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YZ Systems NJEX LVO 610G Manual

Natural gas odorization system
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NJEX LVO 610G
NJEX LVO 610F
N A T U R A L G A S O D O R I Z A T I O N S Y S T E M

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Summary of Contents for YZ Systems NJEX LVO 610G

  • Page 1 NJEX LVO 610G NJEX LVO 610F N A T U R A L G A S O D O R I Z A T I O N S Y S T E M...
  • Page 3 NJEX LVO 610G, 610F Instruction & Operating Manual Version: 11-2023...

  • Page 4: Table Of Contents

    610G Table of Contents 610G Table of Contents ........................I Section 1: First Things To Know About The 610G ................1 How to Use this Manual........................1 Operation Specifications........................2 Theory of Operation..........................2 System Accessories ..........................3 Section 2: System Installation......................4 Standard System Components......................4 System Flow Schematic ........................5 Standard System Mounting .........................6...
  • Page 5 610G Table of Contents Resume On Power Loss........................19 Units ...............................19 Logs ...............................19 DOU Logs ............................19 Config Logs ............................20 Event Logs ............................20 MM100...............................20 Test ...............................20 Test / Prime ............................21 Inhibit Test ............................21 Pulse Test ............................21 Battery Test ............................22 Relay Output Test ..........................22 Screen Test ............................22...

  • Page 6: Section 1: First Things To Know About The 610G

    Section 4, System Control & Electron- , the manual will begin discussing the in-depth operation of the electronic controller where many The NJEX LVO 610G, 610F Operations Manual of these typographic conventions will be found. is a step-by-step guide containing the procedures In the discussion about the controller, the techni- needed to work with the 610G or 610F System.

  • Page 7: Operation Specifications

    Section 1: First Things To Know About The 610G Operation Specifications If enabled, an external relay contact from external device can be connected to the Inhibit/NBS input to inhibit and restart pump operation. Maximum recommended Odorant Output: 0.5 gallons/day Proportional to Time (Timer Mode) Operation: (200 cc/day) In Timer mode, the pump is actuated at a regular time interval by the Z-100 controller determined by...

  • Page 8: System Accessories

    610G Section 1: First Things To Know About The Power Options: • Odorant Injection Probe with Sightglass, (P/N A1-0238) 1/8” drop adapter includes a 316 stainless steel probe, visual odorant sight Long-Life Battery: The controller operates using a indicator, and an isolation valve for location at replaceable internal battery pack.

  • Page 9: Section 2: System Installation

    Section 2: System Installation Standard System Components Figure 1 Primary components of the NJEX LVO-610G & 610F are as follows: A. System Odorant Tank. The odorant tank is tested and pre-assembled with a valve package including a visual level indicator. B.

  • Page 10: System Flow Schematic

    Section 2: System Installation System Flow Schematic Figure 3 610G / 610F ENCLOSURE TABLE 1 Z-100 Pipeline Pressure Actuation Pressure Timer / Controller Analog or Pulse Input S Y S T E M S 100-200 psi (6.89-13.8 bar) 30 psi (2.07 bar) (By Customer) 200-500 psi (13.89-34.5 bar) 40 psi (2.76 bar)

  • Page 11: Standard System Mounting

    Section 2: System Installation Standard System Mounting 1. Securely attach a section of 2″ pipe in a vertical configuration at the location where the NJEX LVO 610G / NJEX LVO 610F is to be installed. Using the mounting clamps provided with the NJEX LVO 610G / NJEX LVO 610F system, attach the system to the pipe.

  • Page 12: Standard System Connections

    The sight glass should be fitted with a 1/4” this manual. If longer tubing lengths are required MNPT x 1/8”t bore through fitting (P/N A1-0283) consult YZ Systems Technical Services at and 1/8” S.S. tubing extending through the bore 800.653.9435 or 1.281.362.6500 of the sight glass fitting until it just protrudes from the 1/4”...

  • Page 13: Section 3: Filling The Bulk Odorant Tank

    Section 3: Filling the Bulk Odorant Tank Filling the Tank for the First Time only inert gas or natural gas is emitting from this valve, then close V11 and V10. The time required to accomplish this task will vary with CAUTION: the tank size.

