Badger Meter Impeller Data Industrial 228PV Series User manual

BadgerMeter, Inc.
®
Installation &
Operation Manual
Series 228PV Plastic Tee Type
Wireless Flow Sensor
880024
3-07

2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Programming Software Installation . . . . . . . . . . . . . . . . . . . . 5
Wireless Receiver Programming . . . . . . . . . . . . . . . . . . . . 5
Wireless Sensor Programming . . . . . . . . . . . . . . . . . . . . . 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION
The Series 228PV wireless flow sensor system includes the
flow sensor mounted in a tee, radio frequency (RF) transmitter
complete with mounting kit, and RF receiver / pulse transmitter.
This system eliminates the need for expensive signal wires
from the sensor output. The battery powered flow sensor
performs flow measurement and scaling and then transmits a
total flow value to the RF transmitter. The transmitter sends an
RF signal approximately every four seconds that the RF re-
ceiver detects. The RF receiver compares the previous flow
total with the most recent flow total to generate a pulse output.
Using PC software, which is part of the software installation kit,
the pulse output can be scaled to represent the desired volume
unit and number of output pulses per unit volume that best fits
the application. Pulse width can also be adjusted to meet the
requirements of an interfacing control system or monitor.
Optional equipment offered with the 228PV wireless system
include two types of antenna kits and a software installation kit
complete with software and programming cables. Addition-
ally, DIN rail mounting clips are available. These accessories
can be ordered by specifying the appropriate model number
from the Sensor System Matrix.
Series 228PV Wireless Flow Sensor
The 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 flow rate from 1 foot per second (fps) to over 20 fps
regardless of conductivity or turbidity of the liquid. The flow
sensor generates a frequency which is proportional to flow
rate. An integral micro controller measures the impeller
frequency and uses the appropriate K factor and offset values
to compute the flow rate. By means of integration, the volume
total is calculated. The output signal to the RF transmitter is a
scaled output pulse. An internal lithium battery provides power
for the flow sensor and is encapsulated to ensure moisture
resistance.
Wireless Badger®ORION RF Transmitter
The Badger ORION®transmitter operates in the 902-928 MHz
frequency band at a power level which requires no F.C.C.
licensing. The transmitter is powered using an internal lithium
battery and is encapsulated to ensure moisture resistance. It
is factory programmed and requires no configuration.
Wireless Badger ORION RF Receiver
The Badger ORION receiver is powered using an external
alternating current (AC) or direct current (DC) power supply.
The wireless receiver receives the scaled total from the
transmitter. Further scaling and unit conversion can be
programmed into the receiver. The optically coupled scaled
pulse output emulates a dry contact closure to ensure
interfacing into various types of controller inputs.
Exam
p
le: 2 28 PV 0 W - 1 2 3 1
Tee Mounted 28
PVC PV
1.5" 15
2" 20
3" 30
4" 40
0
ELECTRONICS
Wireless Transmitter and Receiver W
O-RING
EPDM 1
SHAFT
Tun
g
sten Carbide 2
IMPELLER
420 Stainless Steel 3
BEARING
UHMWPE
(
ultra-hi
g
h molecular wei
g
ht
p
ol
y
eth
y
lene
)
1
ELECTRONICS HOUSING
SIZE
MATERIAL
STYLE
Acetal Housing w/ Fortron Polyphenylene Tip
xx
ANTENNA
No Option
Low Profile Type A355LP Antenna
Whip Type A355 Antenna
MOUNTING
No Option
DIN Rail Mounting Clips
SOFTWARE INSTALLATION KIT
No Option
A301W-20 Cable, IR Cable, Software
0
1
2
XXX
0
1
0
1
Wireless Series 228PV Flow Sensor System Matrix
(1½" to 4")
INSTALLATION
General
As with all flow measuring devices accuracy 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 with a length equivalent to
10 pipe diameters upstream and 5 pipe diameters
downstream of the sensor which are free of flow disturbances.
