Ametek Drexelbrook Z-tron Level Control 502-302X Series User manual

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and Sonic Level
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-ShieldTM Electronics
DREXELBROOK

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.
Copyright 2000 AMETEK Drexelbrook

Series 502-302X
Z-tron Level Control
using 402-302X
Cote-ShieldTM Electronics
205 Keith Valley Road Horsham, PA 19044
US Sales 800-553-9092
24 Hour Service 800-527-6297
International 215-674-1234
Fax [phone]
E-mail [e-mail]
Web www.drexelbrook.com
An ISO 9001 Certified Company
DREXELBROOK

Table of Contents
Paragraph Page
SECTION 1 - INTRODUCTION ......................................................................................... 1
1.1 System Description................................................................................................... 1
1.2 Mo el 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 ...................................................................................... 6
2.5 Relay Connections.................................................................................................... 7
SECTION 3 - OPERATION................................................................................................. 8
3.1 Start-Up ..................................................................................................................... 8
3.2 Controls...................................................................................................................... 8
3.2.1 Setpoint Control .............................................................................................. 8
3.2.2 Time Delay Control......................................................................................... 9
3.2.3 Failsafe Selector ............................................................................................ 10
SECTION 4 - CALIBRATION
4.1 Quick Calibration .................................................................................................... 11
4.2 Calibration of Horizontal Sensing Elements......................................................... 12
4.3 Calibration of Vertical Sensing Elements ............................................................. 14
4.4 Quick Calibration .................................................................................................... 15
4.5 Recalibration ........................................................................................................... 17
4.6 Calibration of Time Delay Units ............................................................................ 18
4.7 A ing a Pa ing Capacitor .................................................................................. 19
SECTION 5 - TROUBLESHOOTING .............................................................................. 20
5.1 Testing the Electronic Unit ................................................................................... 20
5.2 Testing the Sensing Element ................................................................................ 21
5.3 Testing the Coaxial Cable (Remote Systems)....................................................... 25
5.4 Testing the Relay Circuits ..................................................................................... 26
5.5 Possible Problems an Causes .............................................................................. 27
5.6 Telephone Assistance ............................................................................................. 29
5.7 Equipment Return ................................................................................................. 29
5.8 Fiel Service ........................................................................................................... 30
5.9 Customer Training................................................................................................. 30
SECTION 6 - SPECIFICATIONS .................................................................................... 31
EDO 4-96-248
502-302X-LM

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1
502-302X Series Z-tronTM Level Control Introduction
SECTION 1
INTRO UCTION
1.1 System
escription
1.2 Model Number
This manual describes the Drexelbrook Z-tronTM Level
Control Series 50 -3000 with a 40 -30 0 or 40 -30
high sensitivity transmitter.
The Drexelbrook Z-tron Level Control 50 -3000 is a preci-
sion RF (radio frequency) relay output level switch. It
provides relay contact closure when material reaches a
preset point in a vessel. The standard double-pole, double
throw relay contacts may be used to operate alarms, sole-
noid valves, or other low power devices.
Cote-ShieldTM action is designed into each unit and en-
ables the instrument to ignore the effects of most build-up
or material coatings on the sensing element, when prop-
erly installed and applied.
The Z-tron control is mounted so that the sensing element
is in or near the material being measured. It provides a
change in RF admittance indicating presence or absence of
material. The sensor is comprised of a: center (measuring
portion), and Cote-ShieldTM portion. The Cote-Shield
element guards against the transmission of RF current
through most coatings on the sensing element (from the
center measuring element to ground) until the level
reaches the setpoint. The Cote-Shield element also pre-
vents any change in RF current due to temperature effects
on the sensing element.
5 0 2 - 3 0 2 X - 0 0 1 Z-Tron Level Control
Electronic Unit Options:
0 - High Sensitivity
- High Sensitivity with
0-90 Second Time Delay

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502-302X Series Z-tron Level Control Installation
SECTION 2
INSTALLATION
2.1 Unpacking
2.2 Mounting
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.
The Z-tron Level Control is designed for field mounting.
However, it should be mounted on the vessel so that vibra-
tion, corrosive atmospheres, and any possibility of me-
chanical damage is minimized.
For convenience at start-up, it is best to locate the Z-tron
Level Control in a reasonably accessible location. It may
be mounted either vertically or horizontally. See Figure -1.
Avoid mounting closer than 1 inch to any tank structure.
Material bridging from structure to sensing element can
cause false alarms. Close proximity to tank structure also
increases the sensing element’s standing capacitance.
Figure 2-1
Mounting Through a Nozzle
WRONG
GOOD
BEST
EXTENDED
COTE-SHIELD
ELEMENT
(NO NOZZLE)
LONG
NOZZLE
WALL BUILDUP
COVERS COTE-SHIELD
BUILDUP

