EX100
ISO
/
200-Series
INSERTION MAGNETIC
FLOW METER INSTRUCTIONS
EX100/200-SERIES INSERTION MAGNETIC FLOW METER INSTRUCTIONS
EX101
EX201
EX115
EX215
9 001:2008
CERTIFIED COMPANY
TABLE OF CONTENTS
General Information
General Information, Features, Specications .................................................................................................Page 1
Installation
Piping, Distorted Flows, Immersion, Positioning the Meter ............................................................................Page 2
Fitting Installation, Meter Installation ............................................................................................................... Page 3
Proper Depth Setting ......................................................................................................................................... Page 4
Dimension “C”, Pipe Wall Thickness ................................................................................................................. Page 5
Straight Pipe Recommendations ...................................................................................................................... Page 6
Full Pipe Recommendations ..............................................................................................................................Page 7
Electrical Connections
General Electrical Guidelines, Power, Forward (and Reverse) Flow Output,
Grounding Guidelines, Grounding Diagram......................................................................................................Page 8
Connections Diagrams
Counter or PLC, A055 4-20 mA Output, FT520 Controller .............................................................................. Page 9
FT420 Display and Proportional Feed, FT420 & 4-20 mA Output, Dual FT420 Displays ............................. Page 10
DL76 Data Logger, FT420/DL76 ....................................................................................................................... Page 11
Operation & Maintenance
Zero Adjustment, Minimum Flow, Presence of Flow Indication, Filtering,
Electrode Coating, Calibration (“K-Factor”), Flow Rates in Gallons Per Minute ............................................. Page 12
Troubleshooting
Problems, Probable Causes and Things to Try ................................................................................................. Page 13
TABLES, DIAGRAMS & CHARTS
Features .............................................................................................................................................................. Page 1
Distorted Flows, Positioning the Meter ............................................................................................................. Page 2
Meter Installation, Sensor Removal .................................................................................................................. Page 3
Proper Depth Setting ......................................................................................................................................... Page 4
Dimension “C”, Pipe Wall Thickness ................................................................................................................. Page 5
Straight Pipe Recommendations ...................................................................................................................... Page 6
Full Pipe Recommendations ..............................................................................................................................Page 7
Grounding Diagram ............................................................................................................................................ Page 8
Connection Diagrams: Counter or PLC, A055 4-20 mA Output, FT520 Controller ........................................ Page 9
Connection Diagrams: FT420 Display and Proportional Feed, FT420 & 4-20 mA Output,
Dual FT420 Displays .......................................................................................................................................... Page 10
Connection Diagrams: DL76 Data Logger, FT420/DL76 ................................................................................ Page 11
Zero Adjustment, Flow Rates in Gallons Per Minute ........................................................................................ Page 12
Troubleshooting Problems, Probable Causes and Things to Try ..................................................................... Page 13
GENERAL INFORMATION, FEATURES and SPECIFICATIONS
The complete lack of moving parts of the EX100/200-Series insertion
ow sensor is the source of its reliability. Brass and stainless steel
models withstand a variety of temperature, pressure, and chemical
conditions. The EX-Series has no rotor to stop turning in dirty water
and there are no bearings to wear out.
A rapidly reversing magnetic eld is produced in the lower housing.
As the uid moves through this eld, a voltage is generated that is
measured and translated into a frequency signal proportional to ow
rate. This square wave signal can be sent directly to a PLC or other
control or can be converted using any of the Seametrics family of
indicators and converters.
A modular system of electronics can be attached directly to the ow
FEATURES
Cable Strain Relief
Lower Housing
Brass or 316 Stainless Shaft
Compression Nut
Adapter mates with
1 1/2” FNPT threaded tting
Sensor Housing
Electrodes and Cap
sensor or remotely mounted. The Seametrics FT420 provides full
indication of rate and total, plus 4-20 mA output. The AO55 provides
blind 4-20 mA output, and the DL76 is a battery-powered data
logger.
