Max 243 User Manual

Positive Displacement

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Flowmeters

Operational Manual

For Model:
Model 243 Only

240 Helical Series

Positive Displacement Flow Meters

Max Machinery, Inc. Discontued: 243 Manual © Copyright 2014 1

Table of Contents

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Meter General Description ...................................................page 3

Transmitter General Description ...................................... page 4

Meter Specications ..............................................................page 3

Transmitter Specications

Analog .......................................................................................page 4

Transmitter Specications

Frequency (Pulse) ...................................................................page 5

Do and Don’ts ..........................................................................page 8

Installation ...............................................................................page 6

Piping Diagrams ......................................................................page 7

ANSI FlangeANSI Flange Stud Torque ..............................page 8

Operation .................................................................................page 9

Troubleshooting .....................................................................page 12

241 Helical Flow Meter ......................................................... page 16

242 Helical Flow Meter .........................................................page 17

243 Helical Flow Meter .........................................................page 13

Contact for Repairs

& Calibration Services ......................................................... page 14

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 specications 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.

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Meter General Description

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The Max 240 Series Flow Meters are positive displacement helical rotor type units capable of precise measurements

over a wide range of ow rates and uid viscosities.

The three sizes of this series (241, 242, and 243) will measure ows from 0.1 L/min to 1400 L/min. Material viscosities

between 3 and 1,000,000 centipoise may be accommodated.

In a helical rotor type ow meter, a precise amount of the uid 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 ow 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 connes 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.

Meter Specications

Model 243

Gal/min 370
Liters/min 1400

Maximum pressure, bar (psi)

Standard NPT 35, (500)
600 lb ANSI RF anges 105 (1500)
1500 lb ANSI RF anges 245 (3500)
2500 lb ANSI RF anges ---

Pressure drop, bar (PSI)

Operating maximum 5.3 (75)

Absolute maximum 10 (150)
100% ow, 3 CPS 0.7 (10)

Displacement, L/Rev 0.574
Weight, Kg (Lb) 45.5 (100)

295 Transmitter 1500
289-700 Transmitter 58.8
Port size

NPT 3”
ANSI RF anges 4” (DN100)

1

Maximum ow rate,

2

Maximum temperature Up to 265° C (500° F)

3

Recommended ltration 150 micron

4

Typical K-Factor, (pulses/liter)

Notes:

1

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 lter requirements. Consult factory

4

Typical. See ow meter/transmitter calibration sheet for actual K-factor and accuracy data.

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Dos and Don’ts

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DO: DON’T:

• Install a bypass line around the meter

• Clean the lter on a regular basis

• Purge air from the meter before operating your system

(Flowing near the meters maximum ow rate for a

given viscosity will purge air bubbles. Tilting, tapping or

shaking the meter at lower ow rates will also dislodge

entrapped air)

• Run water or aqueous solutions through the meter

• Put steam or compressed air through the meter.

• Disassemble the meter

• Apply excessive differential pressure across the meter

• Exceed the maximum ow rates or pressure ratings for

• Let materials solidify in the meter

• Try to pump through the meter if it contains frozen

(except the 234 Series of meters)

your meter

material. Re-melt the material completely before

trying to pump through the ow meter.

Transmitter Specications - Analog

Supply Voltage 12 Vdc (Models 29X-XXX-100)
24 Vdc (Models 29X-XXX-000)

Supply Current 90 mA max@ 12 Vdc, 45 mA max@ 24 Vdc
Short Circuit Current 21 mA

1

Output Update Rate 1 ms

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)–40ºC to 85ºC (–40ºF to 185ºF)

Maximum Temperature, Process Fluid
For explosion proof models see: http://www.maxmachinery.com/content/explosion-proof-installation-instructions

(20ºC Ambient, 5V supply) Standard Model 90ºC (195°F) – Models 295 & 296
High Temp Model – Model 296
Ultra-High Temp Model 225ºC (435°F) – Models 295 & 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

1

Full step change is subject to signal damping

2

Temperature of metered uid will affect transmitter temperature, see graph below

2

Transmitter (Operation)–40ºC to 80ºC (–40ºF to 175ºF)

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Transmitter Specications - Frequency (Pulse)

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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 Ω

