Seametrics IP800 Series User manual

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MADE
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IP800-Series
Insertion Paddlewheel
Flow Sensor Instructions

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 2 seametrics.com
General Information
General Information ...................................................................................................................................................Page 3
Features...........................................................................................................................................................................Page 3
Specications ................................................................................................................................................................Page 4
Installation
Fitting Installation........................................................................................................................................................Page 5
Meter Installation.........................................................................................................................................................Page 5
Straight Pipe Recommendations ...........................................................................................................................Page 6
Full Pipe Recommendations....................................................................................................................................Page 7
Connections
Overview .........................................................................................................................................................................Page 8
FT430................................................................................................................................................................................Page 8
FT440................................................................................................................................................................................Page 9
FT450................................................................................................................................................................................Page 9
Operation and Maintenance
Minimum Flow..............................................................................................................................................................Page 10
Flow Range Table.........................................................................................................................................................Page 10
Calibration (“K-Factor”) .............................................................................................................................................Page 10
Field Calibration ...........................................................................................................................................................Page 10
Rotor Replacement .....................................................................................................................................................Page 11
Signal Troubleshooting .............................................................................................................................................Page 11
Sensor Replacement...................................................................................................................................................Page 11
Parts List..........................................................................................................................................................................Page 12
Troubleshooting
Problems .........................................................................................................................................................................Page 13
Probable Causes...........................................................................................................................................................Page 13
Things To Try..................................................................................................................................................................Page 13
Warranty
Seametrics Limited Warranty ..................................................................................................................................Page 14
TABLE OF CONTENTS

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 3 seametrics.com
TABLE OF CONTENTS
The IP800-Series are impeller (or “paddlewheel”) insertion
meters 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 nickel-bound 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, 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.
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
Features
GENERAL INFORMATION
and total display, a modular system of electronics can be
installed directly on the ow sensor or mounted remotely.
The FT430 (externally powered with pulse), FT440 (loop
powered), and FT450 (battery powered) all provide digital
rate and total displays, as well as a programmable pulse;
the FT440 also provides a 4-20 mA analog output. The
AO55 blind analog transmitter can be used to convert to a
4-20 mA output. Electronic modules can be wall- or meter-
mounted. (Note: PD10 available only as wall mounted unit.)
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 specic applications.
Tee ttings are individually wet-calibrated at the factory
and marked with the K-factor (pulses per gallon). Saddle
ttings must be eld-installed on the pipe and do not
come wet-calibrated. K-factors for saddles are based on
factory-testing.
Rotor
O-Ring
Retaining Slot (for U-Clip)
For easy installation at correct depth setting
Lower Housing (optional)
Cable-Seal Strain Relief
Housing Screw
(connect ground wire to one)
Optional Electronics Available
Jewel Bearings for superior low-ow performance
High Pressure

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 4 seametrics.com
GENERAL INFORMATION
Speccations*
*Specications subject to change • Please consult our website for current data (www.seametrics.com).
Kynar is a registered trademark of Arkema, Inc., Viton is a registered trademark of DuPont Corporation.
Pipe Size 1/2” to 8”
Power Low Power: 6-36 Vdc/< 2 mA Micropowered (-04 Option): 3.1-16 Vdc/60 μA @ 3.6 Vdc
Sensor Low Power: Digital Magnetoresistive Micropowered (-04 Option): Giant Magnetoresistance (GMR)
Materials Optional Housing Powder-coated cast aluminum
Sensor Body Brass, 316 Stainless Steel, PVC, or Polypropylene
O-ring EPDM (Viton® optional)
Rotor PVDF (Kynar®)
Shaft Kynar® /Tungsten Carbide (Kynar® /Ceramic or Kynar®/Silicon Carbide optional)
Bearings Ruby jewel
Maximum Brass 316 Stainless Steel PVC or Polypropylene
(See Pressure vs. Temp. Chart)
Pressure 200 psi (14 bar) 200 psi (14 bar) 175 psi (12 bar) @ 75˚ F (24˚ C)
High Pressure Not available 400 psi (28 bar) Not available
Temperature 200˚ F (93˚ C) 200˚ F (93˚ C) 130˚ F (55˚ C)
Flow Velocity 0.3 to 30 ft/sec (0.9 to 9.14 m/sec)
Accuracy ± 1.5% of full scale
Output Transistor Maximum Current Sinking 150mA (low power version only)
Cable #22 AWG 3-con, 18’ (6m); 2,000’ (610m) maximum cable run Note: 50’ (15m) maximum for battery powered or
micropowered versions.
Regulatory Mark