The adapter of the EX mates with a standard female NPT tting,
and can be directly threaded into ordinary saddles or threaded weld
ttings. The EX115 and 215 include an isolation valve, allowing hot-tap
installation, or installation and removal under pressure; a bronze ball
valve is standard, with a 316 stainless steel valve option if needed.
Reverse ow output and immersibility are optional.
Housing Screw (connect ground to one)
Cover or Electronics Module
EX101/201
EX115/215
Valve assembly for
hot tap installation
SPECIFICATIONS*
Pipe Sizes
Materials Shaft/Fitting
Electrodes
Electrode Cap
Housing
Valve Assembly
(115/215 Only)
O-Ring
(115/215 Only)
Power Full Power
Low Power
Flow Range
Fitting Size Required
Temperature Ambient
Fluid
Pressure
Minimum Conductivity
Calibration Accuracy
Output
Empty Pipe Detection
*Specications subject to change • Please consult our website for current data (www.seametrics.com).
3” to 48” (up to 72” optional)
316 SS or Brass
Hastelloy
PVDF
Cast powder-coated aluminum
Bronze (stainless optional) with bronze ball valve
EPDM
12-25 Vdc, 250 mA
12-25 Vdc, 40 mA average with 250 mA peaks
0.28 to 20 ft/sec (0.08 - 6.09 m/sec)
EX101/201 EX115/215
1-1/2” FNPT 2” FNPT
0˚ to 160˚ F (-17˚ to 72˚ C)
32˚ to 200˚ F (0˚ to 93˚ C)
200 psi (13.8 bar)
20 microSiemens/cm
+/- 1% of full scale
Square wave pulse, opto isolated, 550 Hz @ 20 ft/sec
6 mA max, 30 Vdc forward ow standard; reverse ow optional
Software, defaults to zero ow
Page 1
INSTALLATION
Piping. For best results, the EX sensor should be in-
stalled with at least ten diameters of straight pipe
upstream and ve downstream. Certain extreme situations
such as partially-opened valves are particularly difcult and
may require more straight diameters upstream (see page 6
for straight pipe recommendations).
DISTORTED FLOWS
Faster Flow
Causes Meter
Distorted
Flow Prole
To Read High
FLOW
10X
5X
POSITIONING THE METER
Fair
(Unacceptable position
if air is present)
Best
Position
Fair
(Unacceptable position if uid
contains sediment)
Immersion. The 100/200-Series sensors are not designed
for underwater operation. Even occasional immersion can
cause damage. If occasional immersion, such as when a
vault oods, then the -40 option, (immersion) is recomended.
Chemical Injection or Fertigation. When any magmeter, by
any manufacturer, is used in a chemical injection application (including fertigation), the chemical line must be placed
downstream of the magmeter OR far enough upstream for
complete mixing to occur before the uid reaches the meter.
When unmixed chemical or fertilizer alternates with water
passing through the meter, the rapid changes in conductivity
may cause sudden spikes and drops in the meter’s reading,
resulting in inaccurate measurement. The magmeter will
restabilize, however, with a steady ow of uid of uniform
conductivity.
Caution: In chemical injection or fertigation applications, install chemical line
downstream of magmeter, or far enough
upstream to allow complete mixing of
uids before the meter.
Vertical ow in upward direction is the preferred installation
orientation, since it improves low-ow performance and avoids
problems with trapped air and sediment. Bottom, top, and
vertical pipe installations are all acceptable if required by
the piping layout.
Caution: These ow sensors are not rec-
ommended for installation downstream
of a boiler feedwater pump where instal-
lation fault may expose the ow sensor
to boiler pressure and temperature. Maximum
recommended temperature is 200°F.
Page 2
INSTALLATION
EX101/201 INSTALLATION
Fitting Installation. EX101/201adapters mate with a 1-1/2” female
NPT pipe thread adapter tting. Any tting that provides the matching
NPT female thread may be used. Installation procedure compensates
for tting height differences. Cut a minimum 1-3/4” hole in the pipe. If
possible, measure the wall thickness and write it down for use in depth
setting. Then install the threaded tting (saddle, weldolet, etc.) on the
pipe.
