GF Signet 2540 User Manual - User Manual

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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)

3. Sensor

Wiring

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.

10x I.D.

5x I.D.

Inlet

Outlet

Flange

15x I.D.

5x I.D.

Reducer

20x I.D.

5x I.D.

90° Elbow

50x I.D.

5x I.D.

40x I.D.

5x I.D.

25x I.D.

5x I.D.

2 x90° Elbow

2 x 90° Elbow

3 dimensions

Valve/Pump

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.

1. Location of Fitting

Recommended sensor upstream/
downstream
mounting requirements.

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.

Signet 2540 High Performance Flow Sensor

+30°

0°

Process Pipe

30°

*3-2540.090*

3-2540.090

D 08/07 English

English

2540 High Performance Flow Sensor

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.

½ in. NPT Threads

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

Liquid Tight Connector-
Compression Fitting
w/ ½ in. NPT threads

Liquid Tight Connector-Cap

Grip the electronics
module at rubber strain
relief

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

2540 High Performance Flow Sensor

process pipe

sensor fitting

bleed valve

make sure
bleed valve
clears isolation
valve handle

5. Installation

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

Depressurize and drain pipe.

Wearing safety face protection, drill a 32 mm (1¼ in.) diameter hole in the

pipe.

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.

Remove sensor fi tting from sensor assembly.

Thread sensor fi tting into pipe fi tting. (Fig. 1)

5.4 Hot-Tap Fitting Installation

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.

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)

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.

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)

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.

pipe
fitting

process
pipe

pipe sealant recommended

sensor
fitting

customer supplied

nipple: 32 x 50 mm

(1.25 x 2 in.) long

customer supplied

ball or gate valve

process pipe (side view)

Fig. 2

Fig. 3

Fig. 1

2540 High Performance Flow Sensor

"H"

alignment rod

sensor flange

process pipe

direction

of flow

pipe side view

5.5 Calculating the H Dimension

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.: ___________

pipe I.D.

wall

thickness

incorrect

correct

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

Wrought Steel Pipe Per ANSI 36.10

NPS

SCH 40

SCH 80

STD

inches

inches inches inches inches

1½

4.924 4.880 4.924 4.880

4.869 4.818 4.869 4.818

2½

4.780 4.722 4.780 4.722

4.707 4.640 4.707 4.640

3½

4.649 4.576 4.649 4.576

4.590 4.510 4.590 4.510

4.467 4.374 4.467 4.374

4.344 4.222 4.344 4.222

4.110

3.968

4.110

3.968

3.863 3.680 3.863 3.755

3.630 3.405 3.655 3.555

3.480 3.230 3.530 3.430

3.230 2.955 3.330 3.230

2.980 2.680 3.130 3.030

2.755 2.405 2.930 2.830

-----

2.130 2.730 2.630

2.280 1.855 2.530 2.430

Stainless Steel Pipe Per ANSI B36.19

NPS

SCH 5S

SCH 10S

SCH 40S

SCH 80S

inches inches inches

inches

1½

4.988

4.953

4.924

4.880

4.940

4.905

4.869

4.818

2½

4.876

4.847

4.780

4.722

4.814

4.784

4.707

4.640

3½

4.764

4.734

4.649

4.576

4.714

4.684

4.590

4.510

4.586

4.567

4.467

4.374

4.480

4.460

4.344

4.222

4.280

4.249

4.110

3.968

4.048

4.023

3.863

3.755

3.830

3.811

3.655

3.555

3.705

3.680

-----

3.498

3.480

-----

3.298

3.280

-----

3.080

3.056

-----

2.880

2.856

-----

2.656

2.630

-----

Wrought Steel Pipe Per ANSI 36.10

NPS

SCH 40

SCH 80

STD

inches inches

inches

1 ½

15.084

15.040

15.084

15.040

15.029

14.978

15.029

14.978

2 ½

14.940

14.882

14.940

14.882

14.867

14.800

14.867

14.800

3½

14.809

14.736

14.809

14.736

14.750

14.670

14.750

14.670

14.627

14.534

14.627

14.534

14.382

14.534

14.382

14.270

14.128

14.270

14.128

14.023

13.840

14.023

13.915

13.790

13.565

13.815

13.715

13.640

13.390

13.690

13.590

13.390

13.115

13.490

13.390

13.140

12.840

13.290

13.190

12.915

12.565

13.090

12.990

-----

12.290

12.890

12.790

12.440

12.015

12.690

12.590

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

15.101

15.065

15.029

14.978

2 ½

15.036

15.007

14.940

14.882

14.974

14.944

14.867

14.800

3 ½

14.924

14.894

14.809

14.736

14.874

14.844

14.750

14.670

14.747

14.727

14.627

14.534

14.640

14.620

14.534

14.382

14.440

14.409

14.270

14.128

14.208

14.183

14.023

13.915

13.990

13.971

13.815

13.715

13.865

13.840

-----

13.658

13.640

-----

13.458

13.440

-----

13.240

13.216

-----

13.040

13.016

-----

12.816

12.790

-----

(-----) unavailable

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.

