YZ Systems NJEX ZEO 6400 Instructions & Operating Manual Download | Manualshive

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YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, PA • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
NJEX ZEO Version 04/13/2021

Page 95

The N-400 controller circuit board has replaceable fuses in the instance of failure.

Please refer to the component layout label inside the controller
door for quick reference on relative fuse position, or the location
can be seen

in Figure 51.

The solid state relays, U22, U25 can also be replaced if
required.

Please refer to the component layout label inside the

controller door for quick

reference on relative fuse position, or

the location can be seen in Figure 51.

Warning:  Substitutions  of  the  fuses  can  impair  intrinsic
safety.   It is recommended  to  order  replacements  directly
from  YZ  Systems  to  ensure  proper  components  are
installed.  A fuse kit will be provided with each controller.
Additional  fuses  can  be  purchased  individually  with  the
part  numbers  below  or  a  kit  containing  all  required  fuses
can be purchased from YZ Systems with part number D3-
0297.

Component

Specification

Description

Manuf. Part Number

F1

62mA

125V / 300A Breaking

Fuse, PICO hazardous area.
ENCAPSULATED

Littelfuse 259.062

F2

62mA

125V / 300A Breaking

Fuse, PICO hazardous area.
ENCAPSULATED

Littelfuse 259.062

F3

50mA

277V/ 1500A Breaking

Fuse, PICO hazardous area.

Littelfuse 305.05

F4*

62mA

125V / 300A Breaking

Fuse, PICO hazardous area.
ENCAPSULATED

Littelfuse 259.062

F5*

62mA

125V / 300A Breaking

Fuse, PICO hazardous area.
ENCAPSULATED

Littelfuse 259.062

BT1

3V 12mm 35mAH

Battery, Coin Cell

Panasonic CR1220

*NOTE: Fuses F4 and F5 are only required on NJEX pneumatic systems. Do not

install F4 and F5 if the N-400 controller is used in an NJEX ZEO system.

Appendix D: Controller Replacement Components

Figure 51: Component layout label. Use

this label to see relative location of
replacement

components

and

the

memory module and power switch.

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95
96
97
98
99
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Summary of Contents for NJEX ZEO 6400

Page 1: ...The NJEX ZEO 6400 7400 8400 9400 Instruction Operating Manual ZERO EMISSIONS ODORIZATION SYSTEM ...

Page 2: ......

Page 3: ... Starting the System 28 Stopping the System 29 Section 5 System Control Electronics 32 Controller Overview 32 To Power Up the System 34 Communications Interface 34 Using the N 400 Home Screen 35 Using the N 400 Main Menu 39 Setting Operator Input Parameters 40 Section 6 Troubleshooting 63 How to Use This Section 63 Section 7 System Maintenance 75 Preventative Maintenance Schedule 75 Appendix A NJE...

Page 4: ......

Page 5: ...cannot be found within this manual contact YZ Systems at T 1 281 362 6500 T 1 800 653 9435 800 NJEX HELP F 1 281 362 6513 E techsupport yzhq com When calling have this manual close at hand Whether calling or writing please include the following information The serial number and model number of the NJEX ZEO System The serial and model numbers are located on the nameplate located on the exterior of ...

Page 6: ...00 7400 8400 9400 Maximum odorant output at 1800 PSI 124 Bar MMCF day 0 5 lb mmcf m3 day 8 mg m3 60 1 28M 175 5 12M 515 10 50M 1000 20 00M MMCF day 1 0 lb mmcf m3 day 16 mg m3 30 0 64M 88 2 56M 258 5 25M 500 10 00M MMCF day 1 5 lb mmcf m3 day 24 mg m3 20 0 43M 58 1 70M 172 3 50M 333 6 67M Maximum operating pressure psig Bar 1800 124 Operating Temp Range 20 to 50 C 4 to 122 F Flow Rate Input Signal...

Page 7: ... 260VAC 1A Max 50 60Hz 24V Power Supply AC 90 264VAC 0 8 0 6A 50 60 Hz Power Requirements Zone 1 ATEX and IECEx Overall System AC 1 Ph 115 230VAC 8 2 5 2A 50 60Hz Injection Pump Power Zone 1 AC 1 Ph 115 230VAC 2 9 1 5A 50Hz 1 Ph 115 230VAC 3 2 1 7A 60 Hz Transfer Pump Power Zone 1 AC 1 Ph 115 230VAC 2 9 1 5A 50Hz 1 Ph 115 230VAC 3 2 1 7A 60 Hz ACC Power AC 85 260VAC 1A Max 50 60Hz 24V Power Supply...