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 5 seametrics.com
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-clip. The clip can be installed from either
side. It may be necessary to rotate the probe back and
forth slightly to start the clip into the slots on the probe.
Slide the clip in as far as it will go.
Horizontal (3 o’clock or 9 o’clock position) is the preferred
installation orientation, since it improves low-ow
performance and avoids problems with trapped air and
sediment. (See Orienting the Meter diagram below.)
Bottom (6 o’clock), top (12 o’clock), and vertical pipe
installations are all acceptable if required by the piping
layout.
Orienting the Meter
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).
Fair
Unacceptable if pipe
contains air
Best
Position
Fair
Unacceptable if pipe
contains sediment
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.
INSTALLATION
Fitting Installation
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 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 prole 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 specic adverse circumstances
(see next page).
If you can’t provide enough straight run to smooth out
the velocity prole, 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.
Distorted Flows
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.
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.
5X
Distorted
Flow Prole
Faster Flow
Causes Meter
To Read High
10X

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 6 seametrics.com
INSTALLATION
Straight Pipe Recommendations (X = diameter)
5X10X
Reduced Pipe
Two Elbows In Plane
Two Elbows, Out Of Plane
Expanded Pipe
Swirling Flow
Propeller Meter
Partially Open
Buttery Valve
Spiral Flow
5X
5X
20X
20X
30X
20X
5X10X

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 7 seametrics.com
INSTALLATION
Caution: These ow sensors are not recommended for installation downstream
of a 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).
Full Pipe Recommendations
Better InstallationPossible Problem
Air can be trapped Allows air to bleed off
Better InstallationPossible Problem
Allows air pockets to form at sensor Ensures full pipe
Post-valve cavitation can create air pocket Keeps pipe full at sensor
Better InstallationPossible Problem

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 8 seametrics.com
CONNECTIONS
Sensors are supplied with 18 ft. (6m) of cable. For sensors with no additional electronics, see diagram for color coding
of connections. For sensors with on-board electronics, see the manual accompanying the electronic module.
POWER
SENSOR
ENGD
+
_
_
+
S
PULSE OUT 2
PULSE OUT 1
+
_
+
_
RED
WHITE
BLACK
+
_7-45Vdc
Supply
Flow
Sensor
FT430 Pulse
Pass-thru
Pulse Responsive
Metering Pump
_
+
S
_
+
_
+
_
+
FT430
RED (+)
Low Power: 6-36 Vdc
Micropowered: 3.1 - 16 Vdc
WHITE
Signal
BLACK (-)
Power

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 9 seametrics.com
CONNECTIONS
FT440
POWER
SENSOR
ENGD
+
_
_
+
S
PULSE OUT 2
PULSE OUT 1
+
_
+
_
RED
WHITE
BLACK
+
_9-30 Vdc
Loop Power
Supply
Flow
Sensor
FT440
Electronic
Metering Pumps
_
+
S
_
+
_
+
_
+
4-20mA
Device
+
_
FT450
POWER
SENSOR
ENGD
+
_
_
+
S
PULSE OUT 2
PULSE OUT 1
+
_
+
_
RED
WHITE
BLACK
Micropower
Flow Sensor
FT450 Pulse
Pass-thru
Pulse Responsive
Metering Pump
Current Sinking
Polarity-Sensitive
Lithium C,
3Vdc
Replaceable
Battery
_
+
S
_
+
_
+

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 10 seametrics.com
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.
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 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.
10031295
MF81T-P200
K: 53.6
Find Your K-Factor Here
Field Calibration
It is possible to eld-calibrate an IP800-Series 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).
OPERATION AND MAINTENANCE
50
100
150
200
60˚ 70˚ 80˚ 90˚ 100˚ 110˚ 120˚ 130˚ 140˚
P
.S.I.
Pressure vs. Temperature (PVC/Polypro)
Nominal
Pipe Size ½” ¾” 1” 1½” 2” 3” 4” 6” 8”
Min GPM
Min LPM
0.28
1.06
0.5
1.89
0.8
3.03
1.9
7.2
3.1
11.7
6.9
26.1
12
45
27
102
46.8
177
Max GPM
Max LPM
28
106
50
189
80
302
190
719
314
1188
691
2615
1190
4504
2700
10221
4680
17716
Flow Range

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 11 seametrics.com
OPERATION AND MAINTENANCE
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.
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.
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.
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.
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.
1. Loosen and unthread
Strain Relief.
2. Remove the Sensor
Capsule by pulling on
the cable.
3. Remove the Sensor
Capsule by pulling on
the cable.
4. Reverse the process to
replace.

