Ametek 502-3000 Series User manual

[phone] Outside North America
1-800-553-9092 US and Canada
www.drexelbrook.com
[e-mail]
Leader in
Level Measurement
For Assistance Call 1-800-527-6297
Outside North America 1-215-674-1234
Installation and
Operating Instructions
Series 502-3000
ZtronTM Level Control
using 402-3000 Electronics
•502-3000
•502-3200
•502-3300
•502-3400
•502-3500
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

EDO #1-99-242
502-3000-LM
Series 502-3000
ZtronTM Level Control
using 402-3000 Electronics
•502-3000
•502-3200
•502-3300
•502-3400
•502-3500
205 Keith Valley Road Horsham, PA 19044
US Sales 800-553-9092
24 Hour Service 800-527-6297
International 215-674-1234
Fax [phone]
E-mail [e-mail]
Web www.drexelbrook.com
An ISO 9001 Certified Company
DREXELBROOK

EDO #1-99-242
502-3000-LM
Table of Contents
SECTION 1 INTRODUCTION .......................................................................................... 1
1.1 System Description .................................................................................................... 1
1.2 Model Number ........................................................................................................... 2
SECTION 2 INSTALLATION .......................................................................................... 3
2.1 Unpacking .................................................................................................................. 3
2.2 Mounting the Level ontrol ..................................................................................... 3
2.3 Power Wiring ............................................................................................................. 8
2.4 Wiring the Relays .................................................................................................... 14
2.5 Wiring the Sensing Element (Integral).................................................................. 15
2.5.1 Spark Protector for Integral Units............................................................... 16
2.6 Wiring the Sensing Element (Remote)................................................................... 17
2.6.1 Spark Protector for Remote Units ................................................................ 19
SECTION 3 OPERATION ................................................................................................ 20
3.1 Setpoint ontrol....................................................................................................... 20
3.2 Time Delay ontrol (optional)................................................................................. 21
3.3 Failsafe Selector....................................................................................................... 21
3.4 Start-up .................................................................................................................... 22
SECTION 4 CALIBRATION ........................................................................................... 23
4.1 alibration in onducting Material ....................................................................... 23
4.2 alibration in Insulating Material (Horizontal Mount) ....................................... 23
4.3 alibration in Insulating Material (Vertical Mount) and 502-3000-918 in
onducting Materials .............................................................................................. 25
SECTION 5 TROUBLESHOOTING................................................................................ 27
5.1 Introduction ............................................................................................................. 27
5.2 Testing the Electronic Unit..................................................................................... 27
5.3 Testing the Sensing Element.................................................................................. 28
5.4 Testing the oaxial able....................................................................................... 30
5.5 Testing the Relay ircuits ...................................................................................... 31
5.6 Testing the Spark Protector .................................................................................... 32
5.7 Possible Problems and auses ................................................................................ 33
5.8 Factory Assistance................................................................................................... 34
5.9 Equipment Return .................................................................................................. 34
5.10 Field Service ............................................................................................................ 35
5.11 ustomer Training .................................................................................................. 35
SECTION 6 SPECIFICATIONS...................................................................................... 36

1
502-3000 Serie ZtronTM Point Level Control Introduction
SECTION 1
INTRODUCTION The instructions in this manual are for the Drexelbrook
Ztron™ Series Point Level ontrol with a 402-3000 electronic
unit (also referred to as MKII Ztron).
The label on top of the electronic unit identifies the model
number of the Ztron level control:
402-3000 402-3302 402-3020 (refer to 402-302X-LM)
402-3002 402-3400 402-3022 (refer to 402-302X-LM)
402-3200 402-3402
402-3202 402-3500
402-3300 402-3502
If there is no model number on the top label of the electronic
unit, it is a 402-2000 type Ztron and the instructions are
included in the 402-2000-LM Instruction Manual. ontact
Drexelbrook’s Service Department at 1-800-527-6297 for a
402-2000-LM.
1.1 System
Description The Drexelbrook Ztron Level ontrol (Figure 1-1) includes a
402-3000 series electronic unit and a 700 series sensing
element. ote-ShieldTM action is designed into all Ztron level
controls (except 502-3X0X-918) and enables the instrument
to ignore the effect of build-up or material coating on the
sensing element.
The 402-3000 electronic unit:
•provides double-pole double-throw dry relay contact
closure when material reaches a specific point on the
sensor. The relay contacts may be used to operate
alarms, solenoid valves, or other low power devices.
•provides an optional 0-90 second time delay for agitated
vessels.
The 700-series sensing element:
•is mounted on the tank or in the process.
•provides a change in RF admittance indicating
presence or absence of material.
•with remote-mounted electronics, the change in RF
admittance at the sensing element is transmitted to the
electronic unit through a Drexelbrook 380 Series coaxial
cable.

