Max Machinery 296, 295 Operational Manual

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Page 1

High Resolution, Linearized Frequency Transmitters

Operational Manual

For Models

295, 296 and G Series Transmitters

Page 2

Table of Contents

General Description ............................................................................................................ 3

Transmitter Specications ................................................................................................ 4

Installation ............................................................................................................................ 5

High Temperature Operation ........................................................................................... 7

Temperature Limits ............................................................................................................ 8

Limited Warranty ................................................................................................................ 9

Custom Instructions for Hazardous Locations/Explosion Proof Housing: www.maxmachinery.com/content/explosion-proof-installation-instructions

Additional technical documents regarding transmitter performance and advanced operation are available at www.maxmachinery.com. Max Machinery, Inc. reserves the right to make changes to the product in this instruction manual to improve performance, reliability, or manufacturability. Contact Max Machinery Inc. for

the latest available specications and performance data. Although every effort has been made to ensure

accuracy of the information in this instruction manual, Max Machinery Inc. assumes no responsibility for inadvertent errors.

Page 3

General Description

The Max frequency transmitters are designed to work with the entire family of Max Flow Meters to provide extremely precise

ow measurement in a cost effective package. Different options

for electrical connections and temperature ranges 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 new 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 frequency proportional to the ow rate. Advanced signal processing provides both ne

angular resolution (0.36 degrees rotation per pulse) and rapid response (output updated every one ms).

These transmitters are typically mated to a mechanical ow meter, congured, and calibrated at the factory as a matched set. This ensures accuracy and allows quick setup in the eld. For eld installations where the

transmitter has not been setup with a meter at the factory, an optional serial interface kit provides full access

to all conguration options and parameters.

Model 296

Model 295

Ex Proof Model 295

Transmitter Features

High resolution measurement - Congured output resolution of 1 to 1000 pulses per revolution. Linearization of up to 16 points to fully describe the 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 ow meter characteristics to provide a stable, undamped output frequency that accurately represents the instantaneous 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 PCA.

Anti-Dither Pulse Buffer - Prevents undesired reverse pulses which can occur at very low ow rates in the

presence of vibration or hydraulic noise. If the meter reverses direction and then resumes forward rotation,

the pulse count will represent only the total forward ow. Reverse ow exceeding the pulse buffer setting will result in an output frequency proportional to reverse ow rate. The buffer quantity can be set from 1% to 100% of a revolution.

Page 4

Transmitter Specications

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

(1)

45 mA

Output Impedance 100 Ω

Rise/Fall Time 0.2 μSec

Output Update Rate

(2)

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)

(3)

–40ºC to 80ºC (–40ºF to 175ºF)

Maximum Temperature, Process Fluid (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 50% of a meter revolution - unidirectional - 2% bidirectional. (software selectable from 1-100% of 1 revolution)

Signal Filtering Software selectable from 1ms to 250ms time constant

( 1) Continuous Short Circuit is not recommended. The output current should not exceed 10 mA (2) Events are seen as output transitions 1 ms after they occur (3) Temperature of metered uid will affect transmitter temperature, see graph

Page 5

Installation

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.

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.

Moisture 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

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

Single Phase

Common Com Black 4

Wiring

Power 5-26 Vdc V+

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

Quadrature

Case Ground Case

Common Com Black 4

Power 5-26 Vdc V+

Output Phase A Ph A White 2

Output Phase B Ph B Grey 5

Models

295 & 296

Models

295 & 296

Mating Cable Wire Color

Blue

Brown

Mating Cable Wire Color

Blue

Brown

Turck Pin #

Current Sinking* Wiring

(models 29X-6XX)

V+

Out

Turck Pin #2

Transmitter

Turck Connector

PLC

Digital Input

Page 6

Installation continued...

LED Rotation/Output Indicators

All of the microprocessor based transmitters incorporate a LED to indicate that they are producing a pulse output and/or detecting magnet rotation in the meter.

An alternating red/green or blue/green LED indicates that the circuit is detecting a rotating magnet and

should provide an output. Additional LED’s are present for setup, programming and troubleshooting and are

not intended for general use.

Error Codes

Flashes 8x a second to indicate that the magnet is not detected

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. Contact the factory regarding P/N 294-100-050, user interface software.

Field Compensation of transmitter

When a new transmitter is attached to a ow meter, the compensation routine should be performed to optimize the performance of the system. This routine requires a steady ow rate which turns the meter at between 15 and 1000 RPM. For the Model 295 and 296, the sequence is as follows:

1. Stabilize the ow rate

2. Push the compensation button on the PCA

3. The blue/green LED will change to solid blue for 6 to 8 revolutions of the meter

4. A green indicator light indicates a successful update of the compensation, a red indicator light indicates that the previous compensation has been retained.