Page 8: ...zardous location requirements and to reduce the risk of ignition of hazardous atmospheres conduit runs must have a sealing fitting not provided connected within 18 inches of the enclosure ATEX IECEx Zone Hazardous Location IECEx ETL 20 0051X Ex db ia ia IIC Ga IIB T4 Gb ITS21UKEX0038X ITS I21ATEX29212X II 2 G Ex db ia ia IIC Ga IIB T4 Gb 2812 0891 20 C Ta 50 C IP43 Specific Conditions of Use 1 Ext...

Page 9: ...ical and electrical work on NJEX ZEO Systems must be performed by trained professionals Proper personal protection equipment PPE such as protective eyewear and gloves should be worn while installing or servicing this equipment WARNING POTENTIAL STATIC CHARGING HAZARD To avoid static buildup use a damp cloth to clean all painted or other non metallic surfaces WARNING MATERIALS USED IN THE CONSTRUCT...

Page 10: ... a proportional to flow mode In the proportional to time mode of operation the user inputs the target lb hr or kg hr rate The ACC adjusts the injection pump capacity to maintain this target In the proportional to flow mode of operation the N 400 controller uses a customer provided gas flow rate input signal and several operator input values to maintain the injection rate setpoint per the measured ...

Page 11: ...YZ System s Sentry Utility Software for future reference CAUTION Excessive tubing lengths should be avoided Installation of the NJEX ZEO Odorization system should be as close to the point of injection and Odorant Storage Tank as possible Tubing length from the Odorant Storage Tank to the system should not exceed 15 feet 4 5 meters Discharge tubing length should not exceed 50 feet 15 meters The tub...

Page 12: ...ne immediately preceding the probe assembly P N A3 0024 1 4 stainless steel tubing Dielectric Isolator Union These should be installed in every tubing line that attaches the odorizer to the pipeline in any manner For example the supply gas and odorant discharge P N A1 0182 NJEX ZEO Scrubbers These filters are designed to scrub vented gas from the system They are available by ordering P N C4 0018 1...

Page 13: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 11 Notes ...

Page 14: ...ield to reduce internal temperatures in the cabinet from solar exposure 2 System Enclosure lower cabinet The System Enclosure lower cabinet houses the magnetic drive transfer pump and Explosion Proof Enclosure 3 N 400 Intrinsically Safe Controller Intrinsically safe system controller 4 Explosion Proof or Flameproof Electrical Housing Houses the intrinsically safe transition board bridging the non ...

Page 15: ... Page 13 7 Bulk Odorant Filter Provides primary odorant filtration between the storage tank and the NJEX ZEO system The Bulk Odorant Filter is integrated into the verometer assembly in the System Enclosure and is field replaceable 8 Transfer Pump Assembly Transfers odorant from bulk odorant tank through the bulk odorant filter and into the verometer ...

Page 16: ...ION 2 SYSTEM INSTALLATION YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 14 NJEX ZEO Version 04 13 2021 System Flow Schematic Figure 2 NJEX ZEO SYSTEM P ID ...

Page 17: ...ystem enclosure to a concrete slab using the four mounting slots 5 8 provided in the bottom of each leg of the enclosure Recommended bolt or stud size for mounting the enclosure is 1 2 See Figure 3 for mounting dimensions Cabinets will be supplied with either tapered or straight legs depending on the application Please see the model code of the NJEX ZEO system to determine which leg type your syst...

Page 18: ...P 281 362 6500 www yzsystems com Page 16 NJEX ZEO Version 04 13 2021 Figure 3 NJEX ZEO Cabinet Footprint Dimensions mm in Dotted lines in cabinet front and side view represent straight leg width and depth Reference the ZEO Model Code to determine if your cabinet has straight or tapered legs ...

Page 19: ... analog flow signal device to the termination block TB8 located in the N 400 Controller OR the pulsed flow input to the termination block TB2 Note the jumper placement JP4 for each analog flow signal type and adjust if necessary If using a pulsed flow input the jumper position JP4 is inconsequential Refer to the Wiring Control Document in Appendix B and the Wiring Diagram reference label located i...

Page 20: ...connecting the NBS output termination block TB14 of the backup system to the Inhibit Input of the primary system TB2 Pins 3 and 4 Refer to the Wiring Control Document in Appendix B the Wiring Diagram reference label located inside the N 400 Controller Door or below in Figure 4 and the Redundancy Wiring Diagram in Figure 5 if needed a On both the primary and backup system remove the shunt across ju...

Page 21: ... 362 6500 8 Connect the odorant supply source to the odorant inlet bulkhead with the recommended 3 8 stainless steel tubing Figure 6 8 A tank isolation valve V15 should be incorporated between the storage tank and this connection 9 Connect the process gas source using stainless steel tubing regulated to 35 60 psi 2 4 4 1 Bar supplied by the NJEX ZEO system owner with a dielectric union to the labe...