Rise/Fall Time 0.2 μSec

1

Output Update Rate 1 ms

Min/Max Frequency 0-60 kHz

Resolution 1 - 1000 pulses/rev, Single Phase
1 - 500 pulses/rev/phase, Quadrature

Ambient Temperature Range Transmitter (Storage)–40ºC to 85ºC (–40ºF to 185ºF)

2

Transmitter (Operation) –40ºC to 80ºC (–40ºF to 175ºF)

Maximum Temperature, Process Fluid
For explosion proof models see: http://www.maxmachinery.com/content/explosion-proof-installation-instructions

(20ºC Ambient, 5V supply) 29X-X0X-XXX Standard Model 90ºC (195°F)
29X-X5X-XXX High Temp Model — 2 part model 225ºC (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 1ms to 250ms time constant

1

Full step change is subject to signal damping

2

Temperature of metered uid will affect transmitter temperature, see graph on previous page

Temperature Range Specication (Analog & Freq.)

Model 29X Transmitter Series

120

110

100

80

60

40

20

295 & 296 296 295 & 296

Standard

High

temperature

2 part pickup

Ultra High

temperature

2 part pickup

Ambient Temperature °C

0

-25

50

100

Process Temperature °C

150 200

225

250

300

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Installation

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For optimum performance, install the ow meter on the discharge side of the pump, in one
of the congurations shown on page 7.

The following items and conditions should be considered:

Location: Install the ow meter in a clean, dry area if possible. Avoid areas with high vibration levels.

Line and Bypass Valves: These valves allow lter cleaning or ow 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 lter is generally recommended,
although materials with very high viscosities may require a coarser lter. For bidirectional ow applications, use a lter
on each side of the ow meter. Materials with brous or non abrasive particulate matter may have to be run without
lters. Follow the recommendation of your Max Sales Engineer or consult Technical Service.

Clean Plumbing: Before installing the ow 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 anges (if applicable).

Pipe Threading: When installing pipe to the ow meter, support the nearest end cap or both end caps (as in a vise). Don’t
clamp the ow meter body. This avoids possible misalignment of ow meter components when the pipe is screwed tight.
Check for proper ow meter operation by rotating the timing gear through the transmitter mounting hole. It should

move freely and without noise.

High Temperatures: Use the “Vertical Installation” drawing. This minimizes heat transfer by convection from the
ow meter to the transmitter. The transmitter is the most heat sensitive element in the system and the transmitter
manual should be consulted for specic limits. Optional heating uid ports are available for the ow 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 owing through the meter.

ANSI Flanges: Using the 241, 242 or 243 meters at pressures greater than 500 psi will also require anges. See the
specications and bolt torque table on page 8. Max has bolt kits available for ange installations.

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Piping Diagrams

HELICAL
FLOW METER

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Vertical Installation

VALVE 2

FILTER

VALVE 1

FLOW

BYPA SS
VALVE 3

Horizonal One Way Flow Installation

Flow

Valve 1

Horizonal Two Way Flow Installation

Flow

Valve 1

Filter

Filter Filter

Valve 2

Helical Flow Meter

Bypass

Valve 3

Valve 2

Helical Flow Meter

Bypass

Valve 3

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ANSI Flange Stud Torque

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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
(Flange)

241 (600# Flange) 4 3/4-1 0 24 (33) 49 (67) 73 (99) 200 (271) 47,904

241 (2500# Flange) 4 1-1/8-7 37 (50) 73 (99) 110 (149) 183 (248) 256 (247) 681 (924) 47,789

242 (600# Flange) 8 3/4-10 24 (33) 47 (64) 71 (96) 200 (271) 47,904

242 (1500# Flange) 8 1-8 31 (42) 63 (86) 94 (128) 157 (213) 219 (297) 483 (656) 47,822

243 (600# Flange) 8 7/8-9 53 (72) 106 (144) 159 (216) 322 (437) 47,9 7 2

243 (1500# Flange) 8 1-1/4-7 76 (103) 151 (205) 227 (308) 378 (513) 529 (718) 965 (1310) 47,802

Studs Torque For Line Pressure ft-lb

(N-m)

See notes below

Qty Size 500 1000 1500 2500 3500

Absolute

Max Torque

ft-lb (N-m)

Stress at
Max Torque
(psi)*

Notes:

Using the 241, 242 or 243 meters at pressures greater than 500 psi

ange 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.