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3
502-302X Series Z-tronTM Level Control
Figure 2-2
Mounting Dimensions
Installation

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4
502-302X Series Z-tron Level Control Installation
The actual mounting location often depends on the place-
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 -1
and -3. Be sure to protect the insulation on the sensing
element against cuts and scrapes during installation.
Figure 2-3
Z-tron Level Control
2.2 Mounting
(cont.)
METAL
TUBE
COTE-SHIELD
LENGTH
INSERTION
LENGTH
INSULATION
COTE-SHIELD
ELEMENT
INSULATION

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5
502-302X Series Z-tronTM Level Control Installation
WARN NG
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. When wiring is completed, the cover must be
replaced and each conduit from the explosionproof
case must be equipped with an approved seal fitting.
The sensing element connections to the integral electron-
ics have been made at the factory. If it is necessary to
rewire the sensing element to the electronics, see Figure -4
for proper connections.
Figure 2-4
Wiring the Sensing Element
2.3 Wiring the
Sensing Element

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

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7
502-302X Series Z-tronTM Level Control
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 -7.
Figure 2-6
Relay Connections (with Power Connected)
Installation
2.5 Relay Connections
Figure 2-7
Relay Contact Chart
LEVEL ABOVE
TRIP POINT
LEVEL BELOW
TRIP POINT
ALARM LED
IS OUTALARM LED
IS OUT
ALARM LED
IS LIT
GND 7 8 9
L1 L2 3 4 5
GND 7 8 9
L1 L2 3 4 5
HIGH LEVEL FAIL SAFELOW LEVEL FAIL SAFE
ALARM LED
IS OUT
ALARM LED
IS LIT
LEVEL BELOW
TRIP POINT
LEVEL ABOVE
TRIP POINT
GND 7 8 9
L1 L2 3 4 5
GND 7 8 9
L1 L2 3 4 5

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8
502-302X Series Z-tron Level Control
This section contains the start-up and operating informa-
tion for the Z-tron level controls (40 -30 0 or 40 -30 ).
Before applying power to the instrument, be sure that the
input power is from a 1 0 vac, 50/60 Hz power source. Also
check wiring connections as described in paragraphs
.3 and .4.
WARN NG
If the Z-tron level control is placed in a hazardous
area, caution must be taken before removing the
explosionproof housing. In order to calibrate the unit,
the area must be checked and known to be non-
hazardous. When calibration is completed, the cover
must be replaced and each conduit from the
explosionproof case must be equipped with an ap-
proved seal fitting.
There is a single adjustment located on top of the instru-
ment (Figure 3-1) that controls the point at which the
relay operates.
•A lighted LED indicates that the relay is energized.
•Each revolution of the control will change the operating
point approximately 0. pF.
•Turning the adjustment clockwise will raise the level at
which the relay operates and turning it counterclockwise
will lower the level at which the relay operates (vertically-
mounted sensing elements only).
Figure 3-1
Setpoint Control
Operation
SECTION 3
OPERATION
3.1 Start-up
3.2 Controls
3.2.1 Setpoint
Control

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9
502-302X Series Z-tronTM Level Control
The optional time delay adjustment is located on top of the
instrument, across from the setpoint adjustment (Figure 3-
). It is used to help stop an oscillating relay output due to
agitation or frothing in the vessel.
•The standard time delay is 0-90 seconds.
•The delay applies only to recovery from the alarm condi-
tion.
•On a High Level Failsafe unit, the delay will be effective
only on falling level. The output will indicate high level
as long as waves continue to touch the sensing element.
The unit will stop indicating high level only after the
delay time has passed, with no further contact between
the sensing element and the material being measured.
•Calibration of a Z-tron with time delay is explained in
paragraph 4.5.
Figure 3-2
Time Delay Control
Operation
3.2.2 Time elay
Control

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10
502-302X Series Z-tron Level Control
3.2.3 Failsafe Selector
Operation
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.
•Low Level Failsafe (LLFS) means the relay will de-
energize under low-level conditions, indicating low level
upon loss of power.
•The instrument is supplied in the failsafe mode that is
requested when the order is placed (HLFS, if not speci-
fied).
•The failsafe is field selectable by a slide switch, acces-
sible through a hole in the side of the chassis. See Figure
3-3.
Figure 3-3
Failsafe Adjustment

