Ametek Z-tron IV User manual

Leader in
Level Measurement
Installation and
Operating Instructions
Z-tron IVTM
Point Level Control
Telephone: [phone]
Fax: [phone]
E-mail: drexelbrook.ser[email protected]
Website: www.drexelbrook.com

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 tness 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 AMETEK Drexelbrook

Z-tron IVTM
Point Level Control
EDO# 5-19-110
Z-tronIV-LM
Issue#5
205 Keith Valley Road, Horsham, PA 19044
Telephone: [phone]
Fax: [phone]
E-mail: drex[email protected]
Website: www.drexelbrook.com
An ISO 9001 Certied Company

Table of Contents

Contents
Section 1: Introduction ....................................................................................................................................1
1.1 System Description .................................................................................................................................1
1.2 Technology.................................................................................................................................................1
1.3 Spare Parts..................................................................................................................................................1
1.4 Model Number..........................................................................................................................................2
Section 2: Installation .......................................................................................................................................3
2.1 Unpacking ..................................................................................................................................................3
2.2 Mounting the Level Control ................................................................................................................3
2.3 Integral Mounting Dimensions...........................................................................................................5
2.4 Remote Mounting Dimensions ..........................................................................................................6
2.5 3A Mounting Dimensions.....................................................................................................................7
2.6 Power Wiring .............................................................................................................................................8
2.7 Relay Wiring ...............................................................................................................................................11
2.8 Wiring the Sensing Element (Remote).............................................................................................12
2.9 Wiring the Sensing Element (Integral) .............................................................................................13
Section 3: Operation .........................................................................................................................................14
3.1 Setpoint Control.......................................................................................................................................14
3.2 Time Delay Control..................................................................................................................................15
3.3 Time Delay Action ...................................................................................................................................15
3.4 Failsafe ........................................................................................................................................................16
3.5 Start-up........................................................................................................................................................16
Section 4: Calibration........................................................................................................................................18
4.1 Calibration in Conducting Material...................................................................................................18
4.2 Calibration in Insulating Material [Horizontal Mount] ...............................................................19
4.3 Calibration in Insulating Material [Vertical Mount] .....................................................................20
Section 5: Troubleshooting ............................................................................................................................22
5.1 Introduction...............................................................................................................................................22
5.2 Testing Electronic Unit...........................................................................................................................22
5.3 Testing Sensing Element.......................................................................................................................23
5.4 Testing Relay Circuits..............................................................................................................................25
5.5 Testing Remote Cable ............................................................................................................................26
5.6 Possible Problems and Causes............................................................................................................27
5.7 Factory Assistance ...................................................................................................................................28
5.8 Field Service...............................................................................................................................................28
5.9 Customer Training ...................................................................................................................................28
5.10 Equipment Return...................................................................................................................................29
Section 6: Specications..................................................................................................................................30
Appendix A: Shortening or Lengthening the Sensing Element ............................................................1

