GF Signet 2540 User Manual

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Page 1

½ in. NPT conduit port

Use 2-conductor shielded cable for cable extensions up to 300m (1000 ft.) Maintain cable shield through splice.

Black (5 to 24 VDC)

Silver (DC return)

Signet Instruments

Other Brands

Input

Gnd.

10 kΩ

5 to 24 VDC

black

silver

red

pull-up resistor required (10 kΩ recommended). Use 2-conductor shielded cable for cable extensions up to 300m (1000 ft.) Maintain cable shield through splice.

Other instrument

Blk, sensor power

Red, freq. input

Shld, Gnd

instrument

Red (signal out)

Signet 2540 High Performance Flow Sensor

*3-2540.090*

3-2540.090 Rev. F 11/12 English

For the most up-to-date information, please refer to our website at www.gfsignet.com

SAFETY INSTRUCTIONS

1. Do not remove from pressurized lines.

2. Do not exceed maximum temperature/pressure speciﬁ cations.

3. Wear safety goggles or faceshield during installation/service.

4. Do not alter product construction.

5. Apply sealant or PTFE tape to sensor threads, inspecting threads to ensure integrity. Do not install a sensor with damaged threads.

Pipe ﬁ ttings MUST be installed by a certiﬁ ed welder only. Signet will not assume liability of any kind for improper ﬁ tting installations.

2540 Hot-Tap sensor speciﬁ cations and limitations depend on the lowest maximum rating of the components associated with the system. For example, if a ball valve in the system is rated at a maximum 100 psi @ 175°F, you must limit the entire system's maximum pressure/temperature rating to 100 psi @ 175°F. All higher maximum speciﬁ cations MUST yield to the component with the lowest maximum speciﬁ cation.

Maximum Operating Pressure/Temperature:

• 17 bar (250 psi) @ 82°C (180°F) with standard FPM sensor ﬁ tting O-rings.

• 17 bar (250 psi) @ 100°C ( 212°F) with optional EPDM sensor ﬁ tting O-rings. Note: Pressure/temperature speciﬁ cations refer to sensor performance in water. Certain chemical limitations may apply.

Chemical compatibility should be veriﬁ ed.

English

Inlet

1. Location of Fitting

Recommended sensor upstream/ downstream mounting requirements.

Flange

10x I.D. 5x I.D.

Outlet

Reducer

2 x 90° Elbow 3 dimensions

Valve/Pump

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

2. Sensor Mounting Position

Vertical mounting is recommended for best overall performance. Mount at a maximum of 30° when air bubbles are present. DO NOT mount on the bottom of the pipe when sediments are present.

3. Sensor Wiring

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

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

2 x90° Elbow

30°

90° Elbow

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

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

0°

+30°

Process Pipe

Page 2

4. Electronics Module Installation and Removal

The electronics module of this sensor can be replaced without removing the steel sensor body from the line.

1. Loosen liquid tight connector cap.

2. Loosen liquid tight connector compression ﬁ tting from sensor body.

3. Grasp the electronics at the rubber strain relief (do not pull on cable) and pull ﬁ rmly. To reinstall the electronics module:

• Insert module into sensor housing, making sure module is fully seated. The tip of the electronic module must bottom-out in the sensor housing.

• Replace the liquid tight connector assembly. NOTE: Apply thread sealant to the liquid tight connector threads.

To install the cable inside protective conduit, remove the liquid tight connector completely. Thread ½ in. conduit into top of sensor body.

Liquid Tight Connector-Cap

½ in. NPT Threads

Liquid Tight ConnectorCompression Fitting w/ ½ in. NPT threads

Electronics Module 3-2541.260-1 (for Standard sensor) 3-2541.260-2 (for Hot-tap sensor)

NOTE: Apply thread sealant to the liquid tight connector threads.

Grip the electronics module at rubber strain relief

2540 High Performance Flow Sensor

Page 3

5. Installation

pipe fitting

process pipe

pipe sealant recommended

sensor fitting

The following items are required to properly install Signet 2540 Sensors.

