Helical Flow Meter Manual
Contents
1. Flow rate Liters min 242 Helical Flow Meter Typical Pressure Drop Delta P versus flow rate for various viscosities Expected Failure Area ntinuous Duty Pressure Drop psi 1 100 500 1000 Flovv rate Liters min 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 2015 Rev 003Q4 14 Limited Warranty The Seller warrants all equipment manufactured by it to be free from defects in materials and workmanship in normal service for a period of twelve 12 months from the date of shipment When given prompt notice by the Purchaser the Seller shall in complete fulfillment of its liabilities under this warranty correct by repair or replacement any such defect without charge F O B the Seller s factory with the following stipulations 1 Product is not to be returned to Seller without first obtaining a product evalu2. Process Temperature C Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 003Q4 Installation For optimum performance install the flow meter on the discharge side of the pump in one of the configurations shown on page 9 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 fla
3. 100 flow 3 CPS 114 0 7 10 2 Maximum temperature Up to 265 C 500 F 3 Recommended filtration 150 micron Displacement L Rev 0 062 0 182 Weight Kg Lb 13 6 30 18 2 40 4 Typical K Factor pulses liter 295 Transmitter 15000 5000 289 700 Transmitter 403 219 Port size NPT 15 2 5 ANSI RF flanges 1 5 DN40 2 5 DN65 Notes For viscosities of 3 CPS or less Derate per pressure drop curves for higher viscosites 2 Limited by meter seal material transmitter model orientation and ambient temp See manual Consult factory 3 Some materials may have different filter requirements Consult factory 4 Typical See flow meter transmitter calibration sheet for actual K factor and accuracy data Dos and Don ts Run water or aqueous solutions through the meter except the 234 Series of meters Install a bypass line around the meter Clean the filter on a regular basis Purge air from the meter before operating your system PUL Sea or Compresso ait Lar OU gine MELIK Flowing near the meters maximum flow rate for a given viscosity will purge air bubbles Tilting tapping or Disassemble the meter Apply excessive differential pressure across the meter shaking the meter at lower flow rates will also dislodge entrapped air Exceed the maximum flow rates or pressure ratings for your meter Let materials solidify in the meter Try to pump through the meter if it contains frozen material Re melt the material completel
4. 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 2015 Rev 00304 10 Installation 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 lb 2 The transmitter lid has four thread paths To realign the cable remove the lid and rotate up 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 transm
5. Helical Flow Meter HELICAL FLOW METER Bypass BYPASS pete VALVE 3 Horizonal Two Way Flow Installation FILTER Flow gt Valve 1 Filter Filter Valve 2 VALVE 1 Helical Flow Meter Bypass FLOW i Valve 3 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 Torque For Line Pressure ft lb Absolute Stress at Flange N m Max Torque Max Torque See notes below ft lb N m a psi Qty Size 500 1000 1500 2500 3500 241 600 Flange 4 3 410 24 33 49 67 73 99 200 271 47 904 241 25004 Flange 4 1 1 8 7 37 50 73 99 110 149 183 248 256 247 681 924 47 189 242 600 Flange 8 3 410 24 33 47 64 71 96 200 271 41904 242 1500 Flange 1 8 31 42 63 86 94 128 157 213 219 297 483 656 47 822 co Notes Using the 241 or 242 meters at pressures greater than 500 psi vvill require flanges Max has bolt hits available for flange installations 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 Manual Cop
6. 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 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 2015 Rev 00304 13 241 Helical Flow Meter Typical Pressure Drop Delta P versus flow rate for various viscosities j o o D o Expected Failure Area e oR O N O O Pressure Drop psi D fee SS a D o N o