Page 22: ...oy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 20 NJEX ZEO Version 04 13 2021 Figure 7 Class 1 Division 1 North American Cabinet Connection Dimensions mm in Figure 6 Class 1 Division 1 North American Cabinet Connections ...

Page 23: ...LATION YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 21 Figure 9 Zone 1 Cabinet Connections Dimensions mm in Figure 8 Zone 1 Cabinet Connections ...

Page 24: ...skid version that would contain 110 of the odorant tank volume The skids are available in a single cabinet or dual cabinet option if system redundancy is required The Skid Mount Systems come standard with an electronic level indicator factory connected to the N 400 controller The controller has an alarm capability to indicate when the liquid level in the storage tank has fallen below a predetermin...

Page 25: ...TBD TBD 60 227 Single 52 1321 52 1321 54 1372 54 1372 800 363 Double TBD TBD TBD TBD TBD 120 454 Single 96 2438 26 660 98 2489 28 711 1000 454 Double TBD TBD TBD TBD TBD 250 946 Single 122 3099 47 1194 124 3150 49 1245 1400 635 Double TBD TBD TBD TBD TBD 500 1893 Single 154 3912 47 1194 156 3962 49 1245 2000 907 Double TBD TBD TBD TBD TBD 1000 3785 Single 220 588 47 1194 222 5639 49 1245 3000 1361...

Page 26: ... 1829 36 914 1200 545 Double TBD TBD TBD TBD TBD TBD 120 454 Single 82 2083 32 813 8 203 98 2489 36 914 1450 658 Double TBD TBD TBD TBD TBD TBD 250 946 Single 108 2743 58 1473 8 203 124 3150 62 1575 2100 953 Double TBD TBD TBD TBD TBD TBD 500 1893 Single 116 2946 58 1473 8 203 154 3912 62 1575 2850 1293 Double 116 2946 80 2032 21 533 167 4241 85 2159 3600 1633 1000 3785 Single 192 4877 64 1626 8 2...

Page 27: ...t of the empty tank d Do not move a system with liquid in the odorant tank WARNING While lifting all personnel should stand clear of the skid assembly Keep all hands fingers etc free from under the cabinet while setting down Lifting must be performed with an adequate lifting system CAUTION Do not move or lift a system with odorant in the tank Tank must be empty and any pressure vented prior to lif...

Page 28: ...self you should contact the manufacturer of your chemical prior to proceeding 1 Verify correct position of valves before beginning Open V12 and V13 Closed V10 V11 and V15 Note Gas Supply to V13 should NOT be turned on during this procedure 2 Attach inert or natural gas supply to V10 3 To purge the tank open valve V10 to introduce inert or natural gas to the tank to begin displacing any ambient air...

Page 29: ...rocess Verify that the entire system has no pressure in it before beginning Additionally all personnel should wear protective clothing and use equipment as recommended by the chemical manufacturer during this time If you are uncertain about any aspect of the odorant itself you should contact the manufacturer of your chemical prior to proceeding 1 Stop the NJEX ZEO system by pressing the Right Arro...

Page 30: ...sfer pump and fill the verometer Before priming the injection pump follow the Injection Pump Oil Fill Procedure in Appendix G of this manual to fill the injection pump with the required oil After filling the injection pump with oil refer to the P ID and the Maintenance Instructions in Section 5 to prime the injection pump After completing the priming steps follow the Calibration instructions in Se...

Page 31: ... be displayed If purging and venting is required for maintenance see the Maintenance instructions in Section 5 of this manual for purging and venting instructions Before disassembling or servicing any system components the system must be disconnected from the provided power source and an appropriate amount of time passed to dissipate any remaining voltage WARNING Explosion Hazard To prevent igniti...

Page 32: ...SECTION 4 SYSTEM OPERATION YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 30 NJEX ZEO Version 04 13 2021 Notes ...

Page 33: ...SECTION 4 SYSTEM OPERATION YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 31 ...

Page 34: ... has 6 keys to navigate through the menus Arrow Keys The arrow keys are used to navigate in their respective direction or to toggle through values in a menu At the home screen the right arrow key is used to start or stop the system At the home screen the left arrow key is used to manually fill the verometer Select Key The select key will be used to select items in the menu to enter submenus or app...

Page 35: ...ck key will bring the controller back to the home menu LED Communication Icons Alarm Icon The Alarm Icon LED will flash red in the instance of an active alarm Information Icon The Information Icon LED will flash green when the unit is running Stop Icon The STOP Icon LED will flash yellow when stopped due to Remote Inhibit or when the system is in Standby Standby mode is only applicable when system...