5.1 Hardware, Standard Sensor

• Female pipe ﬁ tting (weld-on or saddle) with 1½ in. NPT or ISO 7-Rc 1½ threads

• 32 mm (1¼ in.) diameter drill

• Pipe thread sealant

• Tape measure

5.2 Hardware, Hot-Tap Sensor

The Hot-Tap sensor requires all the standard sensor items plus:

• Hot-Tap drilling machine (e.g., Mueller drilling machine or equivalent)

• Female ball or gate valve (full port only) with 1½ in. NPT or ISO 7-Rc 1½ threads

• Male pipe nipple, 32 x 50 mm (1½ x 2 in.) with 1½ in. NPT or ISO 7-R 1½ threads

• Hot-Tap installation tool (purchased separately)

5.3 Standard Fitting Installation A. Depressurize and drain pipe. B. Wearing safety face protection, drill a 32 mm (1¼ in.) diameter hole in the

pipe.

C. Install the pipe ﬁ tting of the outside of the pipe according to the manufacturer's

instructions. Failure to follow these instructions may result in serious bodily injury and/or product failure.

D. Remove sensor ﬁ tting from sensor assembly. E. Thread sensor ﬁ tting into pipe ﬁ tting. (Fig. 1)

Fig. 1

5.4 Hot-Tap Fitting Installation A. Install the pipe ﬁ tting on the outside diameter of the pipe according to the manufacturer's instructions. Failure to follow these

instructions may result in serious bodily injury and/or product failure.

B. Install the pipe nipple and isolation valve (ball or gate valve) onto the external pipe ﬁ tting using pipe sealant on the

threads. (Fig. 2)

C. Wearing safety face protection, install an appropriate hole cutting tool per manufacturer's instructions (e.g., Mueller

drilling machine) with a 32 mm (1.25 in.) drill onto the top of the isolation valve, ensuring a tight ﬁ t. Use the

recommended drill bit size or damage to the isolation valve may occur.

D. Open the isolation valve and insert the drill through the valve and cut the sensor clearance hole. After the hole is cut, withdraw the

drill from the isolation valve and close the valve. Remove the drilling machine per manufacturer's instructions. (Fig. 3)

E. Install the sensor ﬁ tting/bleed valve into the top of the isolation valve. Make sure the bleed valve clears the handle of the isolation

valve during operation.

customer supplied ball or gate valve

sensor fitting

bleed valve

Fig. 2

2540 High Performance Flow Sensor

customer supplied nipple: 32 x 50 mm (1.25 x 2 in.) long

process pipe (side view)

Fig. 3

process pipe

make sure bleed valve clears isolation valve handle

Page 4

5.5 Calculating the H Dimension

pipe I.D.

wall

incorrect

correct

Before installing the sensor some critical dimensions must be established (for Hot-Tap installations, we assume the pipe dimensions are known). The rotor shaft must be located 10% inside the pipe I.D. to ensure accurate calibration capability. To accomplish this, the "H" dimension is measured from the outside surface of the pipe to the bottom of the sensor ﬂ ange.

Nominal "H" dimensions for standard pipes are listed here. For non-standard pipe dimensions, calculate the "H" dimension using the formula listed below. The wall thickness and inside diameter (I.D.) are required for the "H" dimension calculation.

The 6 inch ruler (included) may be used to measure your pipe I.D. and wall thickness up to 5 inches (standard sensors only).

Pipe wall thickness: __________ Pipe I.D.: ___________

H Dimensions, Standard Sensors (2540-1, 2540-2)

Wrought Steel Pipe Per ANSI 36.10

NPS SCH 40 SCH 80 STD XS inches inches inches inches inches

1½ 4.924 4.880 4.924 4.880 2 4.869 4.818 4.869 4.818 2½ 4.780 4.722 4.780 4.722 3 4.707 4.640 4.707 4.640 3½ 4.649 4.576 4.649 4.576 4 4.590 4.510 4.590 4.510 5 4.467 4.374 4.467 4.374 6 4.344 4.222 4.344 4.222 8 4.110 3.968 4.110 3.968 10 3.863 3.680 3.863 3.755 12 3.630 3.405 3.655 3.555 14 3.480 3.230 3.530 3.430 16 3.230 2.955 3.330 3.230 18 2.980 2.680 3.130 3.030 20 2.755 2.405 2.930 2.830 22 ----- 2.130 2.730 2.630 24 2.280 1.855 2.530 2.430