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

2540 High Performance Flow Sensor

lower hex nut

and jam nuts

sensor flange

18 inch

threaded rods

359 mm (14.14 in)

process pipe (side view)

direction

of flow

alignment rod

Upper hex nuts

(3/16 x 1/4-20)
1/4 in. lock

washers

sensor

fitting

bleed valve

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!

alignment
rod

sensor
flange

process pipe
(top view)

The flow alignment rod

MUST

parallel to the process pipe as shown.

flow direction

Fig. 9

Fig. 10

Fig. 11

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)

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)

5.7 Hot-Tap Sensor Installation

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)

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.

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.

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)

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

"H"

process
pipe wall I.D.

sensor
fitting

upper hex nuts
& lockwashers

lower hex nuts

jam nuts

sensor
flange

cap nuts

female pipe fitting

FLOW

sensor fitting

hex nut

Lock washer

alignment
rod

sensor
flange

process pipe
(top view)

The flow sensor alignment rod

MUST

parallel to the process pipe as shown.

flow direction

Fig. 6

Fig. 7

Fig. 8

5.6 Standard Sensor Installation

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. 4)

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)

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

alignment hole on the sensor fl ange is pointing downstream.

sensor fitting

hex nut

Lock washer

Fig. 4

Fig. 5

process pipe

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

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

"H"

sensor fitting

hex nut &
lock washer

2540 High Performance Flow Sensor

protector plate
hex nut

protector plate
cap nuts

protector plate

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.

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)

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.

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)

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

(Fig. 15)

swivel mount
w/cable port

installation tool
threaded shaft

sensor flange

bearing plate

cap nuts

protector plate

hex nuts

sensor body

sensor

cable

Hot-Tap Sensor Installation - Continued

Fig. 13

Fig. 14

Fig. 15

"H"

jam nuts

lower hex nuts

alignment rod

installation
tool shaft

cap nuts

upper hex nuts

direction
of flow

isolation valve

25 mm
(1.0 in.)

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

protector plate
cap nuts

protector plate
removed during
sensor installation

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)

Fig. 12

2540 High Performance Flow Sensor

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.

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)

Raise

one

lower hex and jam nut to bottom of sensor fl ange.

Close isolation valve, remove bearing plate and tool.

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
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.

installation tool
threaded shaft

sensor flange

cap nuts

upper hex nuts

1 lower hex nut

and jam nut

sensor body

installation tool
bearing plate

protector plate

hex nuts

swivel mount
w/cable port

Fig. 18

8. Maintenance

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

protector plate
hex nut

protector plate
cap nuts

protector plate

Fig. 16

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

Fig. 17

7. Hot-Tap Sensor Removal

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

Remove the cap nuts, protector plate and protector plate hex nuts. (Fig. 16)

Thread installation tool in place and secure bearing plate in place of sensor protector plate.

(Fig. 17)

Turn shaft of installation tool

clockwise

to lower tool into opening in sensor fl ange. Guide

cable into the port to prevent damage.

Rotor Replacement Procedure

1. With a small pair of needle-nose

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.

2. Remove retainer from each side by

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

Existing
Retainer

New
Bearings

Rotor
Assembly

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. Tap the second retainer (rotor pin

clearance hole inwards) into the
hole while lining up the rotor pin with
the center of the retainer hole. This
completes the rotor replacement
procedure.

Punch

Retainer

Rotor Pin

2540 High Performance Flow Sensor

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

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

SCH 5S STAINLESS STEEL PIPE
PER ANSI B36.19

K-Factor K-Factor

PIPE PULSES/ PULSES/
SIZE U.S.

GAL LITER

½ 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

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

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

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

2540 High Performance Flow Sensor

SCH 80S STAINLESS STEEL PIPE
PER ANSI B36.19

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

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

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

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

2540 High Performance Flow Sensor

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,

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 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):

Fluoroloy B®

Standard Sensor Dimensions:
• 2540-1(S) = 1½ in. NPT fi tting
• 2540-2(S) = IS0 7-R 1½ fi tting

Hot-Tap Sensor Dimensions:
• 2540-3(S) = 1½ in. NPT fi tting
• 2540-4(S) = IS0 7-R 1½ fi tting

457 mm

(18 in.)

Adjustable

length

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

24 mm (0.94 in.) dia.

64 mm (2.5 in.) dia.

Bleed
valve

7.6 m
(25 ft.)
cable

O-ring
seals (2)

Adjustable

length

7.5 m (25 ft.)
integral cable

24 mm (0.94 in.) dia.

64 mm (2.5 in.) dia.

127 mm

(5.0 in.)

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

O-ring
seal (1)

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.

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.

2540 High Performance Flow Sensor

Notes:

Georg Fischer Signet LLC, 3401 Aerojet 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

3-2540.090 Rev. D 08/07 English

Printed in U.S.A. on recycled paper

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

11. Ordering Information

Mfr.

Part

No.

Code

Description

3-1500.663

198 820 008

Hot-Tap Installation Tool

1220-0021

198 801 186

O-ring, FPM

1224-0021

198 820 006

O-ring, EPDM

1228-0021

198 820 007

O-ring, Kalrez

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, Fluoroloy B

/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

Accessories and Replacement Parts

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

Sensor Part Number

3-2540

Stainless Steel High Performance fl ow sensor with removable electronics

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

3-2540

-1

Example Part Number

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

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