Badger Meter Impeller Data Industrial 228PV Series User manual

Flow Sensors
Series 228PV PVC Tee Type Flow Sensors
SEN-UM-01664-EN-10 (February 2018) User Manual

Flow Sensors, PVC Tee Type Flow Sensors
Page 2 February 2018SEN-UM-01664-EN-10
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Certications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electronic Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IR Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Model 228PV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Mechanical Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
IR Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intrinsically Safe Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Column Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calibration Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Impeller Assembly and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introduction
INTRODUCTION
Used in conjunction with any Badger Meter® impeller flow monitor or endpoint, Badger Meter non-magnetic impeller 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 (610 meters) 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 impeller 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.
This manual provides instructions for the Series 228PV tee type impeller flow sensor.
CERTIFICATIONS
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 (6 meters) of 2-conductor 20 AWG shielded UL type
PTLC 221° F (105° C) cable. Optional sensors designated with the prefix IR feature two single-conductor, 18 AWG solid copper
wire leads 48 inches (122 cm) in length with UL Style 116666 direct burial insulation. These IR models are used in below
grade applications such as irrigation, municipal, and groundwater monitoring. All Badger Meter Series 200 sensor electrical
components are self-contained. Pressure/temperature ratings for the various models are contained in "Specifications" on page
10. These models are further described as follows.
Standard Sensor
Standard sensors are 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 (105° C). Standard
sensors are supplied with 20 feet (6 meters) of 2-conductor 20 AWG shielded UL type PTLC 221° F (105° C) cable.
IR Sensor
IR sensors are 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 (82° C). IR sensors are supplied with two
single-conductor, 18 AWG solid copper wire leads, 48 inches (122 cm) in length, with UL Style 116666 direct burial insulation.
Model 228PV
The model 228PV features a modified PVC tee with solvent weld socket end connections, and a removable PPS or PVDF sensor
insert. Sizes of 1-1/2, 2, 3 and 4 inches are available.
Page 3February 2018 SEN-UM-01664-EN-10

Electronic Types
• The impeller style flow sensor described in this manual is not intended for use in safety critical applications.
Use of the device in this manner is done at the sole discretion of the customer and/or end user of the device.
• The impeller style flow sensor described in this manual is not intended for use in systems with flammable liquids or gases.
Additionally, the device is not intended for systems containing hazardous fluids or fluids other than water.
• The impeller style flow sensor described in this manual must be installed in accordance with all local and federal codes or
end-use standards, as applicable.
• If the devices described in this manual are used in a manner not specified by the manufacturer, the protection provided
by the equipment may be impaired.
ATTENTION
• Le capteur de débit de type turbine décrit dans le présent manuel n’est pas destiné à être utilisé dans des applications de
sécurité critiques. L'utilisation du dispositif de cette manière se fait à la seule discrétion du client et/ou de l'utilisateur final
du dispositif.
• Le capteur de débit de type turbine décrit dans le présent manuel n’est pas destiné à être utilisé dans des systèmes
comportant des liquides ou gaz inflammables. En outre, le dispositif est pas destiné à des systèmes contenant des liquides
dangereux ou autres que l'eau.
• Le capteur de débit de type turbine décrit dans le présent manuel doit être installé en conformité avec tous les codes
locaux et fédéraux ou toutes les normes d'utilisation finale, selon le cas.
• Si les dispositifs décrits dans le présent manuel sont utilisés d'une manière non spécifiée par le fabricant, la protection
fournie par l'équipement peut être altérée.
Page 4 February 2018SEN-UM-01664-EN-10

Mechanical Installation
MECHANICAL INSTALLATION
Depressurize and vent the piping system prior to any installation or maintenance of the flow sensor.
General Information
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, or other obstructions 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:
• 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.
• The preferred location for the sensor around the circumference of a horizontal pipe is at the 12 o'clock position. 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 and increase wear. Any circumferential
location is correct for installation in vertical pipes, with rising flow preferred to reduce the effects of any trapped air.
Mechanical Installation Procedure
OTE:N The intended direction of flow is 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.
1. Remove the clevis pin and remove the sensor from the tee.
2. Properly clean the pipe ends and tee sockets.
3. Use solvent cement to attach the pipe to the tee.
4. Reinstall the sensor in the tee as follows:
a. Align the flow arrow on the top of the sensor housing in the direction of flow.
b. Carefully press the sensor straight into the tee.
c. Install the clevis pin through the tee, the sensor, and the conduit cap, and install the cotter ring.
Page 5February 2018 SEN-UM-01664-EN-10