Meter Installation. Loosen the compression nut so that the adapter
slides freely. Pull the meter fully upward and nger-tighten the compression nut. Using a thread sealant, install the adapter in the pipe tting.
Do not overtighten. Now loosen the compression nut, lower the meter
to the appropriate depth setting (see diagram and instructions that fol-
low). Be sure ow is in the direction of the arrow on the housing. Tighten
compression nut fully.
Compression nut
Adapter mates
with
FNPT
threads
EX115/215 INSTALLATION
‘Hot tap’ EX meters are designed so they can be installed and serviced
without depressurizing the pipe.
Fitting Installation. The EX115 and 215 adapters mate with a 2” FNPT
threaded tting for compatibility with the 2” isolation valve. Any tting
that provides matching NPT female thread may be used. The installation
procedure compensates for differences in tting height.
If initial installation is performed on an unpressurized pipe, cut a
minimum 1-3/4” hole in the pipe. If possible, measure the wall thickness
and write it down for use in depth setting. Then install the threaded tting
(saddle, weldolet, etc.) on the pipe.
If it is necessary to do the initial installation under pressure, any standard
hot tap drilling machine with 2” NPT adapter, such as a Transmate or a
Mueller, can be used. Ordinarily, it is not necessary to use an installation
tool, due to the small diameter tube the meter can be installed by hand
at all but the highest pressures.
Compression nut
Locking collar
2” adapter removes
to mount hot-tap
machine
Full-port 2” ball
valve allows sensor
removal
Mates with 2”
FNPT threads
Meter Installation. Remove the sensor unit from the valve assembly.
Using a thread sealant, install the valve assembly on the pipe tting. If
the initial installation is a pressure (“hot”) tap, remove the 1-1/2” x 2”
adapter bushing at the back of the valve. Thread the tapping machine
on, open the valve, and tap using a minimum of 1-3/4” or maximum
1-7/8” cutter. After retracting the machine and closing the valve, reinstall
the ow sensor. When the sensor is secure, open the valve and adjust
depth setting (see diagram and instructions that follow). Be sure ow is
in the direction of the arrow on the housing. Tighten locking collar and
compression nut fully.
EX115/215 Sensor
Removal
Page 3
INSTALLATION
"D"
PROPER DEPTH SETTING
Caution! Never attempt to remove a ow
sensor when there is pressure in the pipe
unless it is specically designed for hot
tap installation and removal. Loosen the
compression nut slowly to release any trapped pres-
sure. If uid sprays out when removing the sensor,
stop turning and depressurize the pipe. Failure to
do so could result in the sensor being thrown from
the pipe, resulting in damage or serious injury.
Depth Setting. It is important for accuracy that the sensor
be inserted to the correct depth into the pipe.
1. In Table 1, nd Dimension C for your sensor model
and pipe size. Subtract wall thickness of your pipe
(Table 2) to nd Dimension D.
NOTE: When you calculate your K-factor as described
on page 12, Dimension D will be given also.
2. Measuring from the outside of the pipe to the joint in
the housing, as shown in the diagram, adjust the
sensor to Dimension D and hand-tighten compression
nut.
3. Align the conduit housing with the centerline of the
pipe, as shown. Be sure the arrow on the housing
points in the direction of ow.
