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DREXELBROOK
(215) 674-1234 Outside North America
1-800-553-9092 US and Canada
www.drexelbrook.com
Service@Drexelbrook.com
Outside North America 1-215-674-1234
Operating Instructions
Series 502-3000
TM
Ztron
using 402-3000 Electronics
502-3000
•
502-3200
•
502-3300
•
502-3400
•
502-3500
•
Level Measurement
For Assistance Call 1-800-527-6297
Installation and
Level Control
Leader in
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Table of Contents
Related Manuals for Ametek 502-3000 Series
Summary of Contents for Ametek 502-3000 Series
- Page 1 Leader in Level Measurement DREXELBROOK For Assistance Call 1-800-527-6297 Outside North America 1-215-674-1234 Installation and Operating Instructions Series 502-3000 Ztron Level Control using 402-3000 Electronics 502-3000 • 502-3200 • 502-3300 • 502-3400 • 502-3500 • (215) 674-1234 Outside North America 1-800-553-9092 US and Canada www.drexelbrook.com 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 EDO #1-99-242 502-3000-LM Series 502-3000 Ztron Level Control using 402-3000 Electronics •502-3000 •502-3200 •502-3300 •502-3400 •502-3500 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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Page 4: Table Of Contents
EDO #1-99-242 502-3000-LM Table of Contents SECTION 1 INTRODUCTION ..................1 System Description ....................1 Model Number ......................2 SECTION 2 INSTALLATION ..................3 Unpacking ........................3 Mounting the Level Control ..................3 Power Wiring ......................8 Wiring the Relays ....................14 Wiring the Sensing Element (Integral).............. -
Page 5: Section 1 Introduction
502-3000 Series Ztron Point Level Control Introduction SECTION 1 INTRODUCTION The instructions in this manual are for the Drexelbrook Ztron™ Series Point Level Control with a 402-3000 electronic unit (also referred to as MKII Ztron). The label on top of the electronic unit identifies the model... -
Page 6: Model Number
502-3000 Series Ztron Point Level Control Introduction INSERTION LENGTH COTE SHIELD INSULATION LENGTH INSULATION METAL COTE SHIELD TUBE ELEMENT Figure 1-1 Integral Ztron Control with Cote Shield 1.2 Model Number 5 0 2 - 3 X X - X X X... -
Page 7: Installation
502-3000 Series Ztron Point 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 to the factory at 1-800-527-6297 (US and Canada) or 1-215-674-1234 (International). - Page 8 502-3000 Series Ztron Point Level Control Installation WALL BUILD-UP DOES NOT EXTEND PAST FIRST INSULATOR GOOD COTE-SHIELD MUST EXTEND THROUGH NOZZLE AND WALL BUILD-UP NOZZLE TOO LONG and COTE-SHIELD TOO SHORT WRONG NOZZLE GOOD REMOVED BEST FACTORY SUPPLIED EXTENDED COTE-SHIELD...
- Page 9 502-3000 Series Ztron Point Level Control Installation All Connections Sealed and Gaskets In Place DREXELBROOK DREXELBROOK WRONG CORRECT Conduit Breather Drain DREXELBROOK Explosionproof and dust ignition proof (285-1-42 OR 285-1-43 enclosures only) for Div. 1 Class1 Groups ABCD, ClassIIGroupsEFG Class III, NEMA-4For explosionproof...
- Page 10 502-3000 Series Ztron Point Level Control Installation All dimensions in inches (mm) Figure 2-3 Mounting Dimensions Integral Ztron Level Control...
- Page 11 502-3000 Series Ztron Point Level Control Installation All dimensions in inches (mm) Figure 2-4 Mounting Dimensions Remote Ztron Level Control...
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Page 12: Power Wiring
502-3000 Series Ztron Point Level Control Installation 2.3 Power Wiring CAUTION Do not open the enclosure cover or make/break any electrical connections without first discon- necting electrical power at the source. Ensure that the wiring, electrical fittings and conduit connections conform to the electrical codes for the specific location and hazard level. - Page 13 502-3000 Series Ztron Point Level Control Installation Figure 2-5 Wiring the 502-300 (120 Vac) Electronic Unit...
- Page 14 502-3000 Series Ztron Point Level Control Installation Figure 2-6 Wiring the 502-320 X (24 Vdc) Electronic Unit...
