Positive Displacement Flowmeters Operational
Contents
1. Valve 1 Filter Filter Valve 2 Helical Flow Meter VALVE 1 Bypass FLOW Valve 3 Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 11 ANSI Flange Stud Torque 240 Series ANSI Flange Stud Torque Requirements This table shows the minimum torque required for a 2 1 tightening factor at the indicated pressures using zinc plated studs and nuts These values were calculated using studs with a yield strength of Sy 75 000 psi Meter Studs Flange Qty Size 241 600 Flange 4 3 410 241 25004 Flange 4 1 1 8 7 242 600 Flange 8 3 410 242 I500 Flange 8 1 8 243 600 Flange 8 7 8 9 243 ISOOH Flange 8 1 1 4 7 Notes Using the 241 242 or 243 meters at pressures greater than 500 psi will require flanges Max has bolt kits available for flange installations Torque For Line Pressure ft Ib N m See notes below 500 24 33 51050 24 33 31 42 59 72 76 103 1000 49 67 TON EE Af 64 63 86 106 144 151 205 1500 o 110 149 VI EAS 94 128 159 216 22308 2500 183 248 lov 215 SONDI For unplated non lubricated nuts and studs multiply the above torque by 1 5 For lubricated nuts and studs multiply the above torque by 0 9 For cadmium plated nuts and studs multiply the above torque by 0 8 Stress in bolt calculated for thread root diameter Max Machinery Inc 240 Series User M2. 10 20 30 50 100 200 300 500 1k 2k 3k Flow Rate L min Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 19 Contact for Repairs amp Calibration Services Your Max 240 Series Meter should be repaired at the factory or under the direct supervision of the Max Technical Service Department Unauthorized repair work may damage the meter and will void the product warranty Please make note of model and serial numbers on the flow meter before calling the factory A return goods authorization number RMA will be issued if the flow meter has to be sent back for repair Max Machinery Inc Phone 707 433 2662 33A Healdsburg Ave Fax 707 433 1818 Healdsburg CA 95448 www maxmachinery com Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 20
3. T Run water or aqueous solutions not approved by Max through your flow meter because of internal galling DON T Steam clean the meter bypass or remove the meter if necessary DON T Blow down the meter with compressed air or gas because it may over speed and damage the meter DON T Remove the Transmitter from the flow meter body The transmitter is phased to the meter and a measurement error will result Re calibration will be necessary see the transmitter interface software manual DON T Disassemble the flow meter These are precision devices which require special tools and techniques DON T Turn on the pump in a system filled with material that is solid at room temperature Wait until the material is completely melted and use the flow meter bypass valve during start up DON T Apply excessive differential pressure across the flow meter as it will cause internal failure see the pressure drop curves for safe area operation DON T Over pressurize the meter Maximum pressure is either 35 bar 500 PSI 105 bar 1500 PSI or 245 3500 PSI depending on model purchased DON T Exceed the maximum flow rates for the material viscosity DON T Allow materials which solidify in air to set up in the flow meter These may be impossible to remove If the meter needs to be removed for repair and cannot be completely cleaned Plug the inlet and outlet ports at once Rev 002QA 9 Installation For optimum performance install the flo
4. age 40 C to 85 C 40 F to 1850F Transmitter Operation 40 C to 809C 400F to 1759F Maximum Temperature Process Fluid For explosion proof models see http www maxmachinery com content explosion proof installation instructions 209C Ambient 5V supply 29X XOX XXX Standard Model 909C 1959F 29X X5X XXX High Temp Model 2 part model 2259C 435 F Anti dither Range Software selectable from 1 100 of 1 revolution 5090 of a meter revolution unidirectional 2 bidirectional are typical default settings Signal Filtering Software selectable from 1ms to 250ms time constant Full step change is subject to signal damping Temperature of metered fluid will affect transmitter temperature see graph on previous page Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 Do and Don ts DO Install bypass plumbing around the flow meter This is useful during start up for removing dirt and air from the plumbing or when measuring fluid that may freeze inside the line and need to be remelted before it can pass through the meter It also allows removing the flow meter for service without disabling the system DO Be very careful to keep parts clean during installation or teardown A little dirt can look like a truckload compared to the 150 micron filtration requirement for series 240 Meters DO Clean the filter on a regular basis Max Machinery Inc 240 Series User Manual Copyright 2013 DON