Electrical Installation
ELECTRICAL INSTALLATION
MPORTANTI
Disconnect the power from the flow sensor source and/or receiving device prior to any installation or maintenance of the system.
Flow sensor source and/or receiving device must provide basic isolation from mains for safe operation of the system.
OTE:N If the sensor has white and black wires instead of red and black, connect the white wire wherever red is indicated.
Standard Sensors
1. Route the cable from the sensor to a Badger Meter ow monitor/endpoint. The cable may be extended up to 2000 feet
(610 meters), using 2-conductor shielded 20 AWG (or larger) stranded copper wire. Be sure to leave enough exibility in
the cable or conduit to allow for future service of the sensor, if necessary.
2. When connecting to a Badger Meter ow monitor/endpoint, locate the section of terminal strip on the monitor labeled
SENSOR INPUT or SENSOR. Connect the red (or white) wire to IN, SIGNAL(+) OR SIGNAL terminal, connect the black wire
to GND, SIGNAL(–) or COM terminal, and connect the shield drain wire (if applicable) to SLD.
3. When interfacing with other equipment, consult the manufacturer for input designations. The signal wave forms and
power requirements are as shown in "Specications" on page 10.
IR Sensors
The sensor leads are supplied with watertight caps over the ends.
OTE:N DO NOT remove the plastic caps from the sensor leads until ready to splice.
1. Use a twisted pair cable suitable for direct burial to connect the sensor to the endpoint, monitor or controller. Multi-pair
telecommunication cable or direct burial cables may be used.
2. Make a watertight splice. Two-part epoxy type waterproof kits are recommended. Be sure the epoxy seals the ends of the
cable jacket.
3. Make sure the epoxy is hardened before inverting the splice or dropping it in standing water.
OTE:N Do NOT make an underground splice unless absolutely necessary.
4. Route the cable from the sensor to a Badger Meter ow monitor/endpoint. The cable can be extended up to 2000 feet
(610 meters), using 2-conductor shielded 20 AWG (or larger) stranded copper wire with appropriate ratings. Be sure to
leave enough exibility in the cable or conduit to allow for future service of the sensor, if necessary.
5. When connecting to a Badger Meter ow monitor/endpoint, locate the section of terminal strip on the monitor labeled
SENSOR INPUT or SENSOR. Connect the red (or white) wire to IN, SIGNAL(+) OR SIGNAL terminal, connect the black wire
to GND, SIGNAL(–) or COM terminal, and connect the shield drain wire (if applicable) to SLD.
6. When interfacing with other equipment, the signal wave forms and power requirements are as shown in "Specications" on
page 10.
Page 6 February 2018SEN-UM-01664-EN-10

Dimensions
Intrinsically Safe Electrical Installation
The Series 200 sensor is approved, as an entity, as intrinsically safe when installed in conformance with Badger Meter
installation drawings 06-480-001 or 06-480-002 (sample shown in "Impeller Assembly and Shaft Replacement" on page 9) as
specified on the blue label identifying an intrinsically safe sensor.
Entity approval implies that only the sensor is approved as intrinsically safe. Unless power supplies, equipment, and
instruments connected to the sensor are each rated either explosion-proof or intrinsically safe, these devices cannot be
installed in a hazardous area. The referenced installation drawing shows such apparatus located in a non-hazardous location.
Proper interfacing between the hazardous and non-hazardous areas must be provided. This interface must be constructed
and all wiring must be performed by qualified contractors. To make sure the installation is intrinsically safe, the connection of
the intrinsically safe sensor to instruments and or power supplies must take place using an approved intrinsically safe barrier
located in a nonhazardous area. These barriers, listed below, are readily available from various suppliers.
Manufacturer Barrier
Crouse-Hinds Spec 504 Cat No. SB19140M0715
Measurement Technology Ltd. MTL 715+ 15 V
R Stahl Intrinspak 9001/01-158-150-101
DIMENSIONS
Series No. Complete 228PV15XX-XXX 228PV2XXX-XXXX 228PV3XXX-XXXX 228PV4XXX-XXXX
A5
B5
C2
D3
E5
5.0 in. (127 mm)
5.16 in. (131 mm)
2.38 in. (60 mm)
3.97 in. (101 mm)
5.0 in. (127 mm)
5.63 in. (143 mm)
5.64 in. (143 mm)
2.88 in. (73 mm)
4.20 in. (107 mm)
5.0 in. (127 mm)
6.50 in. (165 mm)
6.83 in. (173 mm)
4.23 in. (107 mm)
4.68 in. (119 mm)
5.0 in. (127 mm)
7.38 in. (187 mm)
6.83 in. (199 mm)
5.38 in. (137 mm)
5.10 in. (130 mm)
5.0 in. (127 mm)
E
D
B
A
C
No Fittings
E
D
B
A
C
BSP Fittings
E
D
B
A
C
Flanged (4 in. only)
Figure 1: A = Overall Length; B = Overall Height; C = Diameter;
D = Center of Tube to Top Height; E = Minimum Clearance for Sensor Removal
Page 7February 2018 SEN-UM-01664-EN-10

