max P234 Precision Flow Meters User Manual

max P234 Precision Flow Meters

Safety and Precautions

Never run the meter dry or blow compressed air through the meter.
Damage will occur.
Never steam clean the meter. Damage will occur.
(Bypass or remove the meter if necessary).
Do not disassemble the meter. Damage may occur.
No serviceable parts inside.
Do not over-pressurize the meter. Damage may occur.
The maximum pressure is 3000 psi.
Do not operate P234 flow meters in a hazardous environment. For flow meters rated for ATEX, UL, or cUL Class 1, Div. 1 use in a hazardous environment, contact Max Machinery Sales at 707.433.2662 or www.maxmachinery.com.
Read the entire manual before installing and operating the meter. Verify the fluid to be measured is compatible with the flow meter. Filter your fluid to prevent damage from debris and foreign materials. 10-micron filtration is recommended.
Install bypass plumbing around the flowmeter to allow for easier servicing and line purging/flushing without damaging the meter. Follow all local regulations and your company safety procedures when installing, operating, servicing, and maintaining your flow meter. Max Machinery, Inc. (MMI) reserves the right to change product specifications without notice to improve performance, reliability, or manufacturability. MMI shall not be held liable for operational, technical, or editorial errors/omissions. Visit our website for the latest version of this user manual.

Installation

Max P234 Precision Flow Meters are positive displacement piston meters that can operate over a wide range of flow rates and fluid viscosities and are specifically designed to be compatible with aqueous-based solutions. High accuracy measurement is achieved through precision machined radial pistons that move proportional to the flow. High-resolution outputs are produced by measuring the direction and speed of the pistons and converting the signals to analog and frequency outputs. Flows can be monitored from 1 cc/min up to 2000 cc/min with fluid temperatures from 5 deg C to 90 deg C and a maximum pressure of 3000 psi (210 bar). The meter electronics are protected against water, dust, and most corrosive liquids. The 5-pin Turck connector provided is IP68 and mounts to the meter body via a PG-9 connection that can be adapted to conduit. Optional liquid seal materials may be specified to allow for fluid compatibility.

Max Machinery, Inc. designs, manufactures, calibrates, and refurbishes high- accuracy, high-resolution, precision liquid flow meters under an ISO 9001:2015 certified quality management system. All Max Precision Flow Meters are tested and calibrated in our lab and provide measurements traceable to NIST. If your calibration certificate is lost or missing, contact MMI with your meter serial number for a copy. Orientation: The P234 mounts vertically with the inlet port on the bottom and the outlet port on the top (See diagram on page 2). This is the only manufacturer’s suggested mounting that will allow for air to be purged from the system. Air in the system can cause response delays and errors in measurement. Bypass Valves: Install valves to allow system start-up, filter replacement, or flow meter removal without completely shutting the system down and draining the lines. See diagram.

Failure to use a bypass at start-up may lead to flow meter damage due to debris, overspeeding the meter with air in the lines, and pressure shock due to initial line surges.
Filtration: A 10-micron filter is recommended on the inlet side of the meter. If measuring bi-directional flow, a filter should be installed on both sides of the flow meter. Materials with fibrous or non-abrasive particulate matter may need to be run without filters. Clean Plumbing: Before installing the flow meter, the system lines should be cleaned and free of all debris or manufacturing particulates. Purging lines with compressed air or steam are typical cleaning methods. Do not use compressed air or steam on the Max flow meter, damage will occur.

Mechanical

Inlet and Outlet ports may be NPT or BSPP (G-Type). The product part number defines the type of liquid fitting. Use the part matrix located on page 10 to determine the type of ports on your product and the Specifications section on page 8 to determine the diameter and thread pitch. The P234 may require additional mounting support beyond the fluid connection lines. Additional mounting holes are located on two opposing sides of the base of the product. These holes are 1/4-20 UNC located 1.125 inches apart horizontally.

