Product Overview
The high-flow Industrial Oval Gear meter is a 1 in. body built for throughput — the same 1 in. port carries roughly 2.5 times the flow of the standard 1 in. meter, to about 45 gpm (170 l/min), so a fast line keeps a smaller, lower-cost connection instead of stepping up to a 1-1/2 or 2 in. meter. It is the same positive-displacement measurement as the rest of the line — paired oval rotors sweep a fixed volume per revolution, ±0.5% of reading on fluids above 5 cP with ±0.03% repeatability and no sensitivity to viscosity — and it is offered in 316L stainless, aluminum or PVDF so the throughput comes with the right corrosion and pressure rating (3,000 psi stainless, 2,000 psi aluminum, 230 psi PVDF). It reads in any orientation with no straight run and accepts the full ILR, ER-420, ER-500 and F-series register set with intrinsically safe sensors for classified areas.
Other Industrial Oval Gear bodies & registers
Stainless 316L Oval Gear — widest compatibility, to 3,000 psi, full size range
Aluminum Oval Gear — lighter, lower-cost body for petroleum & fuel
PVDF (Kynar) Oval Gear — all-plastic body for aggressive chemicals
ILR Registers & Sensors — local display, pulse & 4–20 mA
F-Series Registers — HART 7.0, RS-485 & batch control
Key Features & Benefits
- More flow from the same 1 in. port — a widened metering chamber lets a 1 in. connection carry to 45 gpm, so a faster line keeps the smaller, lower-cost port rather than moving to a larger meter and fitting set
- Choose the body for the fluid — offered in 316L stainless, aluminum or PVDF, so the high-flow throughput comes with the corrosion and pressure rating the service needs
- Reading holds as the fluid thickens or thins — volume is measured directly, so accuracy does not drift with viscosity as fluids heat or cool
- Lower pressure drop than a smaller port run hard — sizing the high-flow body instead of running a standard 1 in. at the top of its band keeps the permanent pressure loss down
- Same registers and sensors as the line — it accepts the full ILR, ER and F-series register set and the intrinsically safe sensors, so the electronics match the rest of the plant
- Fast batch and dispense — ±0.03% repeatability at high throughput makes it a strong fast-fill batch and dispense meter
Specifications
- Measurement principle
- Positive displacement — paired oval rotors mesh in the metering chamber and sweep a fixed volume of fluid per revolution; magnets on the rotor ends trip a sensor in the register, so the rotation count is a true volume measurement
- Service / fluids
- Fast batching and dispensing of oils, fuels, chemicals and additives at flows that overrun the standard 1 in. meter — the high-flow body of the line, in a corrosion grade matched to the fluid
- Accuracy
- ±0.5% of reading on fluids above 5 cP (stainless and aluminum bodies); ±1.5% on the PVDF body
- Repeatability
- ±0.03%
- Flow range
- 1.5 to 45 US GPM (5.7 to 170 l/min) in stainless and aluminum; 1.5 to 31 US GPM (5.7 to 120 l/min) in PVDF (all at viscosities above 5 cP)
- Sizes
- 1 in. high-flow (HF) port
- Viscosity
- To 1,000 mPas with standard rotors; to 500,000 mPas with the high-viscosity (HV) modified rotors
- Body material
- 316L stainless, 6061 aluminum or Kynar (PVDF), to suit the fluid
- Rotor materials
- 316L stainless or Ryton (PPS), selected to the fluid; high-viscosity (HV) modified rotors are the order option for heavy fluids
- Spindle / bearings
- 316L stainless spindle (Hastelloy-C on the PVDF body); graphite bearings
- O-rings / seals
- Viton, Aflas, Kalrez or EPDM o-rings, matched to the fluid
- Process / fluid temperature
- Stainless and aluminum −22 to 240°F (−30 to 120°C); PVDF 14 to 140°F (−10 to 60°C); PPS plastic rotors are rated to 176°F (80°C)
- Pressure rating
- Stainless 3,000 psi (210 bar), aluminum 2,000 psi (140 bar), PVDF 230 psi (16 bar), NPT / BSP; flanged ports derate. Higher ratings on request
- Process connections
- NPT, BSP, ANSI 150# / 300# flange, DIN flange and (on the stainless body) sanitary Tri-Clamp on the metal bodies; NPT / BSP on PVDF
- Registers / outputs
- Meter-mounted ILR-700 / 701 / 750 local display (pulse and 4–20 mA on the 750), the ER-420 4–20 mA counter, the ER-500 flow monitor, or the advanced F-series; NAMUR / PNP / NPN / reed / Hall sensor boards for raw pulse
- Hazardous-area sensors
- Intrinsically safe NPN / PNP open-collector and NAMUR sensors — Class I, II and III, Division 1 (Groups A–G) in the USA (Class I, Division 1, Groups A–D in Canada), with ATEX and IECEx Ex ia IIC approvals
- Options