7. 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 0 2 uSec Output Update Rate 1ms Min Max Frequency 0 60 kHz Resolution 1 1000 pulses rev Single Phase 1 500 pulses rev phase Quadrature Ambient Temperature Range Transmitter Storage 40 C to 85 C 40 F to 185 F 2 Transmitter Operation 40 C to 80 C 40 F to 175 F Maximum Temperature Process Fluid For explosion proof models see http www maxmachinery com content explosion proof installation instructions 20 C Ambient 5V supply 29X XOX XXX Standard Model 90 C 195 F 29X X5X XXX High Temp Model 2 part model 225 C 435 F Anti dither Range Software selectable from 1 100 of 1 revolution 50 of a meter revolution unidirectional 2 bidirectional are typical default settings Signal Filtering Software selectable from Ims 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 Temperature Range Specification Analog amp Freq 120 4 no 100 80 60 40 295 amp 296 296 295 amp 296 Standard High Ultra High temperature temperature 2 part pickup 2 part pichup 20 Ambient Temperature C 100 250 300
8. 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 performance 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 2015 Rev 00304 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 Indicator Manual A signal cable available from factory Calibration Certificate The display or signal processing device 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 o
9. ation of up to 16 points to fully describe the flow meter s output curve 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 for a 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 2015 Rev 003Q4 4 Meter Specifications Model 241 242 1 Maximum flow rate Gal min 50 132 Liters min 189 500 Maximum pressure bar psi Standard NPT 35 500 35 500 600 Ib ANSI RF flanges 105 1500 105 1500 1500 Ib ANSI RF flanges a 245 3500 2500 Ib ANSI RF flanges 245 3500 Pressure drop bar PSI Operating maximum 10 150 7 100 Absolute maximum 21 300 15 200
10. ation quote number from our Customer Service Department at 707 433 2662 2 Seller assumes no liability for charges incurred for repairing removal or replacement or for repairs made outside of its factory 3 Seller reserves the right to inspect products claimed defective under warranty and is the final authority on the validity of the warranty claim Actions that void the warranty include but are not limited to disassembly of the meter failure to install recommended filtration or passing incompatible liquids through the meter IT IS EXPRESSLY AGREED THAT THIS WARRANTY OR ANY OTHER WARRANTY STATED OR REFERRED TO ON THE SALES ORDER DOCUMENT IS EXCLUSIVE AND IN LIEU OF ANY OTHER WARRANTY OF MERCHANTABILITY FITNESS OF PURPOSE OR ANY OTHER WARRANTY OF QUALITY EXPRESS OR IMPLIED Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 00304
11. ers to provide extremely precise flow measurement in a cost effective package 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 Lineariz
12. itter 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 Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 003Q4 11 Electrical Installation Wiring Helical 289 NPT Models 6 Pin Connector Circuit Board Mating Cable Pin Amphenol Terminal Wire Color Connector Case Ground 1 Green A Common 2 Black B Power 5 24 VDC 3 Red C Pulse Output 4 White D Electrical Installation Wiring All other transmitters The electrical connector versions are pre wired inside the transmitter and ready to accept a mating cable available from the factory Frequenc Turck Game pime lapse Analoge Mating cable Pin Connector Quadrature Male Female Case Ground Case Ground Case Ground Blue 3 Common Common Common Black 4 4 3 Power 5 26 Vdc Power 5 26 Vdc Power Brown 1 Pu
13. lse Output Output Phase A Signal Output White 2 1 2 N A Output Phase B Signal Output Grey 5 Note There are no selections or adjustments to be made on the circuit board The only method of altering the setup parameters is through the Serial Interface Program Analog transmitters with part numbers 29X XXX O00 or ending in A 1 or C 1 are 24Vdc power Part numbers 29X XXX 100 or ending in B 1 or D 1 are 12Vdc power To minimize noise analog output transmitters are fully isolated If your system does not ground the negative signal input you should install a 10k pull down resistor between Common and Signal Output This will avoid the risk of ground shifts which could drive the signal out of range Current Sinking Wiring Part 295 600 000 and versions ending with S 1 A current sinking device is essentially a switch where the transmitter s output opens and closes a switch A positive DC voltage must be applied to the transmitter s output pin When the output is triggered this voltage will be Digital Input grounded to zero volts by the transmitter Use a 5k ohm resistor to limit current e if your system does not have any other means to limit the current into the Turck Pin 2 transmitter Transmitter Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 00304 12 Troubleshooting Corrective Action No Flow through meter or high pressure drop across meter