- Page 15 502-3000 Series Ztron Point Level Control Installation Figure 2-7 Wiring the 502-330 X (240 Vac) Electronic Unit...
- Page 16 502-3000 Series Ztron Point Level Control Installation Figure 2-8 Wiring the 502-340 X (24 Vdc Isolated) Electronic Unit...
- Page 17 502-3000 Series Ztron Point Level Control Installation Figure 2-9 Wiring the 502-350 X (12 Vdc Isolated) Electronic Unit...
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Page 18: Wiring The Relays
502-3000 Series Ztron Point Level Control Installation 2.4 Wiring the Relays Refer to Figure 2-10 for the relay contact wiring. The Ztron relay has double-pole, double-throw (DPDT) dry contacts. The relay serves as a switch and does not provide the power to operate an annunciator or other equipment. -
Page 19: Wiring The Sensing Element (Integral)
502-3000 Series Ztron Point Level Control Installation 2.5 Wiring the Sensing Element (Integral) If the Ztron level control has the electronic unit mounted in the same housing as the sensing element (integral mount), the sensing element is prewired at the factory, as shown in Figure 2-11. -
Page 20: Spark Protector For Integral Units
502-3000 Series Ztron Point Level Control Installation 2.5.1 Spark Protector for Integral Units Applications involving insulating granulars and insulating liquids may require extra spark protection against static discharge that can damage the electronic unit. If required, a heavy duty spark protector is available as an option and will be prewired at the factory with integrally mounted Ztron level controls. -
Page 21: Wiring The Sensing Element (Remote)
502-3000 Series Ztron Point Level Control Installation 2.6 Wiring the Sensing Element (Remote) If the Ztron electronic unit is mounted remotely from the sensing element, the cable connections from the sensing element to the electronic unit are made to the individual terminals on the side opposite the terminal strips. - Page 22 502-3000 Series Ztron Point Level Control Installation 2.6 Wiring the Sensing Element (cont.) Figure 2-14 Coaxial Cable Following are recommendations for wiring the sensing ele- ments. CAUTION When pulling the cable through the conduit, do not use pulling lubricant. Pulling lubricant changes the electrical characteristics of the cable.
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Page 23: Spark Protector For Remote Units
502-3000 Series Ztron Point Level Control Installation 2.6.1 Spark Protector Measurement of insulating granulars and insulating liquids may require extra spark protection against static discharge that can damage the electronic unit. If required, a heavy duty spark protector can be shipped as an option and must be mounted in the sensing element condulet when wiring the instrument. -
Page 24: Section 3 Operation
502-3000 Series Ztron Point Level Control Operation SECTION 3 OPERATION This section describes the operating switches of the Ztron level control. Remove the dome lid and use a small screw- driver to set the operating controls. 3.1 Setpoint Control There is a single operating point adjustment used to control the level at which the relay operates. -
Page 25: Time Delay Control (Optional)
502-3000 Series Ztron Point Level Control Operation 3.2 Time Delay Control (optional) The time delay adjustment (available as an option 402-3 is located on top of the instrument, as shown in Figure 3-1. It is used to help stop an oscillating relay output due to agitation or waves in the vessel. -
Page 26: Failsafe Selector
502-3000 Series Ztron Point Level Control Operation 3.3 Failsafe Selector Failsafe describes the level condition which causes the output relay to de-energize and the condition of the relay upon loss of power or most component failures. • The failsafe is field selectable by changing the position of the connector located on the instrument circuit board. -
Page 27: Section 4 Calibration
502-3000 Series Ztron Point Level Control Calibration SECTION 4 CALIBRATION This section contains the calibration information for the Ztron Level Control. CAUTION Do not open the enclosure cover or make/break any electrical connections without first discon- necting electrical power at the source. Ensure... - Page 28 502-3000 Series Ztron Point Level Control Calibration 4.2 Calibration in Insulating Material (Horizontal Mount) (cont.) Figure 4-1 Level Below Horizontal Sensing Element b) Turn the setpoint adjustment to the full counterclockwise (CCW) position. NOTES This adjustment does not have a mechanical stop.
