Insertion Style Flow Meter for 3 to 40 in. Pipe

Sensor Insert

220BR sensors by Badger Meter are used in most general flow measuring applications in metallic or non-metallic pipes. These sensors consist of brass tees, feature NPT female threads and are fitted with a removable sensor insert. The sensor mounts in a 2-inch NPT pipe saddle or Threadolet® for installation in pipe sizes from 3 to 40 inches.

Selecting a Pipe Saddle for the 220BR Sensor

The 220BR flow sensor is installed using a 2-inch NPT connection into the pipe. This connection can be provided by a pipe saddle or a welded Threadolet® fitting.

Pipe size (e.g., “8-inch”) refers to the nominal size, but the actual outer diameter (OD) varies depending on pipe material and schedule (wall thickness). Always check your pipe’s outer diameter (OD) to select the correct saddle size.

Example:

• 8” SCH 40 Steel Pipe OD ≈ 8.625”

• 6” SCH 40 Steel Pipe OD ≈ 6.625”

Use the pipe schedule and material to find the correct OD, then match the saddle. Choose a Pipe Saddle with a 2-inch NPT Outlet. You will need a saddle with a 2” NPT (Female) threaded outlet to match the 220BR mounting adapter and is a proper fit to your pipe’s OD.

Example:

• 8 inch PV SCH 40 Pipe Saddle (OD ~8.625”) – McMaster-Carr 4572K264

• 6 inch PV SCH 40 Pipe Saddle (OD ~6.625”) – McMaster-Carr 4572K263

• 8 inch Universal Pipe Saddle – Grainger 5LGT0

For material compatibility, choose a saddle made of material suitable for your pipe type. PVC saddles for plastic pipes. Metal saddles (steel, brass) for metal pipes.

Mechanical Installation

The full PDF installation guide and manual supplied by Badger Meter can be found attached to this article.

Flow measurement accuracy for all flow measuring devices is highly dependent on proper location in the piping system. Irregular flow velocity profiles caused by valves, fittings, and pipe bends can lead to inaccurate overall flow rate indications although local flow velocity measurement may be accurate. A sensor located 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 . Follow these recommendations to provide 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 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 center . The sensor should never be located at the bottom of the pipe, as sediment may collect there . Locations off top 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 .

• Allow an insertion depth of 1-1/2 inches (38 mm) for pipe sizes 2-1/2 inches and larger for accurate flow rate calibration . Detailed installation instructions for various sensor mounting configurations on the following pages include methods for providing correct insertion depth .

• Align the sensor so that the impeller rotation is parallel to flow . Alignment instructions are included on the  following sections.

Installation Procedure

The insertion depth and alignment of the flow sensor assembly are critical to the accuracy of the flow measurement . The flat end of the sensor sleeve assembly MUST BE INSTALLED 1-1/2 inches (38 mm) from the inside wall of the pipe . 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.

There are two methods of mounting these sensors in a 2-1/2 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 (51 mm) hole through a depressurized pipe and then secure the saddle or weld-on fitting to the pipe . (For drilling into a pressurized pipe, see "Installation into a Pressurized Pipeline" on page 7 of the pdf attached to this article.) Install the 2 inch NPT adapter provided, using a thread sealant to prevent leakage . Tighten as necessary . Badger Meter insert style flow sensors are calibrated with the sensor inserted 1-1/2 inches (38 mm) into the pipe flow . To determine the proper insertion depth, follow these steps:

1. Apply anti-seize thread lubricant (supplied with the sensor) to the threaded studs of the mounting adapter.

2. Insert the depth gauge into the mounting adapter and set it against the inside wall of the pipe as shown in Figure 1 . Set the top of the upper adjusting nut to 3-3/4 inches (95 mm) as measured . Lock it in place with the bottom nut on the same stud . Repeat for the other adjusting nuts.
   

3. Clean the O-rings and the flow sensor sleeve, and lightly lubricate the O-rings with silicone grease from the packet provided (or another 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.

5. 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 the positioning collar set screws with a 3/32 inch Allen wrench . Place the alignment rod through the sight holes in the flow sensor. See Figure 2. Using the alignment rod as a guide, align the flow sensor so the flow label arrow matches the pipe flow direction and the alignment rod is exactly parallel to the pipe. This procedure aligns the impeller directly into the fluid flow.
   

2. As a backup to the flow arrow label, there is a small hole next to the larger sight hole of the upstream side . With a  3/32 inch Allen wrench, tighten the positioning collar set screws.

3. Double check that the sight holes in the sleeve are parallel down the pipe and the flow arrow label matches the pipe liquid f low 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 the cable as required . Be sure to leave enough flex in the cable or conduit to allow future removal of the sensor for service or cleaning .

Wiring