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Ametek Drexelbrook Z-tron Level Control 502-302X Series Installation And Operating Instructions Manual

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DREXELBROOK
(215) 674-1234
1-800-527-6297
http://www.drexelbrook.com
e-mail:Service@Drexelbrook.com
Outside North America Call 1-215-674-1234
Operating Instructions
Series 502-302X
Z-tron Level Control
using 402-302X
Cote-Shield
Outside North America
US and Canada
The Leader of RF
For Assistance Call 1-800-527-6297
Installation and
TM
Electronics
and Sonic Level

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Summary of Contents for Ametek Drexelbrook Z-tron Level Control 502-302X Series

  • Page 1 The Leader of RF and Sonic Level DREXELBROOK For Assistance Call 1-800-527-6297 Outside North America Call 1-215-674-1234 Installation and Operating Instructions Series 502-302X Z-tron Level Control using 402-302X Cote-Shield Electronics (215) 674-1234 Outside North America 1-800-527-6297 US and Canada http://www.drexelbrook.com e-mail:Service@Drexelbrook.com...
  • Page 2 AMETEK Drexelbrook makes no warranty of any kind with regard to the material contained in this manual, including, but not limited to, implied warranties or fitness for a particular purpose. Drexelbrook shall not be liable for errors contained herein or for incidental or consequential damages in connection with the performance or use of material.
  • Page 3 Series 502-302X Z-tron Level Control using 402-302X Cote-Shield Electronics 205 Keith Valley Road Horsham, PA 19044 US Sales 800-553-9092 24 Hour Service 800-527-6297 International 215-674-1234 DREXELBROOK 215-674-2731 E-mail deinfo@drexelbrook.com An ISO 9001 Certified Company www.drexelbrook.com...

  • Page 4: Table Of Contents

    EDO 4-96-248 502-302X-LM Table of Contents Paragraph Page SECTION 1 - INTRODUCTION ..................1 1.1 System Description ....................1 1.2 Model Number ......................1 SECTION 2 - INSTALLATION ..................2 2.1 Unpacking......................... 2 2.2 Mounting ........................2 2.3 Wiring the Sensing Element ................... 5 2.4 Wiring the Electronic Unit ..................

  • Page 5: Section 1 - Introduction

    502-302 Series Z-tron Level Control Introduction SECTION 1 This manual describes the Drexelbrook Z-tron Level INTRODUCTION Control Series 502-3000 with a 402-3020 or 402-3022 high sensitivity transmitter. 1.1 System The Drexelbrook Z-tron Level Control 502-3000 is a preci- Description sion RF (radio frequency) relay output level switch. It provides relay contact closure when material reaches a preset point in a vessel.

  • Page 6: Section 2 - Installation

    502-302 Series Z-tron Level Control Installation SECTION 2 INSTALLATION 2.1 Unpacking Carefully remove the contents of the shipping carton and check each item against the packing list before destroying any packing materials. If there is any shortage or damage, report it immediately to the factory. 2.2 Mounting The Z-tron Level Control is designed for field mounting.
  • Page 7 502-302 Series Z-tron Level Control Installation Figure 2-2 Mounting Dimensions _________________________________________________________________________________...
  • Page 8 502-302 Series Z-tron Level Control Installation 2.2 Mounting The actual mounting location often depends on the place- (cont.) ment of nozzles or openings into the vessel. Do not mount the instrument through a nozzle which exceeds the cote- shield element on the sensing element. See Figures 2-1 and 2-3.

  • Page 9: Wiring The Sensing Element

    502-302 Series Z-tron Level Control Installation 2.3 Wiring the WARNING Sensing Element If the Z-tron level control is placed in a hazardous area, caution must be taken before removing the explosionproof housing. In order to wire the unit, the area must be checked and known to be non-hazard- ous.

  • Page 10: Wiring The Electronic Unit

    502-302 Series Z-tron Level Control Installation 2.4 Wiring the All power and relay connections are made to the terminal Electronic Unit strips on the elctronic chassis. Wiring connections should comply with NEC and local electrical codes. The power connections are made to terminals 1, 2, and 6. See Figure 2-5.

  • Page 11: Relay Connections

    502-302 Series Z-tron Level Control Installation 2.5 Relay Connections The Z-tron relay has double-pole, double-throw (DPDT) contacts. The relay serves as a switch and does not provide the power to operate an annunciator or other equipment. All relay connections are made to the terminal strip on the side of the electronic chassis, as shown in Figure 2-7.

  • Page 12: Section 3 - Operation

    502-302 Series Z-tron Level Control Operation SECTION 3 This section contains the start-up and operating informa- OPERATION tion for the Z-tron level controls (402-3020 or 402-3022). 3.1 Start-up Before applying power to the instrument, be sure that the input power is from a 120 vac, 50/60 Hz power source. Also check wiring connections as described in paragraphs 2.3 and 2.4.