Section 1

Introduction
1
Section 1: Introduction
These instructions are for the AMETEK Drexelbrook Z-tron IV™ Series
Point Level Control.
The label on top of the electronic unit identies the model number of the
Z-tron IV level control.
1.1 System Description
Cote-Shield™ action is designed into all Z-tron IV level controls and
enables the instrument to ignore the effect of buildup or material coating
on the sensing element.
The electronic unit:
• Provides double-pole double-throw dry relay that changes state
when material reaches a specic point on the sensor. The relay
contacts may be used to operate alarms, solenoid valves, or other
low power devices.
• Provides a 0-60 second time delay for agitated vessels.
The 700-series sensing element:
• Is mounted on the tank or in the process.
• Provides a change in radio frequency (RF) admittance indicating
presence or absence of material.
1.2 Technology
In a simple capacitance probe type sensing element, when the level rises
and material covers the probe, the capacitance within the circuit between
the probe and the medium (conductive applications) or the probe and the
vessel wall (insulating applications) increases. This is due to the dielectric
constant (k) of the material, which causes a bridge misbalance. The signal
is demodulated (rectied), amplied and the output is increased. There
are drawbacks, however, especially when there is coating of the probe.
An RF Admittance level transmitter is the next generation. Although
similar to the capacitance concept, The Z-tron employs a radio frequency
signal and adds the Cote-Shield™ circuitry within the Electronics Unit.
This patented Cote-Shield™ circuitry is designed into Z-tron series and
enables the instrument to ignore the effect of buildup or material coating
on the sensing element. The sensing element is mounted in the vessel
and provides a change in RF admittance indicating presence or absence of
material.
The Cote-Shield™ element of the sensor prevents the transmission of
RF current through the coating on the sensing element. The only path
to ground available for the RF current is through the material being
measured.
The result is an accurate measurement regardless of the amount of
coating on the probe, making it by far the most versatile technology, good
for very wide range conditions from cryogenics to high temperature, from
vacuum to 10,000 psi pressure, and works with all types of materials.
k air
A
d
Ckmedia
C=kA
d
C = k A
d
A
k air
d
C
kmedia
Figure 1-1
Capacitance Probe
(Insulating Media)
Figure 1-2
RF Admittance Probe
with Cote-Shield
1.3 Spare Parts 115/ 230 VAC Electric Unit Part # - 385-0075-042
24 DC Electronic Unit Part # - 385-0075-041

