Installation & Operation Manual
The alignment of the impeller with the flow in the pipe
is accomplished by aligning the two “sight holes” at the
top of the sensor tube assembly with the center line of
the pipe.
Make sure the alignment is made to the pipe
and not to a wall or surface near the sensor.
To adjust,
loosen the two set screws in the positioning collar with
a 3/32 inch Allen wrench provided in the Series 200 hot
tap installation kit. Slip one end of the 1/4 inch x 18 inch
steel rod (also supplied in the installation kit) through the
holes in the sensor tube. Rotate the sensor tube until the
rod is centered on the pipe. Ensure the flow label “Arrow”
on the sensor matches the liquid flow direction. Tighten
the positioning collar Allen screws to lock the sensor
tube assembly in position. Note: As a backup to the flow
direction arrow label on the tube assembly, there is a
smaller hole located beside one of the sighting holes in
the tube, to also indicate the upstream side of the tube
assembly.
If the Pipe is Depressurized and Drained
1. Drill or cut a 1-7/8 inch hole in the pipe with a drill
or hole saw. Note the pipe wall thickness for use in
calculating sensor assembly depth. A location on the
top of the pipe is best for overall performance and
service life; however, any radial location on the top
half of the pipe is acceptable. Allow a minimum of ten
pipe diameters upstream and five downstream from
the sensor of straight unobstructed pipe to allow full
development of the flow profile.
2. Install either a service saddle or welded pipe fitting (2
inch female NPT) on the outside diameter of the pipe
over the 1-7/8 inch hole.
3. Install the Badger Meter isolation valve and nipple
onto the fitting using pipe thread sealant or Teflon®
tape on all threads.
4. Install the Badger Meter hex mounting adapter onto
the valve assembly. Use pipe thread sealant on the
adapter. Tighten the hex adapter so that no stud is
aligned with the center-line of the pipe. This could
interfere with final sensor alignment. Measure depth
and set the height of the nuts of the hex mounting
adapter.
5. Open the bleed petcock valve on the hex adapter to
relieve the pressure as the sensor tube is installed.
Carefully hand insert the Badger Meter hot tap flow
sensor tube into the hex mounting adapter. The
sleeve should be inserted past the top two O-rings in
the adapter (approx. 1 to 1-1/4 inches).
Take care not
to push the tube in too far as the impeller could be
damaged if it strikes the closed valve.
6. Even if the sensor is installed with system drained,
Badger Meter recommends that a HTT, hot tap
insertion/removal tool be purchased for future
service. This tools allows the sensor tube assembly to
be removed from the pipe line without draining the
entire loop where the sensor is mounted.
7. In a fully depressurized and drained pipe, the sensor
tube assembly may be installed by hand.
Carefully
and very slowly
open the isolation valve to relieve
any pressure that may have built up. Fully open the
isolation valve. Push the sensor tube into the pipe
with a slight twisting motion. Guide the sensor
collar holes over the three hex adapter studs until
the collar rests on the nuts. Hex nuts should have
been previously set to the correct height. Install the
three lock nuts onto these studs at the top of the
positioning collar and securely tighten.
8. Loosen the two set screws in the positioning collar
with a 3/32 inch Allen wrench. Align the sensor
sight holes along the pipe axis using the alignment
rod provided in the installation kit supplied with
the sensor. Ensure that the flow label arrow on the
sensor matches the liquid flow direction inside the
pipe. Tighten the positioning collar set screws. Note:
As a backup to the flow label arrow, there is a small
hole located beside one of the sighting holes to also
indicate the upstream side of the sensor.
INSTALLATION INTO A
PRESSURIZED PIPELINE USING
MODEL HTT
For information on installing hot tap sensor with older
225H consult technical bulletin DID-001.
For pipe sizes 2½” and above; all Badger Meter sensors
are inserted 1 1/2” from the inside wall of the pipe. The
insertion depth is controlled by the position of the hex
nuts on the three threaded rods. The formula below
defines the distance between the top of the sensor hex
mounting adaptor and the bottom of the positioning
collar (the top of the hex nut). Reference Figure 3.
D = 16 3/8” - ( H + Pipe Wall Thi 1.5 “ )
Example: If sensor is installed in a 8 inch Sch 80 pipe with
a pipe wall thickness of 1/2 inch and the “H” dimension is
10 inches then the calculation would be as below:
D = 16 3/8 - ( 10 0.5 1.5 inches)
D = 4 3/8”
BLEED VALVE
HEX NUT
JAM NUT
Figure 3:
Page 5
August 2012
