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IP800-Series
ISO
FLOW SENSOR
INSTRUCTIONS
• IP810
• IP820
IP800-SERIES FLOW SENSOR INSTRUCTIONS
9001:2008
CERTIFIED COMPANY
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TABLE OF CONTENTS
General Information
Features, Specications .....................................................................................................................................Page 3
Installation
Insertion Depth, Distorted Flows, Fitting Installation, Meter Installation, Positioning the Meter...................Page 4
Straight Pipe Recommendations .......................................................................................................................
Full Pipe Recommendations .............................................................................................................................. Page 6
Connection Diagrams
FT415/FT420/AO55, Connecting to PLC's........................................................................................................ Page 7
Operation
Minimum Flow, Flow Range Table, Calibration (“K-Factor”), Field Calibration................................................Page 8
Maintenance
Rotor Replacement, Signal Troubleshooting, Sensor Replacement ............................................................... Page 9
Parts Explosion
Parts List .............................................................................................................................................................Page 10
Troubleshooting
Problems, Probable Causes, To Check, To Repair ............................................................................................Page 11
TABLES AND DIAGRAMS
Page 5
Specifications, Features ........................................................................................Page 3
Distorted Flows, Positioning the Meter ..................................................................Page 4
Straight Pipe Recommendations ...............................................................................
Full Pipe Recommendations ...................................................................................Page 6
Connections Diagrams ...........................................................................................Page 7
Flow Range Table, K-Factor Number on Tee Fitting, K-Factor Chart, Pressure vs. Temp Chart...................Page 8
Rotor and Sensor Replacement .............................................................................Page 9
Parts Explosion, Parts List ........................................................................................................................Page 10
Troubleshooting............................................................................................................................................Page 11
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GENERAL INFORMATION
The IP800-Series are impeller (or “paddlewheel”) insertion me-
ters designed for use with a wide variety of liquids in pipe sizes
1/2" to 8". Sensors are available in brass, 316 stainless steel,
PVC, and polypropylene. Bodies are machined from a solid rod
for maximum precision. High-quality jewel bearings and nickelbound tungsten carbide shafts are used for extreme low friction
and long life. Low-ow performance is good, although other
Seametrics ow meters are recommended where extremely low
ows are being measured.
The rotation of the rotor is detected by a non-drag Hall-effect
sensor. Output is a current-sinking pulse (square wave), which
can be sent long distances (up to 2,000 feet) without a transmitter. This signal can be connected directly to PLC's, counters,
and computer cards, as well as a variety of Seametrics controls
and displays.
FEATURES
Cover or Optional Module
Housing Screw
(connect ground to one)
Cable-Seal Strain Relief
Lower Housing (optional)
Seametrics IP meters are ideal for chemical proportioning applications. If no display is required, a simple divider such as
the PD10 provides adjustable pump pacing. For rate and total
display, the FT415 (battery powered) or FT420 (loop powered)
ow indicator can be mounted directly on the IP800-Series
meter, or remotely on a wall or panel. The AO55 blind analog
transmitter can be used to convert to a 4-20 mA output. IP
meters are also compatible with the DL76 data logger and
FT520 batch processor.
The IP800-Series require special ttings that ensure correct
depth placement in the pipe. Fittings come in a variety of materials for compatibility with specic applications. Tee ttings
are individually wet-calibrated at the factory and marked with
the K-factor (pulses per gallon). Saddle ttings must be eldinstalled on the pipe and do not come wet-calibrated. K-factors
for saddles are based on factory-testing.
Caution: Clip(s)
must be installed
before use.