Calibration
CALIBRATION
Badger Meter impeller sensors use unique K and offset numbers for calibration. These numbers are derived from calibration
runs using NIST traceable instruments. Using both a K and an offset number provides higher accuracy than using a K factor
alone. The K and offset numbers for each tee configuration are listed in the Calibration Table below.
Column Descriptions
Column Description
Column 1 Sensor model number
Columns 2 and 3 The K and offset values to use in the frequency equation:
Freq=Gpm
K– oset
This equation describes the frequency of the output signal of all Badger Meter flow sensors. By
substituting the appropriate K and offset values from the table, the sensor’s output frequency can be
calculated for each pipe size. This information is required when calibrating an output board, or when
using the raw sensor data as direct output to interface with a device that is not a Badger Meter product.
Column 4 This column indicates the suggested flow range of each tee sensor. Badger Meter sensors operate both
above and below the indicated flow rates. However, good design practice dictates the use of this range
for best performance.
Sensors should be sized for flow rather than pipe size. To prevent disturbances to the flow profile,
always connect the sensor tee to pipe nipples measuring at least 10 pipe diameters in length on the
upstream (supply) side, and at least 5 pipe diameters in length on the downstream (delivery) side
before making the transition in pipe size. If a lesser flow rate is chosen, an insufficient span exists for the
proper operation of these circuits. This can result in excessive ripple and fluctuations in signal, which
can adversely affect system performance.
Calibration Table
The table below provides calibration and operation data for Badger Meter plastic tee sensors 1-1/2…4 inches (38…102 mm).
See the column descriptions above for additional information.
Column 1 Column 2 Column 3 Column 4
Model for K Offset Suggested Operating Range
(gpm)
228PV15xx-xxxx
228PV20xx-xxxx
228PV30xx-xxxx
228PV40xx-xxxx
1.697
2.8429
8.309
13.74283
-0.316
0.1435
0.227
0.23707
5…100
10…200
20…300
40…500
Page 8 February 2018SEN-UM-01664-EN-10

Impeller Assembly and Shaft Replacement
IMPELLER ASSEMBLY AND SHAFT REPLACEMENT
If you are replacing an existing Badger Meter sensor and have already calibrated your flow monitor/endpoint, no calibration
changes are necessary. For installation of a new flow monitor or for relocation of a sensor in a new pipe size, refer to the
calibration instructions in this manual.
1. Depressurize and vent the pipe, and remove power to the installation from which the sensor is to be removed.
2. Remove the clevis pin.
3. Remove the sensor from the tee.
OTE:N Note the impeller blade orientation relative to the flow arrows. To maintain proper calibration, the impeller must
be reinstalled in the same manner with the impeller blades pointing toward the flow source as indicated by the
flow arrows.
4. To remove the old impeller blade assembly, push the old shaft out of the sleeve with the new shaft (or small diameter rod)
just far enough to grab the end with a pair of pliers, and pull the shaft completely out. The impeller assembly will now be free,
and will drop out.
5. Inspect the shaft and bearings for wear and replace as necessary.
6. See Figure 2 below. To reinstall, position the impeller in the cavity, oriented so that the impeller blades point in the ow
direction (as described in the NOTE above). The ow direction arrow on the top of the sensor housing should point
downstream with the impeller blades pointing upstream.
7. Carefully push the shaft through the housing and impeller, taking care not to damage the bearings. Make sure the shaft is
inserted far enough so that it clears the housing on each side of the impeller housing.
OTE:N If the shaft is not carefully installed, the bearing can be deformed, preventing free rotation.
8. Inspect the O-rings for damage and replace as necessary. Clean the O-rings and the sleeve, and relubricate with silicone
grease from the packet provided, or use another acceptable lubricant.
9. Install the sensor into the tee so the ow arrow points in the direction of the actual ow.
10. Install or replace the clevis pin.
This completes the replacement procedure. The system can now be repressurized and tested.
NOTE DIRECTION OF ARROW
USE PLIERS HERE
NOTE DIRECTION OF
IMPELLER
USE METAL PIN TO
REMOVE CERAMIC SHAFT
Figure 2: Impeller Assembly and Shaft
Page 9February 2018 SEN-UM-01664-EN-10