Pipe bends, valves, other fittings, pipe enlargements, and
reductions should not be present in this length of pipe.
2) When the sensor is installed in horizontal piping, the
preferred sensor orientation is vertical, on top of the pipe. If
trapped air or debris could potentially interfere with sensor
operation the sensor can be installed as much as 45
degrees from the vertical. Please note that when the sensor
is installed “off the vertical”, impeller friction increases which
may affect performance at low flow rates and increase wear.
The sensor should never be located at the bottom of the
pipe, as sediment may collect there. When the sensor is
installed in vertical piping, it can be installed at any
circumferential position. Rising flow is preferred to reduce
the effects of trapped air.

3
Minimum Distance Minimum Distance
10 x I.D. 5 x I.D.
Power
Supply
FLOW
Flow Sensor
Valve Box Cover
Wireless
Transmitter
Antenna
MaxDistanec 500’
5’ Cable
Pulse
Output
Wireless Series 228PV Plastic Tee Sensor Mechanical
Installation
1) Note intended direction of flow as indicated by arrows on
the tee. There must be free, unrestricted pipe for at least
10 diameters upstream and 5 diameters downstream of
the tee.
Note: Cable length between sensor and wireless
transmitter is 5 feet. Plan for cover removal if inserting
into a valve box.
2) Remove the clevis pin and remove the sensor from
the tee.
3) Properly clean the pipe ends and tee sockets.
4) For 228PV, solvent cement the pipe to the tee.
5) Reinstall sensor in tee as follows:
a) Align small diameter blind hole on top surface of
sensor with tip of flow arrow on tee.
b) Carefully press sensor straight into tee.
c) Install clevis pin through tee and sensor.
d) Install cotter ring.
6) Remove wireless transmitter cap from wireless transmitter
body by unscrewing it in the counterclockwise direction.
7) Insert wireless transmitter body through a minimum 1 5/8"
hole in valve box cover. (maximum hole size 2 1/2")
8) Screw wireless transmitter cap hand tight to wireless
transmitter body then screw nut against the inside of the
valve box cover so cap is tight.
Badger®ORION®Wireless Receiver Mechanical Installation
The wireless receiver may be surface mounted onto a panel or
attached to DIN rails using adapter clips.
Location
Although the wireless receiver is encapsulated, all wiring
connections are made to exposed terminals. The unit should
be protected from weather and moisture in accordance with
electrical codes and standard trade practices. In any mounting
arrangement, the primary concerns are ease of wiring and
attachment of the programming cable.
Typical Wireless Flow Sensor Installation
Wireless
Transmitter
Threaded
Cap
Nut
Figure 1: Badger ORION
Wireless Transmitter with
Threaded Cap Removed
Figure 2: Badger ORION
Wireless Transmitter Installed
in Valve Box Cover
Wireless
Transmitter
Threaded Cap
Nut
5.125”
0.5”
0.5”

4
P/N: 820060-0001
LOW PROFILE ANTENNA PORTABLE
P/N: 840030-0001
ANTENNA CABLE W/BNC CONNECTOR
AND BRASS MOUNTING HARDWARE
LOW PROFILE ANTENNA MOUNTING HOLE = Ø 3/4"
350 RECEIVER ASSEMBLY
ENCLOSURE
(SUPPLIED BY CUSTOMER)
P/N: 820057-0001
8" WHIP STYLE ANTENNA PORTABLE
P/N: 820058-0001
MOUNTING HARDWARE W/BNC CONNECTORS F/F
MOUNTING HOLE: Ø1/2"
P/N: 820056-0001
ANTENNA CABLE W/BNC CONNECTORS M/M
P/N: 820059-0001
90° BNC ADAPTOR
ENCLOSURE
(SUPPLIED BY CUSTOMER)
350 RECEIVER ASSEMBLY
Figure 3: Badger ORION Wireless Receiver Dimensions
RF RCV
LED
BadgerMeter Inc.
