. It is sealed with an o-ring.

4. Attach the tapping adapter, Data Industrial part number A-1027 to the top

of the valve.

5. Any pipe tapping machine with a 1” pipe thread connection may be used.

Use a cutter appropriate for the pipe material being tapped.

6. Attach the tapping machine to the tapping adapter. Ensure that all connections and seals are tight.

7. Slowly open the valve by rotating the handle 90° and lower the cutter past the valve ball to the pipe. Drill the 1” nominal hole according to the manufacturer’s instructions. Withdraw the cutter past the valve ball, close the valve and remove the tapping tool.

8. Remove the Data Industrial tapping adapter from the top of the valve.

9. The sensor rotor assembly is to be located a xed distance from the center of the pipe. To position the impeller at this depth, a reference measurement for the pipe size and schedule is used. Look up the pipe size and schedule number in Table A and note the reference number. Next, measure from the outside wall of the pipe to the top of the ball valve “B” in Figure 8. Add this number to the reference measurement.

The resulting number is the distance from the recess of the sensor

tip to the bottom of the stem collar “C” in Figure 9. Insert the metal tab of a tape measure into the recess of the ow sensor tip. Extend the tape up the stem and mark the shaft with a pencil. 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.

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