Page 36: ...out of the N 400 controller Method 1 utilizes Modbus Communications protocol Specifications to permit configuration can be found on Appendix C N400 Modbus Specifications Connections are via an RS 485 two wire connection In a safe nonhazardous area this may be connected to a RS 232 converter for interface with a SCADA system if required Method 2 utilizes two output relays One relay is for Alarm Out...

Page 37: ...reference for which operational mode the system is operating in The operational modes are Proportional To Flow or Proportional To Time See Setting Operator Input Parameters below on how to adjust these parameters Additional Icons that will display are the Memory Module icon which notifies the user that the MM 400 Memory Module is plugged in properly recognized and collecting data The Remote Inhibi...

Page 38: ...O system The first value displayed is the Target Injection Rate See Setting Operator Input Parameters below to set this parameter The following values are the 60 second 15 minute and 1 hour injection rate average to monitor the injection rate over time for the system The values are displayed with the user selected units Section 4 displays key information on the verometer The percentage displayed s...

Page 39: ... Home Screen to start and stop the unit If the primary unit fails and the backup unit is running the primary unit will display STANDBY If the backup system fails following failure of the primary system both units will run The primary system status will show failed while the system status shows RUNNING In N 400 Backup Redundancy mode Section 5 can display four status for the backup system While the...

Page 40: ...orant tank level percentage with a visual indicator This section also displays the bulk odorant tank pressure in the units that are selected under System Configuration The tank requires 10 25 psi 0 7 1 7 bar blanket pressure during normal operation Section 7 is the Totalizer display The totalizer shows the total odorant injected in the units that are selected under System Configuration Section 8 h...

Page 41: ...s may exist but cannot be displayed on one screen When applicable a small black arrow will be displayed at the bottom or top of the screen indicating that more options are available Use the navigation arrows to navigate in the direction of the arrow to display the options To open a submenu within the Main Menu use the navigation arrows to highlight the selected menu and press the Select Key To ret...

Page 42: ... parameter selected will be identified by the filled circle next to the parameter 1 4 In the instance of a power loss while the system is running the system can be set to resume automatically when power is restored To allow the system to resume on power loss use the navigation arrows to navigate to the Resume on power loss setting and press the select key If selected the selection box will be fill...

Page 43: ...ated to prevent nuisance alarms and allow for the most accurate monitoring Odorant Output will generate a pulse for every lb or kg injected depending on the value input The output relay is located at TB12 terminals 3 and 4 refer to the Wiring Control Document in Appendix B for reference To enable see step 2 7 below To set odorization parameters 2 1 Beginning from the home screen press the Select K...

Page 44: ...le and press the Select Key If the parameter is disabled the box will be displayed empty 3 Calibrating Input Signals The N 400 controller uses inputs from various devices to properly determine the injection rate to the flowing pipeline The Calibration menu is used to manually calibrate each device to ensure proper measurement The measurements that are calibrated include the Injection Pump Flow Sig...

Page 45: ...ter the value 3 1 7 Navigate to the Start Calibration icon at the bottom of the screen Press the Select Key to start the calibration procedure The injection pump will inject odorant against the current back pressure for 30 to 40 seconds and calculate the Max Pump Capacity Once calibration is complete select the Apply Calibration button and the Calibrated indicator box will be filled with a check m...

Page 46: ...ge the calibration will be applied and the box next to Calibrated will display a check mark Note If the controller does not accept the calibration value the voltage at the input terminal is outside of the calibration range of 6V 1 4VDC 2 4 mA 5 6 mA 3 2 6 Select span to calibrate the span set point This adjustment is used to calibrate the N 400 controller for 100 of metered flow in the pipeline Th...

Page 47: ...he system See the example on the next page on how to calculate this value To begin calibrating the pulse flow input press the Select Key from the home screen to open the Main Menu 3 3 1 Navigate to the Calibration Menu and press the Select Key 3 3 2 Select the Flow Signal Menu 3 3 3 Select the Flow Signal Type Pulse The selected parameter will have a filled circle displayed next to it 3 3 4 Using ...

Page 48: ...𝑟 100 000 𝑝𝑢𝑙𝑠𝑒𝑠 𝐻𝑟 Since pulses per hour is not an option for programing the N 400 controller divide by 60 minutes per hour to obtain pulses per minute 100 000 𝑝𝑢𝑙𝑠𝑒𝑠 𝐻𝑟 𝑥 1 𝐻𝑟 60 𝑚𝑖𝑛 1 666 7 𝑝𝑢𝑙𝑠𝑒𝑠 𝑚𝑖𝑛 Since a maximum of 999 pulses per minute may be programmed into the N 400 controller you must now divide by 60 seconds per minutes to obtain pulses per second If this value had calculated to be le...