Page 7

NOTE:

location installations,

customer

n ca bling a nd conduit

between

nd the re ceiving box.

receiving box must be

Com

Case

V+

For Pulse

PhB -- Grey

PhA -- White

Com

PhA/Sig

Ret -- White

Sig -- Grey

For Analog

Case

Ph B/ Re t

8/23/11

DATE

33A HEALDSBURG AVE

HEALDSBURG, CA 95448

MAX MACHINERY

bsnyder

DESIGNER

DESCRIPTION

-1 1

REV

OF 1

SHEET

1:1

SCALE

Wiring Diagram for Remote 295/296 Xmtrs

DRAWING

SIZE

*** COPYRIGHT ***

LIMITED PURPOSES. IT MAY NOT BE

MAX MACHINERY INC. AND CONTAINS

THIS DOCUMENT IS THE PROPERTY OF

Receiver Box Wiring

Shield

Brown

G re y

shield with shrink wrap or tape

and connect to Brown/Com.

receiver box end. MUST cover

Shield is only connected at the

Black

White

Blue

Brown

***

Bla c k

Blue

***

Use Standard

Cable for

Connection to

Instrumentation

AND THEN ONLY BY WAY OF LOAN FOR

CONFIDENTIAL AND TRADE SECRET DATA

AS AUTHORIZED BY MAX MACHINERY INC.

OF MAX MACHINERY INC. THIS DOCUMENT

REPRODUCED IN WHOLE OR IN PART AND

MAY BE TRANSFERRED FROM THE CUSTODY

OR CONTROL OF MAX MACHINERY INC. ONLY

MACHINED

FINISH

MATERIAL

MAX MACHINERY INC.

NEED FOR SUCH USE OR DISCLOSURE

INC. UPON REQUEST AND IN ALL EVENTS

MUST BE RETURNED TO MAX MACHINERY

CONSISTENT WITH THE PURPOSE OF THE

UPON COMPLETIONS OF PURPOSE OF THE

LOAN. NEITHER THIS DOCUMENT NOR THE

OR DISCLOSED TO PERSONS NOT HAVING A

INFORMATION IT CONTAINS MAY BE USED BY

LOAN WITHOUT PRIOR WRITTEN CONSENT OF

FINISH 64

MAX SURFACE

TOLERANCES

STANDARD

FOR FEATURES WITHOUT

TO .010 - .015

3RD ANGLE PROJ.

DRAWN IN INCHES

BREAK ALL EDGES

1°

.0005

1/64

.003

.010

.05

ANGULAR

FRACT.

.XXXX

.XXX

.XX

.010

THESE FEATURES IS

UNLESS OTHERWISE

NOTED, TOLERANCE ON

DIMENSIONS, REFER TO

ELECTRONIC MODEL FILE.

Remote to Receiver

Pigtail Connector from

G re y

White

Brown

Meter Side Wiring

Com

Black

Blue

must supp ly the ir

the me ter side

For ha za rd o us

Case

in a SAFE zo n e!

The

Page 8

High Temperature Operation

Operation Above 65°C (150°F)

The operating limit of the meter/transmitter is a function of both the ambient and the metered uid temperature, as shown in the following graphs. Although the electronic components are rated to 80°C (175°F), additional heat can be conducted from the ow meter into the transmitter housing requiring a lower ambient temperature limit for high uid temperatures.

To prolong the life of the transmitter and reduce the risk of component related failures over time, high

ambient temperatures >65°C (150°F) should be avoided if possible. It is a good idea to locate the transmitter away from hot spots such as steam pipes, ovens and heaters. When working with elevated uid temperatures >65°C (150°F), insulating the ow meter is required to reduce heating of the electronics by convection of hot

air off of the meter (especially for larger meters). The upper temperature limits shown in the curves rely on ambient convection to remove heat from the transmitter housing, cooling the electronics. For this reason, if operating near the upper temperature limit, the transmitter should not be insulated. At these elevated temperatures, the transmitter will be very hot — exercise appropriate caution.

Temperature Limits

Model 29X Transmitter Series

120

110

100

295 & 296 296 295 & 296

Standard

Ambient Temperature °C

-25

High

temperature

2 part pickup

100

Process Temperature °C

Ultra High

temperature

2 part pickup

150 200

225

250

300

Page 9

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 ful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 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 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 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.