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11
502-302X Series Z-tronTM Level Control Calibration
The following paragraphs outline different calibration
procedures for the Z-tron Level Control (50 -30 X).
The high sensitivity 40 -30 X chassis is used primarily for
low bulk density granulars and extra short length sensing
elements used on insulating liquids. The 40 -30 X high
sensitivity chassis is used on the above applications be-
cause the standard chassis 40 -3XXX does not have
enough sensitivity to perform reliably. The 40 -30 X is not
recommended for use on conductive products.
There are three methods of calibrating the high sensitivity
40 -30 X electronic unit:
1. Horizontal calibration.
. Vertical calibration.
3. Quick calibration.
Horizontal calibration and Vertical calibration involve
moving tank level to establish proper calibration. These
methods produce the most accurate and repeatable calibra-
tion.
The Quick calibration procedure does not require moving
material to set calibration.
Calibration requires use of an insulated tool such as
Drexelbrook part number 90-1-1. See Figure 4-1.
SECTION 4
CALIBRATION
4.1 Types of
Calibration
Figure 4-1
nsulated Calibration Tool

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1
502-302X Series Z-tron Level Control
NOTE
All calibrations must be performed with the
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.
WARN NG
o not turn any adjustment past its mechanical
stops. amage to the unit could occur.
•Use the insulated calibration tool (part number 90-1-1).
See Figure 4-1.
•LED lit (on) indicates that the relay is energized, or in
the normal condition (not alarm).
—Horizontal Calibration
a. Begin with level well below the end of the sensing
element.
b. Using the insulated tool supplied with the unit,
turn the setpoint adjustment to the full counterclock-
wise (CCW) position.
c. Turn the adjustment slowly clockwise (CW) until the
relay just operates. LED changes states. This is the
tune point in air.
d. Mentally note the position of the adjustment tool
pointer when at the tune point in air.
Calibration
4.2 Calibration of
Horizontal Sensing
Elements

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13
502-302X Series Z-tronTM Level Control Calibration
e. Increase the material level until it is well above the
sensing element.
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. This is the tune point in material.
g. Turn the adjustment back counterclockwise (CCW)
half the number of turns that were counted.
CALIBRATION IS NOW COMPLETE.
Note
For recalibration purposes, record half the
number of turns that were counted (in step f.
above) as “Preload,” (referred to in section 4.4).
Note
If less than ¼ turn of the adjustment is
observed between the tune point in air and
the tune point in material, please consult the
factory at 1-800-5 7-6 97.
4.2 Calibration of
Horizontal Sensing
Elements (cont.)

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14
502-302X Series Z-tron Level Control Calibration
4.3 Calibration of
Vertical Sensing
Elements
Vertical Calibration is recommended for vertically-
mounted Cote-ShieldTM sensing elements.
WARN NG
o not turn any adjustment past its mechanical
stops. amage to the unit could occur.
•Use the insulated calibration tool (part number 90-1-1).
See Figure 4-1.
•LED lit (on) indicates that the relay is energized, or in
the normal condition (not alarm).
—Vertical Calibration
a. Set the level to a point on the sensing element where
control is desired. A minimum of 3 inches of covering
on the sensing element is required. See Figure 4-4.
Figure 4-4
Vertical Calibration
b. Using the insulated tool supplied with the unit, start
from the full counterclockwise (CCW) position and
counting the number of turns, turn the setpoint adjust
ment clockwise (CW) until the relay just operates.
Record the number of turns from full CCW position for
recalibration.
CALIBRATION IS NOW COMPLETE.
DESIRED
CONTROL
POINT

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15
502-302X Series Z-tronTM Level Control
Quick Calibration can be used for horizontally-mounted,
bare metal, Cote-ShieldTM sensing elements. In all cases, it
is necessary to have the material level below the sensing
element.
WARN NG
o not turn any adjustment past its mechanical
stops. amage to the unit could occur.
•Use the insulated calibration tool (part number 90-1-1).
See Figure 4-1.
•LED lit (on) indicates that the relay is energized, or in
the normal condition (not alarm).
—Quick Calibration
a. For either HLFS or LLFS, begin with the sensing
element in air. See Figure 4-5.
Figure 4-5
Quick Calibration, Sensing Element in Air
b. With the calibration adjustment in the full counter-
clockwise (CCW) position, turn slowly clockwise until
the relay just operates--tune point in air. (LED will
light in HLFS, and turn off in LLFS.)
c. Note the position of the adjustment tool pointer and
turn the adjustment further CW the number of turns
indicated in Table 4-1, Calibration Chart.
4.4 Quick
Calibration
Calibration

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16
502-302X Series Z-tron Level Control Calibration
4.4 Quick Calibration
(cont.) Table 4-1 Calibration Chart
Material Being Number of Adjustment
Measured Turns Clockwise (CW)
From Operate Position
Insulating Liquids-
Organics, Oil, Plastics 3 turns
Granular
Above 50#/Ft33 turns
Granular
Above 30-60#/Ft3 turns
Granular
Above 5-50#/Ft31½ turns
Granular
Above 0-40#/Ft31 turn
Granular
Above 10- 0#/Ft3¾ turn
Granular
Above 5-15#/Ft3½ turn
CALIBRATION IS NOW COMPLETE.