Max Machinery G Series User manual

G-Series User Manual
G004
G015
G045
G105
G240
G004HZ
G015HZ
G045HZ
Positive Displacement Gear Flow Meters

G-Series User Manual Rev2020A i
For ow meters approved for use in a hazardous environment, refer to the EXInstallSheet for installation
instructions. Failure to follow the ExInstallSheet instructions shipped with the product may result in death
or serious injury. For ow 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.
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 run water or aqueous solutions not approved by Max through your ow meter. Damage will occur.
Do not disassemble the meter. Damage may occur. No serviceable parts inside.
Do not over pressurize the meter. Damage may occur.
Do not remove the transmitter from the ow meter body unless advised by Max. Re-phasing the transmitter
to the ow meter body via the Interface Software Kit is required to prevent measurement error. (isnt this
what the gold comepnsation button is for?)
Do not apply excessive differential pressure across the ow meter. Damage will occur. See pressure drop
curves for safe area operation.
Do not exceed maximum ow rate for the material viscosity. Damage will occur.
Do not allow materials to cure in the ow meter. If materials cannot be ushed from the meter, damage may
occur.
Do not ow remeltable materials through the meter until fully liqueed. Solids may damage the meter.
Read the entire manual before installing and operating the meter.
Verify the uid to be measured is compatible with the ow meter.
Filter your uid to prevent damage from debris and foreign materials.
Install bypass plumbing around the owmeter to allow for easier servicing and line purging/ushing without
damaging the meter.
Follow all local regulations and your company safety procedures when installing, operating, servicing, and
maintaining your ow meter.
Safety and Precautions
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G-Series User Manual Rev2020A ii
Max Machinery, Inc. (MMI) reserves the right to change product specications without notice to improve performance,
reliability, or manufacturability. MMI shall not be held liable for operational, technical, or editorial errors/omissions. Visit
our web site for the latest version of this user manual.
Max Machinery, Inc., 33A Healdsburg Avenue, Healdsburg, CA 95448 USA
707.433.2662 | www.maxmachinery.com
Table of Contents
Safety and Precautions ........................................................................ i
Table of Contents.................................................................................. ii
How It Works........................................................................................... 1
Installation Mechanical ........................................................................ 2
Mechanical Operation ..........................................................................4
Installation Electrical............................................................................ 5
Electrical Quick Start ...........................................................................6
Field Compensation of Transmitter .................................................10
LED Functions .......................................................................................12
Specications........................................................................................13
Dimensions ............................................................................................19
Optional Heater Block....................................................................... 30
Charts .................................................................................................... 31
Part Matrix............................................................................................33
Available Accessories.........................................................................35
Troubleshooting and Service Request ...........................................36
Additional Information Available .....................................................36

G-Series User Manual Rev2020A 1
How It Works
Max G-Series Precision Flow Meters are positive displacement gear meters that are able to operate over a wide range
of ow rates and uid viscosities. High accuracy measurement is achieved through precision machined spur gears
that move proportional to the ow. High resolution outputs are produced by measuring the rotation of the gears and
converting the signals to analog or frequency outputs. Flows can be monitored from 0.5 cc/min up to 240 liters/min
with uid temperatures from -40°C to 225°C and pressure ratings of 6000 psi (414 bar) depending upon model. The
industrial meter electronics are protected against water, dust, and most corrosive liquids. The 5-pin Turck connector
provided is IP68. Additionally, 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. Optional seal materials allow for different uid compatibility.
Max Machinery, Inc. designs, manufactures, calibrates, and refurbishes high accuracy, high resolution, precision liquid
ow meters under an ISO 9001:2015 certied quality management system. All Max Precision Flow Meters are tested
and calibrated in our lab and provide measurements traceable to NIST. If your calibration certicate is lost or missing,
contact MMI with your meter serial number for a copy.

G-Series User Manual Rev2020A 2
Your Max Flow Meter has been congured at the factory to be used out of the box based on your submitted application
data. Plumb it, wire it, and use it. The following section will provide instructions on how to properly plumb your Max Flow
Meter in the liquid lines of your application.
Use the “IN” port or follow the ow direction arrow markings for the primary ow direction. Install the meter on the
discharge side of the pump whenever possible. Excessive vibration at the meter should be avoided.
Orientation: Preferred mounting orientation of the meter depends on meter type. The orientation optimizes air purging
and/or minimizes heat transfer to the electronics. G-Series meters, especially when used with thick uids, should mount
with the transmitter on the side and the plumbing oriented vertical ow up. This mounting orientation prevents air in the
system that can cause response delays and errors in measurement.
NPT ttings: Always use pipe sealant or pipe tape to install ttings, and leave the rst thread of pipe exposed. Ensure
the tape or sealant does not accidentally enter the meter.
SAE ttings: Always use process uid compatible lubricant on the o-ring to attach the tting to the meter.
Installation - Mechanical
FLOW
G015

G-Series User Manual Rev2020A 3
Bypass Valves: Install valves to allow system start-up, lter
replacement, or ow 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 ow 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 lter is recommended on the inlet side
of the meter for G004 and G015 ow meters. A 30 micron lter
is recommended for G045, G105, and G240 ow meters. If
measuring bi-directional ow, a lter should be installed on both
sides of the ow meter. Materials with brous or non-abrasive
particulate matter may need to be run without lters.
Clean Plumbing: Before installing the ow meter, the system
lines shall 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 ow meter, damage will occur.
High Temperatures: Orient your meter so the transmitter is to the side
or below to minimize heat transfer by convection from the ow meter
to the transmitter. The transmitter is the most heat sensitive element
in the system. Consult page 8 for specic limits on uid and ambient
maximum temperatures. When operating in the upper temperature
ranges, always insulate the meter but leave the transmitter housing
exposed so it radiates heat. An optional heater block can be used
on the ow meter to keep it at the uid operating temperature.
For substances solid at room temperature, a heater block may be
required to keep material molten to ow through the meter.
Installation - Mechanical
FLOW
INSULATION HERE
RADIATE HEAT HERE