5. anual Copyright 2013 3500 256 247 Ser 529 718 Rev 00204 Absolute Max Torque ft Ib N m 200 271 681 924 ZIDO TD 483 656 322 437 265 1010 Stress at Max Torque psi 47 904 47 189 47 904 47 822 41 912 47 802 Operation Determine that the following parameters of your flow metering system are within specifications for the specific 240 Series Meter being used Maximum System Pressure Specifications Differential Pressure across meter Pressure Drop Curves Maximum Flow Rate Pressure Drop Curves Metered Fluid Temperature Sales specification transmitter manual If the metered fluid is greater than 80 F 28 C over ambient see the High Temperature Start Up section With valves one and two closed slowly open valve three bypass to clear the lines of foreign particles and air Slowly open the inlet valve 1 Slowly open the outlet valve 2 Completely close the bypass valve No routine maintenance cleaning or lubrication of the flow meter is required A routine filter cleaning schedule should be established The system should be shut down if abnormal noises occur or if unusual differential pressures across the meter are encountered High Temperature Start Up For fluids above 150 F 82 C based on 70 F ambient a special procedure is required to prevent thermal shock and permanent damage to the flow meter The warm up time is determined by the equat
6. ckage Different options of industrial housings or IP66 rated explosion proof enclosures combined with a choice of one part and two part high temperature designs with remote electronics cover a wide range of application environments from the laboratory to harsh industrial processes This latest generation of transmitters use modern sensor technology coupled with advanced signal processing to deliver high levels of performance and reliability Hall sensors are used to detect the position of a driven magnet inside a Max Flow Meter Changes in position are tracked by a microprocessor which generates an output proportional to the flow rate Advanced signal processing provides both fine angular resolution 0 36 degrees rotation and rapid response output updated every one millisecond Max transmitters are typically mated to a mechanical flow meter configured and calibrated at the factory as a set This ensures accuracy and allows quick setup in the field For field installations where the transmitter has not been set up with a meter at the factory an optional serial interface kit may be purchased to give full access to configuration options and parameters Transmitter Features High resolution measurement Analog Output Configured output ranges to any value within 10 Vdc or 20 mA Frequency Output Configured output resolution of 1 to 1000 pulses per revolution Linearization of up to 16 points to fully describe the flow meter s output cu
7. e data Although every effort has been made to ensure accuracy of the information contained in this Instruction Manual MMI assumes no responsibility for inadvertent errors Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 2 Before You Install Thank you for choosing to install a Max Machinery precision flow meter To ensure the best experience please take a moment to read through this manual prior to installation When you purchased this meter a flow engineer helped determine many of the factors that will be reviewed on the following pages You may find it useful to fill out the form below and keep it in your files for reference When you are ready to do the installation there will be a few tools you will need Meter Installation The meter and transmitter A signal cable available from factory The display or signal processing device Indicator Manual Calibration Certificate Bypass plumbing supplies Many Max meters are installed and operate for decades so having the following information in your records may prove useful We have provided this outline as a starting point Process Temperatures Fluid Viscosity Operating Range Line Pressure Max Sales or PO Installation Date Meter Model Meter Serial Transmitter Model Transmitter Serial Notes Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 3 Meter General Description The Max 240 Series Flow Meters are positive displac
8. ement helical rotor type units capable of precise measurements over a wide range of flow rates and fluid viscosities inlet outlet The three sizes of this series 241 242 and 243 will measure flows from O 1 L min to 1400 L min Material viscosities between 3 and 1 000 000 centipoise may be accommodated In a helical rotor type flow meter a precise amount of the fluid being measured is trapped between the rotors as they turn This motion is used to turn a gear coupled to a magnet An external transmitter senses the motion of the magnet and converts this signal into a voltage pulse or 4 20 mA current flow rate output For some transmitter models the magnet is eliminated and the motion of the gear itself is sensed The Max Series 240 Meters are of simple and rugged construction They can be expected to perform superbly if treated within the confines of the design envelope For this reason it is important to read this manual and understand the operational requirements and limits of the meter Our Technical Service staff will be happy to answer any questions that this manual does not cover Helical Model 241 Helical Model 242 Helical Model 243 with transmitter attached Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 4 Transmitter General Description Max transmitters are designed to work with the entire family of Max Flow Meters to provide extremely precise flow measurement in a cost effective pa
