Max H242, H241 User Manual

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H-Series Positive Displacement - Helical Flow Meters

Operational Manual

H241, H242

Model H241

Model H242

Table of Contents

Before You Install ...................................................................page 3

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

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

Meter Speciﬁ cations ..............................................................page 5

Do and Don’ts ..........................................................................page 5

Transmitter Speciﬁ cations - Analog ................................ page 6

Transmitter Speciﬁ cations - Frequency (Pulse) .............. page 7

Installation ...............................................................................page 8

Piping Diagrams ......................................................................page 9

ANSI FlangeANSI Flange Stud Torque ..............................page 9

Operation ............................................................................... page 10

Troubleshooting .....................................................................page 13

Flow Meter pressure drop curves

Contact for Repairs & Calibration Services ....................

Part number matrix ............................................................. page 15

Limited Warranty .................................................................. page 16

Custom Instructions for Hazardous Locations/Explosion Proof Housing:

http://www.maxmachinery.com/content/explosion-proof-installation-instructions

page 14

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 speciﬁ 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.

Before You Install

Thank you for choosing to install a Max Machinery precision ﬂ ow meter. To ensure the best experience please take a moment to read through this manual prior to installation.

When you purchased this meter a ﬂ ow engineer helped determine many of the factors that will be reviewed on the following pages. You may ﬁ nd it useful to ﬁ ll out the form below and keep it in your ﬁ les 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

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 __________________________________

Indicator Manual Calibration Certiﬁ cate Bypass plumbing supplies

Meter Model # __________________________________ Meter Serial # ____________________________________

Notes: _____________________________________________________________________________________________

_____________________________________________________________________________________________

Meter General Description

The Max H-Series Flow Meters are positive displacement helical rotor type units capable of precise measurements over a wide range of ﬂ ow rates and ﬂ uid viscosities.

The two sizes of this series (H241 and H242) will measure ﬂ ows 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 ﬂ ow meter, a precise amount of the ﬂ 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 ﬂ ow rate output. For some transmitter models, the magnet is eliminated and the motion of the gear itself is sensed.

The Max H-Series Meters are of simple and rugged construction. They can be expected to perform superbly if treated within the conﬁ 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.

Transmitter General Description

Max transmitters are designed to work with the entire family of Max Flow Meters to provide extremely precise ﬂ ow 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 ﬂ ow rate. Advanced signal processing provides both ﬁ ne angular resolution (0.36 degrees rotation) and rapid response (output updated every one millisecond).

Max transmitters are typically mated to a mechanical ﬂ ow meter, conﬁ gured, and calibrated at the factory as a set. This ensures accuracy and allows quick setup in the ﬁ eld. For ﬁ eld 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 conﬁ guration options and parameters.

Transmitter Features

High resolution measurement –

Analog Output: Conﬁ gured output ranges to any value within ± 10 Vdc or ± 20 mA.

Frequency Output: Conﬁ gured output resolution of 1 to 1000 pulses per revolution. Linearization of up to 16 points to fully describe the ﬂ ow 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 ﬂ ow meter characteristics to provide a stable, undamped output that accurately represents the instantaneous ﬂ ow 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 ﬂ ow 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 ﬂ ow exceeding the buffer setting will result in an output proportional to reverse ﬂ ow rate. The buffer quantity can be set from 1% to 100% of a revolution.

Ex Proof Housing

Industrial Housing

Meter Speciﬁ cations

Model H241 H242

Maximum ﬂ ow rate,

Gal/min 50 132 Liters/min 189 500

Maximum pressure, bar (psi)

Standard NPT* 35, (500) 35, (500) 1500 lb ANSI RF ﬂ anges --- 245 (3500) 2500 lb ANSI RF ﬂ anges 245 (3500) ---

Pressure drop, bar (PSI)

Operating maximum 10 (150) 7 (100) Absolute maximum 21 (300) 15 (200) 100% ﬂ ow, 3 CPS 1 (14) 0.7 (10)

Maximum temperature Up to 225° C (435° F)

Recommended ﬁ ltration 150 micron Displacement, L/Rev 0.062 0.182 Weight, Kg (Lb) 13.6 (30) 18.2 (40)

Typical K-Factor, (pulses/liter) 15000 5000

Port size NPT 1.5” 2.5” ANSI RF ﬂ anges 1.5” (DN40) 2.5” (DN65) *Flange size for low pressure meters 600 lb ANSI RF 900 lb ANSI RF

Notes:

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 ﬁ lter requirements. Consult factory

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

Dos and Don’ts

DO: DON’T:

• Install a bypass line around the meter

• Clean the ﬁ lter on a regular basis

• Purge air from the meter before operating your system (Flowing near the meters maximum ﬂ ow rate for a given viscosity will purge air bubbles. Tilting, tapping or shaking the meter at lower ﬂ ow rates will also dislodge entrapped air)

• Run water or aqueous solutions through the meter (except the 234 Series of meters)

• Put steam or compressed air through the meter.