  • Page 14: Refilling The Bulk Odorant Tank

    Section 3: Filling the Bulk Odorant Tank Refilling the Bulk Odorant Tank 4. Attach odorant supply to V10, open V10, and begin transferring odorant to the bulk tank. CAUTION: CAUTION: Odorant has a very strong odor, which if allowed Fill tank to a maximum level of 80% of the tank to escape into the atmosphere may cause capacity.

  • Page 15: Section 4: System Control & Electronics

    Section 4: System Control & Electronics Overview Figure 8 The electronic control package provided with your 610G / 610F odorizing system consists of Z-100 controller powered by an internal battery or exter- nal power supply and a low power solenoid. The Z-100 Controller will control the timing of the 6000B Pump based on the controller settings and mode of operation, either Prop to flow or time.

  • Page 16: Section 5: Programming The Z-100 Controller

    05, menu screens. ternate between showing DAILY TOTALS and the running mode. It will display TIMER or COUNTER When the controller starts, the YZ Systems logo or ANALOG followed by OFF or ON. will load and the Home Screen will be displayed.

  • Page 17: Totalizer

    Section 5: Programming the Z-100 Controller Totalizer: From the Home Screen, you can navigate to the Totalizer by pressing down on the navigation switch. The totalizer is a running total of how much odor- ant has been pumped. The date the totalizer was When the system is ON, a started will be displayed at the top, along with the countdown to the next...

  • Page 18: Using The Z-100 Controller

    Section 5: Programming the Z-100 Controller Using The Z-100 Controller: For an item that must be selected from a menu such as the pump spacer, the option that is currently selected will be shown with a dash next to it on the The Z-100 user interface has been designed for left.

  • Page 19: System On/Off

    Section 5: Programming the Z-100 Controller System ON/OFF: Timer Mode: In timer mode, the controller actuates the 6000B pump at a set time interval as per the CYCLE TIME setting. The CYCLE TIME range is 0.1 minutes to 180.00 minutes in 0.01 minute increments. To modify the CYCLE TIME, move the * to CYCLE TIME and press enter to select.

  • Page 20: Analog Mode

    Section 5: Programming the Z-100 Controller Analog Mode: In Analog Mode the Z-100 controller monitors a 4-20mA flow signal provided by the customer. In this mode, the Z-100 controller monitors the in- coming flow signal and with the INJECTION RATE and MAX FLOW settings calculates and varies the Flow Span: Apply 20.0mA to the flow signal in pump cycle time as needed to maintain a consistent...

  • Page 21: Changing Z-100 Settings

    Section 5: Programming the Z-100 Controller Changing Z-100 Settings: Injection Rate: To run the 610G/610F system pro- portional to the flow signal, you must enter an injec- In order to operate the 610G / 610F system to tion rate. Navigate to Main Menu->Mode->Injection the proper odorization rate, the settings must be Rate.

  • Page 22: Pump Spacer

    Section 5: Programming the Z-100 Controller Pump Spacer: Enter the density provided in the odorant datasheet. NOTE: The Z-100 does not contain an ambient The PUMP SPACER setting correlates to the temperature sensor. Odorant density is typically pumps configured displacement. To reduce the specified at 60F.

  • Page 23: Diff Alarm Count

    Section 5: Programming the Z-100 Controller Diff Alarm Count: Battery Low: This setting is only available on the 610F models The Battery Low alarm is an indication the battery (F indicates Flow Switch). The PUMP ALARM voltage is low and should be replaced. If enabled, is triggered when the difference, DIFF, between the Relay Output will be activated.

  • Page 24: Clock Menu

    Section 5: Programming the Z-100 Controller Clock Menu: Use the Clock Menu to configure the date and time settings. Having the correct time and date is important for the accuracy of Z-100 event logs and daily odorant usage estimates (DOU). The time can be formatted as a 12- or 24-hour clock.