Page 49: ...librate the zero set point When Zero is selected the calibration instructions are displayed on the screen The N 400 controller is programmed for 0 tank fill to directly correspond to 1 00 VDC 4 0 mA at the flow input terminal board TB11 terminals 2 and 3 Refer to the Wiring Control Document in Appendix B 3 4 6 1 To calibrate the zero set point apply 1 00 VDC 4 0 mA to TB11 terminal 2 and terminal ...

Page 50: ...d the box next to Calibrated will display a check mark Note If an error message appears the voltage at the input terminal is outside of the calibration range of 12 mA 22 mA 3 5 Odorant Inlet Pressure Calibration 3 5 1 To begin calibrating the Inlet Pressure press the Select Key from the home screen to open the Main Menu 3 5 2 Navigate to the Calibration Menu and press the Select Key 3 5 3 Select t...

Page 51: ...et pressure is outside an acceptable range The NJEX ZEO requires 10 25 psi 68 1 73 Bar blanket pressure The default values Odorant Inlet Pressure Low and High values are 10 psi 68 Bar and 30 psi 2 0 Bar If an odorant inlet pressure alarm is active a secondary Odorant Pressure Cable alarm will indicate if communication with the inlet pressure transducer is lost Alarm Out Delay A time delay can be s...

Page 52: ... alarm Press the Select Key to enable or disable each alarm The alarm is enabled when a check mark is displayed next to the word Enabled for that parameter Disabled alarms will not be stored within the audit trail 4 3 7 To enable the system to communicate the alarm to external the communications system use the arrow keys to navigate to the selected alarm output Press the Select Key to enable or di...

Page 53: ...k mark in the box next to the parameter name 4 4 5 2 Verify the alarm is outputting to the external communications system If alarm is not communicating check the applicable connections to ensure proper wiring and test again once confirming 4 4 6 All alarm simulations will turn off upon exiting the Alarm Simulation Menu Figure 35 Alarm Simulation Menu 4 Figure 38 Alarm Simulation Menu 3 Figure 37 A...

Page 54: ...your MODBUS system 5 3 2 For the selected COM port use the navigation arrows to highlight the Slave Address to input the desired address for the SCADA or other Host device Any address from 1 247 may be programmed Press the Select Key to modify When modifiable the parameter will be displayed with light text on a dark background Press or hold the navigation arrow keys to modify the Slave Address val...

Page 55: ...he Totalizer menu and press the Select Key 6 2 Displayed on the screen will be the Odorant Usage in weight in the appropriate system units 6 2 1 To reset back to zero navigate to the Refresh displayed to the right of the Odorant Usage value using the navigation arrows Press the Select Key to refresh 6 3 Also displayed on the screen will be the calculated Odorant Injection Rate that is also shown o...

Page 56: ... enable or disable the screen lighting use the navigation arrows to navigate to the box next to the Enabled parameter When enabled the Enabled parameter will be filled with a check mark 8 Time Date The date and date format and the time can be adjusted to reflect the user preference The clock and date should be properly maintained to reflect the current time and date where the system is installed T...

Page 57: ...a 12 hour clock format repeat to select AM or PM 8 4 2 When adjusting the date the month day and year are adjusted as individual parameters 8 4 2 1 Press the Select Key and if necessary use the Left Arrow Key or Right Arrow Key to cycle to the month parameter Use the Up Arrow Key and Down Arrow Key to adjust the month as needed 8 4 2 2 Press the Select Key to set the month parameter Repeat to set ...

Page 58: ... Key The selected language will be indicated by a filled circle next to the active language 10 Factory Reset The N 400 controller can be reset to factor default when required The User Settings and Calibration Settings are reset as individual options 10 1 To open the Factor Reset Menu press the Select Key from the Home Screen to open the Main Menu Navigate to the Factory Reset icon and press the Se...

Page 59: ...at is factory set for your N 400 controller and the NJEX ZEO system that it controls The About menu displays the Serial Number Pump Model Process type Controller Firmware Version and Intrinsically Safe Transition Board Firmware version These are set at the factory and are not adjustable in the field This information will be important if service is required from a YZ Systems field service technicia...

Page 60: ...ow Key or Right Arrow Key 11 1 System Purge Purging the system will remove odorant from the system and purge it back to the odorant tank 11 1 1 To display the purge maintenance instructions press the Select Key from the Home Screen to open the Main Menu Navigate to the Maintenance menu and press the Select Key Press the Select Key to open the Purge Menu 11 1 2 Use the accompanying P ID in the cabi...