2
Z-tron IV TM Point Level Control
1.4 Model Number
Process gland wetted part (X)
B316/316L SS
PPFA (700-0001-018)
X* Upon request
Sensing Element
Series
1Standard
2China
OEM Code
Insertion Length in mm
XXXXXX Length of the probe in millimeters from process connection to the bottom of the probe
Cote-Shield™ Length in mm
XXXXXX Length of the Cote-Shield in millimeters for 3-terminal probes. Not applicable for 2-terminal probes
Inactive Length in mm
XXXXXX Length of the inactive part of the probe that is not measured.
This option is primarily used in Interface measurement and Desalters
Inactive Material
B316/316L SS
NNot Applicable
X* Many more options are available upon request
Model # Press. &Temp. Wetted Parts
101 700-1202-001 200 psi @ 450°F 316 SS and PEEK
103 700-1202-014 200 psi @ 450°F 316 SS and PEEK
106 700-1202-041 1000 psi @ 250°F / 300 psi @ 450°F 316 SS and PEEK
301 700-0001-022 1000 psi @ 100°F / 500 psi @ 300 °F 316 SS and TFE
325 700-1202-031 200 psi @ 450°F 316 SS and PEEK, FDA approved
327 700-0202-002 50 psi @ 300 °F / 20 psi @ 450 °F* 316 SS and TFE
701 700-0001-018 50 psi @ 300 °F PFA
753 700-0206-101 200 psi @ 250°F 316 SS and PEEK
754 700-0029-001 2 psi @ 500 °F 316 SS and TFE
755 700-0029-002 2 psi @ 500 °F 316 SS and TFE
756 700-0029-003 2 psi @ 500 °F 316 SS and TFE
757 700-0029-004 2 psi @ 500 °F 316 SS and TFE
758 700-0029-005 2 psi @ 500 °F 316 SS and TFE
760 700-0029-021 2 psi @ 500 °F 316 SS and TFE
761 700-0029-022 2 psi @ 500 °F 316 SS and TFE
762 700-0029-023 2 psi @ 500 °F 316 SS and TFE
763 700-0029-024 2 psi @ 500 °F 316 SS and TFE
764 700-0029-025 2 psi @ 500 °F 316 SS and TFE
766 700-0029-102 2 psi @ 1500 °F 316 SS and Alumina
767 700-0029-103 2 psi @ 1500 °F 316 SS and Alumina
768 700-0029-104 2 psi @ 1500 °F 316 SS and Alumina
769 700-0029-105 2 psi @ 1500 °F 316 SS and Alumina
770 700-0029-106 2 psi @ 1500 °F 316 SS and Alumina
777 700-3201-001 200 psi @ 250 °F 316 SS 3A Approved PEEK
Electronics
0Integral (No Cable)
1Remote w/ Out Cable
2Remote w/ 5 Ft Gp Cable
3Remote w/ 10 Ft Gp Cable
4Remote w/ 15 Ft Gp Cable
5Remote w/ 20 Ft Gp Cable
6Remote w/ 25 Ft Gp Cable
7Remote w/ 35 Ft Gp Cable
8Remote w/ 50 Ft Gp Cable
9Remote w/ 75 Ft Gp Cable
ARemote w/ 100 Ft Gp Cable
BRemote w/ 150 Ft Gp Cable
CRemote w/ 5 Ft Hi Temp Cable
DRemote w/ 10 Ft Hi Temp Cable
ERemote w/ 15 Ft Hi Temp Comp Cable
FRemote w/ 20 Ft Hi Temp Comp Cable
GRemote w/ 25 Ft Hi Temp Comp Cable
HRemote w/ 50 Ft Hi Temp Comp Cable
IRemote w/ 75 Ft Hi Temp Comp Cable
JRemote w/ 100 Ft Hi Temp Comp Cable
KRemote w/ 150 Ft Hi Temp Comp Cable
Technology
Z4 Z-tron IV RF Admittance Level Measurement System
Input Power
124 VDC
2115 VAC, Field Selectable
3230 VAC, Field Selectable
* temperatures > 300 °F require a 6" cooling extension
Process connection (XX)
A0 3/4" NPT
B0 1" NPT
C2 1-1/2”TriClamp 316 SS (3A)
E2 2”TriClamp 316 SS (3A)
H2 2-1/2” TriClamp 316 SS (3A)
J2 3”TriClamp 316 SS (3A)
L2 4”TriClamp 316 SS (3A)
BA 1" 150# RF Carbon Steel
BB 1" 150# RF 316/316L Stainless Steel
CA 1" 300# RF Carbon Steel
CB 1" 300# RF 316/316L Stainless Steel
FA 2" 150# RF Carbon Steel
FB 2" 150# RF 316/316L Stainless Steel
GA 2" 300# RF Carbon Steel
GB 2" 300# RF 316/316L Stainless Steel
IA 3" 150# RF Carbon Steel
IB 3" 150# RF 316/316L Stainless Steel
JA 3" 300# RF Carbon Steel
JB 3" 300# RF 316/316L Stainless Steel
KA 4" 150# RF Carbon Steel
KB 4" 150# RF 316/316L Stainless Steel
LA 4" 300# RF Carbon Steel
LB 4" 300# RF 316/316L Stainless Steel
XX* Many more options available upon request (ASME/ANSI, DIN)
* Consult Factory

Installation
3
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 + 215-674-1234.
2.2 Mounting the Level Control
The Z-tron IV Level Control is available with the
electronic unit and sensing element as a single integral
assembly. Extended sensing element lengths and special
mountings can be provided to t specic applications.
• The Z-tron IV Level Control is designed for industrial
applications, but it should be mounted in a location as
free as possible from vibration, corrosive atmospheres,
or any possibility of mechanical damage.
• For convenience when adjusting, place the electronic
unit in a reasonably accessible location. Ambient
temperature should be between -40°F and 145°F (-40°C
to 63°C).
• It may be mounted either vertically or horizontally.
Conduit runs must avoid moisture inltration into the
housing and conduit. See Figures 2-1.
Note: The 700-0001-018 and 700-0001-022 are designed
for vertical mounting only
• 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.
• When installing ange-mounted sensing elements, keep
mating surfaces and bolts free of paint and corrosion to
ensure proper electrical contact with vessel. Avoid using
excessive amounts of TFE tape when installing threaded
sensing elements.
• When installing sensing element with threaded connection,
place the wrench on th eats closest to the mounthing threads,
see g 2.2. For sensing elements without wrench ats a pipe
wrench can be used. Do not turn the housing or conduit.
• The recommended minimum Cote Shield length is to extend
2” into the vessel past the anticipated wall build-up. Consult
factory before mounting the instrument with shorter Cote
Shield lengths
• Protect the insulation on the sensing element against
cuts and scrapes during installation.
Figure 2-3 provides typical mounting dimensions.