  • Page 25: Config Logs

    Section 5: Programming the Z-100 Controller Config Logs: The config logs contain a summary listing with event date and time of system setting change events. The CONFIG log does not include the details for a change. To view detailed information for each change event, the MODZ file from the controller must first be downloaded to an MM-100 memory module.

  • Page 26: Test / Prime

    Section 5: Programming the Z-100 Controller TEST / PRIME: The Test/Prime screen provides If an active input signal is not sensed, the red LED access to two functions. will flash and the test status will indicate INPUT INACTIVE. If an active input signal is sensed the Function 1, press enter on the navigation switch GREEN LED flash and the test status will indicate the UP direction for 1 to 2 seconds will actuate the...

  • Page 27: Battery Test

    Section 5: Programming the Z-100 Controller If the RELAY OUTPUT setting is DISABLE, the test BATTERY TEST: TThe BATTERY TEST is used screen will indicate RELAY OUTPUT NOT CON- to verify the system power supply voltage read FIGURED, CHECK SETUP. Change the RELAY by the controller.

  • Page 28: Section 6: Programming For Proportional-To-Time Operation

    Section 6: Programming for Proportional-to-Time Operation Setting Operator Input Param- Figure 10 eters: Z-100 Controller Setup, Timer Mode The rate at which the solenoid output is activated is controlled by the Cycle Time setting. Use the chart below to calculate the timer setting needed.

  • Page 29: Section 7: Mechanical System

    Section 7: Mechanical System Overview The 610G / 610F mechanical system is composed of the mechanical/electrical enclosure. Individual components of the system are shown below and described in the following pages. Figure 11 Actuation Manifold Flow Switch Model 6000B Metering Pump NJEX Gas Filter NJEX Gas Filter Y Z S y s t e m s M i l t o n R o y •...

  • Page 30: Njex Lvo Gas Filter

    Section 7: Mechanical System NJEX LVO Gas Filter Figure 12 A 25 micron coalescent filter is provided with each 610G / 610F. This filter, as shown, is installed on the back outside of the enclosure and should be con- nected to the regulated (30-60 psi / 2.1-4.1 bar, per Table 1, Page 5) actuation gas supply provided by the system operator.

  • Page 31: Model 6000 Pump

    Section 7: Mechanical System Model 6000 Pump Figure 13 The NJEX 6000 pump, as shown, is a pneumatically actuated, positive displacement, plunger pump. The 6000 is actuated with compressed air or pipeline gas at a pressure of 30-60 psi (2.1 – 4.1 Bar) - refer Table 1, page 5, refer to Section 2, the System Flow Schematic, Figure 2.

  • Page 32: Flow Switch

    Section 7: Mechanical System Flow Switch Figure 15 The flow switch is installed in the discharge line of the flow switch. When flow is pushed through the switch, a magnetic contact will connect and send a signal to the controller. The flow switch will come set at the factory, but may need to be adjusted for the installation site.

  • Page 33: Section 8: System Maintenance

    Section 8: System Maintenance Preventative Maintenance Semi-Annual Inspection Schedule 1. Inspect overflow protector and service as needed A preventative maintenance program serves to 2. Inspect tube fittings and valve packings for anticipate maintenance issues prior to waiting leaks. until the system requires service. Like changing the oil &...

  • Page 34: Section 9: 610G / 610F System Troubleshooting

    Section 9: 610G / 610F System Troubleshooting How to Use This Section Step-by-Step Resolution The recommendations contained in this section Using a step-by-step method to resolve issues should be used as a preliminary information on the NJEX LVO System will reduce maintenance resource to remedy operational issues with the time and assist in returning the odorization NJEX LVO System.

  • Page 35: Battery Power

    Section 9: 610G / 610F System Troubleshooting Battery Power Note: The battery test will send a signal to the solenoid to stroke the pump - the pump will stroke odorant into the discharge line if open. This provides The Z-100 controller and the low powered solenoid the most accurate load on the battery pack to be are normally powered by the Z-100 Battery assem- representative of the available battery life.