• Disassemble the meter

• Apply excessive differential pressure across the meter

• Exceed the maximum ﬂ ow 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 completely before trying to pump through the ﬂ ow meter.

Transmitter Speciﬁ cations - Analog

Supply Voltage 12 or 24 Vdc consult part number matrix

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

Output Update Rate 1 ms

Resolution Adjustable without recalibration to any range of ± 10 Vdc or ± 20 mA

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

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) Standard Model 90ºC (195°F) – Model 295 Ultra-High Temp Model 225ºC (435°F) – Model 295

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 ﬂ uid will affect transmitter temperature, see graph below

Transmitter Speciﬁ cations - 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 Ω

Rise/Fall Time 0.2 μSec

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)

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) Standard Model 90ºC (195°F) 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

Full step change is subject to signal damping

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

Temperature Range Speciﬁ cation (Analog & Freq.)

Model 29X Transmitter Series

120

110

100

Standard

Ultra High

temperature

2 part pickup

Ambient Temperature °C

-25

100

Process Temperature °C

150 200

225

250

300

Installation

For optimum performance, install the ﬂ ow meter on the discharge side of the pump, in one of the conﬁ gurations shown on page 9.

The following items and conditions should be considered:

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

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

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

Pipe Threading: When installing pipe to the ﬂ ow meter, support the nearest end cap or both end caps (as in a vise). Don’t clamp the ﬂ ow meter body. This avoids possible misalignment of ﬂ ow meter components when the pipe is screwed tight. Check for proper ﬂ 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 ﬂ ow meter to the transmitter. The transmitter is the most heat sensitive element in the system and the transmitter manual should be consulted for speciﬁ c limits. Optional heating ﬂ uid ports are available for the ﬂ 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 ﬂ owing through the meter.

ANSI Flanges: Using the H-Series meters at pressures greater than 500 psi (35 bar) will also require ﬂ anges. See the speciﬁ cations and bolt torque table on page 9. Max has bolt kits available for ﬂ ange installations.

Piping Diagrams

Vertical Installation

HELICAL FLOW METER

FLOW

VALVE 2

FILTER

VALVE 1

BYPAS S VALVE 3

Horizonal One Way Flow Installation

Flow

Valve 1

Horizonal Two Way Flow Installation

Valve 1

Filter

Flow

Filter Filter

Valve 2

Helical Flow Meter

Bypass

Valve 3

Valve 2

Helical Flow Meter

Bypass

Valve 3

ANSI Flange Stud Torque

H-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.

Meter (Flange size)

H241LS

H241MS*

(Class 600 Flange) 4 3/4”-10 24 (33)

(Class 2500 Flange) 4 1-1/8”-7 256 (247)

H242LS (Class 900 Flange) 8 3/4”-10 24 (33)

H242MS* (Class 1500 Flange) 8 1”-8 219 (297)

Notes:

H-Series meters that are designated as “LS” may be mounted using their NPT treads. For convenience, wafer style mounting can be made using the ﬂ ange size and bolt speciﬁ cations listed above.

Studs Torque For Line Pressure

ft-lb (N-m) See notes below

Qty Size 500 psi (35 bar) 3500 psi (245 bar)

* Meters that are marked as “MS” must be mounted between ﬂ anges. The studs and nuts listed in the table are provided for use with the customer supplied ﬂ anges.

Operation

Determine that the following parameters of your ﬂ ow metering system are within speciﬁ cations for the speciﬁ c H-Series Meter being used:

Maximum System Pressure (Speciﬁ cations)

Differential Pressure across meter (Pressure Drop Curves)

Maximum Flow Rate (Pressure Drop Curves)

Metered Fluid Temperature (Sales speciﬁ cation, transmitter manual)

If the metered ﬂ 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 ﬂ ow meter is required. A routine ﬁ 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 ﬂ 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 ﬂ 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 ﬂ ow meter. Valve one can then be opened completely. Open valve two slightly. The ﬂ 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).