Power In
AC L /DC
AC C /DC
D.I.C.
Comm Port
Antenna
(50 ohms)
Made in USA
+
-
PO
-
+
PO
Pulse Output
Output LED
Model 350R
S/N 350R-
1.60”
(40.6mm)
3.65”
(92.7mm)
2.95”
(74.9mm)
.88”
(22mm)
.60”
(15mm)
Figure 4: A355LP Antenna Kit
The unit generates very little heat so no consideration needs to
be given to cooling or ventilation.
The ideal receiver location would be within a clear line-of-sight
of the flow sensor. However, this is rarely possible, with the line-
of-sight hindered by obstructions such as trees and vegetation,
buildings and other structures, vehicles, and uneven terrain.
Surface Mount Installation
The wireless receiver may be mounted to the surface of any panel
using double sided adhesive tape or by attaching fasteners
through the holes in the mounting flanges of the unit.
DIN Rail Mounting
Optional clips snap onto the mounting flanges allowing the wire-
less receiver to be attached to DIN 15, 32, 35 mm DIN rail systems.
Antenna Installation
The Badger®ORION®RF receiver requires an external an-
tenna to communicate with the RF transmitter. The antenna is
typically mounted directly to a customer supplied enclosure
which houses the RF receiver. The antenna may also be
installed remotely from the enclosure to be within clear line-of-
sight of the RF transmitter.
Antenna kits are an optional accessory and can be ordered by
specifying the appropriate model number from the Sensor
Selection Matrix. Badger Meter offers two different antenna
kits: the A355LP low profile antenna kit and the A355 whip
style antenna kit.
The A355LP kit includes a low profile antenna and antenna
cable with mounting hardware. The more durable, low profile
antenna is 2.3" in height and designed to operate in a fre-
quency bandwidth of 902 – 928 MHz with a gain of 3 dB.
The A355 kit includes a whip style antenna, antenna cable,
mounting hardware, and 90 degree BNC adaptor. The half-wave,
whip style antenna is 8" in height and designed to operate in a
frequency band of 902 – 970 MHz with a gain of 2.5 dB.
Both kits are supplied with RG58C/U type antenna cable.
Please refer to Figures 4 and 5 for suggested antenna instal-
lation, mounting hole sizes, and component part numbers.
Please note that antenna cable lengths of more than three feet
will negatively affect signal strength. Antennas operate more
effectively when well grounded (with a 3" diameter ground
plane); grounding washers, included in both installation kits,
are strongly recommended. Figure 5: A355 Antenna Kit

5
Badger®ORION®Wireless Receiver Electrical Installation
Per standard wiring practices, the power must be off before
making any wire connections. The terminal strips have
removable plug-in connectors to make wiring easier.
1. Refer to Figure 6 for terminal connections and wiring
example.
2. Connect DC power supply positive (+) or AC Line to
wireless receiver terminal marked AC L /DC (+).
3. Connect DC power supply negative (-) or AC Common
to wireless receiver terminal marked AC C /DC (-).
4. Connect Pulse(+) of a pulse input device to wireless
receiver terminal marked PO(+). Connect Pulse(-) of the
input device to wireless receiver terminal marked PO(-).
5. Connect 50Ω(ohm) Antenna to BNC Antenna
connector of wireless receiver.
THEORY OF OPERATION
The Badger ORION RF recevier can be located up to 500 feet
away from the RF transmitter and must be powered with 12-
24 VAC/VDC. A BNC connector is provided on the RF receiver
to accept a 50 Ohm, half wave antenna.
There are two red LED’s on the Badger ORION RF receiver.
The “RF RCV” LED in the middle of the unit flashes each time
it receives an updated total from the RF transmitter, approxi-
mately every four seconds. The “OUTPUT” LED flashes each
time an output pulse is generated by the receiver.
