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 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 Certifi cateBypass 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 # ____________________________________
The Max P-Series of Flow Meters are positive displacement
piston type units capable of great accuracy over a wide range
of fl ow rates and fl uid viscosities. The fi ve basic sizes of this
series will measure fl ows from 0.005 cc/min to 35 Liter/min.
Various “O” ring and internal plating options are available to
meet temperature and fl uid compatibility requirements.
In a piston type fl ow meter, four pistons and cylinders are
arranged in a radial fashion around a central crankshaft.
Two fl uid ports on the cylinder wall, a port at the top of the
cylinder, and a grooved piston enable fl uid entering the fl ow
meter’s central cavity to be measured and pumped out by
each piston in turn. The valving action for each cylinder is accomplished by the piston adjacent to it. The accuracy of
a piston fl ow meter is dependent on close tolerances in the cylinder wall and piston. Max Machinery regularly holds
tolerances as fi ne as 0.00005 inches in the production of these meters.
The movement of the pistons is converted to a circular motion at the
central crankshaft, which is coupled to a magnet in the fl ow meter. This
motion is sensed by an external electronic transmitter, which converts
fl ow into a voltage, pulse train, or current for further processing.
The Max P Series of meters can be expected to perform superbly if
operated within the confi nes of their 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.
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).
The Max transmitter will be 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: Programmed output ranges to any value within ± 10 Vdc or ± 20 mA.Frequency Output: Programmed 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.
Supply Voltage 12 or 24 Vdc Consult part number matrix
Supply Current 90 mA max@ 12 Vdc, 45 mA max@ 24 Vdc
Short Circuit Current 21 mA
1
Output Update Rate 1 ms
Resolution Adjustable without recalibration to any range of ± 10 Vdc
(e.g. 0 to 5 V) or ± 20 mA (e.g. 0 to 20 mA or 4 to 20 mA)
Ambient Temperature Range Transmitter (Storage)–40ºC to 85ºC (–40ºF to 185ºF)
2
Transmitter (Operation)–40ºC to 80ºC (–40ºF to 175ºF)
Max Temperature, Process Fluid Standard Model 90ºC (195°F)
(20ºC Ambient, 5V supply) High Temp Model 155°C (310°F) – Model P001 and P002, only
Ultra-High Temp Model 225ºC (435°F)
For explosion proof models see:
Anti-dither Range Software selectable from 1-100% of 1 revolution.
50% of a meter revolution - unidirectional - 2% bidirectional
are typical default settings
Signal Filtering Software selectable from 1 ms to 64 sec. time constant
1
Full step change is subject to signal damping
2
Temperature of metered fl uid will affect transmitter temperature, see graph below
Supply Voltage 5-26 Vdc
Supply Current 25-30 mA typical
Output (5.0 Volt Supply) No Load 0.00 / 4.80 Volts
(TTL and CMOS compatible) 2.5K Load to Common 0.00 / 4.60 Volts
2.5K Load to +5 Volts 0.25 / 4.80 Volts
Short Circuit Current 45 mA
Output Impedance 100 Ω
Pulse Rise/Fall Time 0.2 μSec
1
Output Update Rate 1 ms
Min/Max Frequency 0-60 kHz
Resolution See Table on Page 6
Ambient Temperature Range Transmitter (Storage)–40ºC to 85ºC (–40ºF to 185ºF)
Max Temperature, Process Fluid Standard Model 90ºC (195°F)
(20ºC Ambient, 5V supply) High Temp Model 155°C (310°F) – Model P001 and P002, only
For explosion proof models see:
Anti-dither Range Software selectable from 1-100% of 1 revolution.
50% of a meter revolution - unidirectional - 2% bidirectional
are typical default settings
Signal Filtering Software selectable from 1ms to 250ms time constant
1
Full step change is subject to signal damping
2
Temperature of metered fl uid will affect transmitter temperature, see graph on previous page
DO:
Install bypass plumbing around the fl ow meter. This is useful during start up for removing dirt and air from
the plumbing or when measuring fl uid that may freeze inside the line and need to be remelted before it can
pass through the meter. It also allows removing the
fl ow meter for service without disabling the system.
DO:
Be very careful to keep parts clean during installation
or teardown. A little dirt can look like a truckload
compared to the 10 micron fi ltration requirement for P Series Meters.
DO:
Clean the fi lter on a regular basis.
DON’T:
Run water or aqueous solutions not approved by Max
through your fl ow 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 fl ow 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 fl ow meter. These are precision devices which require special tools and techniques.
DON’T:
Turn on the pump in a system fi lled with material that is solid at room temperature. Wait until the material
is completely melted and use the fl ow meter bypass valve during start up.
DON’T:
Apply excessive differential pressure across the fl ow meter as it will cause internal failure (see the pressure
drop curves for safe area operation).
DON’T:
Over pressurize the meter. Maximum pressure is either
3,000 PSI (210 bar) or 7250 PSI (500 bar) depending
on model purchased.
DON’T:
Exceed the maximum fl ow rates for the material
viscosity.
DON’T:
Allow materials which solidify in air to set up in the
fl ow 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.