2
502-3000 Serie ZtronTM Point Level Control Introduction
Figure 1-1
Integral Ztron Control with Cote ShieldTM
1.2 Model Number 5 0 2 - 3 X X X - X X X Ztron Point
Level Control
Switch
Input Power:
0 - 120 Vac with relay
2 - 24 Vdc with relay
3 - 220 Vac with relay
4 - 24 Vdc isolated
5 - 12 Vdc isolated
Sen itivity:
0 - Standard Sensitivity
2 - High Sensitivity
Electronic Unit Option :
0 - Standard Electronic Unit
1 - Fixed Time Delay
2 - 0-90 Second Time Delay
Mounting:
0 - Remote
9 - Integral
Sen ing Element:
Various
;;;
;;
INSULATION
METAL
TUBE
INSULATION
INSERTION LENGTH
COTE SHIELD
LENGTH
COTE SHIELD
ELEMENT

3
502-3000 Serie ZtronTM Point Level Control Installation
SECTION 2
INSTALLATION
2.1 Unpacking arefully remove the contents of the shipping carton and
check each item against the packing list before destroying
any packing materials. If there is any shortage or damage,
report it to the factory at 1-800-527-6297 (US and anada)
or 1-215-674-1234 (International).
2.2 Mounting the
Level Control The 502-3000 Ztron Level ontrol is available with the
electronic unit and sensing element as a single integral
assembly or connected by a coaxial cable in the remote
configuration. Extended sensing element lengths and special
mountings can be provided to fit specific applications.
• The Ztron Level ontrol 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 -40oF and 145oF (-40o to 63o).
• It may be mounted either vertically or horizontally. See
Figures 2-1 and 2-2. NOTE
The 502-3000-918 model is designed for verti-
cal-mount only.
• Avoid mounting closer than 1 inch to any tank structure.
Material bridging from structure to sensing element can
cause false alarms. lose proximity to tank structure also
increases the sensing element’s standing capacitance.
• 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 Figure 2-1.
• Protect the insulation on the sensing element against cuts
and scrapes during installation.
Figures 2-3 and 2-4 provide the typical mounting dimensions
for the integral and remote units respectively.

4
502-3000 Serie ZtronTM Point Level Control Installation
Figure 2-1
Ztron Level Control
Mounting Reco endations
;
;;
;
;;
;
;;
;
;
;
GOOD
BEST
NOZZLE TOO
LONG and
COTE-SHIELD
TOO SHORT
WRONG
COTE-SHIELD MUST
EXTEND
THROUGH NOZZLE
AND WALL BUILD-UP
GOOD
NOZZLE
REMOVED
FACTORY SUPPLIED
EXTENDED COTE-SHIELD
EXTENDS THROUGH NOZZLE
AND WALL BUILD-UP
WALL BUILD-UP
DOES NOT EXTEND
PAST FIRST
INSULATOR

5
502-3000 Serie ZtronTM Point Level Control Installation
WRONG CORRECT
Conduit
Breather
Drain
DREXELBROOK
DREXELBROOK
All Connections Sealed
and Gaskets In Place
DREXELBROOK
Explosionproof and dust ignition proof
(285-1-42 OR 285-1-43 enclosures only) for
Div. 1 Class1 Groups ABCD, ClassIIGroupsEFG
Class III, NEMA-4For explosionproof
installations:
Turn off power before removing cover, locate
conduit
seals within 18 inches of housing. Install per
Drexelbrook instructions.
DREXELBROOK
Explosionproof and dust ignitionproof
(285-1-42 OR285-1-43 enclosures only) for
Div. 1 Class1 Groups ABCD, ClassIIGroupsEFG
Class III, NEMA-4For explosionproof
installations:
Turn off power before removing cover, locate
conduit
seals within 18 inches of housing. Install per
Drexelbrook instructions.
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 2-2
Ztron Level Control Installation Guidelines

6
502-3000 Serie ZtronTM Point Level Control Installation
Figure 2-3
Mounting Di ensions
Integral Ztron Level Control
All dimensions in inches (mm)