H Dimensions, Hot-Tap Sensors (2540-3, 2540-4)

Wrought Steel Pipe Per ANSI 36.10 NPS SCH 40 SCH 80 STD XS inches inches inches inches inches

1 ½ 15.084 15.040 15.084 15.040 2 15.029 14.978 15.029 14.978 2 ½ 14.940 14.882 14.940 14.882 3 14.867 14.800 14.867 14.800 3½ 14.809 14.736 14.809 14.736 4 14.750 14.670 14.750 14.670 5 14.627 14.534 14.627 14.534 6 14.534 14.382 14.534 14.382 8 14.270 14.128 14.270 14.128 10 14.023 13.840 14.023 13.915 12 13.790 13.565 13.815 13.715 14 13.640 13.390 13.690 13.590 16 13.390 13.115 13.490 13.390 18 13.140 12.840 13.290 13.190 20 12.915 12.565 13.090 12.990 22 ----- 12.290 12.890 12.790 24 12.440 12.015 12.690 12.590

(-----) unavailable

Stainless Steel Pipe Per ANSI B36.19

NPS SCH 5S SCH 10S SCH 40S SCH 80S inches inches inches inches inches

1½ 4.988 4.953 4.924 4.880 2 4.940 4.905 4.869 4.818 2½ 4.876 4.847 4.780 4.722 3 4.814 4.784 4.707 4.640 3½ 4.764 4.734 4.649 4.576 4 4.714 4.684 4.590 4.510 5 4.586 4.567 4.467 4.374 6 4.480 4.460 4.344 4.222 8 4.280 4.249 4.110 3.968 10 4.048 4.023 3.863 3.755 12 3.830 3.811 3.655 3.555 14 3.705 3.680 ----- ----16 3.498 3.480 ----- ----18 3.298 3.280 ----- ----20 3.080 3.056 ----- ----22 2.880 2.856 ----- ----24 2.656 2.630 ----- -----

(-----) unavailable

Stainless Steel Pipe Per ANSI B36.19

NPS SCH 5S SCH 10S SCH 40S SCH 80S inches inches inches inches inches

1 ½ 15.148 15.113 15.084 15.040 2 15.101 15.065 15.029 14.978 2 ½ 15.036 15.007 14.940 14.882 3 14.974 14.944 14.867 14.800 3 ½ 14.924 14.894 14.809 14.736 4 14.874 14.844 14.750 14.670 5 14.747 14.727 14.627 14.534 6 14.640 14.620 14.534 14.382 8 14.440 14.409 14.270 14.128 10 14.208 14.183 14.023 13.915 12 13.990 13.971 13.815 13.715 14 13.865 13.840 ----- ----16 13.658 13.640 ----- ----18 13.458 13.440 ----- ----20 13.240 13.216 ----- ----22 13.040 13.016 ----- ----24 12.816 12.790 ----- -----

Standard Sensors: H = 5.23 - wall thickness - (0.10 x I.D.) Hot-Tap Sensors: H=15.39 in. - wall thickness - (0.10 x I.D.)

Example: 3.0 inch schedule 80 wrought steel Wall thickness = 0.3 in. / Inside diameter = 2.9 in.

H = 5.23 - 0.3 - (0.10 X 2.9) / H = 117.86 mm (4.64 in.) Record your sensor's "H" dimension for future reference: H= ___________

After correct dimensions are calculated and recorded, the sensor can be installed in the ﬁ tting. The Standard and Hot-Tap versions require substantially different procedures.

sensor flange

"H"

pipe side view

alignment rod

process pipe

direction of flow

2540 High Performance Flow Sensor

Page 5

lower hex nuts (3/16 x 1/4-20)

jam nuts (5/32 x 1/4-20)

359 mm

(14.14 in.)

sensor fitting

UNDER PRESSURE!

sensor fitting

hex nut

Lock washer

5.6 Standard Sensor Installation

sensor fitting

hex nut

Lock washer

A. Thread one hex nut onto each of the three threaded rods

included in package. Install threaded rod with a lock washer

Fig. 4

onto the sensor ﬁ tting. Secure rods in place by tightening each hex nut against the sensor ﬁ tting. (Fig. 4)

B. Thread one jam nut and lower hex nut onto each threaded

rod so that the top surface of each nut is at the proper "H" dimension for your pipe. Secure each hex nut with a jam nut. (Fig. 5)

C. Insert the ﬂ ow sensor into the sensor ﬁ tting, making sure the

alignment hole on the sensor ﬂ ange is pointing downstream.