Operation

• Determine that the following parameters of your flow metering system are within the specifications for the specific 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 specifications)
If the difference in metered fluid temperature versus ambient is greater than 75°F (41.6°C), see the “Hig Temperature Start Up” section below. With valves (#1) and (#2) closed, slowly open valve (#3) (bypass) to clear the lines of foreign particles and air.
Slowly open the inlet valve (#1). Slowly open the outlet valve (#2). Completely close the bypass valve (#3). 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 145°F (62.8°C) based on 70°F (21°C) ambient, a specific procedure is required. To avoid temperature shock, the flow should be very slowly ramped up over approximately 5 min per 75°F (41.6°C) over ambient. Start with all valves closed and smoothly open valve #3 to allow bypass flow around the meter. Then over the calculated time interval for warmup, incrementally open valves #1 and #2 and incrementally close the valve If valving and a bypass circuit were not installed, then use supply pressure control to similarly ramp up the flow rate slowly over time.

Electrical
Environment: The transmitter is rated to operate in the 5 C to 90 C fluid temperature range at an ambient temperature range of 5 C to 80 C. If the ambient temperature rises above 55 C (130F), the maximum fluid temperature at the flow meter is de-rated as shown in the chart below. Transmitter installation is via a 5-pin, M12-style Turck connector. The connector is sealed to the body at the factory and is ready for use. If your installation requires conduit, PG-9 to conduit adapters are available from third parties. If using a conduit setup, use a sealed conduit connection and conduit stop to protect the electronics from moisture and corrosion. Follow the wiring diagrams on page 4 for replacing the 5-pin Turck connector with your own wiring.

WARNING

Electrical shock hazard. Serious or fatal injury may occur. ! Installation/Removal should only be completed by trained and authorized personnel.

WARNING
The P234 is not designed for use in hazardous locations. Adapting the meter to a conduit connection does not protect the system in a hazardous location. Do not use in a hazardous location as death or severe injury may occur.

CAUTION: Verify transmitter output type (Analog or Frequency) before wiring. Inappropriate wiring could result in damaging the circuit. Installation/Removal should only be completed by trained and authorized personnel.

Frequency Output Transmitters (Versions ending with N/2)

Current Sinking Wiring (Versions ending with S/2)

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.

• Current Output Transmitters (Versions ending with A/2 or B/2)
• Voltage Output Transmitters (Versions ending with C/2 or D/2 )

Voltage or Current Analog Transmitters (Models ending with A/2, B/2, C/2 or D/2)
Analog transmitters with part numbers ending in A/2 or C/2 are 24V DC power. Part numbers ending in B/2 or D/2 are 12V DC 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 occurring please consider installing a 10k pull-down resistor between Common and Signal Output (-).

Field Compensation of Transmitter
The transmitter LED on the P234 top cover indicates a functioning system when it is producing a pulse output or detecting magnet travel in the meter. An alternating blue/green LED indicates that the circuit is detecting a magnet and provides an output signal.
A steady or flashing red LED indicates a problem with the transmitter PCA. Contact Max Machinery to have your P234 flow meter refurbished.

The Compensation Algorithm adjusts for variations in Hall sensor and flow meter characteristics to provide a stable, undamped output frequency that accurately represents the instantaneous flow rate. This feature is factory set when the meter is assembled. If the transmitter PCA is replaced or reset, the compensation can be performed via the gold PCA button or through the software kit. The only method of altering additional factory set parameters of the meter is through the Interface Software Kit, part number SFT-KIT-001. Pulse Output Scaling, Analog Output Limits and Scaling, Signal Filtering Options and Compensation settings are the adjustable variables.

WARNING
Electrical shock hazard. Serious or fatal injury may occur. ! Access should only be completed by trained and authorized personnel.

CAUTION
Before opening/accessing the electronics lid, make sure the top of the P234 meter and surrounding components are dry and no moisture or fluids can contact the electrical components. Non-warranty damage may occur.