strain
relief
4. Check Dimension D one more time.
FLOW
Page 4
5. Tighten the compression nut fully.
INSTALLATION
TABLE 1: DIMENSION “C”
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36”
EX101
EX201
EX115
EX215
10.04 9.93 9.69 9.46 9.22 8.99 8.75 8.52 8.28 8.05 7.58 6.87 6.17
15.04 14.93 14.69 14.46 14.22 13.99 13.75 13.52 13.28 13.05 12.58 11.87 11.17
17.04 16.93 16.69 16.46 16.22 15.99 15.75 15.52 15.28 15.05 14.58 13.87 13.17
21.04 20.93 20.69 20.46 20.22 19.99 19.75 19.52 19.28 19.05 18.58 17.87 17.17
TABLE 2: PIPE WALL THICKNESS
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36”
PVC/Steel
Sch. 40
PVC/Steel
Sch. 80
Stainless
Steel (10S)
0.216 0.237 0.280 0.322 0.365 0.406 0.438 0.500 0.562 0.593 0.687
0.300 0.337 0.432 0.500 0.593 0.687 0.750 0.843 0.937 1.031 1.218
0.120 0.120 0.134 0.148 0.165 0.180 0.188 0.188 0.188 0.218 0.250 0.312 0.312
Stainless
Steel (40S)
Copper Tubing
(Type L)
Copper Tubing
(Type K)
Brass Pipe
Duct. Iron
(Class 52)
0.216 0.237 0.280 0.322 0.365 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375
0.090 0.110 0.140 0.200 0.250 0.280
0.109 0.134 0.192 0.271 0.338 0.405
0.219 0.250 0.250 0.312 0.365 0.375
0.280 0.290 0.310 0.330 0.350 0.370 0.390 0.400 0.410 0.420 0.440 0.470 0.530
Page 5
INSTALLATION
STRAIGHT PIPE RECOMMENDATIONS
(X = diameter)
Reduced Pipe
Two Elbows In Plane
Two Elbows, Out Of Plane
10X
20X
5X
5X10X
5X
Page 6
Expanded Pipe
Spiral Flow
Swirling Flow
Propeller Meter
Partially Open
Buttery Valve
20X
5X
30X
50X
INSTALLATION
FULL PIPE RECOMMENDATIONS
Allows air pockets to form at sensor
Better InstallationPossible Problem
Ensures full pipe
Better InstallationPossible Problem
Post-valve cavitation can create air pocket Keeps pipe full at sensor
Better InstallationPossible Problem
Air can be trapped
Allows air to bleed off
Caution: These ow sensors are not recommended for installation down-
stream of a boiler feedwater pump where installation fault may expose the
ow sensor to boiler pressure and temperature. Maximum recommended
temperature is 200°F.
Page 7
ELECTRICAL CONNECTIONS
General Electrical Guidelines:
• Whenever possible avoid running control cables in
the same conduit with or bundled with AC power.
• Using shielded cable, be sure to connect shield to
ground at power supply end of the cable. Do not
connect other end of shield.
• Avoid routing ow sensor cables in close proximity to
a variable frequency drive.
• Recommended power and output wiring is shielded
twisted pair 18-22 AWG control cable.
• Recommended voltage is 12-24 Vdc. Note that
unregulated power supplies can vary from nameplate
voltage by a considerable amount, especially with AC
line voltage uctuation. Therefore 24V power supplies
must be regulated.
See the Connections diagrams on the following pages for the
appropriate terminals.
Grounding Guidelines:
For best results, use a good quality earth ground, such as
metallic water piping or a driven ground, to ensure a good
connection to earth ground and good noise suppression.
If the ow sensor is installed in metallic piping, for optimum
connection clamp wire to the piping a short distance to one
side of the ow sensor using an electrical grounding clamp.
Connect the wire to the earth ground and to one of the housing
screws.
For Non-Metallic Pipe: Connect one to the housing screws by
wire to a good earth ground, such as metalic water piping or a
rod driven into the ground.
EX meters are usually unaffected by moderate levels of electrical noise. In some applications performance may be improved
by taking the following steps:
• Use shielded twisted pair cable (Belden 8723 or
equivalent above ground or Alpha 35482 or
equivalent burial).
Power: A 12 - 24 Vdc power supply capable of at least 250
mA current output is needed.
Output: The standard output is pulses with ow in the forward
direction (Reverse ow output is optional [-15] ). Electrically
it is an open collector opto isolated switch. The output is not
internally powered.
Note: This output is limited to 6 mA at 30 Vdc maximum.
• Clamp a ferrite bead (Steward 28A2029-OAO or
equivalent) on meter signal/power wire within 3/4”
of the meter strain relief (tape or tie wrap in place if
necessary). See diagram below.
• IMPORTANT - Connect the cable shield ground
wire to ground, ONLY at power supply end of cable.