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 12 seametrics.com
OPERATION AND MAINTENANCE
IP800-Series Parts List
IP800 Series Parts
White Housing
1a thru 7a
Blue Housing
1b thru 7b
1 Upper housing/
electronics
Contact service
representative
for your specic
model
Contact service
representative
for your specic
model
2 Housing gasket/seal 102025 100411
3 Lower housing Not eld
replaceable
Not eld
replaceable
4 Housing screw/washer
kit (4 each)
100414 100414
5 Plug, steel (battery
units)
100360 100360
6 Strain relief kit, small
(includes 2)
100364 100364
7 Strain relief kit, large
(includes 1) (externally
powered units)
101850 101850
8 Sensor pickup 100508 (Micropower, gray cable,
FT450)
100419 (Standard, blue cable,
FT430/440)
9 Sensor retaining screw 100298
10a U-clip, retainer 100154
10b High pressure retaining
clip (requires 2)
101776
11 O-ring 100264 (EPDM)
12 Body See distributor
13 Bearings (includes 2) 103315
14 Rotor with shaft 100035 (Kynar®/tungsten carbide)
100036 (Kynar®/ceramic)
100435 (Kynar®/silicone carbide)
15 Rotor repair kit (#13 &
#14 above)
100317 (Kynar®/tungsten carbide)
100043 (Kynar®/ceramic)
100556 (Kynar®/silicone carbide)
1a
8
9
6a
4a
7a
3a
2a
11
15
14
13
12
10a
10b
5a
Blue Housing
1b
6b
4b
7b
3b
2b
5b

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 13 seametrics.com
TROUBLESHOOTING
Problem Probable Cause Things to Try...
No signal after installation Insufcient ow Consult Flow Rate Chart
Reduce pipe size or use different sensor
Bad connections to control
electronics
Check connections at control:
Red (+), Black (-), White (signal)
Incompatible control Use 6-36 Vdc power supply - for low power
Use 3.1-16 Vdc power supply - for micropowered
Add pull up resistor, if using current-sourcing
device
Damaged or missing rotor Remove ow sensor from tting and check for free
spinning; replace rotor
Failed magnetic sensor See Signal Troubleshooting (page 11); replace
magnetic sensor
Inaccurate metering Not enough straight pipe
between meter and severe ow
disturbance
Move meter away from ow disturbance or eld
calibrate
Wrong K-Factory entered Check tting for K-Factor, check indicator to see
if it is entered properly ("Set K" on FT430, FT440,
FT450, or FT520)
Magnetic sensor failing to pick up
each blade
Remove ow sensor from pipe. If indicator is
FT430, FT440, FT450, or FT520, set K to 1.00, turn
rotor slowly by hand, indicator should cound each
blade; replace sensor
Wrong time units on ow
indicator
If using FT430, FT440, or FT520, check left side of
display (sec, min, hr, day); change to desired unit