7
502-3000 Serie ZtronTM Point Level Control Installation
Figure 2-4
Mounting Di ensions
Re ote Ztron Level Control
All dimensions in inches (mm)

502-3000 Series ZtronTM Point Level Control Installation
8
2.3 Power Wiring CAUTION
Do not open the enclosure cover or make/ reak
any electrical connections without first discon-
necting electrical power at the source. Ensure
that the wiring, electrical fittings and conduit
connections conform to the electrical codes for
the specific location and hazard level.
The 502-3000 Ztron level control is not approved
for use in a hazardous location.
Refer to Figures 2-5 through 2-9 for the appropriate power
wiring drawing and use the following procedure to wire the
Ztron level control:
a. Ensure that all power to the wiring is off.
b. Remove the cover.
c. he power connections are made to terminals 1, 2, and 3
on the electronic chassis as shown in Figures 2-5 through
2-9, using 12-28 gauge wire. he Ztron level control
requires at least 1 watt of power (up to 5 watts).
d. he alarm relays are wired as shown in Figure 2-10.
e. Review Checklist:
•Wiring correct.
•Input voltage matches instrument label.
•Proper output connections.
f. Replace the cover prior to restoring power if in hazardous
area.
g. urn power on.

502-3000 Serie ZtronTM Point Level Control Installation
9
Figure 2-5
Wiring the 502-300X (120 Vac)
Electronic Unit

502-3000 Serie ZtronTM Point Level Control Installation
10
Figure 2-6
Wiring the 502-320X (24 Vdc)
Electronic Unit

502-3000 Serie ZtronTM Point Level Control Installation
11
Figure 2-7
Wiring the 502-330X (240 Vac)
Electronic Unit

502-3000 Serie ZtronTM Point Level Control Installation
12
Figure 2-8
Wiring the 502-340X (24 Vdc Isolated)
Electronic Unit

502-3000 Serie ZtronTM Point Level Control Installation
13
Figure 2-9
Wiring the 502-350X (12 Vdc Isolated)
Electronic Unit

502-3000 Serie ZtronTM Point Level Control Installation
14
2.4 Wiring the Relays Refer to Figure 2-10 for the relay contact wiring. The Ztron
relay has double-pole, double-throw (DPDT) dry contacts. The
relay serves as a switch and does not provide the power to
operate an annunciator or other equipment. All relay connec-
tions are made to the terminal strip on the electronic unit.
N. . =
Normally losed
N.O. =
Normally Open
Figure 2-10
Wiring the
Relays
LED ON
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
HIGH LEVEL
FAIL-SAFE
LED ON
TANK EMPTY
HIGH LEVEL
FAIL-SAFE
LED OFF
(ALARM)
TANK FULL
LOW LEVEL
FAIL-SAFE
LED OFF
(ALARM)
TANK EMPTY
LOW LEVEL
FAIL-SAFE
TANK FULL
HIGH LEVEL
FAIL-SAFE
HIGH LEVEL
FAIL-SAFE
LOW LEVEL
FAIL-SAFE
LOW LEVEL
FAIL-SAFE
Level Below Sensing Element
Level Above Sensing Element
Level Below Sensing Element
Level Above Sensing Element

15
502-3000 Serie ZtronTM Point Level Control Installation
Figure 2-11
Sensing Ele ent Wiring
Integral Mount
2.5 Wiring the
Sensing Element
(Integral) If the Ztron level control has the electronic unit mounted in
the same housing as the sensing element (integral mount),
the sensing element is prewired at the factory, as shown in
Figure 2-11. All of the sensing element connections are made
to the foil side of the circuit board. The shield wire (orange)
and the center wire (blue) are twisted.

502-3000 Serie ZtronTM Point Level Control Installation
16
2.5.1 Spark Protector
for Integral Units Applications involving insulating granulars and insulating
liquids may require extra spark protection against static
discharge that can damage the electronic unit. If required, a
heavy duty spark protector is available as an option and will
be prewired at the factory with integrally mounted Ztron level
controls. Figure 2-12 shows an integral Ztron control wired
with optional spark protector (377-1-24).
Figure 2-12
Ztron Level Control
Integral Unit with Spark Protection
377-1-24
RED
GREEN
BLUE
RED
ORANGE
WIRE
GREEN
WIRE BLUE
ORANGE
WIRE
SENSOR