The following items and conditions should be considered:
Line and Bypass Valves: These valves allow fi lter cleaning or fl ow 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 fl ow meter piston and cylinder wall are typically 0.0002” to 0.0004”. Any dirt
present in the system can jam or damage the unit. A 10 micron fi lter (such as a Max 381 Series stainless steel unit) is
generally recommended, although materials with very high viscosities may require a coarser fi lter. 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 fi lters. Follow the recommendation of your Max Sales Engineer or consult our Technical Service
Department.
Installation: Use the “IN” port as the inlet for the predominant fl ow direction. Install the meter on the discharge side of
the pump whenever possible. Excessive vibration at the meter should be avoided.
Orientation: The preferred orientation for the meter is dependant on the type of meter and is intended to optimize air
purging and/or to minimize heat rising into the electronics. Standard piston meters with inline ports should be mounted
with the transmitter either on the side or upside down. Ultra high pressure piston meters with offset inlet and outlet
ports should be mounted with the transmitter on top. See diagrams on page 11.
NPT fi ttings: Always use either pipe sealant or pipe tape when installing fi ttings, but take great care to leave the fi rst
thread of the pipe exposed. This ensures that the tape or sealant will not accidentally fall inside the meter.
SAE fi ttings: Always lubricate the o-ring fi tting when attaching to the meter.
Compression Fittings: The P001 compression fi ttings are based on Swagelok style ferrules. Do not use other
manufacturer’s parts because the sealing angle may not be the same. Fitting kits contain detailed instructions and are
shipped with every meter (spares are available: P001-2-040 for 6mm and P001-2-042 for 1/4 “ tubing). Always select
tubing grades that meet or exceed your system pressure requirements. If using fl exible tubing, always install a tubing
insert to provide the stiffness required for the compression ferrules to seal (such as Swagelok SS-405-2, SS-405-03
or SS-405-170). To reuse a tube fi tting fi rst mark the nut and meter and upon re-installing tighten enough to align the
marks then tighten a quarter turn farther.
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. An optional fl uid heater block can be used on the fl ow 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 fl owing through the meter.
Clean Plumbing: Before installing the fl ow 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!
Determine that the following parameters of your fl ow metering system are within the specifi cations for the specifi c
meter being used:
Maximum System Pressure (Specifi cations)Differential Pressure across meter (Pressure Drop Curves)
Maximum Flow Rate (Pressure Drop Curves)
Metered Fluid Temperature (Sales specifi cation, transmitter specifi cations page 7)
If the metered fl uid is greater than 80°F (28°C) 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 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:
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 fl ow meter. Valve (#1)
can then be opened completely.
Open valve (#2) 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 (#2) can be gradually opened all the way. Slowly close the
bypass valve (#3).
Removal note: The transmitter does not need to be removed from the fl ow meter for any fi eld servicing or adjustments.
The fl ow meter and transmitter should be shipped back to the factory for calibration or service as a unit. If the
transmitter needs to be removed from the fl ow 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 fl ow 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 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.
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/-)
Frequency Single
Phase
Power (+5 to 26 Vdc) V+1Brown
CommonCom4Black
Pulse OutputPh A2White
Output Phase B (Quad only)Ph B5Grey
Case GroundCase3Blue
Current Sinking Wiring
PCA
Label
Turck®
Connector
Pin #
Mating Cable
Wire Color
(Model # 295-600-000 and versions ending with S/-)
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.
V+
V+
0V
Out
Turck Pin #2
Transmitter
PLC
Digital
Input
Voltage or Current Analog Transmitters(Models ending with A/-, B/-, C/- or D/-)
Turck®
Connector
PCA
Label
Power *V+1Brown
CommonCom4Black
Signal Output (+)Sig5 Grey
Signal Output (—)**Ret2White
Case GroundCase3Blue
* Analog transmitters with part numbers 29X-XXX-000 or ending in A/- or C/- are 24Vdc power. Part numbers 29X-XXX-100 or ending i n B / - o r 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 (-).
No Flow through meter or high pressure drop across meter
Solidifi ed material blocking rotation
Heat meter to melt material
Debris blocking rotation
Meter broken
Remove plumbing base, inspect crankshaft and piston
rods for damage. If intact fl ush the inside of the meter
and try to work pistons free by rocking the crankshaft
back and forth gently with a small rod or retracted pen
If you fi nd 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 fl ow
Improper hook-up of transmitter
Meter not turning
Verify that DC power is present at the PCA. Use a multi-
meter to measure the transmitter output independent
of the display or PLC
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 fl ow 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
Excessive reverse fl ow in system
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 fl ow. An incorrect
fl ow total can be reported if the pumping causes a
fl ow and ebb of greater than 1 meter revolution.
Your Max P Series Flow 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 fl ow meter has to be sent back for repair.
Max Machinery, Inc. Phone: 707-433-2662
33A Healdsburg Ave Fax: 707-433-1818
Healdsburg, CA 95448 www.maxmachinery.com
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:
1. 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.
2. Seller assumes no liability for charges incurred for repairing, removal or replacement, or for repairs made
outside of its factory.
3. 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.