Nivetec Signet P525-1 User manual

*P52590-1*
P52590-1 Rev. S 8/15
Signet 525 Metalex Flow Sensor
Operating Instructions
Dimensions
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 fiber reinforced PTFE
Gasket ...............................KLINGER® sil C-4401 (supplied with fitting)
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 fittings................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)
Specifications
* 7.6 m (25 ft) cable included
**
SIGNET SIGNET
38.4 mm
(1.5 in.) 63.5 mm
(2.5 in.)
27 mm
(1.06 in.)
27 mm
(1.06 in.)
P525-1, P525-1S P525-2, P525-2S
P525-2, P525-2S
retainer retainer
rotor pin
bearing bearing
rotor
P52509 & P52509-2 Rotor Kits
P525-1, P525-1S
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2Signet 525 Metalex Flow Sensor
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.
Refer to your local Georg Fischer Sales office 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 office 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 buffers, 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,
chemical poisoning, dry-out) or
mishandling (e.g. broken glass, damaged membrane, freezing
and/or extreme temperatures).
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
Location of Fitting
Sensor Mounting Position
Warranty Information
Product Registration
Safety Information
Recommended sensor
upstream and downstream
mounting requirements.
45°
45°
• 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
flow only.
1. Do not remove from pressurized lines.
2. Do not exceed maximum temperature and pressure
specifications.
3. Pipe fitting must be installed by certified 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!
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
25x I.D. 5x I.D.
2 x 90° Elbow
Maintenance
The 525 sensor requires little or no maintenance of any kind,
with the exception of an occasional sensor/paddlewheel cleaning.
Paddlewheel Maintenance:
Paddlewheel flow 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 specifications,
characteristics of the measured fluid, and installation details.
These can include, but are not limited to: process flowrate,
occurrence of water hammer, fluid corrosiveness and
abrasiveness, sensor installation relevant to other equipment.
GF Signet offers individual replacement parts and rotor
replacement kits, which include replacement instructions,
allowing customers to perform field 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 flange bolts and lock washers.
Pull upward on the sensor flange with an alternating
twisting motion.
WARNING!
Do not remove from pressurized lines.
Wear safety goggles and faceshield
during installation/service.

3
Signet 525 Metalex Flow Sensor
Sensor-Fitting Selection
The 525 is designed for installation into SCH 40 stainless steel
pipes via the Signet Metalex Tee, Mini-Tap.
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
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
Mini-Tap Fitting,
hardware included
525-2 Sensor
(525-2S for stainless steel pin)
Wetted fitting
materials:
316 SS
347 SS
+GF+
Tee Fitting,
hardware included
+GF+
525-1 Sensor
(
525-1S for stainless steel
p
in
)
Wetted fitting
materials:
316 SS
Required Hardware
Sensor Installation
Sensor Wiring
Tee & Mini-Tap Fitting Installation
Signet Metalex Tee & Mini-Tap Fittings, P526-2XXX
• 0.5 to 1 inch pipes: P526-2 series fitting required
• 1.25 to 12 inch pipes: P526-2 series fitting and 27 mm
(1-1/16 in.) diameter drill required
NOTE: Mini-Tap fittings are welded onto the pipe and are used
with Signet 525-1 and 525-2 sensors.
1. Set the gasket supplied with the fitting onto the fitting
flange, making sure the holes align.
2. Remove the red rotor protection cap and insert the
sensor into the fitting, making sure not to bump the rotor
assembly. Make sure the arrow on the side of the sensor
is pointing in the direction of flow.
Flow
Flow sensor
arrow
Fitting
flange
3. Slip two washers onto each bolt and insert the bolt/
washer onto each of the four fitting flange holes.
4. Snug all four flange bolts in a criss-cross pattern. Using a
torque wrench (when possible), torque the flange nuts in
a crisscross pattern to 52 foot pounds.
14
23
Flange
bolt torque
pattern
• 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.
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 fitting/pipe size:
Signet Tee Fittings, 0.5 in. to 1 in.
• Insert pipe into fitting socket
• Make sure the pipe is parallel to the bottom of the
Mini-Tap fitting.
• 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 fitting onto the pipe, making sure the
hole in the pipe is lined up with the Mini-Tap fitting hole.
• Weld the Mini-Tap fitting onto the pipe.
CAUTION
Welds MUST be made by a certified welder who
is licensed to weld stainless steel and other high
carbon grade steels.
9900 Terminal
DATA
GND
SHLD
V+
Black
Red
Shield
No Connection
Frequency

K-Factors
The K-Factor is the number of pulses the
sensor will generate for each engineering
unit of fluid 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 fluid 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
SCH 40S Stainless Steel Pipe per ANSI B36.19
Pipe Size
(inch)
K-Factor Pulses/
U.S. GAL
K-Factor Pulses/
U.S. Liter
A-Factor
GPM / Hz
A-Factor
LPM / Hz
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
Rotor Replacement Procedure
1. With a small pair of needle-
nose pliers, firmly 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.
Rotor Pin
Existing
Retainer New
Bearings
Rotor
Assembly
Punch
Retainer
Rotor Pin
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.
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
Part No. Code Description
P525-1 198 801 494 Metalex Flow sensor with tungsten carbide pin; ½ in. to 1 in. socket-weld tee fittings
P525-2 198 801 495 Metalex Flow sensor with tungsten carbide pin; 1¼ in. to 12 in. weld-on mini-tap fittings
P525-1S 159 000 963 Metalex Flow sensor with stainless steel pin; ½ in. to 1 in. socket-weld tee fittings
P525-2S 159 000 964 Metalex Flow sensor with stainless steel pin; 1¼ in. to 12 in. weld-on mini-tap fittings
Accessories and Replacement Parts
P52509 198 801 501 Rotor kit: rotors, 316 stainless steel pin, carbon fiber reinforced PTFE bearings, SS retainers
P52509-2 159 000 480 Rotor kit: rotors, tungsten carbide pin, carbon fiber 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 fiber 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
P52590-1 Rev. S 8/15 English
Ordering Information