9. have anti dither functions which can buffer up to 1 revolution of reverse flow An incorrect flow total can be reported if the pumping causes a flow and ebb of greater than 1 meter revolution Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 16 241 Helical Flow Meter CONNECTIVITY DIMENSIONS 9 55 243 mm Add 0 4 10mm for high pressure body Top View End View TYPICAL PRESSURE DROP Delta P versus Flow rate for various viscosities OV I o O i z 8 n I en Pressure Drop psi Co O 40 Flow Rate L min Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 17 242 Helical Flow Meter CONNECTIVITY DIMENSIONS 10 85 276 mm awe Zon 2e Ly Sei Add 1 32 34mm for high pressure body TYPICAL PRESSURE DROP Delta P versus Flow rate for various viscosities dq ec 8 100 _ az 3 b B 2 o S co Continuous gi l 5 A 40 n l 2 be EE Ea EE a 1 2 3 5 10 20 30 50 100 200 300 1k 2k Flow Rate L min Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 18 243 Helical Flow Meter CONNECTIVITY DIMENSIONS Top View End View TYPICAL PRESSURE DROP Delta P versus Flow rate for various viscosities 8 bar Pressure Drop psi O
10. imum 21 300 15 200 10 150 100 flow 3 CPS 1 14 O 7 10 O 7 10 Maximum temperature Up to 265 C 5OO F 3 Recommended filtration 150 micron Displacement L Rev 0 062 0182 0 574 Weight Kg Lb 13 6 30 18 2 40 45 5 100 Typical K Factor pulses liter 295 Transmitter 15000 5000 1500 289 00 Transmitter 403 219 58 8 Port size NPT 15 2 9 Es ANSI RF flanges 1 5 DN40 2 5 DN65 4 DN100 For viscosities of 3 CPS or less Derate per pressure drop curves for higher viscosites Limited by meter seal material transmitter model orientation and ambient temp See manual Consult factory Some materials may have different filter requirements Consult factory Typical See flow meter transmitter calibration sheet for actual K factor and accuracy data Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002QA Transmitter Specifications Analog Supply Voltage Supply Current Short Circuit Current Output Update Rate Resolution Ambient Temperature Range 12 Vdc Models 29X XXX 100 24 Vdc Models 29X XXX 000 90 mA max 12 Vdc 45 mA max 24 Vdc 21 mA 1ms Adjustable without recalibration to any range of 10 Vdc Model 29X 3XX XXX or 20 mA Model 29X 2XX XXX Transmitter Storage 409C to 85 C 40 F to 1850F Transmitter Operation 40 C to 80 C 40 F to 1759F Maximum Temperature Process Fluid For explosion proof models see http www maxmachinery com c
11. ion below TIME minutes connector size in inches x operating temperature F 125 10 OR TIME minutes connector size in inches x operating temperature C 52 10 Valves one and two must be closed Open the bypass valve 3 in gradual steps until the bypass piping is stabilized at operating temperature Open valve one slightly and allow the temperature to stabilize around the flow meter Valve one can then be opened completely Open valve two slightly The flow meter may make unusual noises or bind at this point Leave the valve at this setting until normal meter operation occurs at which point valve two can be gradually opened all the way Slowly close the bypass valve 3 Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 13 Electrical Installation Wiring 290 Series Transmitters Removal note The transmitter does not need to be removed from the flow meter for any field servicing or adjustments Normally the flow meter and transmitter are shipped back to the factory for calibration or service as a unit If the transmitter needs to be removed from the flow meter for installation be sure to retighten the transmitter snugly in order to ensure proper sensor alignment Mechanical Installation 1 The transmitter is attached to the flow meter s threaded magnet shield Hand tighten only 3 ft Ib 2 The transmitter lid has four thread paths To realign the cable remove the lid and rotate u
12. is fully isolated If attached to a true differential input a 10K Ohm pulldown resistor should be installed between and common at the receiving end Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 14 Electrical Installation Wiring Wiring FREQUENCY The electrical connector versions are pre wired inside the transmitter and ready to accept a mating cable available from the factory The liquid tight NPT models need to be wired during installation as shown in the table below Frequency Current Sinking Wiring Single Phase All Other Mating Cable Turck models 29X 6XX Models Wire Color Pin H Case Ground Case Blue 3 Common Com Black 4 Power 5 26 Vdc We Brown 1 SC Pulse Output Ph A White 2 N A NC Grey 5 A current sinking device produces an output pulse which is the opposite of a sourcing device A positive DC voltage must be applied to the wire running between PhA and your PLC When the output is triggered this voltage will be grounded to zero volts Note use a 5k ohms resistor to limit the current flow in the signal line l Transmitter Frequency All Other Models Mating Cable Turck Turck Connector Quadrature Wire Color E Case Ground Case Blue 3 3 Common Com Black 4 Power 5 26 Vdc V Brown 1 Output Phase A Ph A White E ws Output Phase B Ph B Grey 5 Electrical Installation Wiring 280 Series Transmitters Wiring The 6 pin connector version is pre wired inside the transmit