  • Page 13: Time Delay Control

    502-302 Series Z-tron Level Control Operation 3.2.2 Time Delay The optional time delay adjustment is located on top of the Control instrument, across from the setpoint adjustment (Figure 3- 2). It is used to help stop an oscillating relay output due to agitation or frothing in the vessel.

  • Page 14: Failsafe Selector

    502-302 Series Z-tron Level Control Operation 3.2.3 Failsafe Selector Failsafe describes the level condition which causes the the output relay to de-energize and the condition of the relay upon loss of power or instrument failure. •High Level Failsafe (HLFS) means the relay will de- energize under high level conditions, indicating high level upon loss of power.

  • Page 15: Section 4 - Calibration

    Calibration 502-302 Series Z-tron Level Control SECTION 4 The following paragraphs outline different calibration CALIBRATION procedures for the Z-tron Level Control (502-302 4.1 Types of The high sensitivity 402-302X chassis is used primarily for Calibration low bulk density granulars and extra short length sensing elements used on insulating liquids.

  • Page 16: Calibration Of Horizontal Sensing Elements

    502-302 Series Z-tron Level Control Calibration 4.2 Calibration of NOTE Horizontal Sensing All calibrations must be performed with the Elements sensing element permanently installed in a tank. Calibration cannot be performed out- side of the tank or in a bucket of material. This is because the RF energy seeks the nearest metal object and uses the tank wall as a return path to the electronic chassis.
  • Page 17 502-302 Series Z-tron Level Control Calibration 4.2 Calibration of e. Increase the material level until it is well above the Horizontal Sensing sensing element. Elements (cont.) f. Counting the number of turns, turn the adjustment slowly clockwise (CW) until the relay once again just operates or you come to the end of the adjustment travel.

  • Page 18: Calibration Of Vertical Sensing Elements

    502-302 Series Z-tron Level Control Calibration 4.3 Calibration of Vertical Calibration is recommended for vertically- Vertical Sensing mounted Cote-Shield sensing elements. Elements WARNING Do not turn any adjustment past its mechanical stops. Damage to the unit could occur. •Use the insulated calibration tool (part number 290-1-1). See Figure 4-1.

  • Page 19: Quick Calibration

    502-302 Series Z-tron Level Control Calibration 4.4 Quick Quick Calibration can be used for horizontally-mounted, Calibration bare metal, Cote-Shield sensing elements. In all cases, it is necessary to have the material level below the sensing element. WARNING Do not turn any adjustment past its mechanical stops.
  • Page 20 Calibration 502-302 Series Z-tron Level Control 4.4 Quick Calibration Table 4-1 (cont.) Calibration Chart Material Being Number of Adjustment Measured Turns Clockwise (CW) From Operate Position Insulating Liquids- Organics, Oil, Plastics 3 turns Granular Above 50#/Ft 3 turns Granular Above 30-60#/Ft 2 turns Granular Above 25-50#/Ft...

  • Page 21: Recalibration

    Calibration 502-302 Series Z-tron Level Control 4.5 Recalibration If the amount of preloading was recorded at the time of initial calibration, it is possible to replace the instrument or check calibration without moving tank level. —Recalibration of Horizontal Sensing Elements a.

  • Page 22: Calibration Of Time Delay Units

    Calibration 502-302 Series Z-tron Level Control 4.6 Calibration of Standard time delay units are adjustable over the range of Time Delay Units approximately 0-90 seconds. —Calibration of Time Delay Units a. Turn the time delay adjustment to the extreme coun- terclockwise (CCW) position (i.e.

  • Page 23: Adding A Padding Capacitor

    502-302 Series Z-tron Level Control Calibration 4.7 Adding a The tuning range of the 402-302X transmitter is 0-8 pico- Padding Capacitor farads. Long insertion length sensing elements or sensing elements mounted in pipes or near metal objects may generate in excess of 8 pF resulting in the inability to find a tune point (the unit will always show alarm).

  • Page 24: Section 5 - Troubleshooting

    502-302 Series Z-tron Level Control Troubleshooting SECTION 5 The Z-tron Level Control is a solid-state device with no TROUBLESHOOTING moving parts other than its relays, and requires no main- tenance or adjustments. The units are designed to give years of unattended service. A spare electronic chassis is recommended for every 10 units so that, in case of a failed unit, a critical application will not be held up while the unit is returned to the factory...