- High-viscosity (HV) rotors; 5-point calibration report; 9-point linearization at the register (ILR-701 / ILR-750); EN 10204 3.1 material certificate (metal bodies); silicone-free build; meter serialization
- Certifications / documentation
- Certificate of Conformance; NIST-traceable calibration certificate; EN 10204 3.1 material certificate for pressurized parts (aluminum or stainless housings)
- Calibration
- Factory-calibrated and field-recalibratable through the electronic register; 5-point calibration report available as a documented option to be specified at time of order
Common Applications
- Fast bulk dispensing and batching of oils, fuels and additives where the standard 1 in. meter runs out of flow
- High-throughput chemical and additive transfer on blending skids
- Tanker and IBC fill metering
- Lube and fuel transfer at higher flow rates
- Bulk coolant and process-fluid totalizing
Design & Selection Considerations
- Chemistry and pressure set the body — the body alloy is the first decision and it is fluid-driven: 316L stainless is the industrial workhorse, the highest-pressure body with the widest fluid compatibility; 6061 aluminum is the lighter, lower-cost body for petroleum, lubricants and fuel where the fluid is aluminum-compatible; and Kynar (PVDF) is the all-plastic body (Hastelloy-C spindle) for acids, caustics and solvents that attack metal. Pressure capability follows the body alloy, and it also falls as the size grows and as you move from threaded to flanged ports, so the alloy and the connection are decided together. Use the input form to give us the fluid and the working pressure together and we’ll set the body and the connection.
- Viscosity sets the rotor; chemistry sets the wetted stack — standard rotors handle fluids to 1,000 mPas; for greases, heavy oils, polymers and adhesives the high-viscosity (HV) modified rotors run to 500,000 mPas — an order option on the same body, not a separate model. Within the meter the rotor and o-ring materials are matched to the fluid, so the whole wetted path is spec’d to service. Use the input form to tell us the fluid and its viscosity at operating temperature and we’ll specify standard or HV rotors with the right seals.
- It is a positive-displacement meter — no straight run, any orientation — because the measurement is mechanical displacement rather than velocity, the meter needs no upstream straight pipe run or flow conditioning, reads true in any orientation and in tight pipework, and is unaffected by viscosity shifts and pulsating flow. That is the opposite of a turbine or paddlewheel, whose reading moves with the flow profile. It is the meter for accurate batching and totalizing where a velocity meter would need pipe it does not have.
- Keep the fluid reasonably clean — the oval rotors mesh on close tolerances, so abrasive grit and hard particulate are the wear enemy — a strainer ahead of the meter protects the gears on debris-prone fluids, and the meter is not the right choice for abrasive slurries. Use the input form to tell us the fluid’s cleanliness and we’ll advise on upstream filtration.
- Size to the flow, not the pipe — each port size covers its own flow band, with a dedicated low-flow body at the bottom of the range and a high-flow body at the top, and the meter reads its tightest accuracy class in the larger sizes on fluids above 5 cP — so the right size is the one that runs mid-band at your normal flow, not the one that matches the line. Use the input form to send the normal and maximum flow and we’ll pick the size that reads mid-band at your pressure.
- Pick the register for what the reading has to do — the meter mounts a register or sensor on top, and the choice follows the host: a local display at the meter (ILR family), a remote analog counter (ER-420), a monitor with alarms and a fieldbus (ER-500), or the advanced F-series for HART, RS-485 or batch control — with intrinsically safe sensors where the area is classified. Use the input form to tell us the output, protocol, power and area classification and we’ll configure the register into the part number.
To size & select the right High-Flow oval-gear meter:
Use the input form to send your fluid, its viscosity at operating temperature, the normal and maximum flow, the line size and the working pressure — with any corrosion or hazardous-area requirement — and we’ll spec the body alloy, rotors, seals, connection and the ILR, ER or F-series register for your application.
Flow Meter Application Sheet ›Talk to an engineer directly — Scott Prater, Principal · 917-580-0878 · scott@pratertechnical.com
Specifications compiled by Prater Technical Partners from Badger Meter Industrial Oval Gear positive-displacement meter product literature.