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Page 29: Calibration In Insulating Material (Vertical Mount) And 502-3000-918 In Conducting Materials
502-3000 Series Ztron Point Level Control Calibration 4.2 Calibration in Insulating Material (Horizontal Mount) (cont.) Mentally note the position of the screwdriver. Counting the number of turns, turn the setpoint adjust ment slowly clockwise (CW) until the relay once again just operates, or you come to the end of the adjustment travel. - Page 30 502-3000 Series Ztron Point Level Control Calibration 4.3 Calibration in Insulating Material (Vertical Ztron) and 502-3000-918 in Conducting Materials DESIRED CONTROL POINT Figure 4-3 Vertical Ztron, Material Covering Sensing Element b) Start from the full counterclockwise (CCW) position. Turn the setpoint adjustment clockwise (CW) until the relay just operates (LED changes states).
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Page 31: Section 5 Troubleshooting
502-3000 Series Ztron Point Level Control Troubleshooting SECTION 5 TROUBLESHOOTING 5.1 Introduction The Ztron Level Control is a solid-state device with no moving parts other than its relays, and requires no maintenance or adjustments. The units are designed to give years of unat- tended service. -
Page 32: Testing The Sensing Element
502-3000 Series Ztron Point Level Control Specifications 5.3 Testing the Sensing Element NOTE The sensing element is intrinsically safe. There- fore, when using this product, it is recommended that all service activity comply with appropriate guidelines. The following procedure is used to test the sensing element: Remove all wires leading from the sensing element to the electronic unit. - Page 33 502-3000 Series Ztron Point Level Control Specifications 5.3 Testing the Sensing Element (cont.) If the process material is conductive, you may read some resistance between sensing element terminals. The lowest permissable resistance values are: Center wire to ground 1000 ohms.
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Page 34: Testing The Coaxial Cable
502-3000 Series Ztron Point Level Control Troubleshooting 5.4 Testing the Coaxial Cable NOTE Water or other conductive material in the con- duit can change the electrical properties of the coax cable and cause the system to perform poorly. Moisture in the conduit may not be detected by the following test. -
Page 35: Testing The Relay Circuits
502-3000 Series Ztron Point Level Control Troubleshooting 5.5 Testing the Relay Circuits Using an ohmmeter, perform the following steps to check out the relay circuits: a. The relay circuits consist of double-pole double-throw relay contacts brought out to terminal strips. When... -
Page 36: Testing The Spark Protector
502-3000 Series Ztron Point Level Control Troubleshooting 5.6 Testing the Spark Protector Refer to Figure 5-4 to test the spark protector. ANALOG OR DIGITAL OHMMETER TO COAX SHIELD TO COAX WIRE CENTER CONDUCTOR CORRECT METER READINGS CENTER CONDUCTOR - TAB =... -
Page 37: Possible Problems And Causes
502-3000 Series Ztron Point Level Control Troubleshooting 5.7 Possible Problems and Causes Problem Possible Cause Solution 1. Instrument indicates a. Severe coating build-up a. Need longer Cote-Shield. alarm at all times. on sensing element (HLFS). Consult factory. b. Sensing element not “seeing” b. Need longer insertion material (LLFS) due to fill length. -
Page 38: Factory Assistance
502-3000 Series Ztron Point Level Control Troubleshooting 5.8 Factory Assistance If you are experiencing difficulty with your Drexelbrook equipment and attempts to locate the problem have failed: • contact your local Drexelbrook representative, • call the Service department toll-free at 1-800-527-6297 (in US and Canada) or 1-215-674-1234 (International), •... -
Page 39: Field Service
502-3000 Series Ztron Point Level Control Troubleshooting 5.9 Equipment Return (cont.) To obtain a return authorization (RA#), contact the Service department at 1-800-527-6297 (US and Canada) or 1-215-674-1234 (International). Please provide the following information: Model Number of Return Equipment ____________________... -
Page 40: Section 6 Specifications
502-3000 Series Ztron Point Level Control Specifications SECTION 6 SPECIFICATIONS Power Requirements: AC Units: 95-145 Vac (402-3000), 50/60 Hz, 5 watts 215-265 Vac (402-3300), 50/60 Hz, 5 watts maximum DC Units: 24 Vdc Unit (402-3200): 19-29 Vdc input, 3W maximum... - Page 41 502-3000 Series Ztron Point Level Control Specifications Stability: .1pF/6 mo. max. shift Spark Protection: 10 amp Mounting: ¾-inch NPT standard 1½-inch sanitary clamp (502-3000-903) Insertion Length: 18 inches (457.2 mm) or 36 inches (914.4 mm) (standard) Housing: The standard explosionproof housing meets the following classifications:...
- Page 42 205 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...