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 14 seametrics.com
The limited warranty set forth below is given by Seametrics, with respect to Seametrics and INW brand products purchased in the
United States of America.
Seametrics warrants that products manufactured by Seametrics, when delivered to you in new condition in their original containers
and properly installed, shall be free from defects in material and workmanship. Seametrics products are warranted against
defects for a period of two (2) years from date of installation, with proof of install date. If no proof of install date can be
provided, warranty period will be two (2) years from date of shipment from Seametrics, as dened on Seametrics’ invoice.
Seametrics’ obligation under this warranty shall be limited to replacing or repairing the part or parts, or, at Seametrics’ option, the
products, which prove defective in material or workmanship. The following are the terms of Seametrics’ limited warranty:
a. Buyer must give Seametrics prompt notice of any defect or failure and satisfactory proof thereof.
b. Any defective part or parts must be returned to Seametrics’ factory or to an authorized service center for inspection.
c. Buyer will prepay all freight charges to return any products to Seametrics’ factory, or another repair facility. as designated by
Seametrics.
d. Defective products, or parts thereof, which are returned to Seametrics and proved to be defective upon inspection, will be
repaired to factory specications.
e. Seametrics will deliver repaired products or replacements for defective products to the buyer (ground freight prepaid) to the
destination provided in the original order.
f. Products returned to Seametrics for which Seametrics provides replacement under this warranty shall become the property
of Seametrics.
g. This limited warranty covers all defects encountered in normal use of Seametrics products, and does not apply to the
following cases:
i. Loss of or damage to Seametrics product due to abuse, mishandling, or improper packaging by buyer
ii. Failure to follow operating, maintenance, or environmental instructions prescribed in Seametrics’ instruction manual
iii. Products not used for their intended purpose
iv. Alterations to the product, purposeful or accidental
v. Electrical current uctuations
vi. Corrosion due to aggressive materials not approved for your specic product
vii. Mishandling, or misapplication of Seametrics products
viii. Products or parts that are typically consumed during normal operation
ix. Use of parts or supplies (other than those sold by Seametrics) which cause damage to the products, or cause
abnormally frequent service calls or service problems
h. A new warranty period shall not be established for repaired or replaced material, products, or supplied. Such items shall
remain under warranty only for the remainder of the warranty period on the original materials, products, or supplies.
i. In the event that equipment is altered or repaired by the buyer without prior written approval by Seametrics, all warranties
are void. Damage caused by equipment or accessories not manufactured by Seametrics may void the product’s warranty.
j. SOFTWARE: The Seller grants the user a non-exclusive license to use Seametrics’ software, according to the following
limitations and conditions:
i. The user may install the software on one or more desktop or laptop computers.
ii. All title and intellectual rights to the software are owned by Seametrics.
iii. No copies may be made or distributed except as described above.
iv. The user may not modify or reverse-engineer the software.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, WHETHER ORAL, WRITTEN, EXPRESSED, IMPLIED OR STATUTORY.
NO IMPLIED WARRANTY, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,
APPLIED TO THE PRODUCTS AFTER THE APPLICABLE PERIOD OF THE EXPRESS LIMITED WARRANTY STATED ABOVE, AND NO OTHER
EXPRESS WARRANTY OR GUARANTY, EXCEPT AS MENTIONED ABOVE, GIVEN BY ANY PERSON OR ENTITY WITH RESPECT TO THE
PRODUCTS, SHALL BIND SEAMETRICS. SEAMETRICS SHALL NOT BE LIABLE FOR LOSS OF REVENUES, OR PROFITS, OR INCONVENIENCES,
EXPENSE FOR SUBSTITUTE EQUIPMENT OR SERVICE, STORAGE CHARGES, LOSS OF DATA, OR ANY OTHER SPECIAL, INCIDENTAL, OR
CONSEQUENTIAL DAMAGE CAUSED BY THE USE OR MISUSE OF, OR INABILITY TO USE THE PRODUCTS, REGARDLESS OF THE LEGAL
THEORY ON WHICH THE CLAIM IS BASED, AND EVEN IF SEAMETRICS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. IN NO
EVENT SHALL RECOVERY OF ANY KIND AGAINST SEAMETRICS BE GREATER IN AMOUNT THAN THE PURCHASE PRICE OF THE PRODUCT
SOLD BY SEAMETRICS AND CAUSING THE ALLEGED DAMAGE. WITHOUT LIMITING THE FOREGOING, YOU ASSUME ALL RISK OF LIABILITY
FOR LOSS, DAMAGE, OR INJURY TO YOU AND YOUR PROPERTY AND TO OTHERS AND THEIR PROPERTY ARISING OUT OF USE OR MISUSE
OF, OR INABILITY TO USE THE PRODUCTS NOT CAUSED DIRECTLY BY THE NEGLIGENCE OF SEAMETRICS.
SOME STATES DO NOT ALLOW LIMITATIONS ON THE DURATION OF AN IMPLIED WARRANTY, SO THE ABOVE LIMITATIONS MAY NOT
APPLY TO YOU. SIMILARLY, SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATIONS OF CONSEQUENTIAL DAMAGE, SO THE
ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS; HOWEVER,
YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE.
SEAMETRICS LIMITED WARRANTY

IP800-SERIES INSTRUCTIONS
Seametrics • 253.872.0284 Page 15 seametrics.com

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