Page 61: ...intenance menu and press the Select Key Navigate to the Vent menu and press the Select Key 11 2 2 Use the accompanying P ID in the cabinet door for referencing valve locations 11 2 3 Follow the Vent instructions on the screen or they will be listed below 11 2 3 1 Open V5 11 2 3 2 Wait until verometer inlet pressure reaches zero 11 2 3 3 Begin maintenance 11 2 3 4 After maintenance is complete rest...

Page 62: ...ect Key from the Home Screen to open the Main Menu Navigate to the Maintenance menu and press the Select Key Navigate to the Prime Transfer Pump menu and press the Select Key 11 3 2 Use the accompanying P ID in the cabinet door for referencing valve locations 11 3 3 Follow the Prime Transfer Pump instructions shown on the screen or they will be listed below 11 3 3 1 Open V17 to allow odorant to fl...

Page 63: ...11 4 3 1 Open V1 11 4 3 2 Press the Select Key to begin filling the verometer 11 4 3 3 The transfer pump will begin filling the verometer and shut off at 100 11 4 3 4 The verometer level is shown at the bottom of the screen for reference 11 5 Prime Injection Pump Priming the mROY injection pump prior to starting the system will ensure no trapped air is in the injection pump for accurate pump perfo...

Page 64: ...3 2021 11 5 3 4 Confirm the injection pump is running in a closed loop by noting the verometer level oscillation 11 5 3 5 Press the Select Key to start and stop the system again as needed until the injection pump is primed 11 5 3 6 Close V2 11 5 3 7 Open V8 11 5 3 8 Open V17 11 5 3 9 Return to the Home Screen and Press the Right Arrow Key to start the system ...

Page 65: ...nce troubleshooting etc should be performed by a trained professional Before performing any maintenance power to the cabinet must be de energized While servicing units proper PPE must be worn such as gloves and protective eyewear For Additional Help For issues that cannot be resolved from using this manual please call YZ Technical Service at T 1 800 653 9435 1 800 NJEX HELP T 1 281 362 6500 F 1 28...

Page 66: ... Verify the tank level indication on the manual tank gauge If the level indication does not approximately match the electronic level indication perform the following checks 1 1 Inspect to verify that the wiring to the controller termination strip TB11 is still intact Look for loose or broken wires at TB11 pin number 2 Red Wire 3 Black Wire and 1 Shield Repair any loose or broken wires 1 2 Inspect ...

Page 67: ...the pipeline and therefore no odorant is currently being injected This alarm will be present along with the green indication LED and will only be present if Flow No Signal parameter is disabled Low Flow Shut Off is an indication that the flow signal being received by the odorizer signals that the present flow in the pipeline is less than the set value for the Low Flow Shut Off set in the in the Od...

Page 68: ...verify it is set as desired As a second step evaluate the flow signal being received Verify that the signal indicates the correct flow and that the signal spanned and zero referenced correctly If necessary correct as required 4 Flow no signal indication is not an actual alarm but an indication that the system is injecting to the rate stipulated by the Flow no signal parameter This is used to conti...

Page 69: ...Verometer fails to fill to 100 within 6 minutes after a fill is requested Slow Fill alarm is indicated when a fill of the Verometer is requested and the Verometer does not fill to 100 within 3 minutes This alarm actuates with either an automatic or manual fill request Leakage is indicated when the verometer level drops while the injection pump is not energized Transfer Pump Leak is indicated when ...

Page 70: ... to troubleshooting a slow fill alarm verify that the Verometer is not in a full level position as the transfer pump commands cannot be processed if the Verometer is full 1 Refer to the P ID to ensure the correct valves are fully open to allow the verometer to fill 2 Check bulk odorant supply filter and valves for possible restriction or closure and adjust or replace as necessary 3 Check tubing be...

Page 71: ...he external cable sleeve or moisture inside the cable connector 2 Loosen and inspect the RTD connection threaded into the back of the verometer 3 Reinstall RTD in the back of the verometer Observe if the alarm is still active if it is contact YZ Technical Services Verometer Over Fill Non Alarm Indicator Troubleshooting Steps When an active Over Fill non alarm is indicated the following steps shoul...

Page 72: ...gh Alarm Troubleshooting When an active Odorant Inlet Pressure High Alarm is indicated the following steps should be taken 1 Verify the blanket pressure on the bulk odorant tank is in the range of 10 25 psi 68 17 2 Bar and reestablish the correct pressure if applicable 2 If the alarm is still active verify the programmed high and low values in the Set Alarm Parameters menu 3 Recalibrate the Inlet ...