  • Page 25: Testing The Sensing Element

    502-302 Series Z-tron Level Control Troubleshooting 5.1 Testing the a. Disconnect ALL wires from the sensing element Electronic connection screws on the electronic chassis. See Figure Unit (cont.) 5-1. b. Turn the operating point adjustment fully counter- clockwise using an insulated tool. c.
  • Page 26 502-302 Series Z-tron Level Control Troubleshooting 5.2 Testing the d. The high sensitivity 402-302 Z-tron is usually used to Sensing Element measure non-conductive, granular material. If this is (cont.) the case, typical sensing element readings will be open circuit (infinite ohms). A new sensing element that is clean and not coated or wet should read open circuit on all sensing element connections.
  • Page 27 502-302 Series Z-tron Level Control Troubleshooting 5.2 Testing the Sensing Element (cont.) AN ALOG ANALOG OHM M ETER OH MME T ER E LEC T R O N IC TO C EN TER U N IT C OND U C TOR TO C EN TER R ED SC R EW B LU E SC R EW...
  • Page 28 502-302 Series Z-tron Level Control Troubleshooting 5.2 Testing the Sensing Element (cont.) AN ALOG OR D IGIT AL OH MME TE R TO COAX SHIELD TO COAX W IRE CENTER CONDUCTOR C OR R E C T ME T E R R E AD IN GS CENTER CONDUCTOR - TAB = 47 OHM S C E N TE R C ON D U C TOR - S H IE L D W IR E = O P E N...

  • Page 29: Testing The Coaxial Cable (Remote Systems)

    502-302 Series Z-tron Level Control Troubleshooting 5.3 Testing the Troubleshoot the coaxial cable in a remote-mounted system Coaxial Cable using the following procedure. (Remote-mounted Systems only) NOTE If there is water or other conductive material in the conduit, it could cause the instrument to fail.

  • Page 30: Testing The Relay Circuits

    Troubleshooting 502-302 Series Z-tron Level Control 5.4 Testing the Use the following steps to check out the relay circuits: Relay Circuits a. The relay circuits consist of double-pole double-throw relay contacts brought out to terminal strips. When the relays are operating properly, two pairs of contacts will be open with high or low level, and two pairs will be closed with high or low level.

  • Page 31: Possible Problems And Causes

    Troubleshooting 502-302 Series Z-tron Level Control 5.5 Possible Problems PROBLEM POSSIBLE CAUSES SOLUTION and Causes Instrument Severe coating build-up Need longer on sensing element indicates alarm Cote-Shield. at all times. (HLFS) > ¾-inch. See Figure 2-3. Consult factory. Shorted spark protector.
  • Page 32 502-302 Series Z-tron Level Control Troubleshooting 5.5 Possible Problems PROBLEM POSSIBLE CAUSES SOLUTION and Causes (cont.) Instrument Improper wiring Need longer insertion can’t be length or larger surface calibrated. area. Insufficient signal Add pad capacitor - from sensing element. Section 4.6. Setpoint is beyond the Consult factory.

  • Page 33: Telephone Assistance

    Troubleshooting 502-302 Series Z-tron Level Control 5.6 Telephone If you are having difficulty with your Drexelbrook equip- Assistance ment, and attempts to locate the problem have failed, notify your local Drexelbrook representative, or call the factory toll free 1-800-527-6297. Drexelbrook Engineering Company is located at 205 Keith Valley Road, Horsham, PA 19044.

  • Page 34: Field Service

    Troubleshooting 502-302 Series Z-tron Level Control 5.8 Field Service Trained field servicemen are available on a time-plus- expense basis to assist in start-ups, diagnosing difficult application problems, or in-plant training of personnel. Contact the service department for further details. 5.9 Customer Training Periodically, Drexelbrook instrument training seminars for customers are held at the factory.

  • Page 35: Section 6 - Specifications

    502-302 Series Z-tron Level Control Specifications SECTION 6 —Power Requirements SPECIFICATIONS 95-145 Vac, 50-60 Hz Power consumption, 3 watts —Sensitivity .02 pF —Tuning Range 0-8 pF —Fail-safe Field selectable high-level fail-safe (HLFS) or low-level fail-safe (LLFS). —Contact Ratings (DPDT) 250 Vac, 5A Resistive Load 30 Vdc, 5A Resistive Load 250 Vac, 2A Inductive Load 30 Vdc, 3A Inductive Load...
  • Page 36 502-302 Series Z-tron Level Control Specifications SECTION 6 —Spark Tolerance SPECIFICATIONS 10 amp standard (cont.) 100 amp optional —Housing 5-inch integral explosionproof, standard meets the following classifications: Nema 1 General Purpose Nema 2 Drip-Tight Nema 3 Weather-Resistant Nema 4 Waterproof Nema 5 Dust-Tight Nema 12 Industrial Use FM approved for Class I, Groups A,B,C, and D (Div.
  • Page 37 205 Keith Valley Road Horsham, PA 19044 US Sales 800-553-9092 24 Hour Service 800-527-6297 International 215-674-1234 DREXELBROOK 215-674-2731 E-mail deinfo@drexelbrook.com An ISO 9001 Certified Company www.drexelbrook.com...

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