max H-Series Positive Displacement Helical Flow Meters User Manual

: June 16, 2024
: max

max H-Series Positive Displacement Helical Flow Meters

Specifications

Product: H-Series Positive Displacement – Helical Flow Meters
Models: H241, H242
Flow Rates: 0.1 L/min to 500 L/min
Viscosities: 3 to 1,000,000 centipoise

Product Usage Instructions

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

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 flow rates and fluid viscosities.

The two sizes of this series (H241 and H242) 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 thissignal 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 H-Series 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.

Transmitter General Description

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.

FAQ

Q: Where can I purchase the optional serial interface kit for field

installations?

A: The optional serial interface kit can be purchased from our authorized retailers or directly from Max Machinery, Inc. Please contact our customer service for more information.

H-Series
Positive Displacement – Helical Flow Meters

Operational Manual
H241, H242

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-1

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 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
Indicator Manual
Calibration Certifi cate
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.

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-2

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.

Meter Speciﬁcations

Model| H241| H242|
---|---|---|---
1 Maximum flow rate,

Gal/min

|

50

|

132

Liters/min| 189| 500
Maximum pressure, bar (psi)

Standard NPT*

|

35, (500)

|

35, (500)

|
1500 lb ANSI RF flanges

2500 lb ANSI RF flanges

| —

245 (3500)

| 245 (3500)

—

|
Pressure drop, bar (PSI)

Operating maximum

|

10 (150)

|

7 (100)

|
Absolute maximum| 21 (300)| 15 (200)|
100% flow, 3 CPS| 1 (14)| 0.7 (10)|
2 Maximum temperature| | Up to 225° C (435° 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)| 15000| 5000|
Port size NPT|

1.5”

|

2.5”

|
ANSI RF flanges

*Flange size for low pressure meters

| 1.5” (DN40)

600 lb ANSI RF

| 2.5” (DN65)

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 filter on a regular basis

• Purge air from the meter before operating your system (Flowing near the meters maximum flow rate for a given viscosity will purge air bubbles. Tilting, tapping or shaking the meter at lower flow 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 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 completely before trying to pump through the flow meter.

Transmitter Speciﬁ cations – Analog

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-4

Transmitter Speciﬁ cations – Frequency (Pulse)

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-5

Temperature Range Speciﬁ cation (Analog & Freq.)

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-6

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 ﬁlter 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 ﬁlter. 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 ﬁlters. 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 pipeline 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 ﬂow 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

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-8

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)| Studs| Torque For Line Pressure ft-lb (N-m)

See notes below

---|---|---
| Qty| Size| 500 psi (35 bar)| 3500 psi (245 bar)
H241LS (Class 600 Flange)| 4| 3/4”-10| 24 (33)|
H241MS (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.

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 ﬂanges.

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
Differential Pressure across meter
Maximum Flow Rate
Metered Fluid Temperature
(Speciﬁ cations)
(Pressure Drop Curves)
(Pressure Drop Curves)
(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:

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-13

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 ﬂow meter for installation, be sure to retighten the transmitter snugly in order to ensure proper sensor alignment.

Mechanical Installation

The transmitter is attached to the ﬂ ow meter’s threaded magnet shield. Hand tighten only. (~ 3 ft-lb)
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

Remove electrical connections
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/-)

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

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

Analog transmitters with part numbers 29X-XXX-000 or ending in A/- or C/- are 24Vdc power. Part numbers 29X-XXX-100 or ending in B/- or 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 (-).

Troubleshooting

Trouble	Corrective Action

No Flow through meter or high pressure drop across meter
Solidified material blocking rotation Debris blocking rotation

Meter broken

| Heat meter to melt material.

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

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

Indicator not calibrated properly

Excessive reverse flow 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 flow. An incorrect flow total can be reported if the pumping causes a flow and ebb of greater than 1 meter revolution.

H241 Helical Flow Meter

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-10

H242 Helical Flow Meter

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-11

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 ﬂow meter has to be sent back for repair.

Max Machinery, Inc. 33A Healdsburg Ave Healdsburg, CA 95448

Phone: 707-433-2662 Fax: 707-433-1818 www.maxmachinery.com

Positive Displacement Flow Meters Helical Rotor Type, H-Series

max-H-Series-Positive-Displacement-Helical-Flow-Meters-
FIG-12

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.)

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:

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.
Seller assumes no liability for charges incurred for repairing, removal or replacement, or for repairs made outside of its factory.
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.