Georg Fischer 525 Operating Manual

Signet 525 Metalex Flow Sensor

P525-1, P525-1S P525-2, P525-2S

retainer retainer

rotor pin

bearing

bearing

rotor

*P52590-1*

P52590-1 Rev. 19 12/18

Dimensions

P525-1, P525-1S

English

Operating Instructions

**

P525-2, P525-2S

P52509 & P52509-2 Rotor Kits

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SIGNET

38.4 mm
(1.5 in.)

27 mm

(1.06 in.)

* 7.6 m (25 ft) cable included

SIGNET

63.5 mm
(2.5 in.)

27 mm

(1.06 in.)

Specications

General

Operation Range ............... 0.5 m/s to 6 m/s (1.6 ft/s to 20 ft/s) (depending on pipe size)

Pipe Size Range ................DN15 to DN300 (½ in. to 12 in.)

Linearity ............................. ±1% of max. range @ 25 °C (77 °F)

Repeatability ...................... ±0.5% of max. range @ 25 °C (77 °F)

Wetted Materials

Sensor Body ...................... 316 SS (ACI type CF-8M per ASTM A351), DIN 17440

Rotor Material ....................17-4PH-1 Stainless Steel

Rotor Pin............................ Tungsten Carbide GRP 1 or 316 SS

Retainers (2) ......................316 stainless steel (1.4401)

Rotor Bearings (2) .............Carbon ber reinforced PTFE

Gasket ............................... KLINGER® sil C-4401 (supplied with tting)

Electrical

Frequency..........................39 Hz per m/s (12 Hz per ft/s) nominal

Amplitude...........................5 to 8 mV p-p per Hz

Source Impedance ............11.6 KΩ

Coil Inductance ..................3.5 Henrys @ 25 °C

Cable Length ..................... 7.6 m (25 ft), can be extended up to 61 m (200 ft)

Cable Type ........................22 AWG, 2-conductor w/shield

Maximum Temperature/Pressure Rating

Socket Weld or Weld-On

Mini-Tap ttings................ 103 bar @ 149 °C (1500 psi @ 300 °F)

Operating Temperature ......-18 °C to 149 °C (0 °F to 300 °F)

Standards and Approvals

• Manufactured under ISO 9001 for Quality,

ISO 14001 for Environmental Management and

OHSAS 18001 for Occupational Health and Safety.

• RoHS compliant

China RoHS (Go to www.gfsignet.com for details)

Warranty Information

45°

45°

15x I.D. 5x I.D.

20x I.D. 5x I.D.

40x I.D. 5x I.D.

50x I.D. 5x I.D.

Reducer

90° Elbow

2 x 90° Elbow
3 dimensions

Pump/Valve

Maintenance

Refer to your local Georg Fischer Sales o󰀩ce for the most
current warranty statement.

All warranty and non-warranty repairs being returned must

include a fully completed Service Form and goods must be
returned to your local GF Sales o󰀩ce or distributor.
Product returned without a Service Form may not be
warranty replaced or repaired.

Signet products with limited shelf-life (e.g. pH, ORP, chlorine
electrodes, calibration solutions; e.g. pH bu󰀨ers, turbidity

standards or other solutions) are warranted out of box but not

warranted against any damage, due to process or application

failures (e.g. high temperature,
mishandling (e.g. broken glass,

chemical poisoning, dry-out) or

damaged membrane, freezing

and/or extreme temperatures).

Product Registration

Thank you for purchasing the Signet line of Georg Fischer
measurement products.

If you would like to register your product(s), you can now

register online in one of the following ways:

• Visit our website www.gfsignet.com.

Under Service and Support click on

Product Registration Form

• If this is a pdf manual (digital copy), click here

The 525 sensor requires little or no maintenance of any kind,
with the exception of an occasional sensor/paddlewheel cleaning.

Paddlewheel Maintenance:

Paddlewheel ow sensors are subject to wear and may require
maintenance and replacement of mechanical parts (rotors,
pin, bearings, retainers, etc.). The frequency of recommended
maintenance will vary based upon application specications,
characteristics of the measured uid, and installation details.
These can include, but are not limited to: process owrate,
occurrence of water hammer, uid corrosiveness and

abrasiveness, sensor installation relevant to other equipment.

GF Signet o󰀨ers individual replacement parts and rotor
replacement kits, which include replacement instructions,
allowing customers to perform eld maintenance and reduce
application down-time. Please refer to the Paddlewheel
Replacement section (page 4) or contact your local GF Sales

Representative with any questions.

Sensor Removal Procedure

1. Depressurize and drain pipe.

2. Remove the four sensor ange bolts and lock washers.

Pull upward on the sensor ange with an alternating

twisting motion.

Safety Information

1. Do not remove from pressurized lines.

2. Do not exceed maximum temperature and pressure

specications.