After each update, the RF receiver compares this updated
total with the last one received. The difference is the total
volume in gallons which has passed through the sensor for the
period in question. The RF receiver then generates a continu-
ous burst of output pulses with a duty cycle of 50%. These
pulses can be scaled using the DIC Com Port and Badger
Meter software to represent the desired volume unit, number
of volume units per pulse, and pulse width which best fit the
application. Default values for these settings are gallons, 10
gallons per pulse, and 50 milliseconds, respectively.
Should a combination of volume units, volume units per pulse,
and pulse width be selected such that the number of corre-
sponding output pulses cannot be generated in the 4-5 sec-
ond update window, the RF receiver will simply delay the next
update until the pulse string has been completed.
Example:
Sensor Model: 228PV200W-1231-000
Line Size: 2"
Gallons per Integer Output
from Transmitter: 1 (default)
Volume Unit Selected in Receiver: liters
Volume Units per Pulse Output
from Receiver: 10
Pulse Width: 50 milliseconds
If 10 gallons pass through the sensor in a given four second
window, 10 integer values would be sent by the transmitter in
the next update, representing a volume of 10 gallons. The
receiver would, in turn, convert the 10 gallons into 37.8 liters
and generate three output pulses, representing a volume of 30
liters. Because partial counts exist in both the sensor and
receiver, the remaining 7.8 liters would be sent as part of the
next update from the sensor.
Note:
The Badger Meter Model A301W cable will work with all
Series 300 products. However the older version of the
cable (A300) does not have sufficient bandwidth to work
with this receiver.
PROGRAMMING SOFTWARE INSTALLATION
Communications Cable Wiring
To change parameters in the receiver or sensor, a Badger
Meter Model A301W Programming Kit (consisting of a custom
cable, IR dongle, and software) and a PC running Windows®
9x, ME, NT, 2000 or XP is required. In order to program, the
wireless receiver must be connected to power, and the
communications cable must be connected to the D.I.C.
Comm port and an available DB9 Comm. port on a computer.
Location of the DIC Com Port
CDROM Installation
Insert the Badger Meter Model 350W WS/R CD into a
CDROM drive of a Windows based PC. Software should
start automatically. Follow instructions from the
InstallShield Wizard to complete installation. From the
Windows Start\Programs\Badger Meter Inc. menu, select
Model 350W to start the application software.
Web Installation
Badger Meter provides free programming software updates
via the Internet for all field programmable devices. The
installation software can be found in the support section of
the Data Industrial website (www.dataindustrial.com).
Figure 6: Sample Badger ORION Wireless Receiver
Electrical Wiring
RF RCV
LED
BadgerMeter Inc.
Power In
AC L /DC
AC C /DC
D.I.C.
Comm Port
Antenna
(50 ohms)
Made in USA
+
-
PO
-
+
PO
Pulse Output
Output LED
Model 350R
S/N 350R-
12-24VDC
or 12-24VAC
Power Supply
+
-
36 VDC Max
Counter with
Internal
Pull-up
Resistor
+
-
Side View - Typical Series 300 Removable Connector Wiring
3/32”Flathead
Screwdriver
Series300
Connector
Wire
R
F
LE
D.I.C.
Comm Port
Made in USA
+
-
-
+

6
8. Program wireless receiver using diagram below as a reference.
Step 3
Enter the desired volume
per scaled output pulse.
Step 4
Enter the scaled output pulse width.
Note: The default pulse width is
50 milliseconds. Minor variation in
pulse width may be required
dependingon controller interface.
Step 2
Enter the desired volume unit
for scaled output pulses
Step 1
Enter serial number of
wireless transmitter. Thisinformation
can be found on the cable
between sensor and transmitter
or engraved on transmitter body.
Note: If serial number iseight digits
in length and startswith the number
“7”, the leading“7” should not be
entered. Otherwise all digitsshould
be entered.
Step 6
Press the send button to
calibrate the wireless receiver
with the information that was
entered in steps1-5
Step 5
Configure thisselection
depending on the application
requirements.