Page 73: ...nd check for the alarm again 3 If the Injection Pump alarm is still active begin replacing the diaphragms See Appendix H for Injection Pump diaphragm replacement Injection Rate Alarms The NJEX ZEO system monitors and controls the volume of odorant injected and calculates an actual injection rate over time The injection rate alarm is tied to the 1 hour injection rate value If the system detects a d...

Page 74: ... unable to write to its internal memory HW Error 2 will enable if the N 400 real time clock has failed IS Transition Board Cable Troubleshooting Steps When an active IS Transition Board alarm is indicated the following steps should be taken 1 Verify the wiring is properly connected within the N 400 controller Please refer to the Wiring Control Document located in Appendix B 2 If the alarm persists...

Page 75: ...SECTION 6 TROUBLESHOOTING YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 73 Notes ...

Page 76: ...SECTION 6 TROUBLESHOOTING YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 74 NJEX ZEO Version 04 13 2021 Notes ...

Page 77: ...manifold intermediate block etc Purging and venting removes odorant and pressure in the suction line up to the pump head and intermediate block Discharge pressure and odorant will remain beyond the manifold check valve into the discharge lines and must be purged and vented by another means Recommended Maintenance Schedule Weekly Inspection 1 Verify odorant tank pressure and level 2 Check for gas a...

Page 78: ... worn such as gloves and protective eyewear Purging and venting the NJEX ZEO system purges gas and vents pressure in the suction lines of the system This allows for maintenance on the inlet filters transfer pump and suction check valves If maintenance is required on a discharge check valve or the discharge lines the discharge pressure must be relieved WARNING Power must be disconnected or locked o...

Page 79: ...SECTION 7 SYSTEM MAINTENANCE YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 77 Notes ...

Page 80: ...SECTION 7 SYSTEM MAINTENANCE YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 78 NJEX ZEO Version 04 13 2021 ...

Page 81: ...______________ Conditions Pipeline Pressure _________________ Bulk Tank _______________________ 10 25 psi 0 7 1 7 Bar bulk tank pressure range is required Supply Pressure __________________ 35 60 psi 2 4 4 1 Bar supply pressure is required Gas Flow Rate ____________________ Record in MMCF hr or m3 sec Bulk Odorant Storage Level _________ Ambient Temp Range ______________ Parameters Injection Rate ...

Page 82: ... Date of Last Problem mm yy ________ Parameters Injection Rate _____________________ Odorant Density ___________________ Max Gas Flow _____________________ Pipeline Pressure ___________________ Low Flow Shutoff ___________________ Flow no signal ____________________ Alarms Verometer Loss of Signal Leakage No Fill Temp Cable Leak Transfer Pump Leak Flow Signal Loss of Signal Flow no signal Overflow...

Page 83: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 81 Appendix B Wiring Control Document ...

Page 84: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 82 NJEX ZEO Version 04 13 2021 ...

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Page 89: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 87 ...

Page 90: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com Page 88 NJEX ZEO Version 04 13 2021 ...

Page 91: ...ading a single coil per query Function 5 allows writing single or multiple coils per query Control Functions The control functions available via Modbus are listed below The registers are accessed using Modbus functions 1 and 5 The master device can initiate a state change by setting a control coil The N 400 Controller will clear non toggle type coils to acknowledge the state change has been acted ...

Page 92: ...Read Only Pump Diaphragm Failure 00205 Read Only Flow no signal active non alarm 00206 Read Only Flow Signal loss of signal 00207 Read Only Flow Signal no flow non alarm 00208 Read Only Flow Signal 110 non alarm 00209 Read Only Flow Signal 125 00210 Read Only Verometer loss of signal 00211 Read Only Verometer no fill 00212 Read Only Verometer slow fill 00213 Read Only Verometer overfill non alarm ...

Page 93: ...ata Available 1 not available 0 since last coil read 01014 Read Only Metric Units 1 English Units 0 01015 Read Only Memory Module Present 1 Not Present 0 01016 Read Only Resume Operation on Power Loss Enabled 1 Disabled 0 01017 Read Only Low injection rate alarm enabled 1 disabled 0 01018 Read Only High injection rate alarm enabled 1 disabled 0 01019 Read Only Bulk Tank Low Alarm Enabled 1 Disable...

Page 94: ...40007 Read Only Most recent HOU LOU Start Date Day of Month 40008 Read Only Most recent HOU LOU Start Date Month 40009 Read Only Most recent HOU LOU Start Date Year 40010 Read Only Most recent HOU LOU Start Date Hours 24 hour format 40011 Read Only Most recent HOU LOU Start Date Minutes 40012 Read Only Most recent HOU LOU Start Date Seconds 40013 Read Only Most recent HOU LOU End Date Day of Month...

