GF Signet 2540 User Manual
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
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
2
2540 High Performance Flow Sensor
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
3
5.5 Calculating the H Dimension
A
B
1
2
3
4
5
6
1
2
3
4
5
A
B
1
2
3
4
5
6
1
2
3
4
5
pipe I.D.
wall
A
B
1
2
3
4
5
6
1
2
3
4
5
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.
4
sensor flange
"H"
pipe side view
alignment rod
process pipe
direction
of flow
2540 High Performance Flow Sensor
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