G-Series User Manual Rev2020A 4
Mechanical - Operation
Determine that the following parameters of your ow metering system are within the specications for the specic
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 specications page 8)
If the metered uid is greater than 28°C (80°F) over ambient, see the “High 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.
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 82°C (150°F) based on 21°C (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 (inches) x (operating temperature (°F)-125)
10
— OR —
TIME (minutes) = connector size (inches) x (operating temperature (°C)-52)
10
Valves (#1) and (#2) must be closed. Open the bypass valve (#3) in gradual steps until the bypass piping is stabilized at
operating temperature. Open valve (#1) slightly and allow the temperature to stabilize around the ow meter. Valve (#1)
can then be opened completely.
Open valve (#2) 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 (#2) can be gradually opened all the way. Slowly close the
bypass valve (#3).

G-Series User Manual Rev2020A 5
Max G-Series Precision Flow Meters transmitters come from the factory pre-assembled to the mechanical metering
component and congured to be used out of the box based on your submiited application data. Plumb it, wire it, and use
it. The following section will describe how to properly wire your Max Flow Meter into the electronics of your application.
There are various combinations of transmitter components and outputs. These options include:
- Industrial or Hazardous Location Transmitter Housing
- Frequency or Analog Output Signal
- Uni-directional or Bi-directional Output Signal
- Standard, High Temperature, and Ultra High Temperature Housings
To determine what transmitter type you have, refer to the Max part number matrix on pages 33-34 and decode your ow
meter’s part number.
Installation - Electrical
WARNING: Refer to the EXInstall Sheet for proper installation in hazardous
locations.
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WARNING: Electrical shock hazard. Serious or fatal injury may occur.
Installation/Removal should only be completed by trained and authorized
personnel.
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!CAUTION: Verify transmitter output type (Analog or Frequency) before wiring.
Inappropriate wiring could result in damaging the circuit.
CAUTION: Before opening/accessing the electronics lid, make sure the top of
the meter and surrounding components are dry and no moisture or uids can
contact the electrical components. Non-warranty damage may occur.
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G-Series User Manual Rev2020A 6
Quick Start - No adjustments to factory settings
Your Max Flow Meter is connected to your process automation electronics via a 5-pin M12 Turck connector if an Industrial
Transmitter or via a 5-pin connector within a Hazardous Location housing with a 1/2 inch conduit connection. Please
refer to the EXInstall Sheet for proper installation of the wiring to the Hazardous Location housing.
Wire the 5-pin Turck cable to your process automation equipment in accordance with the diagrams below depending
upon which transmitter type you purchased. Then connect the Turck cable to the Turck tting on the Max Flow Meter.
Set your ouput reading on your process automation electronics to match the calibration sheet supplied with your ow
meter.
You are ready to measure your liquid ow application.
Start-up Instructions - Adjustments to Factory Settings Required
If you need to make adjustments to your Max Flow Meter prior to use, you will need to purchase and use the Max
Machinery Interface Software Kit. This will allow you to change the ow meter output signal frequency or analog range
to meet your application’s equipment needs.
To access the port on the circuit board, unscrew the transmitter lid by hand. The transmitter lid has four thread paths.
When reinstalling the lid, the cable may be misaligned. 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.
Max Flow Meters do not come with a visual interface, they must be connected to an electronic display, PLC/DAC/counter
card or other process automation electronics to collect the data and display a visual reading.
You must determine if your process automation electronics have the capability to accept the high frequency output
of the Max Flow Meter. If your system cannot accept the data at the pre-set frequency, then use the Max Machinery
Interface Software Kit to adjust the frequency output to a lower setting that matches your system.
Refer to the Max Machinery Interface Software Kit Manual for instructions on how to change the ow meter output signal
frequency or analog range to meet your application’s equipment needs.
Installation - Electrical

G-Series User Manual Rev2020A 7
Applies only to transmitters with 5-pin, M12 style connectors. For hazardous location transmitters with 1/2 inch conduit
connections, please refer to the EXInstall sheet.
A current sinking device uses the transmitter’s transistor output to act as a
switch. Positive DC voltage must be applied to the transmitter's output pin (#2).
When the pulse output is triggered, this voltage is grounded to zero volts by the
transmitter. Warning: Use a 5k ohm resistor to limit current if your system does
not have other means to limit current into the transmitter.
PLC
Digital
Input
V+
V+
Out
0V
Transmitter
Turck Pin #2 on
Industrial housings
Terminal 3 on ATEX
rated housings
Current Sinking Wiring (PN ending S/-)
Electrical Installation Instructions - 5-pin Turck Connectors
Turck®
Connector
PCA
Label Pin #
Mating Cable
Wire Color
Power * V+ 1 Brown
Common Com 4Black
Signal Output (+) Sig 5 Grey
Signal Output (—)** Ret 2White
Case Ground Case 3 Blue
21
4
5
3
Analog Current or Voltage Output Transmitters (PN ending A/-, B/-, C/-, or D/-)
* Analog transmitters with part numbers ending in A/- or C/- are 24Vdc power.
Part numbers 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, install a 10k pull down resistor between Common and Signal
Output (-).
Turck®
Connector
PCA
Label Pin #
Mating Cable
Wire Color
Power (+5 to 26 Vdc) V+ 1 Brown
Common Com 4Black
Pulse Output Ph A 2White
Output Phase B (Quad only) Ph B 5Grey
Case Ground Case 3 Blue
21
4
5
3
Frequency Output Transmitters (PN ending N/-)