4
Z-tron IV TM Point Level Control
WRONG CORRECT
Conduit
Breather
Drain
All Connections Sealed
and Gaskets In Place
WRONG CORRECT
CONDULET
Packing
Gland
Assembly
Do Not
Disturb!
Hold here when
tightening
Condulet
Hold here to install
or remove Sensing
Element from
Vessel
Figure 2-1
Z-tron IV Level Control Mounting Recommendations
2.2 Mounting the Level Control (continued)
Figure 2-2
Z-tron IV Level Control Installation Guidelines
WRONG CORRECT
Conduit
Breather
Drain
All Connections Sealed
and Gaskets In Place
WRONG CORRECT
CONDULET
Packing
Gland
Assembly
Do Not
Disturb!
Hold here when
tightening
Condulet
Hold here to install
or remove Sensing
Element from
Vessel

Installation
5
2.3 Integral Mounting Dimensions
Figure 2-3-1
Mounting Dimensions

6
Z-tron IV TM Point Level Control
2.4 Remote Mounting Dimensions
Figure 2-3-2
Mounting Dimensions

Installation
7
2.5 3A Probe Mounting Dimensions
Figure 2-3-3
3A Mounting Dimensions
Insertion Length Limited to 12"
Insertion Length Limited to 36"
For Longer Lengths Contact Factory

8
Z-tron IV TM Point Level Control
2.6 Power Wiring
CAUTION
Do not make/break any electrical connections without
rst disconnecting electrical power at the source.
Ensure that wiring, electrical ttings and conduit
connections conform to the electrical codes for the
specic location.
The Z-tron IV level control is a general purpose device
and is not agency approved for use in hazardous
locations. If agency approval is required, contact your
local AMETEK Drexelbrook representative or call
1-215-674-1234.
Refer to Figures 2-4-1 and 2-4-2 for the appropriate power
wiring and use the following procedure to wire the Z-tron IV
level control:
1. Ensure that all power to the wiring is off.
2. Remove the cover.
3. The power connections are made to terminals 1, 2, and 3
on the electronic chassis, using 12 gauge wire (max.).
4. 115 / 230 VAC Only (Input voltage is eld selectable)
a. Use jumpers on side of electronic chassis to select
input voltage.
b. Input voltage jumper selection must match input
voltage or electronic chassis may be damaged.
5. The alarm relays are wired as shown in Figure 2-5.
6. Review Checklist:
a. Wiring correct.
b. Input voltage matches instrument label and jumper
selection.
c. Proper output connections.
d. Use 12 gauge wire max.
7. Replace the cover prior to restoring power.
Be sure the power wiring and voltage are correct.
Improper wiring may cause permanent damage,
personal injury, and void the factory warranty!
STOP
8. Apply power.

Installation
9
2.6 Power Wiring (continued)
Figure 2-4-1
Power Wiring
Input Voltage
Selection
115 / 230 VAC
Only