13. max Positive Displacement Flowmeters Operational Manual For Models Model 241 242 243 240 Helical Series Positive Displacement Flow Meters Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 00204 Table of Contents BOrere OU MIA EE page 3 Meter General Description eee page 4 Transmitter General Description eese page 5 Meter Specifications esee eene eene nnns page 6 Transmitter Specifications EO OO P page 7 Transmitter Specifications xen ui E page 8 Biekciielg feig page 9 IVS el Wet Maesen a page 10 PIC RP re Le page 11 ANSI FlangeANSI Flange Stud Torque page 12 CT QUOI EN page 13 Aigo gleiche e wine RM page 16 241 Helical Flow Meter page 17 242 Helical Flow Meter page 18 243 Helical Flow Meter eere page 19 Contact for Repairs amp Calibration SEM VIC Eet page 20 Custom Instructions for Hazardous Locations Explosion Proof Housing http www maxmachinery com content explosion proof installation instructions DO NOT ATTEMPT TO INSTALL OR START FLOW METER WITHOUT READING THIS ENTIRE MANUAL Max Machinery Inc MMI reserves the right to make changes to the product in this Instruction Manual to improve performance reliability or manufacturability Consequently contact MMI for the latest available specifications and performanc
14. ontent explosion proof installation instructions 209C Ambient 5V supply Anti dither Range Signal Filtering Standard Model 909C 1959F Models 295 amp 296 High Temp Model Model 296 Ultra High Temp Model 225 C 435 F Models 295 amp 296 Software selectable from 1 1009 of 1 revolution 50 of a meter revolution unidirectional 2 bidirectional are typical default settings Software selectable from 1 ms to 64 sec time constant Full step change is subject to signal damping Temperature of metered fluid will affect transmitter temperature see graph below Ambient Temperature 9C 110 100 80 60 40 20 Model 29X Transmitter Series 295 amp 296 296 295 amp 296 Standard High Ultra High temperature temperature 2 part pickup 2 part pichup 50 100 150 200 225 250 300 Process Temperature 9C Max Machinery Inc 240 Series User Manual O Copyright 2013 Rev 002Q4 Transmitter Specifications Frequency Pulse Supply Voltage 5 26 Vdc Supply Current 25 30 mA typical Output 5 0 Volt Supply No Load 0 00 4 80 Volts TTL and CMOS compatible 2 5K Load to Common 0 00 4 60 Volts 2 5K Load to 5 Volts 0 25 4 80 Volts Short Circuit Current 45 mA Output Impedance 100 Q Rise Fall Time O 2 uSec Output Update Rate 1 ms Min Max Frequency O 60 kHz Resolution 1 1000 pulses rev Single Phase 1 500 pulses rev phase Quadrature Ambient Temperature Range Transmitter Stor
15. p to 180 and retighten using an alternate starting point Tighten to compress the O ring seal Removal 1 Remove electrical connections 2 Unscrew transmitter using a wrench if necessary WARNING Installation and removal should only be facilitated by trained personnel Verify transmitter output type ANALOG or FREQUENCY before wiring inappropriate wiring could result in damaging the circuit Moisture Seal Protection On all models the housing is designed as a liquid and vapor tight enclosure There are O ring seals at the lid and possibly also the base of the housing these need to be fully seated A properly sealed transmitter will prevent the formation of damaging moisture inside the housing Turck connector Model The connector is sealed to the lid at the factory and is ready for use NPT Model To ensure a moisture tight seal apply appropriate sealant to the threads at installation Wiring ANALOG The electrical connector versions are pre wired inside the transmitter and ready to accept a mating cable available from the factory The liquid tight NPT models need to be wired during installation as shown in the table below 294 NPT model All Other Models Mating Cable Turck Analog VVire Color Pin Case Ground In lid Case Blue 3 Common 1 Com Black 4 Power 2 V Brown 1 Signal Output 5 Sig Grey 5 Signal Output 4 Ret White 2 Model 29X xxx 000 24vdc powered Model 29X xxx 100 12vdc powered Signal output