High Pressure Model
Retaining Slot (for U-Clip)
For easy installation at correct depth setting
O-Ring
Jewel Bearings for superior low-ow performance
Rotor
SPECIFICATIONS*
Power Source Standard Micropowered (-04 Option)
Supply Voltage/Current 6-40 Vdc/< 2 mA 3.5-16 Vdc/60 μA @ 3.5 Vdc
Sensor Hall Effect sensor, 12 Vdc current sinking pulse
Materials Sensor Body
Rotor PVDF (Kynar)
Shaft Nickel-bound tungsten carbide (zirconia ceramic optional)
Bearings Ruby jewel
O-Ring
Rotor Pickup
Maximum
Pressure
High Pres-
sure
Temperature
Flow Range
Accuracy +/- 1.5% of full scale
Signal Hall effect current sinking pulse
Power 6-24 Vdc, 2 mA
Maximum Current
Cable #22 AWG 3-con, 18’ (6m); 2,000’ (650m) maximum cable run
Regulatory
*Specications subject to change • Please consult our website for current data (www.seametrics.com).
Brass, 316 Stainless Steel, PVC, or Polypro
EPDM (Viton optional)
GMR (Giant Magnetoresistive) Sensor
Brass 316 Stainless Steel
200 PSI (14 bar) 200 PSI (14 bar) 175 PSI (12 bar) @ 75˚ F
Not Available 400 psi (28 bar) Not Available
200˚ F (93˚ C) 200˚ F (93˚ C) 130˚ F (55˚ C)
0.3 - 30 ft./sec
20 mA
Mark (Standard Power Only)
PVC or Polypro
(See Pressure vs. Temp. Chart)
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INSTALLATION
Insertion Depth. The IP800-Series are xed-depth meters
that must be used with matched ttings appropriate to the
application and pipe size. This ensures that the ow sensor
is installed at the correct insertion depth to measure the average ow velocity of the stream.
Straight Pipe. Straight pipe of at least 10 diameters upstream and ve diameters downstream of the meter is
strongly recommended for proper accuracy. This is necessary because the shape of the velocity prole changes as the
rate increases around an elbow; placing the meter too near
the elbow causes a distorted reading. Additional straight run
may be needed under specic adverse circumstances (see
next page).
If you can’t provide enough straight run to smooth out the
velocity prole, some decrease in accuracy may result. This
does not mean the meter’s reading is meaningless, however.
In some applications (e.g., control system, valve operation)
a repeatable reading may be more important than a highly
accurate one.
POSITIONING THE METER
Okay, if no air in pipe
BEST
Okay, if no sediment in pipe.
DISTORTED FLOWS
Faster Flow
Distorted
Flow Prole
Fitting Installation. Stainless steel and brass ttings have
female pipe threads, requiring the appropriate male threaded ttings. Saddle ttings require a hole to be cut in the
pipe (recommended hole size is 1-3/4”). Before cutting into
the pipe, observe the drawing below to choose your meter
orientation.
Causes Meter
To Read High
FLOW
10X
Diameter Minimum
(See Below)
5X
Diameter Minimum
(See Below)
PVC Fittings. A PVC tting is usually installed by solvent
welding. PVC tees are supplied with some upstream straight
pipe, less than the recommended straight pipe requirements. It is not advisable to connect directly to the end of
these ttings with a ow disturbing device (valve, elbow), but
rather add straight pipe to the end of these ttings to meet
the straight pipe requirements for your application.
Meter Installation. After the meter tting is installed in the
pipeline, the meter can be installed in the tting. Press the
meter into the tting as far as it will go. Retain the meter in
place by inserting the u-pin. The pin can be installed from
either side. It may be necessary to rotate the probe back
and forth slightly to start the pin into the slots on the probe.
Slide the pin in as far as it will go.
Caution: Never remove the u-clip retainer when
the pipe is under pressure. Always remove
pressure from the pipe before you attempt to
remove the meter. Removal under pressure
may result in damage or serious injury.