10
Z-tron IV TM Point Level Control
Figure 2-4-2
Power Wiring
2.6 Power Wiring (continued)
INPUT VOLTAGE
JUMPER SELECTION
DISCONNECT POWER
BEFORE CHANGING
JUMPER SELECTION
WARNING
HIGH VOLTAGE
ELECTRICAL
SHOCK HAZARD
115 VAC 230 VAC
270-0102-079
INPUT VOLTAGE
JUMPER SELECTION
DISCONNECT POWER
BEFORE CHANGING
JUMPER SELECTION
WARNING
HIGH VOLTAGE
ELECTRICAL
SHOCK HAZARD
115 VAC 230 VAC
270-0102-079
INPUT VOLTAGE
JUMPER SELECTION
DISCONNECT POWER
BEFORE CHANGING
JUMPER SELECTION
WARNING
HIGH VOLTAGE
ELECTRICAL
SHOCK HAZARD
115 VAC 230 VAC
270-0102-079
INPUT VOLTAGE
JUMPER SELECTION
DISCONNECT POWER
BEFORE CHANGING
JUMPER SELECTION
WARNING
HIGH VOLTAGE
ELECTRICAL
SHOCK HAZARD
115 VAC 230 VAC
270-0102-079
JUMPER POSITION
JUMPER POSITION

Installation
11
2.7 Relay Wiring
Refer to Figure 2-5 for the relay contact wiring. The Z-tron
IV 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. All relay
connections are made to the terminal strip on the electronic
unit. Refer to Figure 3-1 for the Fail Safe Selector Switch
location.
Figure 2-5
Relay Wiring
HLFS Switch
Up = High Level Fail Safe
HLFS Switch
Up = High Level Fail Safe
LLFS Switch
Down = Low Level Fail Safe
LLFS Switch
Down = Low Level Fail Safe
4 5 6 7 8 9
4 5 6 7 8 9
HLFS Switch
Up = High Level Fail Safe
HLFS Switch
Up = High Level Fail Safe
LLFS Switch
Down = Low Level Fail Safe
LLFS Switch
Down = Low Level Fail Safe
4 5 6 7 8 9
4 5 6 7 8 9
High Level Fail Safe
Low Level Fail Safe

12
Z-tron IV TM Point Level Control
Figure 2-6
Wiring the Remote Sensing Element
2.8 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.
See Figure 2.6 / 2.7.
NOTE
It is important that the sensing element cable is
mechanically separated from the power wiring.
When installing remote-mount electronics, you must use
the Drexelbrook supplied coaxial cable. The cable can be
a maximum of 150 feet (46 meters). Termination kits are
available to shorten the cable if necessary.
Drexelbrook, Coaxial
General Purpose (GP),
Three Terminal, Cable

Installation
13
2.9 Wiring the Sensing Element (Integral)
NOTE
It is important that the sensing element cable is
Mechanically separated from the power wiring.
Figure 2-7
Wiring the Integral Sensing Element

14
Z-tron IV TM Point Level Control
Section 3: Operation
This section describes the operating switches of the Z-tron
IV level control. Remove the dome lid and use a small
screwdriver to set the operating controls.
The green LED (on) indicates power is applied to the unit.
3.1 Setpoint Control
There is a single operating point adjustment used to control
the level at which the relay operates. See Figure 3-1.
This adjustment is an 20-turn potentiometer and does
not have a mechanical stop. When in High Level Fail
Safe condition, if the red light (LED) is OFF - turn
CCW to nd SP (relay changes state w/click & light
turns ON)... turn CW if red light (LED) is initially ON.
In Low Level Fail Safe turn the setpoint adjustment in
the opposite direction.
• Turning the setpoint adjustment clockwise (CW) raises
the level at which the relay operates.
• Turning the setpoint counterclockwise (CCW) lowers the
level at which the relay operates.
• The red LED (on) indicates that the relay is de-
energized and the unit is in the alarm condition.
Figure 3-1
Z-tron IV Operating Controls and LED
Fail Safe Selector Switch
(Up= High Level Fail Safe Down= Low Level Fail Safe)
Time Delay Selector Switch
(Up= Forward Acting Down= Reverse Acting)
Setpoint Adjustment
(Clockwise Increases Level)
Green Power LED
Red Alarm LED
Time Delay Adjustment
(Clockwise Increases Delay)