Page 95: ...010 to save the updated parameters before restarting the system Address Access Descriptions 40101 Read Write Current time day of month 40102 Read Write Current time month 40103 Read Write Current time year 40104 Read Write Current time hours 24 hour format 40105 Read Write Current time minutes 40106 Read Write Current time seconds 40107 Read Write Injection Rate See formatting info 40108 Read Writ...

Page 96: ...GM X XX kg pulse Exception Responses Exception responses are a means for the Slave device to indicate to the Master device that a query received could not be acted upon for a particular reason Below is a listing of Exception codes Exception Code Name Description 1 Illegal Function Function received in the query is not supported by the slave 2 Illegal Data Address Data address received in the query...

Page 97: ...Additional fuses can be purchased individually with the part numbers below or a kit containing all required fuses can be purchased from YZ Systems with part number D3 0297 Component Specification Description Manuf Part Number F1 62mA 125V 300A Breaking Fuse PICO hazardous area ENCAPSULATED Littelfuse 259 062 F2 62mA 125V 300A Breaking Fuse PICO hazardous area ENCAPSULATED Littelfuse 259 062 F3 50m...

Page 98: ...021 The N 400 controller is to be mounted with the supplied hardware to the backplate that is fastened in the NJEX ZEO cabinet The controller is rated for an IP64 environment and must be installed inside the cabinet to maintain proper environmental protection Figure 52 N 400 Controller Mounting Appendix E Controller Mounting ...

Page 99: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland PA USA 18974 P 281 362 6500 www yzsystems com NJEX ZEO Version 04 13 2021 Page 97 Appendix F Bulk Odorant Filter Replacement ...

Page 100: ... While filling monitor the open sight glass port if applicable Reinstall the sight glass if oil begins to purge from this port or reinstall after approximately 20 ounces of oil has been added 6 Continue to fill until the sight glass appears approximately one quarter 1 4 to one third 1 3 full Oil will expand after warming do not overfill 7 Purge the oil drain line tubing into a suitable container u...

Page 101: ...heck the sight glass on the back of the pump and ensure it is approximately 1 2 full Add oil if required Replace the oil reservoir cap and tighten hand tight Adjust the valves for normal operation Adjust the parameters as applicable to the application and continue starting up the system If the oil reservoir has been overfilled and the oil expands after warming the sight glass will be full and oil ...

Page 102: ...se of used oil in accordance with local laws and regulations for where the system is installed 3 Remove the intermediate block to perform maintenance on the injection pump by removing the three screws on the front face and two on the right face 4 Note the location of the face seal o rings on both the manifold and pump head Collect o rings and discard 5 Collect any hardware for reuse when reassembl...

Page 103: ...e 65 Injection Pump Liquid End Assembly for reference Ensure the diaphragms are not scratched or damaged by the exposed locating pins See Figure 58 Placing Diaphragms and Shims for reference 12 Replace the o ring within the pump head Install the contour plate in the pump head aligning the pin in the contour plate with the mating pinhole in the pump head 13 Prepare the pump head with contour plate ...

Page 104: ... to align the intermediate block and pump head Fasten the remaining two cap screws 22 Torque cap screws items 930 and 940 to 5 4 ft lbs 0 61 Nm 23 Torque cap screws items 920 and 923 to 2 3 ft lbs 0 26 Nm 24 Ensure the oil drain valve is closed and refill the injection pump with oil 25 Follow the maintenance instructions in this manual to prime the system for normal operation and follow the oil fi...

Page 105: ...scription QTY 552 Pump Head 1 800 Manifold Assembly 1 905 Intermediate Block 1 920 10 32 x 1 0 SHCS Stainless Steel 2 923 10 32 x 1 25 HDFHS Stainless Steel 82deg Countersink 1 930 1 4 28 x 2 75 SHCS Stainless Steel 1 940 1 4 28 x 2 00 SHCS Stainless Steel 1 950 O Ring 109 Nitrile 2 960 O Ring 107 Nitrile 2 Figure 64 Intermediate Block Assembly ...

Page 106: ...w yzsystems com Page 104 NJEX ZEO Version 04 13 2021 Item Number Description QTY 552 Pump Head 1 558 3 8 16 x 1 0 SHCS Stainless Steel 8 560 Pump Head O Ring 2 041 Viton 1 562 Diaphragm 2 564 Contour Plate 2 566 Shim 1 2 568 Shim 2 2 Figure 65 Injection Pump Liquid End Assembly ...

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