D. Place the alignment rod in the alignment hole

on the sensor ﬂ ange. Align the ﬂ ange so rod is parallel to the process pipe. (Fig. 6)

E. Thread upper hex nuts with lock washers until they

contact the sensor ﬂ ange and tighten. Check for proper "H" dimension and readjust if necessary. (Fig. 7)

sensor flange

flow direction

alignment rod

process pipe (top view)

The flow sensor alignment rod MUST be parallel to the process pipe as shown.

Fig. 6

5.7 Hot-Tap Sensor Installation A. Thread one hex nut onto each of the three threaded rods included in package. Install threaded

rod with a lock washer onto the sensor ﬁ tting. Secure rods in place by tightening each hex nut against the sensor ﬁ tting. (Fig. 8)

Fig. 5

"H"

sensor flange

jam nuts

sensor fitting

Fig. 7

FLOW

lower hex nuts (3/16 x 1/4-20)

jam nuts (5/32 x 1/4-20)

hex nut & lock washer

sensor fitting

process pipe

cap nuts

upper hex nuts & lockwashers

lower hex nuts

female pipe fitting

process pipe wall I.D.

B. Thread one jam nut and lower hex nut onto each threaded rod so that the top surface of each

nut is 359 mm (14.14 in.) from the top surface of the sensor ﬁ tting. Secure each hex nut with a jam nut. (Fig. 9)

CAUTION: This setting is critical to ensure an adequate sensor seal and to prevent the rotor from hitting the isolation valve oriﬁ ce during installation.

C. Wipe the sensor body with a dry, clean cloth. Orient the alignment hole on the sensor ﬂ ange

to point downstream. Place the slotted ﬂ ange over the threaded rods. Lower the sensor into the ﬁ tting until the sensor ﬂ ange rests on the lower hex and jam nuts.

D. Secure the sensor with lock washers and upper hex nuts on the top of the ﬂ ange. Before

tightening, align the sensor ﬂ ange so that the alignment rod is parallel and level with the process pipe. (Fig. 10 & Fig. 11)

E. Make sure the bleed valve is closed (full clockwise position).

sensor flange

flow direction

alignment rod

process pipe (top view)

The flow alignment rod MUST be parallel to the process pipe as shown.

sensor flange

lower hex nut and jam nuts

18 inch threaded rods

sensor fitting

Fig. 8

Upper hex nuts (3/16 x 1/4-20)

1/4 in. lock washers

alignment rod

359 mm (14.14 in)

bleed valve

Fig. 9

2540 High Performance Flow Sensor

Fig. 10

Fig. 11

direction of flow

process pipe (side view)

Page 6

Hot-Tap Sensor Installation - Continued

F. Thread protector plate hex nuts onto each of the three

threaded rods. Adjust each hex nut to a height of approximately 25 mm (1 in.) from the top of each rod. (Fig. 12)

protector plate cap nuts

25 mm (1.0 in.)

protector plate removed during sensor installation

protector plate hex nut (3/16 x ¼ -20)

Fig. 12

G. Position the installation tool bearing plate by rotating it so that it is approximately 40 mm (1.6 in.) from the swivel mount. Mount

the installation tool by placing the threaded rods through the holes in the tool's bearing plate, resting the bearing plate on top of the protector plate hex nuts. Make sure the swivel mount's ears are mounted between the threaded rods (not over the rods). Install the bearing plate cap nuts. Tighten the bearing plate cap nuts to secure the installation tool in place. (Fig. 13)

H. Align the sensor cable with the swivel mount cable port to prevent cable pinching. Use a 3/8 inch wrench or socket to turn the

installation tool shaft clockwise until it is seated in the hole at the top of the sensor ﬂ ange.