3. Pipe tting must be installed by certied welder only.

4. Do not install/service without following installation

instructions (see sensor manual).

5. Wear safety goggles and face shield during installation
and service.

6. Do not alter product construction.

7. Failure to follow safety instructions could result in severe
personal injury!

Caution / Warning / Danger

Indicates a potential hazard. Failure to follow all warnings

may lead to equipment damage, injury, or death

Personal Protective Equipment (PPE)

Always utilize the most appropriate PPE during

installation and service of Signet products.

Pressurized System Warning

Sensor may be under pressure, take caution to vent

system prior to installation or removal. Failure to do so
may result in equipment damage and/or serious injury.

Note / Technical Notes

Highlights additional information or detailed procedure.

2

Signet 525 Metalex Flow Sensor

WARNING!

Do not remove from pressurized lines.

Wear safety goggles and faceshield
during installation/service.

Location of Fitting

Recommended sensor

upstream and downstream
mounting requirements.

Reducer

15x I.D. 5x I.D.

2 x 90° Elbow
3 dimensions

40x I.D. 5x I.D.

2 x 90° Elbow

90° Elbow

Pump/Valve

Sensor Mounting Position

• Horizontal pipe runs: Mount
sensor in the upright (0°) position

for best overall performance.

Mount at a maximum of 45° when
air bubbles are present.
Do not mount on the bottom of
pipe when sediments are present.

• Vertical pipe runs: Sensor must be
mounted in lines with UPWARD

ow only.

25x I.D. 5x I.D.

20x I.D. 5x I.D.

50x I.D. 5x I.D.

Sensor-Fitting Selection

hardware included

(525-2S for stainless steel pin)

Wetted fitting

hardware included

(525-1S for stainless steel pin)

Wetted fitting

Flow

Flow sensor
arrow

Fitting

flange

14

23

Flange
bolt torque
pattern

9900 Terminal

Shield

Tee & Mini-Tap Fitting Installation

The 525 is designed for installation into SCH 40 stainless steel
pipes via the Signet Metalex Tee, Mini-Tap.

materials:

+GF+

525-1 Sensor

316 SS

Tee Fitting,

Signet Metalex Tee Fittings (Sensor PN P525-1/-1S)

Pipe (in.) Fitting Code

0.50 P526-2005 198 840 501

0.75 P526-2007 198 840 502

1.00 P526-2010 198 840 503

materials:

+GF+

525-2 Sensor

316 SS
347 SS

Mini-Tap Fitting,

Signet Metalex Mini-Tap Fittings (Sensor PN P525-2/-2S)

Pipe (in.) Fitting Code

1.25 P526-2012 159 000 494

1.50 P526-2015 198 840 506

2.00 P526-2020 159 000 495

2.50 P526-2025 159 000 496

3.00 P526-2030 159 000 497

4.00 P526-2040 159 000 498

5.00 P526-2050 159 000 499

6.00 P526-2060 159 000 500

8.00 P526-2080 159 000 501

10.0 P526-2100 159 000 502

12.0 P526-2120 159 000 503

1. Select an appropriate mounting location as outlined in

sections 1 and 2.

2. Depressurize and drain pipe.

3. Use the following welding and installation procedures

appropriate for your tting/pipe size:

Signet Tee Fittings, 0.5 in. to 1 in.

• Insert pipe into tting socket

• Make sure the pipe is parallel to the bottom of the

Mini-Tap tting.

• Weld pipe into place.

Signet Mini-Tap Fittings, 1.25 in. to 12 in.

• Drill a 27 mm (1-1/16 in.) diameter hole completely through the
ONE surface of the pipe. Thoroughly deburr inner and outer

edges of hole.

• Tack weld the Mini-Tap tting onto the pipe, making sure the

hole in the pipe is lined up with the Mini-Tap tting hole.

• Weld the Mini-Tap tting onto the pipe.

Sensor Installation

1. Set the gasket supplied with the tting onto the tting

ange, making sure the holes align.

2. Remove the red rotor protection cap and insert the

sensor into the tting, making sure not to bump the rotor

assembly. Make sure the arrow on the side of the sensor

is pointing in the direction of ow.

3. Slip two washers onto each bolt and insert the bolt/

washer onto each of the four tting ange holes.

4. Snug all four ange bolts in a criss-cross pattern. Using a

torque wrench (when possible), torque the ange nuts in
a crisscross pattern to 52 foot pounds.

Sensor Wiring

Required Hardware

Signet Metalex Tee & Mini-Tap Fittings, P526-2XXX

• 0.5 to 1 inch pipes: P526-2 series tting required

• 1.25 to 12 inch pipes: P526-2 series tting and 27 mm

NOTE: Mini-Tap ttings are welded onto the pipe and are used

with Signet 525-1 and 525-2 sensors.

CAUTION

Welds MUST be made by a certied welder who
is licensed to weld stainless steel and other high
carbon grade steels.