Specications
SPECIFICATIONS
Wetted Materials (except tees) See Ordering Matrix in the Series 228PV Product Data Sheet for material specifics.
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.
Pressure/Temperature Ratings
(DO NOT EXCEED)
Depends on hardware configurations.
Temperature (°C)
0
20
40
60
80
100
02
560
Pressure (psi)
Rated Temperature
(DO NOT EXCEED)
Operating: 35…110° F (2…43° C)
Storage 14…110° F (-10…43° C)
Recommended Design Flow Range 0.5…30 ft/sec
Accuracy ± 1.0% of full scale over recommended design flow range
Repeatability ± 0.3% of full scale over recommended design flow range
Linearity ± 0.2% of full scale over recommended design flow range
Transducer Excitation
Supply voltage = 8V DC min. 35V DC max.
Quiescent current = 600 µA (typical)
OFF State (VHigh) = Supply voltage – (600 µA
*
Supply impedance)
ON State (VLow) = 1.2V DC @ 40 mA (15 Ω + 0.7V DC)
Output Frequency 3.2…200 Hz
Output Pulse Width 5 msec ±25%
Environmental
• IP 68 / NEMA 4X
• Suitable for pollution degree 4 environments
• Suitable for outdoor use above grade, IR version below grade
• Suitable for use in 100% humidity
Electrical Cable for Standard Sensor
Electronics
20 feet (6 meters) of 2-conductor AWG 20 with AWG 22 drain wire shielded UL type PTLC wire
provided for connection to display or endpoint unit. Rated to 221° F (105° C). May be
extended to a maximum of 2000 feet (610 meters) with similar cable and insulation appropriate
for application.
Electrical Cable for IR Sensor
Electronics
48 inches (122 cm) of UL Style 116666 copper solid AWG 18 wire with direct burial insulation.
Rated to 221° F (105° C).
Page 10 February 2018SEN-UM-01664-EN-10

Troubleshooting
TROUBLESHOOTING
Series 200 flow sensors are active devices that are most easily tested at the connection point of the controller to which they
are connected.
The sensor is essentially a 15 Ohm switch with a 600 uA leakage current. With no flow running (the impeller not turning), the
sensor will appear to the controller input as a small current load. When the impeller is turning, it appears a quick series of
5 ms short circuits.
• Before trying to troubleshoot, confirm that the flow rates are well above the minimum recommended flow rates. This will
usually purge any air out of the line, and make sure that the impeller is actually spinning in the flow.
• If the controller is not recognizing a flow input from this sensor, test the controller itself by disconnecting the flow sensor,
and very quickly and repeatedly short together the two terminals that the flow sensor was connected to. The controller
should report some flow. If it does not, the problem is in the controller, and not the flow sensor or the wiring to it.
• If the controller appears to be working, while the sensor is still disconnected, measure the open circuit voltage on the
controller's sensor input terminals. This voltage must be between 8…24V DC for the sensor to operate. If the voltage is
acceptable, reconnect the flow sensor and re-measure. Depending on the age of the flow sensor, the voltage should drop
slightly. Current production sensors will drop about a volt or so. Sensors manufactured prior to 2001 will drop to about
8V DC. If no drop is observed, the sensor is wired backwards, or there is a break in a wire or splice, or the sensor is open
internally. If the voltage drops to near zero, there is either a short in the wiring or splice or the sensor is shorted internally.
If the voltage drops below 7V—but not to levels indicating a short—there is most likely moisture penetration or corrosion
in the wiring or in the sensor itself.
• If the electrical tests all look normal, you will have to drain the pipe, remove the sensing element, and spin the impeller
by hand. When spun by hand, the impeller should spin freely and slide smoothly to a stop, with no evidence of damage
or wear on any of the surfaces, and the controller should recognize the signal and report a flow. If it does not, the sensor
electronics are no longer operational and must be replaced.
• If the impeller/bearing is simply worn or damaged, and signal is observed when the impeller is forced to turn, then an
impeller repair kit can be installed as described in "Impeller Assembly and Shaft Replacement" on page 9.
Page 11February 2018 SEN-UM-01664-EN-10

Flow Sensors, PVC Tee Type Flow Sensors
www.badgermeter.com
Trademarks appearing in this document are the property of their respective entities. Due to continuous research, product improvements and enhancements, Badger Meter reserves
the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists. © 2018 Badger Meter, Inc. All rights reserved.
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