If Required
Press to see current
programming of the
wireless receiver
If Required
Note: Thiswill
overwrite all settings.
Press to enter in the factory default
programming.
Step 7
Press to exit Parametersscreen
WIRELESS RECEIVER PROGRAMMING
To change settings in the wireless receiver, Badger Meter
software must be installed and the new values entered using
a Windows based program as outlined below.
1. Install the 350 wireless PC software into the computer.
2. Connect the computer to the wireless receiver using the
Badger Meter Model A301W communications cable. Plug
the Model A301W cable to the socket labeled “D.I.C.
Comm Port” taking care to properly align the tab on the
plug and socket to maintain polarity. Then plug the DB9
connector of the Badger Meter Model A301W
communications cable to an available PC Com port that
has the wireless sensor software installed. If a DB9
connector is not available, a USB to DB9 adapter (ex
IOGEAR GUC232A) are available, and can be used.
3. Connect the wireless receiver to a power supply.
4. Open the 350 Wireless PC Software.
5. Select the Model 350WR as shown below.
6. Select configuration and open the Set Comm Port screen
to set the appropriate comm port for the A301W cable as
shown in the dialog boxes below.
7. Open the Parameters screen.
To
g
o to the calibration
settingsscreen select
“Parameters” from either
place shown

7
WIRELESS FLOW SENSOR PROGRAMMING
The wireless flow sensor is factory programmed based on
the line size for your application using the default settings
given in the table, below (based on 15 fps flow velocities.)
Model No. K Offset
Recommended
Volume / Pulse
Output (gallons)
Minimum / Maximum
Flow Range
(gpm)
228PV150W-xxxx-xxx
228PV200W-xxxx-xxx
228PV300W-xxxx-xxx
228PV400W-xxxx-xxx
0.275171
0.577369
1.679052
2.989980
-11.367570
-2.751717
-3.337804
0.881112
1
1
10
10
6 - 95
10 - 156
23 - 345
39 - 595
These factory settings consist of the K and Offset values and
Gallons per Pulse Output.
The K and Offset values, empirically derived from flow test
using NIST traceable instruments, are used in the calibration
equation (Frequency = GPM/K – Offset) to calculate sensor
frequency at any flow rate within its operational range. Factory
settings for K and Offset are normally changed only when
installing the sensor in a different line size or when custom
values are required, e.g. non-standard piping. Should custom
values for K and Offset be required, contact the factory for
assistance. Note: If no line size is specified at the time of order
placement, default values for K and Offset of 0.5 and 0,
respectively, will be used.
The value for Gallons per Pulse Output sets system resolu-
tion. Lowering the factory default value for gallons per pulse
output is not recommended because it will decrease transmit-
ter battery life and may affect transmitter operation.
Badger Meter sensors will operate both above and below the
suggested flow range for each tee size. Test results have
shown, however, that the highest accuracy and best repeat-
ability are achieved in this flow range.
To change settings in the wireless sensor, Badger Meter
software must be installed and new values entered using a
Windows®based program as outlined below.
1. Open the 350 Wireless PC Software.
2. Connect the computer to the wireless sensor using an
infrared cable (IR dongle).
Note: IR Device must be placed no more then 3 inches
from top of sensor.
3. Select the Model 350WS as shown below.
4. Open the interface software then select Configuration
and Set Comm Port and select the appropriate Comm
Port for the IR cable as shown in the dialog boxes
below.
5. Open the Parameters screen.
To
g
o to the calibration
settingsscreen select
“Parameters” from either
place shown
6. Program wireless sensor using diagram below as a reference.
Step 1
Select sensor size from pull
down menu. If the acustom K
and offset are required select
“other”(unlisted) from the pull
down menu.
The K and offset numberswill automatically
appear here for the flow sensor size selected
If “other”was selected in step 1 enter in
desired k and offset numbers
Step 2
Enter the desired unit for flow rate display.
Step 3
Enter desired volume per output pulse.
