Max G Series Quick start guide

G series
Flow Metering
Systems
Operational Manual
For Models G004 thru G240
This manual is for the Max 260 series of gear flow meters
and the integrated model 269 solid state transmitter

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Table of Contents
General Description ................................... 3
Installation ............................................. 4 - 7
High Temperature Operation ..................5
Specifications .............................................8
Additional technical documents regarding transmitter performance and advanced
operation are available at: http://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
specifications 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.
260-000-350 Rev D, 4/10 © 2009-10 Max Machinery, Inc.

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The G-Series flow metering systems are the combination
of a high pressure gear meter and a high resolution,
microprocessor based transmitter. While gear meters are
traditionally based on a design similar to a conventional
hydraulic pump, the G Series of flow meters has been
engineered to increase signal resolution, prevent internal
cavitation and greatly reduce the pressure drop required to
move fluid through the gears.
The G-Series transmitter uses modern sensor technology
coupled with advanced signal processing to deliver new
levels of performance and reliability. Solid state sensors are
used to detect the position of a driven magnet inside the
Max flow meter. Changes in position are tracked by a microprocessor, which generates an output
frequency proportional to the flow rate. Advanced signal processing provides both fine angular
resolution (0.36 degrees rotation per pulse) and rapid response (output updated every 1 ms).
The flow meter and transmitter are calibrated at the factory as a matched set. This ensures the
highest accuracy and allows for quick setup in the field. For field installations where the transmitter
has not been setup with a meter at the factory, an optional serial interface kit is available to provide
full access to all configuration options and parameters.
Flow Meter Features
Capable of operating at high pressures (425 bar/6000 psi).
Compatible with a wide range of fluid types and viscosities.
Can operate at high temperatures with a suitable high temperature transmitter.
Transmitter Features
High resolution measurement - Available in four configurations: frequency, Quadrature, Voltage or
Current outputs. Linearization of up to 16 points to fully describe the flow 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 flow meter characteristics
to provide a stable, undamped output that accurately represents the instantaneous flow rate.
Adjustable Anti-Dither Pulse Buffer - Prevents undesired output which can occur at very low
flow rates in the presence of vibration or hydraulic noise. If the meter reverses for less than the
programmed fraction of a revolution and then resumes forward rotation, the output will represent
only the total forward flow. Reverse flow which exceeds the buffered amount will result in an output
proportional to reverse flow rate.
General Description

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Prior to installing the flow meter remove the storage caps from the ports and look carefully
into each port of the meter. Ensure that no dirt or foreign particles have gotten into the ports
of the meter. Make sure that adequate filtration exists upstream of the flow meter and that no
contaminants exist in the line between the filter and flow meter. It is recommended that the flow
meter be connected to the circuit by means of unions close to the flow meter to allow easy removal.
A by-pass valve should be installed between the inlet and outlet ports in parallel to the flow meter
to allow flow through the system in the event that the flow meter becomes blocked by foreign
material.
Operation
Confirm that the following parameters of your flow metering system are within the specifications
for the meter being used:
Maximum System Pressure (Specification sheet)
Differential Pressure across meter (Pressure Drop Curves)
Maximum Flow Rate (Pressure Drop Curves)
Metered Fluid Temperature (Specification sheet)
If the metered fluid is a solid at room temperature, it is critical that it be fully melted before
applying pressure to the meter in order to avoid excessive loading on the bearings or potentially
fracturing the sensor magnet. To determine melt times, measure the surface temperature as near
as possible to the transmitter. Wait until the body temperature exceeds the melting point, allowing
additional time if the fluid is a poor heat conductor.
Starting with the valving to the flow meter closed, slowly open the bypass valve to establish flow.
Then slowly open the inlet and outlet valves at the flow meter. When the meter turns smoothly and
you detect a flow signal, slowly close the bypass valve completely.
If a bypass valve was not installed in the system, initiate flow in the system as gradually as possible.
If you do not generate a flow signal, or the line pressure increases, stop the pump and allow more
time for the material in the meter to liquefy.
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.
For further detailed information on installation, refer to the G-series Installation Instructions
(included with each unit at shipment) available on our website, www.maxmachinery.com
Installation - Flow Meter

5
Mechanical
Transmitters are installed on the meter at the factory. If a transmitter needs to be replaced in the
field, use the following procedure:
1. Disconnect wiring and remove the two socket cap screws to remove old transmitter.
2. Align rounded alignment key on new transmitter with corresponding notch on flow meter and
drop into place.
3. Tighten both socket cap screws until snug. Ensure that the transmitter is not crooked, then turn
screws a 1/4 turn. Do not over tighten.
Electrical
This model is wired at the factory. All that is required is to connect the 4-pin Connector mating cable
into the remainder of the system as follows:
Frequency Output Blue: Case Ground Black: Common Brown: Power (+5 to 26 Vdc) White: Output Signal
Analog Output Blue: Case Ground Black: Common Brown: 12 or 24 Vdc (see housing)
Grey: Output Signal + White: Output Signal —
High Temperature Operation above 65°C (150°F)
The operating limit of the meter/transmitter is a function of both the ambient and the metered fluid
temperature, as shown in the graph below. Although the electronic components are rated to 80°C
(175°F), additional heat can be conducted from the flow meter into the transmitter housing requiring
a lower ambient temperature limit for high fluid 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 fluid temperatures >65°C (150°F), insulating the flow meter is recommended to reduce the
risk of burns, and to reduce the 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.
Installation -Transmitter
0 50 80 170 210 280265
20
40
60
80° C
100 150 200 250 300° C
Temperature Limits
Model 269 Transmitter Series
Process Temperature °C
Standard
model limit
Hi temp 24vdc
model limit
Ultra Hi*
model 5vdc
operation
Ultra Hi*
model 24vdc
operation
Hi temp 5vdc
model limit
Ambient Temperature °C
*Note: Ultra high temp model must be mounted
with transmitter on side of the flow meter

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INSTALLATION DO’S & DON’TS
DO: Read entire manual before installation. If
you need further information, contact MAX and
ask for Flow Meter Technical Service.
DO: Install proper filtration immediately
upstream of the flow meter.
DO: Install the meter in the pressurized/
upstream section of the circuit if the working
fluid is prone to cavitation (thin fluids or low
boiling points).
DO: Install bypass plumbing around the flow
meter. Use the bypass during start-up while
flushing the system to (1) remove dirt by
filtration and (2) bleed air and vapor from the
system. Open the meter valves slowly on start-up
to avoid over-speeding the meter with entrapped
air. The bypass also allows removal of the meter
for service without disabling the system.
DO: Be very careful to keep all parts clean during
installation or tear down. In particular, ensure
that no metal shavings from inserting the pipe
fittings end up in the meter. Particles larger
than a few thousandths of an inch can cause
significant damage to the meter.
DO: Add protective sealants to exposed socket
head cap screws if meter is used in a highly
corrosive environment.
DON’T: Ever apply more pressure to the meter
than its pressure rating. In particular beware of
sudden spikes, surges or hammering that may
occur. If pressure limits are exceeded, return the
meter to the factory for inspection and repair.
DON’T: Run water or aqueous solutions not
approved by MAX through your flow meter as it
may cause internal galling.
DON’T: Steam clean the meter (bypass or
remove the meter if necessary).
DON’T: Disassemble the flow meter. These are
precision devices which require special tools and
techniques.
DON’T: Blow through the meter with compressed
air, gas, etc., because it can easily be over-sped
and may result in damage to the meter.
DON’T: Turn on the pump if the meter is
filled with material which is a solid at room
temperature until the material has been melted
completely. Use a bypass around the meter
during start up.
DON’T: Apply excessive differential pressure
across meter (see pressure drop graphs) as it will
cause internal parts to fail prematurely.
DON’T: Exceed the maximum flow rates specified
(see performance curves) as it will cause internal
parts to fail prematurely.
DON’T: Operate the meter at a flow rate where
the fluid is cavitating inside the meter.

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Trouble Probable Cause Corrective Action
No Flow thru meter or high
pressure drop
Foreign particles or solidified
matter in meter
Flush meter with suitable solvent.
Return to Factory for repair if
unsuccessful.
Flow but no transmitter
output
Incorrect Wiring Verify wiring.
Failed transmitter Remove cap on transmitter and
observe flashing LED’s. See page
10 for details.
Defective Cable Remove cap on transmitter.
Repair or replace cable. Contact
Factory.
Output is high compared to
actual flow.
Incorrect scaling on analog
output
Correct scaling on transmitter or
display system
Air in the lines Purge lines or re plumb.
Electrical Noise Confirm proper grounding and
shield cables.
Magnetic Interference Avoid placing near strong
magnetic fields.
Indicator out of calibration See indicator manual.
Output is low compared to
actual flow
Leaky bypass valve Repair or replace valve
Flow is below specified
minimum rate
Increase flow or replace with
appropriately sized meter
Indicator out of calibration See indicator manual
Meter damaged from
particulates in fluid
Contact Factory
Troubleshooting
Repairs
The Max G-Series Meters are not designed for user repair and all such work should be done 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 flow meter before calling the factory. A Return Material Authorization (or
RMA) number will be issued if the flow meter has to be sent back for repair.