GROUNDING DIAGRAM
PLACE FERRITE BEAD HERE
Earth
Ground
Housing Screw
Page 8
Metallic Pipe
Grounding Clamp
CONNECTIONS DIAGRAMS
+
_
+
_
00
9
8
7
6
5
4
3
2
1
00
9
8
7
6
5
4
3
2
1
00
9
8
7
6
5
4
3
2
1
00
9
8
7
6
5
4
3
2
1
+
_
S
+
_
+
_
+
_
+
+
_
_
+
_
+
+
_
_
+
_
+
_
COUNTER OR PLC
AO55 4-20 mA OUTPUT
Power
Forward Output
Reverse Output
(Option-15 only)
Power
Forward Output
(open collector)
Reverse Output
(Option -15 only)
EX-SERIES
*See Dual FT420 Diagram for an
example of bidirectional connections.
24 Vdc Power
EX-SERIES
+
–
*See Dual FT420 Diagram for an
example of bidirectional connections.
12 - 24 Vdc
Max. 6 mA, 30 Vdc
Max. 6 mA 30 Vdc
Sensor
FREQUENCY
4-20 mA
COUNTER OR PLC DIGI-
TAL INPUT
24 Vdc Power
4-20 mA
AO55
FT520 CONTROLLER
Pulse
Out
*See Dual FT420 Diagram for an
example of bidirectional connections.
+12V
SEN1
SEN2
FT520
24 Vdc Power
EX-SERIES
Power
G
Forward Output
Reverse Output
+
(Option-15 only)
–
Page 9
CONNECTIONS DIAGRAMS
+
_
S
+
_
+
_
+
+
_
_
+
_
+
_
+
_
FT420 DISPLAY AND PROPORTIONAL FEED
Power
Forward Output
Reverse Output
(Option-15 only)
EX-SERIES
*See Dual FT420 Diagram for an
example of bidirectional connections.
FT420 DISPLAY AND 4-20 mA OUTPUT
Power
Forward Output
Reverse Output
(Option-15 only)
*See Dual FT420 Diagram for an
example of bidirectional connections.
+
_
+
_
EX SERIES
24 Vdc Power
24 Vdc
+
Power
_
24 Vdc
Power
_
4-20 mA Device
(e.g. pump, PLC)
FT420
Sensor
Input
Power
4-20mA
_
Sensor
Input
+
S
Pulse
Scaled
Pulse
Pass-Thru
+
_
To
Proportional
Feed
Metering
Pump
FT420
Pulse
Scaled
_
+
+
+
_
+
Power
4-20mA
_
Pulse
Pass-Thru
DUAL FT420 DISPLAYS
(Example of Bidirectional Connection)
FT420
Power 4-20mA
Pulse
Pass-Thru
Page 10
Pulse
Scaled
Sensor
Input
24 Vdc
Power
Forward Output
Reverse Output
(Option-15 only)
EX-SERIES
Power
Sensor
Input
Power 4-20mA
FT420
Pulse
Scaled
Pulse
Pass-Thru
+
_
S
+
+
_
_
+
_
+
_
+
_
S
+
_
+
_
+
_
CONNECTIONS DIAGRAMS
DL76 DATA LOGGER
Power
Forward Output
Reverse Output
(Option-15 only)
*See Dual FT420 Diagram for an
example of bidirectional connections.
EX-SERIES
12-24 Vdc
DL76
Sensor
Input
FT420/DL76
24 Vdc
Power
Forward Output
Reverse Output
(Option-15 only)
EX-SERIES
*See Dual FT420 Diagram for an
example of bidirectional connections.
Power
Sensor
Input
Power 4-20mA
FT420
Pulse
Scaled
Pulse
Pass-Thru
DL76
Sensor
Input
Page 11
OPERATION & MAINTENANCE
30Vdc
Max. 6mA
- + -
+
12-24Vdc
3 4 5 6 2 1
Power
Forward
Output
Status
LED
Zero
Adjust
Pins
Zero Adjustment. When the EX100/200-Series meter is powered up and there is no ow, there should be no output pulses
(or, if connected to the FT420, ow rate should read “0”). If
there are pulses, it may be necessary to adjust the ow meter
under no-ow conditions after it has been installed. This should
only be done if the indicated ow is low, near the lower cutoff.