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INSTALLATION
STRAIGHT PIPE RECOMMENDATIONS
(X = diameter)
Reduced Pipe
Two Elbows In Plane
Two Elbows, Out Of Plane
10X
20X
5X
IP800
5X10X
IP800
5X
Expanded Pipe
Spiral Flow
Propeller Meter
20X
IP800
5X
IP800
30X
IP800
50X
Swirling Flow
Partially Open
Buttery Valve
IP800
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INSTALLATION
FULL PIPE RECOMMENDATIONS
Possible Problem:
Allows air pockets to form at sensor
Better Installation:
Ensures full pipe
Possible Problem:
Post-valve cavitation can create air pocket
Possible Problem:
Air can be trapped
Caution: These ow sensors are not recommended for installation downstream of the boiler feedwater pump where installation fault may expose the
ow sensor to boiler pressure and temperature. Maximum recommended
temperature is 130°F (Plastic), 200°F (Metal).
Better Installation:
Keeps pipe full at sensor
Better Installation:
Allows air to bleed off
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CONNECTION DIAGRAMS
Input Designed for Current
Sinking (NPN) Devices
Input Designed for Current
Sourcing (PNP) Devices
All Seametric Controls (FT415/FT420/AO55)
(Except FT520)
Sensor
Red (+) 6-24 Vdc
(signal)
White
Black (-)
+
Input
s
-
Figure 1
PLC's and other non Seametric Controls
NPN
Device
2.2k Ohm Pull-up
Resistor
Red
White
Black
Red
White
Black
Figure 2
+
DC
Voltage
Signal
Ground
+
DC
Voltage
Signal
Ground
NPN
Device
Figure 3
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10031295
MF81T-P200
K: 53.6
OPERATION
60˚ 70˚ 80˚ 90˚ 100˚ 110˚ 120˚ 130˚ 140˚
P
Minimum Flow. As with any other ow sensor, there is a rate
below which the IP800-Series sensor cannot read. Check the
ow rate table below for the minimum ow rate detectable by
the sensor for a given pipe size.
Flow Range (Gallons per Minute)
½" ¾"
Min 0.28 0.5 0.8 1.9 3.1 6.9 12 27 46.8
Max 28 50 80 190 314 691 1190 2700 4680
1" 1½" 2" 3" 4" 6" 8"
Flow Range (Liters per Minute)
½" ¾"
Min
1.06 1.89 3.03 7.19 11.73 26.11 45.42 102.21 1 17.16
Max
105.99 189.27 302.83 719.22 1188.61 2615.72 4504.64 10220.61 17715.73
1" 1½" 2" 3" 4" 6" 8"
Calibration (“K-factor”). The K-factor represents the number
of pulses per gallon the meter produces during a ow test.
This number must be entered into your electronic control to
make it read properly. If the IP800-Series meter is ordered
with a tee tting, it is factory-calibrated in the tting and the
K-factor is indicated on the side (see below).
If a saddle or weld-type tting has been ordered, use the K-
factor calculator at the bottom of the www.seametrics.com
home page to determine the K-factor. In PVC, however, it is
possible to order a saddle pre-installed on a standard length
of pipe, and the tting can be wet-calibrated in this case.
Field Calibration. It is possible to eld-calibrate an IP800Series ow sensor to determine an accurate K-factor in the
actual installation. The reason for doing this would be to
compensate for an unusual condition, for instance, applications with higher viscosity uid (IP meters are calibrated for
water use) or which lack adequate straight pipe ahead of the
meter. Field Calibration procedures are described in a Technical Bulletin on our website (www.seametrics.com).
PRESSURE VS. TEMPERATURE (PVC/Polypro)
200
150
.S.I.
100
Find Your K-Factor Here
50
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MAINTENANCE
Caution: Never remove the u-clip retainer
when the pipe is under pressure. Always
remove pressure from the pipe before attempting to remove the meter. Removal
under pressure may result in damage or
serious injury.
Rotor Replacement. It is unusual for a rotor to require replacement due to damage sustained in normal service. More
commonly, the meter is dropped while it is out of the pipe.
Another reason for rotor replacement is shaft wear after long
service. Rotors are easily eld-replaced.
Sensor Replacement. It is very unusual for a sensor to require replacement in normal use. The primary cause of sensor
failure is overvoltage (inadvertent connection of high voltage,
for example) or incorrect polarity on hookup. The sensor is
replaced by removing the strain relief, then threading out
the sensor retainer plug. Remove the entire sensor capsule
by pulling on the cable. The new sensor capsule can then be
installed. Replace the retainer plug, and then replace and
tighten the strain relief.