  • Page 36: Troubleshooting: Pump Performance

    Section 9: 610G / 610F System Troubleshooting Troubleshooting: Pump Performance 1. Verify operating conditions. Correct as a. If pump actuation does not occur as the needed. test key is pressed, remove the actuation gas line at the top of the pump and test the pump 2.

  • Page 37: Troubleshooting: Flow Switch

    Section 9: 610G / 610F System Troubleshooting e. With the actuation gas line reconnected 8. If problem persists, contact YZ technical to the pump, test stroke the pump. service for additional assistance. Observe if there is an audible pump stroke with the piston bottoming out and returning to the top of the pump housing.

  • Page 38: Njex Lvo Model 6000 Pump Assembled

    Appendix A: Illustrations NJEX LVO Model 6000B pump Assembled Figure 16 Actuation Gas Actuation Gas Odorant Odorant Outlet Odorant Inlet 6000B Pump Repair Kit (P/N D3-0140) Y Z S y s t e m s M i l t o n R o y • 2 0 1 I v y l a n d R o a d • I v y l a n d , P A • U S A • 1 8 9 7 4 • P : 2 8 1 . 3 6 2 . 6 5 0 0 • w w w . y z s y s t e m s . c o m Page 33 NJEX 610G / 610F ver.11-2023...

  • Page 39: Appendix A: Illustrations

    Appendix A: Illustrations Figure 17 Actuation Fitting Assembly P/N A1-0216 * O-Ring 40430 P/N A5-1013 Optional Stroke Spacer 60% P/N B0-1041 40% P/N B0-1043 20% P/N B0-1040 * O-Ring P/N A5-1127 Actuation Plug P/N B0-1039 Piston/Plunger P/N B0-1005 * Actuation Seal P/N A6-0076 Actuation Spring P/N C3-0036...

  • Page 40: Njex Lvo Model 6000 Pump Check Valve Assemblies, And Seals, Exploded View

    Appendix A: Illustrations Figure 18 PLUNGER SEAL ASSEMBLY Seal Spacer P/N B0-1035 DISCHARGE CHECK ASSEMBLY Secondary Seal P/N A6-0091 Discharge CV Cap Seal Support P/N B0-1036 P/N A6-0090 O-Ring P/N A5-1014 V-014 Primary Seal P/N A6-0089 CV Discharge Wafer P/N B0-1021 O-Ring CV Wafer Spring P/N A5-1113...

  • Page 41: Njex Lvo Gas Filter

    Appendix A: Illustrations Figure 19 Gas Filter Label PN: D5-0074 Gas Filter Cap PN: C4-0130 O-Ring 334 Viton PN: A5-1334 Filter Suspension Rod PN: C4-0109 Coalescing Filter Element PN: C4-0133 Filter Locator Bushing PN: C4-0132 Filter Retainer Washer PN: C4-0102 1/4”...
  • Page 42 Appendix A: Illustrations Figure 20 Y Z S y s t e m s M i l t o n R o y • 2 0 1 I v y l a n d R o a d • I v y l a n d , P A • U S A • 1 8 9 7 4 • P : 2 8 1 . 3 6 2 . 6 5 0 0 • w w w . y z s y s t e m s . c o m Page 37 NJEX 610G / 610F ver.11-2023...
  • Page 43 Appendix A: Illustrations Figure 21 Y Z S y s t e m s M i l t o n R o y • 2 0 1 I v y l a n d R o a d • I v y l a n d , P A • U S A • 1 8 9 7 4 • P : 2 8 1 . 3 6 2 . 6 5 0 0 • w w w . y z s y s t e m s . c o m NJEX 610G / 610F ver.11-2023 Page 38...
  • Page 44 201 Ivyland Road Ivyland, PA 18974 P: 281.362.6500 F: 281.362.6513 techsupport@yzsystems.com www.yzsystems.com Y Z S y s t e m s M i l t o n R o y • 2 0 1 I v y l a n d R o a d • I v y l a n d , P e n n s y l v a n i a • U S A • 1 8 9 7 4 • P : 2 8 1 . 3 6 2 . 6 5 0 0 • w w w. y z s y s t e m s . c o m NJEX 610G / 610F ver.11-2023...

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