Status
LED
Zero
Adjust
Pins
To perform the adjustment, after determining that there is a
full pipe with no ow, short between the two pins marked “Zero
Adjust”. A red LED light will come on for approximately 50 seconds and then go out. The zero adjustment is completed.
Minimum Flow. As with any other ow sensor, there is a rate
below which the EX100-Series sensor cannot read. Check
the table below for the minimum ow rate detectable by the
sensor for a given pipe size.
Presence of Flow Indication. To assist in troubleshooting,
the “Status LED” has two blinking modes in normal operation.
When there is no flow detectable by the meter (below
minimum threshold) the LED blinks every 8.0 seconds. When
there is detectable ow, the same indicator blinks every 3.0
seconds (Pulses are being output when indicator is blinking
every 3 seconds).
Filtering. The software of the EX100/200-Series lters out
electrical noise and averages sudden variations in the ow
to smooth the output. It takes a matter of seconds for the
ow sensor to get up to full output when it is powered up or
when ow begins.
Electrode Coating. Grease or other adhering, non-conductive
materials can stop ow detection if the electrodes become
heavily coated. To clean the electrodes, remove the sensor
from the pipe and gently scrub the electrodes (three silver
bumps) on the reading face of the ow sensor. A mild soap
(dishwashing liquid for example) can be used to aid the
cleaning process.
Calibration (“K-Factor”). In order to properly process pulses
from the ow sensor, a number must be entered into the
control to which the sensor is connected. This number,
called the K-factor, is the number of pulses the sensor puts
out per unit of uid passing through the pipe. It is normally
provided for Seametrics sensors in pulses per gallon, and
can be ascertained by using the “K-Factor Calculator” on the
Seametrics website. These numbers are based on extensive
testing, which has shown close agreement among different
EX sensors in the same installation. Typically, most K-factor
error can be attributed to installation variables, such as depth
setting and tting conguration.
Using the K-Factor Calculator:
1) Go to the Seametrics webpage, EX K-factor calculator
(http://www.seametrics.com/node/223)*
2) Select your meter
3) Choose units
4) Input external pipe diameter (measure) and wall
thickness (measure, or look-up in Table 2 on page 5
of this manual)
5) Press Calculate to determine your K-factor
(NOTE: Dimension D is also calculated.)
FLOW RATES (IN GALLONS PER MINUTE)
Feet Per
Second
Min 0.28
Max 20.0
NOMINAL PIPE SIZE
3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36” 48”
6 11 25 44 69 99 134 175 222 274 395 617 888 1580
440 783 1,762 3,133 4,895 7,050 9,596 12,533 15,863 19,584 28,200 44,064 63,452 112,804
Page 12
6) Enter your K-factor into your controller
*For pipe sizes larger than 50”, please consult factory.
TROUBLESHOOTING
Problem
No pulse output
Output pulses incorrect
Probable Cause Try...
Unit not grounded
Below minimum ow cutoff
Flow reversed
Output connections reversed
Pipe not full
Excessive electrical noise
No power
Power reversed
Fluid conductivity <20 microSiemens/cm
Missing or incorrect ground wire
Incorrect depth setting
Connect to earth ground
Check the Presence of Flow LED (see p. 12)
Note ow direction arrow,
reverse direction to meter
Change output connections
Check plumbing
Check for proper electrical wiring
Check for power across power input terminals
Reverse connections
Select another ow meter
Check for proper ground
Check depth setting from
Dimension “C” table (page 4)
Jumpy reading
Fluid conductivity <20 microSiemens/cm
Empty pipe
Not enough straight pipe
Excessive electrical noise
Rapidly changing conductivity (in chemical
injection or fertigation applications)
Select another ow meter
Check for full pipe or install meter in the vertical
position
Check for air pockets or turbulence. Refer to
installation, page 6
Check for proper electrical wiring
Install chemical injection line downstream of
magmeter (or far enough upstream to allow
complete mixing of uids before meter)
Page 13
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-65200196-061213
6/12/13
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