Installation

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

Electrical Installation - Wiring

This page covers the installation of transmitters with 5-pin, M12 style connectors only. For hazardous location devices with 1/2" conduit connections, please refer to the EXInstall sheet.

Frequency Output Transmitters (Models ending with P..N/- or Q..N/-)

Frequency Single Phase

Power (+5 to 26 Vdc) V+ 1 Brown

Common Com 4 Black

Pulse Output Ph A 2 White

Output Phase B (Quad only) Ph B 5 Grey

Case Ground Case 3 Blue

Current Sinking Wiring

PCA Label

Turck®

Connector

Pin #

Mating Cable Wire Color

(Model # 295-600-000 and versions ending with S/-)

A current sinking device uses the transmitter’s transistor output to act as a switch. A positive DC voltage must be applied to the transmitter's output pin (#2). When the pulse output is triggered, this voltage will be grounded to zero volts by the transmitter. Warning: Use a 5k ohm resistor to limit current if your system does not have any other means to limit the current into the transmitter.

V+

Out

Turck Pin #2

Transmitter

PLC

Digital Input

Voltage or Current Analog Transmitters (Models ending with A/-, B/-, C/- or D/-)

Turck®

Connector

PCA Label

Power * V+ 1 Brown

Common Com 4 Black

Signal Output (+) Sig 5 Grey

Signal Output (—)** Ret 2 White

Case Ground Case 3 Blue

* Analog transmitters with part numbers 29X-XXX-000 or ending in A/- or C/- are 24Vdc power. Part numbers 29X-XXX-100 or ending i n B / - o r D / - are 12Vdc power. ** To minimize signal noise, analog output transmitters are fully isolated. If your PLC does not ground the negative signal input, there is a risk of a ground shift that could drive the signal out of the range of detection. To prevent this from occuring please consider installing a 10k pull down resistor between Common and Signal Output (-).

Pin #

Mating Cable Wire Color

Troubleshooting

Trouble Corrective Action

No Flow through meter or high pressure drop across meter

Solidiﬁ 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 ﬁ 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 ﬂ 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 ﬂ ow does not agree with expected readings

Air in the line

Indicator not calibrated properly

Excessive reverse ﬂ 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 ﬂ ow. An incorrect

ﬂ ow total can be reported if the pumping causes a ﬂ ow and ebb of greater than 1 meter revolution.

H241 Helical Flow Meter

H242 Helical Flow Meter

Contact for Repairs & Calibration Services

Your Max H-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 ﬂ ow meter before calling the factory. A return goods authorization number (RMA) will be issued if the ﬂ ow 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

Positive Displacement Flow Meters

Helical Rotor Type, H-Series

Flow Meter Selections Transmitter Selections

Model # 0 Non-standard options

Max Flow Range

189 Liters/min 189 Liters/min

500 Liters/min 500 Liters/min

H241 H241

H242 H242

LS MS

Pressure

500 psi (35 bar)

3500 psi (245 bar)

Includes Flange Bolt Kit (see below)

Fluid Connection Electrical Connection

NPT 1

Wafer-mounted between customer’s ﬂ anges 5

Bi-directional cal BID

0 Transmitter Type

Output Type

A A A

A P

Q P

1 Turck

2 Hazardous location, 1/2 inch conduit *

4-20mA output – powered by 24Vdc

4-20mA output – powered by 12Vdc

0-10Volt output – powered by 24Vdc

0-10Volt output – powered by 12Vdc

5V Pulse/Quad – powered by 5-26Vdc 5V Quadrature - powered by 5-26Vdc

Current Sinking, single phase

Temperature Rating

Standard 90°C 2-part, Haz-Loc Transmitters 130°C** 2-part Industrial Transmitters 225°C †

connector

Seal Selection

® -

Viton

Teflon

Perfluoroelastomer - FFKM

® -

FKM

PTFE

1 3 5

Signal Type

Pulse

Analog

Quadrature

Options

Flange Bolt Kit Details

None

Heat trace option

Calibration

Price includes unidirectional calibration

* See temp chart ** Receiver portion of 2 part transmitters are not rated Ex-Proof, consult factory

† Not available for hazardous location use. (Exceeds 130°C temp. limit.)

Model H241 bolts 3500 psi bolt kit for 2500 lb. ANSI Flanges

Model H242 bolts 3500 psi bolt kit for 1500 lb. ANSI Flanges

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 fulﬁ llment 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 ﬁ rst obtaining a product-evaluation 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 ﬁ nal 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 ﬁ ltration 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 H242, H241 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual