Positive Displacement
Flowmeters
Operational Manual
Model G004
Model G015
For Models
G004, G015, G045, G105, G240
Model G045
Model G240
Model G105
Gear - G Series
Positive Displacement Flow Meters
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
1
Table of Contents
Before You Install................................................................................................page 3
Meter General Description............................................................................. page 4
Transmitter General Description................................................................. page 5
Meter Specifications......................................................................................... page 6
Transmitter Specifications..............................................................................page 7
Transmitter Specifications Temp................................................................ page 8
Do’s & Don’ts........................................................................................................ page 9
Installation............................................................................................................page 10
Operation............................................................................................................... page 11
Electrical Installation - Wiring.................................................................page 12-13
Troubleshooting.................................................................................................page 14
Diagrams & Pressure Drop:
Model G004 Flow Meter...............................................................page 15
Model G015 Flow Meter.................................................................page 16
Model G045 Flow Meter................................................................ page 17
Model G105 Flow Meter.................................................................page 18
Model G240 Flow Meter................................................................page 19
Contact for Repairs & Calibration Services.......................................... page 20
Optional Heater Block Details.................................................................... page 20
Installation Instructions
— Hazardous Locations.............................................................................page 21-22
Electrical Requirements................................................................................page 23
EC Declaration of Conformity.....................................................................page 24
DO NOT ATTEMPT TO INSTALL OR START FLOW METER WITHOUT READING THIS ENTIRE MANUAL
G-000-350 © 2012 Max Machinery, Inc.
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 specifications 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.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
2
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 the best meter for you based on many of the factors
that will be reviewed on the following pages. If you have any questions about installation or operation please don't hesitate
to call Max Machinery, Inc. at 707-433-2662
When you are ready to install 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
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.
Process Temperatures ____________________________ Fluid Viscosity_____________________________________
Operating Range _________________________________ Line Pressure______________________________________
Max Sales # or PO #_______________________________ Installation Date___________________________________
Meter Model # ___________________________________ Meter Serial #_____________________________________
Transmitter Model #_______________________________ Transmitter Serial #________________________________
Notes: ______________________________________________________________________________________________
______________________________________________________________________________________________
______________________________________________________________________________________________
______________________________________________________________________________________________
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
3
Meter General Description
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
operating range.
Max entire
Model G004
meter’s
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.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
4
Transmitter General Description
Max transmitters are designed to work with the entire family of Max Flow Meters to provide extremely precise flow
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 flow rate.
Advanced signal processing provides both fine angular resolution (0.36 degrees rotation) and rapid response (output
updated every one millisecond).
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.
Transmitter Features
High resolution measurement –
Analog Output: Configured output ranges to any value within ± 10 Vdc or ± 20 mA.
Frequency Output: Configured output resolution of 1 to 1000 pulses per revolution.
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. 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 flow 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 flow exceeding the buffer setting will result in an output proportional to reverse flow rate. The buffer quantity can
be set from 1% to 100% of a revolution.
G004 Standard
Max Machinery, Inc. G Series User Manual G004 2-Part Pickup
© Copyright 2012
Rev. #0312
G004 Ex-Proof
5
Meter Specifications
Model
G004 G015 G045 G105 G240
1
Maximum flow rate
Liters/min: 4
15
45 105 240
Gal/min:
1
4
11.9 28 64 Maximum pressure (psi)
|-----------------------425 bar (6000 psi)-----------------------|
see below
2
Maximum temperature
--------------------- 2 part: 225°C (435°F) --------------------
3
Recommended filtration
10 micron
15 micron
20 micron
20 micron
30 micron
Displacement (cc/rev)
1.8
4.2
13.5
38
133
Weight (kg)
1.2 1.8
3.7
7.7
21
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)
For viscosities of 100 cps or more, derate per pressure drop curves for higher viscosities.
Standard transmitter capable to 90°C (195°F)
3
Some materials may have different filter requirements, consult factory.
1
2
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
6
Transmitter Specifications
Supply Voltage & Current
Frequency output Analog output
5-26 Vdc @ 30 mA typical
12Vdc @ 90 mA typical
24Vdc @ 45 mA typical
Analog Resolution
Adjustable without recalibration to any range of
+/- 20mA - Models ending in “A1” and “B1”
+/- 10 Vdc - Models ending in “C1” and “D1”)
FREQUENCY MODEL SPECIFICATIONS
Output (5.0 Volt Supply) Short Circuit Current (1) Output Impedance Rise/Fall Time Output Update Rate(2) Min/Max Frequency Resolution Ambient Temperature Range 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
45 mA
100 Ω
0.2 μ Sec
1 ms
0-60 kHz
1 - 1000 pulses/rev
Transmitter (Storage) –40ºC to 85ºC (–40ºF to 185ºF)
Transmitter (Operation) (3) –40ºC to 80ºC (–40ºF to 175ºF)
Maximum Temp, Process Fluid
(Standard Model)
90ºC (195°F)
(20ºC Ambient, 5V supply) (High Temp Model)
155ºC (310°F)
(Ultra High Temp Model) 225ºC (435°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
(3) Temperature of metered fluid will affect transmitter temperature, see graph
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
7
Transmitter Specifications
Temperature graph
Model 29X Transmitter Series
120
110
100
Ambient Temperature °C
80
60
40
One piece
model limits
High temperature
2 part pickup
Ultra high temperature
2 part pickup
20
0
-25
50
150
200
© Copyright 2012
Rev. #0312
100
225
250
300
Process Temperature °C
Max Machinery, Inc. G Series User Manual 8
Do’s & Don’ts
DO:
Install bypass plumbing around the flow meter. This is
useful during start up for removing dirt and air from
the plumbing or when measuring fluid that may freeze
inside the line and need to be remelted before it can
pass through the meter. It also allows removing the flow
meter for service without disabling the system.
DO:
Install the meter on its side.
DO:
Be very careful to keep parts clean during installation
or teardown. A little dirt can look like a truckload
compared to the 10 to 30 micron filtration requirement for G-Series Meters.
DO:
Clean the filter on a regular basis.
Max Machinery, Inc. G Series User Manual DON’T:
Run water or aqueous solutions not approved by Max through your flow meter because of internal galling.
DON’T:
Steam clean the meter (bypass or remove the meter if
necessary).
DON’T:
Blow down the meter with compressed air or gas
because it may over-speed and damage the meter.
DON’T:
Remove the Transmitter from the flow meter body.
The transmitter is phased to the meter and a
measurement error will result. Re-calibration will be
necessary; see the transmitter interface software
manual.
DON’T:
Disassemble the flow meter. These are precision
devices which require special tools and techniques.
DON’T:
Turn on the pump in a system filled with material that
is solid at room temperature. Wait until the material
is completely melted and use the flow meter bypass
valve during start up.
DON’T:
Apply excessive differential pressure across the flow
meter as it will cause internal failure (see the pressure
drop curves for safe area operation).
DON’T:
Over pressurize the meter. Consult specification table for maximum pressure.
DON’T:
Exceed the maximum flow rates for the material
viscosity.
DON’T:
Allow materials which solidify in air to set up in the
flow meter. These may be impossible to remove. If
the meter needs to be removed for repair and cannot
be completely cleaned. Plug the inlet and outlet ports
at once.
© Copyright 2012
Rev. #0312
9
Installation
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.
The preferred orientation for the meter is to place the transmitter to the side of the flow meter. Such an installation
ensures that bubbles will not accumulate within the meter. In a high pressure installation, the compression and expansion
of gas bubbles from the bearing pockets may create undesirable side forces on the gears. Mounting the meter with the
transmitter to the side will purge the air from the meter. This orientation is also preferred as it reduces the amount of heat
that rises from the meter into the transmitter circuitry.
The following items and conditions should be considered:
Line and Bypass Valves: These valves allow filter cleaning or flow meter removal without completely shutting the system
down and draining the lines. They also allow system start up under conditions which could damage the meter; such as: air
in the lines, high temperature materials, or initial line surges.
Filtration: Clearances between the gears and internal wall are typically 0.001” to 0.002”. Any dirt present in the system
can jam or damage the unit. A 10 micron filter (such as a Max 381 Series stainless steel unit) is generally recommended,
although materials with very high viscosities may require a coarser filter. For bidirectional flow applications, use a filter on
each side of the flow meter. Materials with fibrous or non abrasive particulate matter may have to be run without filters.
Follow the recommendation of your Max Sales Engineer or consult our Technical Service Department.
Inlet and Outlet Ports: Use the “IN” port as the inlet for the most predominant flow direction. Install the flow meter on the
discharge side of the pump whenever possible. Excessive vibration at the meter should be avoided.
High Temperatures: Mount the meter so that the transmitter is below or to the side of the meter. This minimizes heat
transfer by convection from the flow meter to the transmitter. The transmitter is the most heat sensitive element in the
system and the transmitter manual should be consulted for specific limits. An optional fluid heater block can be used
on the flow meter to keep it at operating temperature during standby conditions. For substances that are solid at room
temperature, the block may be required to keep the material molten and flowing through the meter.
Clean Plumbing: Before installing the flow meter, clean the inside of the pipe line with compressed air or steam (especially
when using new pipe). Don’t use water, steam, or compressed air on the meter itself!
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
10
Piping Diagram
Horizontal Installation
Vertical Installation
FLOW
FLOW METER
VALVE 1
VALVE 2
VALVE 2
FILTER
VALVE 3
BYPASS
FLOW METER
Horizontal Two-Way Flow
VALVE 3
BYPASS
FLOW
FLOW METER
VALVE 1
FILTER
VALVE 2
FILTER
FILTER
VALVE 3
VALVE 1
FLOW
BYPASS
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 page 8)
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 if unusual differential pressures across the meter
are encountered.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
11
Electrical Installation - Wiring
Removal note: The transmitter does not need to be removed from the flow meter for any field servicing or adjustments.
Normally, the flow 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
1. The transmitter is attached to the flow 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.
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 is an O—ring seal at the lid 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.
Wiring ANALOG
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:
Analog
PCA label
Mating Cable
Wire Color
Turck
Pin #
Case Ground
Case
Blue
3
Common
Com
Black
4
Power *
V+
Brown
1
Signal Output (+)
Sig
Grey
5
Signal Output (-)**
Ret
White
2
*Model 29X-xxx-000, 24vdc powered, Model 29X-xxx-100, 12vdc powered
** Signal output is fully isolated: If attached to a true differential input a 10K Ohm pulldown resistor
should be installed between (—) and common at the receiving end.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
12
Electrical Installation - Wiring
Wiring FREQUENCY
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
Case
Mating Cable
Wire Color
Blue
Turck
Pin #
3
Com
Black
4
Power 5-26 Vdc
V+
Brown
1
Pulse Output
Ph A
White
2
N/A
NC
Grey
5
PCA label
Frequency
Single Phase
Common
Wiring
Case Ground
Current Sinking* Wiring
(models 29X-6XX)
V+
PLC
V+
0V
Digital
Input
Out
Turck Pin #2
* 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 flow in the signal line.
Frequency
Quadrature
PCA label
Mating Cable
Wire Color
Turck
Pin #
Case Ground
Case
Blue
3
Common
Com
Black
4
Power 5-26 Vdc
V+
Brown
1
Output Phase A
Ph A
White
2
Output Phase B
Ph B
Grey
5
Transmitter
Wiring Diagram
Model 295/296
Turck Connector
*
*
(Brown)
(Black)
(Grey)
(White)
(Blue)
Freq
V+
Com
PhA
PhB
Case
(Brown)
(Black)
(Grey)
(White)
(Blue)
Analog
V+
Com
Sig
Ret
Case
4
3
5
1
2
*Serial interface receptacle.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
13
Troubleshooting
Trouble
Corrective Action
No Flow through meter or high pressure drop across meter
Solidified material blocking rotation
Heat meter to melt material
Debris blocking rotation
Flush the inside of the meter and try to work the gear free
by displacing debris
If you find damaged parts in the meter, return the meter to the factory for repair
Meter broken
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
Meter not turning
Remove transmitter from meter and place a paper clip against the magnet shield. Clip should be drawn to magnet inside of the meter and move with the meter’s rotation
Indicated flow does not agree with expected readings
Air in the line
Air bubbles displace the meter just as a liquid would. If you are over-reporting, verify that there is no air in the lines.
Indicator not calibrated properly
Verify the K-Factor for the meter in use and compare this value to the setting used in the display.
Excessive reverse flow in system
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.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
14
Model G004 Flow Meter
2.26”
(57mm)
1.93”
(49mm)
1/2”
NPT
3.70”
4.09”
(94mm)
(104mm)
1.75”
1.75”
(45mm)
(45mm)
1/8” NPT
1/8" NPT
1/8” NPT
1/8" NPT
MODEL G004 WITH INDUSTRIAL
HOUSING TRANSMITTER
MODEL G004 WITH EX-PROOF
HOUSING TRANSMITTER
2.75”
2.26”
(70mm)
(57mm)
2.26”
(57mm)
2.6”
(66mm)
0.65”
mounting holes
1/4” - 20NC
(4) places
(17mm)
not to scale
1.5”
EX-PROOF HOUSING
TOP VIEW
(38mm)
BOTTOM VIEW
TYPICAL PRESSURE DROP
Expected Failure Area
140
Intermittent Duty Area
Pressure Drop (psi)
120
— 8 bar
Continuous Duty Area
100
80 — 6 bar
0
,00
10
cP
60 — 4 bar
cP
1000
40
100 cP
30 cP
2 cP
— — 2 bar
20
0.001
0.01
1
0.1
10
Flow Rate (liters/min)
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
15
Model G015 Flow Meter
2.26”
(57mm)
1.93”
(49mm)
1/2”
NPT
4.33”
3.94”
(110mm)
(100mm)
2.0”
2.0”
(51mm)
(51mm)
3/8” NPT
3/8” NPT
1/8" NPT
MODEL G015 WITH EX-PROOF
HOUSING TRANSMITTER
MODEL G015 WITH INDUSTRIAL
HOUSING TRANSMITTER
3.23”
(82mm)
2.26"
(57mm)
2.26"
3.07”
(57mm)
(78mm)
mounting holes
1/4” - 20NC
(4) places
0.65"
(17mm)
not to scale
1.75”
(44mm)
EX-PROOF HOUSING
TOP VIEW
BOTTOM VIEW
TYPICAL PRESSURE DROP
Expected Failure Area
— 8 bar
Intermittent Duty Area
cP
100
10
,00
0
Pressure Drop (psi)
120
80 — 6 bar
60 — 4 bar
c
P
140
00
10
Continuous Duty Area
40
— — 2 bar
20
0.01
0.1
Max Machinery, Inc. G Series User Manual 2 cP
100
10
1
© Copyright 2012
cP
100
cP
30
Rev. #0312
16
Model G045 Flow Meter
2.26”
(57mm)
1.93”
(49mm)
1/2”
NPT
4.84”
4.45”
(123mm)
(113mm)
2.52”
(64mm)
2.52”
(64mm)
1/8" NPT
1/8" NPT
1/2” NPT
1/2” NPT
MODEL G045 WITH EX-PROOF
HOUSING TRANSMITTER
MODEL G045 WITH INDUSTRIAL
HOUSING TRANSMITTER
3.98”
2.26”
(101mm)
(57mm)
2.26”
(57mm)
3.82”
(97mm)
0.65”
(17mm)
mounting holes
1/4” - 20NC
(4) places
not to scale
EX-PROOF HOUSING
TOP VIEW
2.25”
(57mm)
BOTTOM VIEW
TYPICAL PRESSURE DROP
Expected Failure Area
— 8 bar
100
Intermittent Duty Area
00
,0
10
80 — 6 bar
cP P
c
00
10 300
Continuous Duty Area
60
cP
— 4 bar
0
10
40
— — 2 bar
20
30
5
c
0.01
cP
cP
120
P
Pressure Drop (psi)
140
0.1
100
10
1
Flow Rate (liters/min)
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
17
Model G105 Flow Meter
2.26”
(57mm)
1.93”
(49mm)
1/2”
NPT
5.67”
5.28”
(144mm)
(134mm)
3.35”
3.35”
(85mm)
(85mm)
3/4” NPT
3/4” NPT
MODEL G105 WITH INDUSTRIAL
HOUSING TRANSMITTER
MODEL G105 WITH EX-PROOF
HOUSING TRANSMITTER
4.96”
2.26”
(126mm)
(57mm)
2.26”
(57mm)
4.72”
(120mm)
0.65”
(17mm)
mounting holes
1/4” - 20NC
(4) places
not to scale
EX-PROOF HOUSING
TOP VIEW
2.75”
(70mm)
BOTTOM VIEW
TYPICAL PRESSURE DROP
Expected Failure Area
120
— 8 bar
Intermittent Duty Area
100
00
Continuous Duty Area
10
60 — 4 bar
cP
0
10
cP
0
3
40
20
0
30
cP
80 — 6 bar
cP
10,
00
0c
P
— 2 bar
0.1
c
P
Pressure Drop (psi)
140
5
1.0
100
10
1000
Flow Rate (liters/min)
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
18
Model G240 Flow Meter
2.26”
1.93”
(57mm)
(49mm)
1/2”
NPT
7.13”
6.73”
(181mm)
(171mm)
4.80”
4.80”
(122mm)
(122mm)
1” NPT
1” NPT
MODEL G240 WITH INDUSTRIAL
HOUSING TRANSMITTER
MODEL G240 WITH EX-PROOF
HOUSING TRANSMITTER
6.69”
2.26”
(170mm)
(57mm)
2.26”
4.0”
6.96”
(102mm)
(177mm)
(57mm)
0.65”
(17mm)
mounting holes
1/4” - 20NC
(4) places
not to scale
EX-PROOF HOUSING
TOP VIEW
2.5”
(64mm)
TYPICAL PRESSURE DROP
Expected Failure Area
Pressure Drop (psi)
140
120
— 8 bar
Intermittent Duty Area
100
80 — 6 bar
Continuous Duty Area
60 — 4 bar
40
cP
300
0 cP
10,00
— — 2 bar
cP
1,000
P
30 c 2 cP
20
0.1
cP
100
1.0
100
10
1000
240
Flow Rate (liters/min)
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
19
Contact for Repairs
& Calibration Services
The G Series is 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 goods
authorization number 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
Optional Heater Block Details
Temperature probe holes (all models)
1/8" NPT
1/16" NPT
Liquid trace ports
G004, G015 G045, G105
G240 (Qty 2)
1/4" NPT
3/8" NPT
3/8" NPT
Electric Cartridge requirements
G004
G015
G045
G105
G240 (Qty 2)
3/8" x 1"
3/8" x 1.3"
1/2" x 2.1"
1/2" x 3.1"
1/2" x 4.7"
Heater block for G015
(typical)
1/8” NPT
2.262
2.051
.1895±.0025
1.55
.376±.001
1.25
.1275±.0025
.749
.529
0
1/16” NPT
1/4” NPT (2 places)
NOTES:
1: HEATER PORT CLEARANCE IS FOR A PROBE WITH 250 WATT/DENSITY MAX AT 400º F
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
20
Installation Instructions
— Hazardous Locations
Applies only to Max Model EX295 and EX296 Transmitters with explosion proof certification.
These transmitters provide protection via a flame proof housing and through current limiting to the circuit board: Must
wire with a class 2 power supply (See table for loads page 23).
Meets US and Canadian Haz-Loc classifications, Class I, Div 1, Groups C and D, Tx
As well as ATEX/IECEx II 2 G Ex d IIB Tx Gb
Certification numbers Demko 11 ATEX 1013058X and IECEx UL 10.0048X
Mechanical Installation
The outer housing freely rotates to align the conduit hole with your electrical connection point. If the transmitter is already
attached to the meter skip to step 5:
1. To attach the transmitter to the flow meter, apply a small amount of low strength thread adhesive, such as Loctite™, on
the threads and screw the transmitter onto the exterior threads on top of the flow meter.
2. Locate the locking set screw below the conduit hole and using a 3/32" hex wrench remove it. Rotate the outer housing
clockwise until the screw hole lines up with a hole in the inner housing. (Inserting an Allen key into the threaded hole while
rotating the housing can help in finding the point of alignment.) Now re-insert the set screw and hand-tighten it to lock the
inner and outer housing together.
3. Finish tightening the transmitter onto the meter by applying a torque of 2 to 5 ft.-lb. (2.7 to 6.78 N-m).
4. Now back out the locking set screw until it is flush with the surface of the transmitter.
5. The housing can now be rotated to align the conduit port in the desired direction.
6. To remove the lid for wiring, remove the safety screw at the edge of the lid and then remove the cap using a 3/8”
socket drive.
7. Install conduit. Within 18” of the housing install a conduit stop and fully seal with potting compound.
8. Connect wires to terminal block as shown below, using 2 mm screw driver.
9. A case ground terminal is provided internally, but if grounded metallic conduit is not used, then one of the external
grounds below the conduit fitting must be used. For metric- use either a 6 or 8 mm long stainless steel M5 x 8.0 bolt. For
inch measurement – use either a 1/4” or 5/16” long stainless steel #10-32 bolt.
10. Reattach cap and tighten to 40 in-lbs to seal enclosure. Install safety lock screw at the edge of the lid and hand tighten.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
21
Removal from Flow Meter
Note: the transmitter does not need to be removed from the flow meter for any field servicing or adjustments. Normally,
the flow meter and transmitter are shipped back to the factory for calibration as a unit.
1. Remove the locking screw at the edge of the lid and then remove the cap using a 3/8” socket drive.
2. Disconnect wires at the terminal block and remove wiring conduit from transmitter.
3. Locate the locking set screw below the conduit hole and remove it. Rotate the outer housing clockwise until the screw
hole lines up with a hole in the inner housing. (Inserting an Allen key into the threaded hole while rotating the housing can
help in finding the point of alignment.) Now re-insert the set screw and hand-tighten it. This will lock the inner and outer
housing together.
4. Unscrew the transmitter, using a strap wrench if necessary.
Moisture Protection
The housing is a liquid and vapor-tight enclosure certified to IP66. There is an O-ring seal at the lid of the housing — the
seal needs to be fully seated to provide moisture protection and achieve flameproof specifications.
About Explosion proof installations
For the Model 295 and 296 to fully adhere to the HazLoc certifications, the wiring must meet the appropriate codes. (Use
of a wire conduit does not make the installation explosion proof – read below.) The transmitters which are certified for use
in hazardous locations require the use of a 1/2” NPT hazardous location rated conduit fitting. The wiring conduit must be
sealed with a conduit stop within 18” of the device. If you choose to use exposed cables, cable seals must be used with
sealing fittings and the wiring must be an approved armored cable.
Electrical Installation
Use wiring that is between 20 and 28 gauge and rated to at least 5°C above the maximum ambient temperature, and rated
to at least 80% of the maximum fluid temperature.
Pulse Output
Wiring
Power *
Pulse
PCB
Label
V+
Analog Output
Wiring
Power
Analog
PCB
Label
V+
Wiring Adaptor
Pin # **
1
Two Part Transmitter Wiring **
Ex-Proof Sender
(Ex.: 29x-051-000)
Case
Remote Receiver
(Ex.: 296-x8x-xxx)
Case
Common
Com
Common
Com
2
5V
5V
Signal
Output
PhA
Signal Output (+)
Sig
3
Ra
Ra
(Quad only)
PhB
Signal Output (-)
Ret
4
Rb
Rb
Case Ground
Case
Case Ground
Case
5
Com
Com
* Consult Table
** (Customer supplied cabling required “from“ Max Ex-Proof products)
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
22
Electrical Requirements
The device must be powered with a Class 2 power supply. Electrical loads are specific to model number’s:
Part #’s
Transmitter Type
Electrical Input
Requirements
Output Electrical Requirements
29x-0xx-
Pulse Output Transmitter
5-28Vdc 40mA
Single Line 0-5V 10mA (500 ohm pulldown or greater)
29x-1xx-0xx
Quadrature Output
Transmitter
5-28Vdc 50mA
2 Lines 0-5V 10mA each (500 ohm pulldown or greater)
29x-2xx-
mA Output Transmitter
24-28Vdc 50mA
Isolated current loop, max 500 ohms in line, 12Vdc max
29x-2xx-1xx
mA Output Transmitter (12Vdc)
12-15Vdc 100mA
Isolated current loop, max 500 ohms in line, 12Vdc max
29x-3xx-
V Output Transmitter (24Vdc)
24-28Vdc 50mA
Isolated voltage loop, min 1000 ohms across line, 12Vdc
29x-3xx-1xx
V Output Transmitter (12Vdc)
12-15Vdc 100mA
Isolated voltage loop, min 1000 ohms across line, 12Vdc
29x-6xx0xx
Level Shifter Pulse Output
Transmitter
5-28Vdc 30mA
Single line, current sinking, max 28Vdc, max 25mA
Temperature Classification
Temperature class is a function of fluid temperature used in the meter and ambient temperature. For hot fluids, meter
must be insulated and transmitter must be left exposed. All transmitters are rated to operate within the BLUE region, but
only the remote sender unit variants (295-x5x-xxx) can operate up to the maximum temperatures shown in the chart.
Consult factory for installation details when operating near temperature limits.
Temperature class chart for all explosion proof variants:
100-
100
90
90 -
Ambient Temperature °C
8075
75-
60-
T6
T5
T4
40-
2075
-25
0
20
40
60
90
80
130
100
120
130
Fluid Temperature °C
Note: Consult factory to determine the functional temperature limit of your transmitter variant. Temperature class ratings
do not correspond with the continuous duty area for the electronics within the transmitter. A complete description of your
transmitter may be found on the Max Machinery web site (www.maxmachinery.com). Individual specification sheets and
product family manuals are also available for viewing or downloading.
Max Machinery, Inc. G Series User Manual © Copyright 2012
Rev. #0312
23
EC Declaration of Conformity
We, Max Machinery Inc. declare as manufacturer under our sole responsibility that the product series 295/296 Explosion
Proof Flow Transmitter is in conformity with the provisions of the European Community Directives as shown below.
Applicable Series: Part numbers of the format EX295-xx1-x00 and EX296-xx1-x00 where ‘x’ does not affect conformity to
the standards.
Low Voltage Directive 2006/95/EC
EMC Directive 2004/108/EC
EN 61000-6-2:2005 Electromagnetic Immunity
EN 61000-6-4:2007 Electromagnetic Emission
ATEX Directive 94/9/EC designed and manufactured in accordance with Annex II of the Atex Directive
EN 60079-0:2009
Explosive atmospheres general requirements
(Note: no routine verification and tests are required by clause 27)
EN 60079-1:2007
Protection by flameproof enclosures type d”
Designation:
0539
II 2 G Ex d IIB Tx Gb
EC Type examination certificate DEMKO 11 ATEX 1013058X provided by
UL International DEMKO A/S NB Number: 0539
P.O. Box 514, Lyskaer 8, DK-2730 Herlev, Denmark
Product quality assurance notification #11 ATEX Q1116140 provided by UL Demko
Production control done to ISO 9001:2008, certificate #C2010-01864
Bryan Snyder
Engineering Manager
May 24, 2011
Max Machinery Inc.
33A Healdsburg Ave.
Healdsburg, CA USA
(707) 433-2662
Max Machinery, Inc. G Series User Manual Rev. #0312
© Copyright 2012
24