14. max Positive Displacement Flowmeters Operational Manual For Models Model 241 242 240 Helical Series Positive Displacement Flow Meters Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 003Q4 Table of Contents Before You lNstall irsinin page 3 Meter General Description uu eesececeestssceceesectceseeeeseeees page 3 Transmitter General Description ee eeeseeseceeecteeeeeeeees page 4 Meter Specifications sssscssesscsceccecssscscsesscsceseeseeseeees page 5 Do and DOM TS iaia aa EU EGGU Ga cama ii page 5 Transmitter Specifications Analog oc seeeeteteeeeeeeees page 6 Transmitter Specifications Frequency Pulse page 7 installati Meen aaia page 8 Piping Dia Qrann 4 ccescecscaes cece czesdecdesen cesscees ceceeteasateacescestecstcnee page 9 ANSI FlangeANSI Flange Stud Torque ou eeeeceeteeeeeeees page 9 QD ORATION cisescsecescstcescsasseertcectanntzeateesseastecsescaterssanntaneecvteenanse page 10 TroubleSNOOtN Genina page 13 241 Helical FlOW MCleM in sicannaniannaunndngandanaats page 14 242 Helical Flow Meter Contact for Repairs amp Calibration Services Limited Warranty c icceiediccaiesSecocacecgesesdecesecbeecococecsceceaesecoeeea page 15 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
15. nges 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 meter 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 Or clamp both endcaps o WIE Not 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 or 242 meters at pressures greater than 500 psi will also require flanges See the specifications and bolt torque table on page 9 Max has bolt kits available for flange installations Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 00304 8 Piping Diagrams Vertical Installation Horizonal One Way Flow Installation Flow gt VALVE 2 Valve 1 Filter Valve 2
16. r PO Installation Date Meter Model Meter Serial Transmitter Model Transmitter Serial Notes Meter General Description The Max 240 Series Flow Meters are positive displacement helical rotor type units capable of precise measurements over a wide range of flow rates and fluid viscosities The two sizes of this series 241 and 242 will measure flows from 0 1 L min to 500 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 Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 00304 3 Transmitter General Description Max transmitters are designed to work with the entire family of Max Flow Met
17. y before trying to pump through the flow meter Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 00304 5 Transmitter Specifications Analog Supply Voltage 12 Vdc Models 29X XXX 100 24 Vdc Models 29X XXX O00 Supply Current 90 mA max 12 Vdc 45 mA max 24 Vdc Short Circuit Current 21mA Output Update Rate 1ms Resolution Adjustable without recalibration to any range of 10 Vdc Model 29X 3XX XXX or 20 mA Model 29X 2XX XXX Ambient Temperature Range Transmitter Storage 40 C to 85 C 40 F to 185 F 2 Transmitter Operation 40 C to 80 C 40 F to 175 F Maximum Temperature Process Fluid For explosion proof models see http www maxmachinery com content explosion proof installation instructions 20 C Ambient 5V supply Standard Model 90 C 195 F Models 295 amp 296 High Temp Model Model 296 Ultra High Temp Model 225 C 435 F Models 295 amp 296 Anti dither Range Software selectable from 1 100 of 1 revolution 50 of a meter revolution unidirectional 2 bidirectional are typical default settings Signal Filtering 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 Max Machinery Inc 240 Series User Manual Copyright 2015 Rev 00304 Transmitter Specifications Frequency Pulse Supply
18. yright 2015 Rev 00304 9 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 I 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 equation 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
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