Instructions to access the gold PCA button and software serial port

• Unscrew the captured Philips head screws on the electronics lid.
• Remove and set aside the lid with an o-ring seal.
• Optional: follow instructions for SFT-KIT-001 to connect to the software serial port.
• Follow field compensation instructions on page 6.
• To reinstall, ensure the o-ring seal is firmly seated. Assembly is then the reverse of disassembly

Field Compensation of Transmitter Continued

When a transmitter PCA is replaced or reset in the field, the compensation routine should be performed to optimize the performance of the system. This routine requires a steady flow rate between 35 cc/min and 2000 cc/min. The flow meter being compensated must not be used for system flow rate feedback control during this process. The transmitter output is disabled during the compensation routine. If you are unable to run a stable flow in the field, send your meter in to Max Machinery for calibration.

For the P234, the compensation routine is as follows

1. Place your system in ‘manual’ mode or run in ‘open loop’ mode with no flow meter feedback control. Max transmitter output shuts off during the field compensation routine.
2. Loss of signal to ‘closed loop control’ modes can affect the flow stabilization of the system and the compensation of the Max meter.
3. Stabilize the flow rate between 35 cc/min and 2000 cc/min.
4. Activate the compensation routine: A – When using the software via the serial port connection, select ‘field compensation’ in the software. OR B – If NOT using software, push the Gold PCA Button using a non-conductive tool.
5. The blue/green LED will change to solid blue for 4 revolutions of the meter. See table LED Functions on the next page for the duration of the compensation process. Duration is dependent upon flow rate.
6. A green LED light indicates a successful update of the compensation, a red LED light indicates the new compensation failed. Additional information is available through the interface software.
7. ‘Return your system to ‘operating’ mode or restore settings to allow for feedback control.

LED Functions

Normal Operation

STATUS| LED| ACTION
Functioning – System Not Flowing| Blue or Green Steady| Meter is functioning, but no flow is detected in

the system.

Functioning – System Flowing| Blue / Green alternating colors| Meter is functioning, flow is occuring in the system. Note: At high flow rates the alternating Blue/Green flashes may appear as a single steady color.
Meter Malfunction| Red Steady| Refurbish Meter.
No Power / Meter Failure| No Light| –  Verify power supply to meter.

–  Verify wiring follows diagrams on page 4.

–  If power and wiring are verified, refurbish

meter.

Compensation via Interface Software Kit or Gold PCA Button

STATUS| LED| ACTION
Compensate button pushed/clicked| Blue Steady| – Steady light for 4-5 revolutions of meter.
Compensation Succeeded| Green Steady| –  Steady light for 5 seconds.

–  Software will show “Success” on screen.

Compensation Failed| Red Steady| –  Steady light for 5 seconds.

–  Software wil show “Flow too low/ too high/

unstable” on screen.

Note: Revolutions of meter are dependent on expected fluid flow rate. Per the P234 specifications, 4-5 revolutions of the meter take approximately the following amount of time at the stated flow rates:

35 cc/min (minimum compensation flow rate) – 90 seconds

100 cc/min – 35 seconds

1000 cc/min – 1 5 seconds

2000 cc/min (maximum meter flow rate)             – 10 seconds

If compensation fails, restart the compensation process. When using the Interface Software Kit, follow instructions provided to correct errors prior to attempting compensation again. If problems persist, contact Max Machinery at 707-433-2662 or at www.maxmachinery.com .