Step 4
Press the send button to
calibrate the wireless sensor
with the information that was
entered in steps1-3
If Required
Press to see current
programming of the
wireless sensor
Step 5
Press to exit Parametersscreen
If Required
Note: Thiswill
overwrite all settings.
Press to enter in the factory default
programming.

®
Due to continuous research, product improvements and enhancements, Badger
Meter reserves the right to change product or system specifications without notice,
except to the extent an outstanding contractual obligation exists.
BadgerMeter, Inc.
6116 E. 15th Street, Tulsa, Oklahoma 74112
[phone] / Fax: [phone]
www.dataindustrial.com
Please see our website at www.dataindustrial.com
for specific contacts.
Copyright © Badger Meter, Inc. 2007. All rights reserved.
SPECIFICATIONS
Wetted Materials (Except Tee)
• Refer to the Sensor Selection Matrix
Tee for 228PV
• Schedule 80 PVC per ASTM D-2462 and D-2467.
Virgin, unplasticized PVC resin, Type 1 cell
classification 12454-B. Fittings and solvent carry approval for
potable water by NSF and IAMPO.
Power Requirements
• Flow sensor-lithium battery powered
(typical battery life - > 5yr)
• ORION®transmitter-battery powered
(typical battery life > 10yr)
• ORION receiver-external power 12-24VAC/VDC
Current Draw:
36 mA @ 12 VDC
16 mA @ 24 VDC
40 mA rms@ 12 VAC rms
30 mA rms@ 24 VAC rms
Recommended Flow Range
• 5 to 20 FPS
• Extended flow range 1 to 20 FPS
Accuracy
• Standard ± 2% of rate
• Repeatability ± 0.5%
Maximum Operating Temperature
• 32 - 150°F (0 - 65°C)
Sensor Pressure Drop
• 0.5psi or less at 10 FPS for all pipe sizes 1.5"
diameter and larger
Programming
• Sensor and transmitter programming is accomplished
using PC software via an infrared (IR) link
• ORION RF receiver programming is accomplished using
PC software via the A301W connector cable
Flow Sensor
Programmable Parameters
• K & Offset dependent upon pipe size
• Flow units (gpm, gph, lps, lpm, ft3/sec, ft3/min, m3/sec, m3/min)
• Scaled pulse output (units/pulse)
ORION Transmitter
Programmable Parameters
• Customer programming not required
ORION Receiver
Programmable Parameters
• Serial number (unique to the ORION Transmitter ID)
• Volume units (gallons, ft3, m3, ltrs)
• Scaled pulse output (units/pulse)
• Scaled pulse output (pulse width)
MINIMUM SCALED PULSE OUTPUT
• Scaled pulse output from the sensor and Badger®ORION
RF receiver are programmed using PC software. Minimum
recommended pulse output from the sensor for various
"tee" sizes are listed below. (Based on 15 FPS flow
velocities)
SENSOR PRESSURE RATINGS
B
D
E
C
A
OVERALL LENGTH
OVERALL
HEIGHT
MINIMUM CLEARANCE
REQUIRED FOR SENSOR
REMOVAL
DIA
SeriesNo.
Complete
A 5.0" (127mm) 5.63(143mm) 6.50" (165mm) 7.38" (187mm)
B5.16"(131mm) 5.64" (143mm) 6.83" (173mm) 6.83" (199mm)
C2.38" (60mm) 2.88" (73mm) 4.23" (107mm) 5.38" (137.mm)
D3.97" (101mm) 4.20" (107mm) 4.68" (119mm) 5.10" (130mm)
E5.5"(139.7mm) 5.5" (139.7mm) 5.5" (139.7mm) 5.5" (139.7mm)
228PV152W-1201 228PV202W-1201 228PV302W-1201 228PV402W-1201
Badger®and ORION®are registered trademarks of Badger Meter, Inc.
Windows®is a registered trademark of The Microsoft Corporation.