I. Wearing safety face protection, slowly open the isolation valve to the full open position. Loosen the lower hex and

jam nuts and move them to the proper "H" dimension. Turn the installation tool shaft clockwise until the sensor ﬂ ange contacts the lower hex and jam nuts. Thread the upper hex nuts down until they contact the sensor ﬂ ange. Tighten the upper hex nuts to secure the sensor. (Fig. 14)

J. Remove cap nuts and withdraw the installation tool. Be careful to not damage cable. Replace protector plate and cap nuts.

(Fig. 15)

Fig. 14

Fig. 13

cap nuts

protector plate

hex nuts

sensor

cable

installation tool threaded shaft

bearing plate

swivel mount w/cable port

sensor flange

installation tool shaft

upper hex nuts

"H"

cap nuts

alignment rod

lower hex nuts

jam nuts

isolation valve

Fig. 15

protector plate cap nuts

protector plate

sensor body

hex nut

direction of flow

6. Standard Sensor Removal

To remove the sensor from a depressurized empty pipe, simply remove the cap nuts and upper hex nuts located above the sensor

ﬂ ange. Pull up on sensor ﬂ ange with twisting motion.

2540 High Performance Flow Sensor

Page 7

installation tool threaded shaft

process pipe (side view)

372 mm

(14.6 in.)

upper hex nuts and lock washers

sensor flange

lower hex and jam nuts

UNDER PRESSURE!

sensor fitting

isolation valve

7. Hot-Tap Sensor Removal

Punch

Retainer

To remove the Hot-Tap sensor safely from a pressurized active pipe, the entire installation process must be reversed.

A. Remove the cap nuts, protector plate and protector plate hex nuts. (Fig. 16) B. Thread installation tool in place and secure bearing plate in place of sensor protector plate.

(Fig. 17)

C. Turn shaft of installation tool clockwise to lower tool into opening in sensor ﬂ ange. Guide

cable into the port to prevent damage.

protector plate

Fig. 16

cap nuts

protector plate

protector plate hex nut

Fig. 17

D. Wearing safety face protection, loosen the upper hex nuts and raise to 372 mm (14.6 in.) from top of sensor ﬁ tting to

bottom of upper hex nuts/lock washers. CAUTION! This measurement is critical to maintain watertight seal in sensor while allowing clearance to close the isolation valve.

E. Wearing safety face protection, turn the installation tool shaft

counterclockwise to withdraw sensor until the sensor ﬂ ange contacts

the upper hex nuts. (Fig. 18)

F. Raise one lower hex and jam nut to bottom of sensor ﬂ ange. G. Close isolation valve, remove bearing plate and tool. H. Wearing safety face protection, cover the bleed valve with suitable

protection (rag, towel, etc.) and open the bleed valve (ccw rotation) to relieve internal pressure. Pull sensor up until bleed valve purges some ﬂ uid (indicating sensor is past 1st o-ring seal inside sensor ﬁ tting).

CAUTION: In case of a leaky isolation valve, the sensor will be under a slight

cap nuts

protector plate

hex nuts

upper hex nuts

Fig. 18

installation tool threaded shaft

installation tool bearing plate

swivel mount w/cable port

sensor flange 1 lower hex nut

and jam nut

sensor body

amount of pressure. Care should be taken when removing the sensor. Use the bleed valve to relieve this pressure taking care not to spray ﬂ uid on yourself or others.

Sensor can now be safely removed. When reinstalling the sensor: leave one lower hex nut in position to guide sensor to proper

isolation valve clearance height before opening isolation valve. Return to "H" dimension height after valve is opened.

8. Maintenance

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

Rotor Replacement Procedure

1. With a small pair of needle-nose

2. Remove retainer from each side by

2540 High Performance Flow Sensor

pliers, ﬁ 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.

gently tapping it inwards using a punch. Install a new retainer with its rotor pin clearance hole inward. Only install one retainer at this time.

Rotor Pin

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 vise is not available.