Specifications

• Flow Range 1 to 2000 cc/min
• Accuracy (1 cP) ± 0.4% of reading over a 100:1 range
• Maximum Operating Pressure 3000 psi (210 bar)
• Weight 4.1 kg
• Recommended Filtration 10 micron
• Port Size(s) 1/4 inch NPT or G 1/4-19 BSPP
• Fluids Most aqueous-based fluids with a pH between 4 and 12

MATERIALS OF CONSTRUCTION

• External Stainless steel, type 316, type 304; Blue Xylan 316 fasteners;
• Polycarbonate LED cover – avoid contact with solvents
• Wetted Stainless steel, type 316; Graphite; PEEK; Nickel Carbide
• O-Rings Standard: Viton®
• Optional: Teflon®, Perfluoroelastmer

FREQUENCY TRANSMITTER

• Output Signal Standard: 5 Vdc, single phase
• Optional: Quadrature 5 Vdc, two phase
• Current sinking, 20 mA max., single phase
• K-Factor Single Phase: 180 pulses/cc
• Two Phase: 360 pulses/cc, 4x decoded
• (90 pulses/cc/phase, 1x decoded)
• Power Supply Requirements 5-26 Vdc @ 30ma
• Ambient Operational Range 5°C to 80°C
• Metered Liquid Temp Range 5°C to 90°C
• (based on 20° ambient)

ANALOG TRANSMITTER

• Output Signal Any range of ± 10V or ± 20mA linearized and damped with anti-dither protection
• Power Supply Requirements 12Vdc @ 90 mA, 24Vdc @ 45 mA
• Ambient Operational Range 5°C to 80°C
• Metered Liquid Temp Range 5°C to 90°C
• (based on 20° ambient)

Dimensions

Charts

Positive Displacement Flow Meters
Piston Type, P-Series 3000 psi (210 bar) rated, Water-Based Fluids The product includes single-directional calibration, bi-directional calibrations for Analog and Quadrature devices are optional.

Available Accessories
Accessories to support your system and simplify your installation and maintenance are available directly from Max. Request yours when you order your flow meter. See the website for information and options.

Interface Software Kit

following adjustments may be made to the signal output: Pulse Output Scaling, Analog Output Limits and Scaling, Signal

Filtering Options and Compensation settings.

Cables

Model 122 Combination Rate Indicator/Totalizers

Description
Panel mount indicator with dual-line, 6-digit display (0.6” and 0.46”). Produces an isolated 4-20mA analog output. Provides 24 Vdc transmitter power. Can be programmed to show rate, total and/or grand total. Initial programming included as default or customer-specified values.

381 Series Filters and Filter Elements

available to match your flow meter and system requirements.

Troubleshooting and Service Request

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

Debris damage or internally clogged Meter broken

| Heat meter to melt material. Do not exceed maximum meter operating temperature.

Refurbish meter. Refurbish meter.

Fluid passes through meter, but no flow is indicated
Transmitter cable or conduit cable incorrectly wired

Meter not turning

| Verify DC power is present at the PCA. Use a multi-meter to measure the transmitter output independent of the display or PLC.

Refurbish meter.

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 like a liquid. If you see over- reporting, purge all air from lines.

Verify K-Factor for the meter in use and compare

this value to the setting used in the display.

Max transmitters’ anti-dither function buffers up to 1 revolution of reverse flow. An incorrect flow total can be reported if the system reverse flow is greater than 1 meter revolution.

Additional Information Available
MMI provides refurbishment and calibration services. For more details or to submit your Service Request, go to https://www.maxmachinery.com/services/.
Additional information about our products, including STEP files and Sample Calibration sheets, may be found on our website at https://www.maxmachinery.com/downloads/.
MMI products are covered under our standard manufacturer’s warranty. Details may be found at https://www.maxmachinery.com/warranty/.

Max Machinery, Inc., 33A Healdsburg Avenue, Healdsburg, CA 95448 USA
707.433.2662 | www.maxmachinery.com

References

• Manual-Hub.com - Free PDF manuals!
• Homepage - Max Precision Flow Meters
• Homepage - Max Precision Flow Meters
• Manual-Hub.com – Free PDF manuals!
• Downloads - Max Precision Flow Meters
• Services - Max Precision Flow Meters
• Warranty & Limited Liability - Max Precision Flow Meters

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