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will require anges

. Max has bolt kits available for

Operation

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Determine that the following parameters of your ow metering system
are within specications for the specic 240 Series Meter being used:

Maximum System Pressure (Specications)

Differential Pressure across meter (Pressure Drop Curves)

Maximum Flow Rate (Pressure Drop Curves)

Metered Fluid Temperature (Sales specication, transmitter manual)

If the metered uid 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 (# l). Slowly open the outlet valve (# 2). Completely close the bypass valve.

No routine maintenance, cleaning, or lubrication of the ow meter is required. A routine
lter 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 uids above 150°F (82°C) based on 70°F ambient, a special
procedure is required to prevent thermal shock and permanent damage to the ow 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 (# 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 ow meter. Valve one
can then be opened completely. Open valve two slightly. The ow 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).

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Electrical Installation - Wiring

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290 Series Transmitters

Removal note: The transmitter does not need to be removed from the ow meter for any eld servicing or adjustments.
Normally, the ow 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 ow 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 ow 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 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:

Analog

Case Ground In-lid Case Blue 3

Common 1 Com Black 4

Power * 2 V+ Brown 1

Signal Output (+) 3 Sig Grey 5

Signal Output (-)** 4 Ret White 2

*Model 29X-xxx-000, 24vdc powered, Model 29X-xxx-100, 12vdc powered

** Signal output 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.

294 NPT model All Other Models Mating Cable

Wire Color

Turck
Pin #

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21

4

5

3

Electrical Installation - Wiring

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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
Single Phase

Frequency

Case Ground Case Blue 3

Single Phase

Common Com Black 4

Wiring

Power 5-26 Vdc V+ Brown 1

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 ow in the signal line.

Frequency

All Other

Models

All Other Models Mating Cable

Quadrature

Case Ground Case Blue 3

Common Com Black 4

Power 5-26 Vdc V+ Brown 1

Output Phase A Ph A White 2

Output Phase B Ph B Grey 5

Mating Cable

Wire Color

Wire Color

Turck
Pin #

Turck
Pin #

Current Sinking* Wiring

(models 29X-6XX)

V+

V+

0V

Out

Turck Pin #2

Transmitter

Turck Connector

PLC

Digital
Input

Electrical Installation - Wiring

280 Series Transmitters

Wiring

The 6-pin connector version is pre-wired inside the transmitter 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
Terminal #

Case Ground 1 Green A

Common 2 Black B

Power (+5-24 VDC) 3 Red C

Pulse Output 4 White D

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Mating Cable

Wire Color

Pin #

Troubleshooting

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Trouble Corrective Action

No Flow through meter or high pressure drop across meter

Solidied material blocking rotation

Heat meter to melt material.

Debris blocking rotation

Meter broken

Remove meter from line. Flush with an organic solvent or
petrochemical. Try to work debris out of the meter.

If you nd 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 ow

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 ow does not agree with expected readings

Air in the line

Indicator not calibrated properly

Excessive reverse ow in system

Air bubbles displace the meter just as a liquid would.

If you are over-reporting, verify that there is no air in
the lines.

Verify the K-Factor for the meter in use and compare

this value to the setting used in the display.

Max transmitters have anti-dither functions which can

buffer up to 1 revolution of reverse ow. An incorrect
ow total can be reported if the pumping causes a
ow and ebb of greater than 1 meter revolution.

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7.53”

(191 mm)

13.10”

(333 mm)

3.00” NPT

6.15”

(156 mm)

243 Helical Flow Meter

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CONNECTIVITY/DIMENSIONS

- Top View - - End View -

Max Machinery, Inc. Discontued: 243 Manual © Copyright 2014 13

Contact for Repairs

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& 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 ow meter before calling the factory. A return goods authorization number
(RMA) will be issued if the ow meter has to be sent back for repair.

Max Machinery, Inc. Phone: [phone]

33A Healdsburg Ave Fax: [phone]
Healdsburg, CA 95448 www.maxmachinery.com

Max Machinery, Inc. Discontued: 243 Manual © Copyright 2014 14