Existing Retainer

Rotor Pin

New Bearings

Rotor Assembly

Page 8

9. K-Factors (Stainless Steel, Wrought Steel & Plastic Pipe)

SCH 5S STAINLESS STEEL PIPE PER ANSI B36.19

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER 1½ in. 115.1900 30.433

2 in. 71.3960 18.863 2 ½ in. 49.263 13.015 3 in. 32.636 8.622 3 ½ in. 24.537 6.483 4 in. 19.1350 5.055 5 in. 12.4490 3.289 6 in. 8.4602 2.235 8 in. 4.9137 1.298 10 in. 3.1228 0.825 12 in. 2.1772 0.575 14 in. 1.7977 0.475 16 in. 1.3717 0.362 18 in. 1.0855 0.287 20 in. 0.8801 0.233 22 in. 0.7293 0.193 24 in. 0.6141 0.162

SCH 10S STAINLESS STEEL PIPE PER ANSI B36.19

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1½ in. 127.930 33.799 2 in. 76.439 20.195 2 ½ in. 51.946 13.724 3 in. 34.174 9.029 3½ in. 25.571 6.756 4 in. 19.829 5.239 5 in. 12.730 3.363 6 in. 8.5938 2.270 8 in. 5.0062 1.323 10 in. 3.1793 0.840 12 in. 2.1914 0.579 14 in. 1.8147 0.479 16 in. 1.3798 0.365 18 in. 1.0912 0.288 20 in. 0.8855 0.234 22 in. 0.7334 0.194 24 in. 0.6175 0.163

XS WROUGHT STEEL PIPE PER ANSI B36.10

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 161.79 42.745 2 in. 95.713 25.287 2 ½ in. 66.686 17.618 3 in. 42.986 11.357 3 ½ in. 31.983 8.450 4 in. 24.668 6.517 5 in. 15.480 4.090 6 in. 10.691 2.825 8 in. 5.9733 1.578 10 in. 3.6489 0.964 12 in. 2.4548 0.649 14 in. 1.9931 0.527 16 in. 1.4970 0.396 18 in. 1.1727 0.310 20 in. 0.9388 0.248 22 in. 0.7685 0.203 24 in. 0.6446 0.170

STD WROUGHT STEEL PIPE PER ANSI B36.10

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 140.030 36.996 2 in. 83.240 21.992 2 ½ in. 59.034 15.597 3 in. 38.674 10.218 3 ½ in. 28.752 7.596 4 in. 22.226 5.872 5 in. 14.061 3.715 6 in. 9.5160 2.514 8 in. 5.4523 1.441 10 in. 3.4507 0.912 12 in. 2.3318 0.616 14 in. 1.9186 0.507 16 in. 1.4483 0.383 18 in. 1.1390 0.301 20 in. 0.9146 0.242 22 in. 0.7506 0.198 24 in. 0.6311 0.167

SCH 40S STAINLESS STEEL PIPE PER ANSI B36.19

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 140.030 36.996 2 in. 83.240 21.992 2 ½ in. 59.034 15.597 3 in. 38.675 10.218 3 ½ in. 28.752 7.596 4 in. 22.226 5.872 5 in. 14.061 3.715 6 in. 9.5160 2.514 8 in. 5.4523 1.441 10 in. 3.4507 0.912 12 in. 2.3318 0.616

SCH 40 STAINLESS STEEL PIPE

14 in. 1.9556 0.517 16 in. 1.4970 0.396 18 in. 1.1900 0.314 20 in. 0.9577 0.253 24 in. 0.6662 0.176

SCH 40 WROUGHT STEEL PIPE PER ANSI B36.10

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 140.030 36.996 2 in. 83.240 21.992 2- ½ in. 59.034 15.597 3 in. 38.674 10.218 3 ½ in. 28.752 7.596 4 in. 22.226 5.872 5 in. 14.061 3.715 6 in. 9.5160 2.514 8 in. 5.4523 1.441 10 in. 3.4507 0.912 12 in. 2.3517 0.621 14 in. 1.9556 0.517 16 in. 1.4970 0.396 18 in. 1.1900 0.314 20 in. 0.9577 0.253 24 in. 0.6662 0.176

K-factors are listed in U.S. gallons and in liters. Conversion formulas for other engineering units are listed below.

• K = 60/A The K-factor is the number of pulses generated by the 2540 paddlewheel per unit of liquid in a

speciﬁ c pipe size.