16. rve and achieve the highest system linearity over the meter s entire operating range Compensation Algorithm Compensates for variations in Hall sensor and flow meter characteristics to provide a stable undamped output that accurately represents the instantaneous flow rate This feature is factory set when the meter and transmitter are mated together If the transmitter is changed the compensation can be performed via a button on the circuit board Anti Dither Buffer Masks the false output that may occur at very low flow rates in the presence of vibration or hydraulic noise If the meter reverses direction the output signal will be interrupted fora EX Proof Housing user selected portion of a meter rotation Reverse flow exceeding the buffer setting will result in an output proportional to reverse flow rate The buffer quantity can be set from 1 to 100 of a revolution Model 289 Model 295 Analog Frequency Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 5 Meter Specifications Notes Model 241 242 243 Maximum flow rate Gal min 50 140 370 Liters min 189 540 1400 Maximum pressure bar psi Standard NPT 35 500 35 500 35 5OO 600 Ib ANSI RF flanges 105 1500 105 1500 105 1500 1500 Ib ANSI RF flanges g 245 3500 245 3500 2500 Ib ANSI RF flanges 245 3500 Se Se Pressure drop bar PSI Operating maximum 10 150 1 100 5 3 75 Absolute max
17. ter and is ready to accept a mating cable available from the factory The Liquid Tight and NPT models need to be wired during installation as shown in the table below NPT Models 6 Pin Connector Circuit Board Mating Cable Date Terminal Wire Color Case Ground 1 Green A Common 2 Black B Power 5 24 VDC 3 Red e Pulse Output 4 White D Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 15 Troubleshooting Corrective Action No Flow through meter or high pressure drop across meter Solidified material blocking rotation Heat meter to melt material Debris blocking rotation Remove meter from line Flush with an organic solvent or petrochemical Try to work debris out of the meter Meter broken If you find damaged parts in the meter return the meter to the factory for repair Fluid is passing through the meter but there is no indication of flow Improper hook up of transmitter Verify that DC power is present at the PCA Use a multi meter to measure the transmitter output independent of the display or PLC Inspect cabling Indicated flow does not agree with expected readings Air in the line Air bubbles displace the meter just as a liquid would If you are over reporting verify that there is no air in the lines Indicator not calibrated properly Verify the K Factor for the meter in use and compare this value to the setting used in the display Excessive reverse flow in system Max transmitters
18. ter body This avoids possible misalignment of flow meter components when the pipe is screwed tight Check for proper flow meter operation by rotating the timing gear through the transmitter mounting hole It should move freely and without noise Clamp here Clamp here Hat here High Temperatures Use the Vertical Installation drawing This minimizes heat transfer by convection from the flow meter to the transmitter The transmitter is the most heat sensitive element in the system and the transmitter manual should be consulted for specific limits Optional heating fluid ports are available for the flow meter to keep it at operating temperature during standby conditions For substances that are solid at room temperature these ports are generally required to keep the material molten and flowing through the meter ANSI Flanges Using the 241 242 or 243 meters at pressures greater than 500 psi will also require flanges See the specifications and bolt torque table on page 12 Max has bolt kits available for flange installations Max Machinery Inc 240 Series User Manual Copyright 2013 Rev 002Q4 10 Piping Diagrams Vertical Installation Horizonal One Way Flow Installation Flow VALVE 2 Filter E Valve 2 Helical Flow Meter Valve 1 HELICAL FLOW METER Bypass Valve 3 BYPASS VALVE 3 13 Horizonal Two Way Flow Installation in Flow _ gt FILTER
19. w meter on the discharge side of the pump in one of the configurations shown on page 11 The following items and conditions should be considered Location Install the flow meter in a clean dry area if possible Avoid areas with high vibration levels Line and Bypass Valves These valves allow filter cleaning or flow meter removal without completely shutting the system down and draining the lines They are important for system start up under conditions which could damage the meter such as air in the lines solid materials at room temperature high temperature materials or initial line surges Filtration Any dirt present in the system can jam or damage the meter A 150 micron filter is generally recommended although materials with very high viscosities may require a coarser filter For bidirectional flow applications use a filter on each side of the flow meter Materials with fibrous or non abrasive particulate matter may have to be run without filters Follow the recommendation of your Max Sales Engineer or consult Technical Service Clean Plumbing Before installing the flow meter clean the inside of the pipe line with compressed air or steam especially when using new pipe Don t use water steam or compressed air on the meter itself Remove any protective covering from the flanges if applicable Pipe Threading When installing pipe to the flow meter support the nearest end cap or both end caps as in a vise Don t clamp the flow me
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