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Model # G004 G015 G045 G105 G240
Max Flow (1) 4 LPM
(1GPM)
15 LPM
(4 GPM)
45 LPM
(11.9 GPM)
105 LPM
(28 GPM)
240 LPM
(64 GPM)
Operating
Pressure
425 bar
(6000psi)
425 bar
(6000psi)
425 bar
(6000psi)
425 bar
(6000psi)
see below
Filtration 10 micron 15 micron 20 micron 20 micron 30 micron
Max Temp (2) 160°C
(320°F)
160°C
(320°F)
160°C
(320°F)
160°C
(320°F)
160°C
(320°F)
Weight 1.2 kg 1.8 kg 3.7kg 7.7kg 21 kg
Displacement
cc/rev
1.8 4.2 13.5 38 133
Typical
K-Factor
(Pulses/cc)
500 200 70 25 7
NPT Port Size 1/8” 3/8” 1/2” 3/4” 1” to 280 bar (4000 psi)
SAE Port Size #4 #6 #8 #10 #16 to 425 bar (6000psi)
(1) For fluids above 100cps fluid, flow rate must be derated. See graphs.
(2) Standard transmitter capable to 85°C (185°F).
Flow meter Specifications

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Supply Voltage & Current Frequency output 5-26 Vdc @ 30 mA typical
Analog output 12Vdc @ 90 mA typical
24Vdc @ 45 mA typical
Analog Resolution Adjustable without recalibration to any range of
+/- 20mA - Models ending in “A0” and “B0”
+/- 10 Vdc - Models ending in “C0” and “D0”)
FREQUENCY MODEL SPECIFICATIONS
Output (5.0 Volt Supply) No Load 0.00 / 4.80 Volts
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 μ Sec
Output Update Rate(2) 1 ms
Min/Max Frequency 0-60 kHz
Resolution 1 - 1000 pulses/rev
Ambient Temperature Range Transmitter (Storage) –40ºC to 85ºC (–40ºF to 185ºF)
Transmitter (Operation) (3) –40ºC to 80ºC (–40ºF to 175ºF)
Maximum Temp, Process Fluid FREQ OUTPUT ANALOG OUTPUT
(30ºC Ambient, 5V supply)
(Standard Model) 90ºC (195°F) 80ºC (175°F)
(High Temp Model) 160ºC (320°F) Not Available
(Ultra High Temp Model) 232ºC (450°F) 200ºC (392°F)
Anti-dither Range Default 50% Revolution of Meter for unidirectional (software selectable
from 1 - 100% of 1 revolution). 2% for bi-directional meters
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
Transmitter Specifications
- or -

10
(3) Temperature of metered fluid will affect transmitter temperature, see graph
Rotation/Output Indicators
Output LED (D1): This LED indicates the status of the output
terminal. It is green when high (5V) and Red when low (0V).
With power supplied, this should always be illuminated (red
or green).
Rotation LED (D3): This LED is on (red) for half of the meter
rotation and then off for half of the meter rotation. Blinking
indicates flow meter rotation.
This LED may be on or off if the flow meter is stationary,
depending on where in the rotation the meter has stopped.
Note: There are no settings or adjustments that can be made
on the circuit board. The only method of altering the setup
parameters is through the Serial Interface Program (see
separate manual).
Flow Measurement Stability:
The Max G Series meter family utilizes a sensitive measurement circuit that tracks the meter
rotation to within a fraction of a degree of rotation. This gives extremely responsive measurement
of flow changes combined with excellent measurement of very low flows. This same high resolution
can lead to an increased sensitivity to signal noise. Signal instability can be caused by physical flow
fluctuations that are present in the fluid stream or by electrically or magnetically induced noise. This
variation will be most noticeable at the lower flow rates.
To decrease noise in the flow signal, the model 269 transmitter uses proprietary software with
selectable dampening. Changes to the default setting to achieve faster response or, inversely, a
more stable output, require the use of the transmitter interface software.