(1-1/16 in.) diameter drill required

• Use 2-conductor shielded cable for

cable splices to 61 m (200 ft).

• Maintain cable shield through splice.

• Shield the unjacketed silver (ground)

wire using electrical tape to prevent
potential noise interference and/or

shorting hazards.

Frequency

Signet 525 Metalex Flow Sensor

Black

Red

V+

GND

DATA

SHLD

No Connection

3

Rotor Replacement Procedure

Rotor Pin

Existing
Retainer

New
Bearings

Rotor
Assembly

Punch

Retainer

Rotor Pin

1. With a small pair of needle-

nose pliers, rmly grip the
center of the rotor pin (axle)

and with a twisting motion,
bend the rotor pin into an
"S" shape. This should pull
the ends of the pin out of
the retainers and free the
rotor assembly.

2. Remove rotor pin retainer from each

side by gently tapping it inwards

using a punch. Install a new retainer

into the sensor body with its rotor pin

clearance hole inward. Only install

one retainer at this time.

K-Factors

The K-Factor is the number of pulses the
sensor will generate for each engineering
unit of uid which passes.

They are listed in U.S. gallons and in liters.

For example, in a 1 inch SCH 40S stainless

steel pipe, the sensor generates 266.17

pulses per gallon of uid passing the rotor.
K-Factors are listed for SCH 40S stainless
steel pipes up to 12 inch.

Conversion Formulas

1 U.S. gallon = 0.003785 cubic meters

0.000003069 Acre feet

8.3454 pounds of water

Ordering Information

3. Insert the new rotor
assembly and bearings
into the rotor housing of

the sensor and place the

new rotor pin (axle) through
the open end of the rotor
housing, through the rotor
and bearings, and into the
previously installed retainer.

4. Using a vise or C-clamp, press the

second retainer into the hole in the

sensor body while lining up the rotor

pin with the center of the retainer hole.

NOTE: A hammer and center punch

can also be used if a clamp or
vice is not available

SCH 40S Stainless Steel Pipe per ANSI B36.19

Pipe Size

(inch)

½ 873.03 230.66 0.0687 0.2601
¾ 515.41 136.17 0.1164 0.4406
1 266.17 70.322 0.2254 0.8532
1 ¼ 148.84 39.324 0.4031 1.5258
1 ½ 107.98 28.528 0.5557 2.1032
2 64.808 17.122 0.9258 3.5042
2 ½ 44.685 11.806 1.3427 5.0822
3 28.579 7.5506 2.0994 7.9464
4 16.302 4.3070 3.6805 13.931
5 10.237 2.7046 5.8611 22.184
6 7.0057 1.8509 8.5645 32.416
8 3.9641 1.0473 15.136 57.289
10 2.4690 0.6523 24.301 91.981
12 1.6894 0.4463 35.516 134.43

K-Factor Pulses/

U.S. GAL

K-Factor Pulses/

U.S. Liter

A-Factor

GPM / Hz

A-Factor

LPM / Hz

Part No. Code Description

P525-1 198 801 494 Metalex Flow sensor with tungsten carbide pin; ½ in. to 1 in. socket-weld tee ttings
P525-2 198 801 495 Metalex Flow sensor with tungsten carbide pin; 1¼ in. to 12 in. weld-on mini-tap ttings
P525-1S 159 000 963 Metalex Flow sensor with stainless steel pin; ½ in. to 1 in. socket-weld tee ttings
P525-2S 159 000 964 Metalex Flow sensor with stainless steel pin; 1¼ in. to 12 in. weld-on mini-tap ttings

Accessories and Replacement Parts

P52509 198 801 501 Rotor kit: rotors, 316 stainless steel pin, carbon ber reinforced PTFE bearings, SS retainers
P52509-2 159 000 480 Rotor kit: rotors, tungsten carbide pin, carbon ber reinforced PTFE bearings, SS retainers
P52504-1 198 801 500 Rotor Pin, Stainless steel (1.4401) (optional)
P52504-2 198 820 023 Rotor Pin, Tungsten Carbide (standard)
P52618 159 000 493 Gasket
P52503 198 820 013 Bearing, carbon ber reinforced PTFE
P52527 159 000 481 Retainers, Stainless steel
P52628 159 000 504 Fitting cap kit (cap and gasket)
P51589 159 000 476 Conduit adapter kit
5523-3222 159 000 393 Cable (per foot) 2 cond. with shield, 22 AWG

Georg Fischer Signet LLC, 3401 Aero Jet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. [phone] • Fax [phone]
For Worldwide Sales and Service, visit our website: www.gfsignet.com • Or call (in the U.S.): [phone]
For the most up-to-date information, please refer to our website at www.gfsignet.com

P52590-1 Rev. 19 12/18 English © Georg Fischer Signet LLC 2018