To convert multiply K from: to: K by:

U.S. gallons cubic feet 7.479 U.S. gallons cubic inches 0.00433 U.S. gallons cubic meters 263.85 U.S. gallons pounds of water 0.120 U.S. gallons acre feet 325853 U.S. gallons Imperial gallons 1.201

2540 High Performance Flow Sensor

Page 9

K-Factors (Stainless Steel, Wrought Steel & Plastic Pipe) continued

SCH 80S STAINLESS STEEL PIPE PER ANSI B36.19

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 161.790 42.745 2 in. 95.710 25.287 2 ½ in. 66.686 17.618 3 in. 42.986 11.357 3 ½ in. 31.983 8.450 4 in. 24.668 6.517 5 in. 15.480 4.090 6 in. 10.691 2.825 8 in. 5.9733 1.578 10 in. 3.6489 0.964 12 in. 2.4548 0.649

SCH 80 STAINLESS STEEL PIPE 14 in. 2.1557 0.570

16 in. 1.6444 0.434 18 in. 1.3036 0.344 20 in. 1.0533 0.278 22 in. 0.8689 0.230 24 in. 0.7335 0.194

SCH 80 WROUGHT STEEL PIPE PER ANSI B36.10

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 161.790 42.745 2 in. 95.713 25.287 2 ½ in. 66.686 17.618 3 in. 42.986 11.357 3 ½ in. 31.983 8.450 4 in. 24.668 6.517 5 in. 15.480 4.090 6 in. 10.691 2.825 8 in. 5.9733 1.578 10 in. 3.7983 1.004 12 in. 2.6198 0.692 14 in. 2.1557 0.570 16 in. 1.6444 0.434 18 in. 1.3036 0.344 20 in. 1.0533 0.278 22 in. 0.8689 0.230 24 in. 0.7335 0.194

SCH 40 Plastic pipe per ASTM-D-1785

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 139.850 36.948 2 in. 82.968 21.920 2 ½ in. 60.194 15.903 3 in. 39.513 10.439 3 ½ in. 29.295 7.740 4 in. 22.565 5.962 5 in. 14.308 3.780 6 in. 9.8630 2.606 8 in. 5.6400 1.490 10 in. 3.4476 0.911 12 in. 2.3786 0.628

SCH 80 Plastic pipe per ASTM-D-1785

K-Factor K-Factor PIPE PULSES/ PULSES/ SIZE U.S. GAL LITER

1 ½ in. 162.290 42.877 2 in. 97.186 25.677 2 ½ in. 68.559 18.113 3 in. 43.870 11.590 3 ½ in. 32.831 8.674 4 in. 25.250 6.671 5 in. 15.835 4.184 6 in. 11.041 2.917 8 in. 6.2877 1.661 10 in. 3.8529 1.018 12 in. 2.6407 0.698

2540 High Performance Flow Sensor

Page 10

10. Speciﬁ cations

General Data

Flow velocity range: 0.1 to 6 m/s (0.3 to 20 ft/s) Linearity: ±1% of full range Repeatability: ±0.5% of full range Pipe range:

• Standard version: 38 to 610 mm (1.5 to 24 in.)

• Hot-Tap version: 38 to 914 mm (1.5 to 36 in.) Sensor ﬁ tting options: 316 SS with 1.5 in. NPT threads,

OR 316 SS with IS0 7-R

1½ threads Cable length: 7.6 m (25 ft), can splice up to 300 m (1000 ft) Cable type: 2-conductor twisted-pair with

22 AWG shield

Electrical Data

Supply voltage: 5 to 24 VDC Supply current: 1.5 mA max. Output type: Open collector, sinking Output current: 10.0 mA max.

Wetted Materials

Sensor body: 316 stainless steel Sensor ﬁ tting: 316 stainless steel Sensor ﬁ tting O-rings: Standard FPM, optional EPDM Rotor: CB7 Cu-1 alloy 17-4 per AMS5355H Rotor shaft: Tungsten carbide (standard) 316 stainless steel (option) Shaft retainers (2): 316 stainless steel Rotor bearings (2): Carbon ﬁ ber reinforced PTFE

Quality Standards

• Manufactured under ISO 9001 for Quality, ISO 14001

for Environmental Management and OHSAS 18001 for

Occupational Health and Safety. China RoHS (Go to www.gfsignet.com for details)

This device complies with Part 15 of the FCC rules

Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and, (2) This device must accept any interference received, including interference that may cause undesired operation.

64 mm (2.5 in.) dia.