Sensor Replacement
To install a rotor, follow these steps:
1. Unscrew the threaded bearing housings to expose
the shaft ends. If bearings are being replaced,
back them completely out.
2. Remove the rotor. Put the new rotor in its place.
3. Thread in one bearing housing part way, then the
other. Take care to start the end of the shaft into
the bearing hole before tightening further.
4. Screw in bearing housings until they bottom.
Note: Do not use excessive force.
5. Check for free spin. Blowing lightly on the rotor
should result in it spinning rapidly and coasting to a
smooth stop.
1) Loosen and unthread
Strain Relief
2) Remove Sensor Retainer
Plug by inserting a
screwdriver blade into
one side of the slot and
turning
3) Remove the Sensor
Capsule by pulling on
the cable
4) Reverse the process
to replace
Signal Troubleshooting. The ow sensor has only one moving part, the rotor. If this is turning properly and there is no
signal, the magnetic sensor is not operating properly. To check
the signal, apply 12 Vdc power to the red (+) and black (-)
leads. Set a multimeter to voltage reading. Put the positive
multimeter lead on the red wire and the negative lead on the
white wire. Slowly turn the rotor. Voltage reading should swing
between -12 Volts and 0 Volts as the rotor turns. If it does
not, the solid-state magnetic sensor is not working properly.
Checking for continuity is not a useful test of these sensors.
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PARTS EXPLOSION
OPTIONAL
4
1
7
2
7
11
15
16
12
10
8
9
13
3
5
6
14
IP800-Series Parts List
1
MODEL
SERIAL
Upper Housing
2
Gasket
3
Lower Housing
4
Housing Screw Assembly
HPS
5
6
Plug, Steel
Plug, Plastic
100662
100411
100502
100414
100360
100364
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MODEL
SERIAL
7
Strain Relief
8
Sensor Retainer
9
Sensor, Low Power
10
Body
11
O-Ring, EPDM
12
Bearing Assembly (Qty 2 Included)
Rotor (Nickel/Carbide Shaft)
13
Rotor (Ceramic Shaft)
Rotor Repair Kit (Kynar/Carbide)
14
Rotor Repair Kit (Kynar/Ceramic
15
Standard Fitting
16
High Pressure Fitting
101850
100298
100419
*
100264
103315
100035
100036
100317
100043
*
*
* Consult distributor
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TROUBLESHOOTING
Problem
No signal
after installation
Inaccurate
metering
Probable Cause Try...
Insufcient ow
Bad connections to control electronics
Incompatible control
Damaged or missing rotor
Failed magnetic sensor
Not enough straight pipe between meter and
severe ow disturbance
Wrong K-Factor entered
Consult Flow Range Chart
Reduce pipe size or use different
sensor
Check connections at control;
Red (+), Black (-), White (signal)
Use 6-24 Vdc power supply
Add pull up resistor, if using currentsourcing device
Remove ow sensor from tting and check
for free spinning; replace rotor
See signal troubleshooting; replace
magnetic sensor
Move meter away from ow disturbance, or
eld-calibrate
Check tting for K-Factor, check indicator to
see if it is entered properly ("Set K" on
FT420, FT415, FT520)
Magnetic sensor failing to pick up each blade
Wrong time units on ow indicator
Remove ow sensor from pipe. If indicator
is FT415, FT420, FT520, set K to 1.00,
turn rotor slowly by hand, indicator should
count each blade; replace sensor
If using FT415 or FT420, check left side of
display (sec, min, hr, day); change to
desired unit
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Seametrics Incorporated • 19026 72nd Avenue South • Kent, Washington 98032 • USA
(P) 253.872.0284 • (F) 253.872.0285 • 1.800.975.8153 • www.seametrics.com
LT-65200040-043015
4/30/2015
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