Fluid Conditions

Maximum operating pressure/temperature:

• Sensor with standard FPM sensor ﬁ tting O-rings: 17 bar (250 psi) @ 82°C (180°F)

• Sensor with optional EPDM sensor ﬁ tting O-rings: 17 bar (250 psi) @ 100°C (212°F) Note: Pressure/temperature speciﬁ cations refer to sensor performance in water. Certain chemical limitations may apply. Chemical compatibility should be veriﬁ ed.

manufactured date code = mm/yy ex. 04/08 04 - month of April

04/08

08 - year 2008

Caution: The 2540 Hot-Tap system's overall speciﬁ cations and limitations depend on the lowest maximum rating of the components associated with the system. In other words, the Hot-Tap system is only as

strong as its weakest link. For example, a ball valve, a component of the system, is rated at a maximum 100 psi @ 175°F, limiting the entire system's maximum pressure/temperature rating to 100 psi @ 175°F. All higher maximum speciﬁ cations MUST yield to the component with the lowest maximum speciﬁ cation.

64 mm (2.5 in.) dia.

7.5 m (25 ft.) integral cable

127 mm

Adjustable

length

O-ring seal (1)

(5.0 in.)

Sensor fitting: 1½ in. NPT or ISO 7-R 1½ thread

24 mm (0.94 in.) dia.

Standard Sensor Dimensions:

• 2540-1(S) = 1½ in. NPT ﬁ tting

• 2540-2(S) = IS0 7-R 1½ ﬁ tting

7.6 m (25 ft.) cable

O-ring seals (2)

Adjustable

length

457 mm

(18 in.)

Sensor fitting: 1½ in. NPT or ISO 7-R 1½ thread

24 mm (0.94 in.) dia.

Hot-Tap Sensor Dimensions:

• 2540-3(S) = 1½ in. NPT ﬁ tting

• 2540-4(S) = IS0 7-R 1½ ﬁ tting

2540 High Performance Flow Sensor

Bleed valve

Page 11

Notes:

2540 High Performance Flow Sensor

Page 12

11. Ordering Information

Sensor Part Number 3-2540 Stainless Steel High Performance ﬂ ow sensor with removable electronics

3-2540 -1 Example Part Number

*Must use 3-1500.663 Hot-Tap installation tool (ordered separately)

Mounting option - choose one

-1 1½ inch NPT thread

-2 1½ inch ISO thread

-3 1½ inch NPT thread, hot tap design*

-4 1½ inch ISO thread, hot tap design* Rotor Pin Material

- Tungsten Carbide

-S Stainless Steel

Mfr. Part No. Code 3-2540-1 198 840 035 3-2540-2 198 840 036 3-2540-3 198 840 037 3-2540-4 198 840 038

Mfr. Part No. Code 3-2540-1S 159 001 501 3-2540-2S 159 001 502 3-2540-3S 159 001 503 3-2540-4S 159 001 504

Accessories and Replacement Parts

Mfr. Part No. Code Description

3-1500.663 198 820 008 1220-0021 198 801 000 O-ring, FPM 1224-0021 198 820 006 O-ring, EPDM 1228-0021 198 820 007 O-ring, FFPM 3-2540.321 159 000 623 Rotor Kit, 2540 Tungsten Carbide Pin 3-2540.322 159 000 864 Rotor kit, Stainless Steel pin P52504-3 159 000 866 Rotor pin, Tungsten Carbide P52504-4 159 000 867 Rotor pin, 316 SST 3-2540.520 159 000 648 Bearing, PTFE P52527 159 000 481 Retainers, SS (1.4401) 3-2541.260-1 159 000 849 Standard replacement electronics module 3-2541.260-2 159 000 850 Hot-Tap replacement electronics module 5523-0222 159 000 392 Cable, per ft. P51589 159 000 476 Conduit Adapter Kit P31934 159 000 466 Conduit Cap

Hot-Tap Installation Tool

Georg Fischer Signet LLC, 3401 Aero Jet Avenue, El Monte, CA 91731-2882 U.S.A. • Tel. (626) 571-2770 • Fax (626) 573-2057 For Worldwide Sales and Service, visit our website: www.gfsignet.com • Or call (in the U.S.): (800) 854-4090 For the most up-to-date information, please refer to our website at www.gfsignet.com