Milton Roy YZ Systems NJEX 6300G-PM Parts list manual

NJEX 6300G
PoleMounted
N A T U R A L G A S O D O R I Z A T I O N S Y S T E M

T HE NJEX 6300G
P OLE M OUNTED
I NSTRUCTION & O PERATING M ANUAL
Version: NJEX6300G-PM 04142004

YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
Page INJEX 6300G ver.092001 • pub. no. 37300
6300G T6300G T
6300G T6300G T
6300G TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF CC
CC
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
6300G T6300G T
6300G T6300G T
6300G TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF CC
CC
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
6300G Table of Contents ..................................................................................................................I
Section 1: First Things To Know About The 6300G .....................................................................1
How to Use this Manual.......................................................................................................................1
Typographic Conventions....................................................................................................................1
GettingHelp.........................................................................................................................................1
Operation Specifications .....................................................................................................................2
Warranty..............................................................................................................................................2
Theory of Operation ............................................................................................................................3
System Accessories ...........................................................................................................................3
Section 2: System Installation.........................................................................................................5
Standard System Components...........................................................................................................5
System Flow Schematic .....................................................................................................................6
Standard System Mounting .................................................................................................................7
Standard System Connections ...........................................................................................................8
Skid System Components ................................................................................................................10
System Flow Schematic ...................................................................................................................12
Skid System Mounting.......................................................................................................................13
Skid System Connections.................................................................................................................14
Section 3: Filling the Bulk Odorant Tank ....................................................................................17
Filling the Tank for the First Time.......................................................................................................17
Refilling the Bulk Odorant Tank .........................................................................................................18
Section 4: System Control & Electronics ....................................................................................19
Overview ...........................................................................................................................................19
To Use The Key Pad .........................................................................................................................19
To Power Up The System .................................................................................................................20
Test & Standby Keys .........................................................................................................................21
Battery & Solar PanelAssembly........................................................................................................22
LPS and Battery w/Cover Removed .................................................................................................22
Solar Panel........................................................................................................................................22
SPS and Battery w/Cover Removed.................................................................................................22
Communications Interface ................................................................................................................23
Comm-Link Configuration .................................................................................................................23

YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
Page II NJEX 6300G ver.092001 • pub. no. 37300
6300G T6300G T
6300G T6300G T
6300G TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF CC
CC
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
Section 5: Programming for Proportional-to-Flow Operation ...................................................25
Setting Operator Input Parameters ...................................................................................................25
Odorant injection rate in lbs/MMCF (mg/m3) of gas..........................................................................25
Pump displacement in cc/stroke.......................................................................................................25
Odorant density in lbs/gallon (g/cc) @ 60º F.....................................................................................25
Max gas flow in MMCF/Hour (m3/sec) ..............................................................................................26
Low Flow Shut Off.............................................................................................................................26
Flow (no signal) input ........................................................................................................................26
MaximumTime/Stroke.......................................................................................................................27
The Odorant Output Setting ..............................................................................................................27
Odorant Tank.....................................................................................................................................28
ExpansionTank Pressure Monitoring ................................................................................................28
Odorant Inlet Pressure Monitoring.....................................................................................................29
Alarm to Relay Delay.........................................................................................................................30
Alarm to Call Out Delay.....................................................................................................................30
MODBUSAddress ............................................................................................................................30
MODBUS Parameters.......................................................................................................................31
Conclusion ........................................................................................................................................31
Section 6: Programming for Proportional-to-Time Operation ..................................................33
Setting Operator Input Parameters ...................................................................................................33
Pump displacement in cc/stroke.......................................................................................................33
Odorant density in lbs/gallon (g/cc.) @ 60ºF.....................................................................................33
Time interval between strokes of the pump in xx.xx minutes/stroke:.................................................33
The Odorant Output Setting ..............................................................................................................34
Odorant Tank.....................................................................................................................................34
ExpansionTank Pressure Monitoring ................................................................................................35
Odorant Inlet Pressure Monitoring.....................................................................................................35
Alarm to Relay Delay.........................................................................................................................36
Alarm to Call Out Delay.....................................................................................................................36
MODBUSAddress ............................................................................................................................37
MODBUS Parameters.......................................................................................................................37
Conclusion ........................................................................................................................................38
Section 7: Calibrating Signal Inputs ............................................................................................39
Analog Flow Input Calibration, 1-5 VDC / 4-20 mA ............................................................................39
Expansion Tank Pressure Transmitter Zero Calibration ....................................................................41
Odorant Inlet Pressure Transmitter Zero Calibration.........................................................................42
Pulse Flow Input Calibration, Dry Contact & Voltage Pulse...............................................................44
Calculation for Determining the Span Frequency Example ...............................................................45

YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
Page IIINJEX 6300G ver.092001 • pub. no. 37300
6300G T6300G T
6300G T6300G T
6300G TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF CC
CC
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
Section 8: Working with the N-300 System Displays ..................................................................47
DisplayFunctionality .........................................................................................................................47
To View Real Time Displays ..............................................................................................................48
Strokes Signaled .........................................................................................................................48
Odorant Injected ..........................................................................................................................48
Pump Displacement....................................................................................................................48
Pump Alarms............................................................................................................................48
MeterLevel–Verometer..............................................................................................................49
MeterAlarms – Verometer ........................................................................................................49
MeterIndicators,non-alarm......................................................................................................49
ExpansionTank ...........................................................................................................................50
OdorantInlet................................................................................................................................50
BatteryVoltage ............................................................................................................................50
BatteryAlarm ............................................................................................................................50
FlowInput ....................................................................................................................................50
Flow InputAlarms .....................................................................................................................50
Flow Input Indicators, non-alarm ..............................................................................................50
TankLevel....................................................................................................................................51
TankLevelAlarm.......................................................................................................................51
Odorant Temperature ..................................................................................................................51
Section 9: Setting & Testing Alarms ............................................................................................53
Setting Alarm Out Status ...................................................................................................................53
Testing Alarm Out Status...................................................................................................................55
Setting The Clock..............................................................................................................................58
Section 10: Mechanical System....................................................................................................61
Overview ...........................................................................................................................................61
Odorant Inlet Manifold & Bulk Odorant FilterAssembly .....................................................................62
FillValve ............................................................................................................................................62
Verometer..........................................................................................................................................63
Model 6000 Pump .............................................................................................................................64
Odorant Discharge Manifold..............................................................................................................64
NJEXGasFilter.................................................................................................................................65
Solenoid Valve & Pneumatic Relay Manifold .....................................................................................66
ExpansionTank .................................................................................................................................66
Section 11: System Operation ......................................................................................................67
Setting System Pressures and Valves ..............................................................................................67
Low Pressure Relief Adjustment .......................................................................................................67
Starting The System..........................................................................................................................68
To Stop The System ..........................................................................................................................69

YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
Page IV NJEX 6300G ver.092001 • pub. no. 37300
6300G T6300G T
6300G T6300G T
6300G TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF CC
CC
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
Section 12: System Maintenance .................................................................................................71
PreventativeMaintenanceSchedule .................................................................................................71
Recommended Maintenance Schedule ......................................................................................71
Weekly Inspection ....................................................................................................................71
Semi-AnnualInspection............................................................................................................71
AnnualInspection .....................................................................................................................71
Bi-AnnualInspection.................................................................................................................71
Recommended Spare Parts List.................................................................................................71
Overflow Protector Assembly Inspection ..........................................................................................72
Low Pressure Relief Adjustment .......................................................................................................73
Conducting a Forward Purge ............................................................................................................74
Venting Pressure Gas .......................................................................................................................76
FillingtheVerometer..........................................................................................................................78
Priming & Starting the NJEX System ................................................................................................80
Section 13: 6300G System Troubleshooting ...............................................................................83
How to Use This Section...................................................................................................................83
ForAdditional Help.......................................................................................................................83
Step-by-StepResolution ..............................................................................................................83
Tank LevelAlarms .............................................................................................................................83
Tank LevelAlarm Troubleshooting Steps .....................................................................................84
BatteryAlarm.....................................................................................................................................84
BatteryAlarm Troubleshooting Steps ..........................................................................................84
SignalAlarms ....................................................................................................................................85
SignalNon-AlarmIndicators..............................................................................................................85
SignalAlarm & Non-Alarm Indicator Troubleshooting Steps .......................................................85
Loss of Flow Alarm Troubleshooting Steps ..............................................................................85
OverflowAlarm Troubleshooting Steps.....................................................................................85
Low Flow Non-Alarm Indicator Troubleshooting Steps .............................................................86
Overflow Non-Alarm Indicator Troubleshooting Steps ..............................................................86
VerometerAlarms..............................................................................................................................86
Verometer Non-Alarm Indicators ......................................................................................................87
Verometer Troubleshooting Steps ...............................................................................................87
Verometer CableAlarm Troubleshooting Steps ........................................................................87
Verometer No-FillAlarmTroubleshooting Steps .......................................................................87
Verometer Slow-Fill Alarm IssuesTroubleshooting Steps ........................................................88
Verometer LeakageAlarm Troubleshooting Steps....................................................................88
Verometer Fill Valve FailureAlarm Troubleshooting Steps........................................................89
Verometer Odorant Inlet CableAlarm Troubleshooting Steps...................................................89
Verometer Odorant Inlet LowAlarm Troubleshooting Steps .....................................................90
Verometer Odorant Inlet HiAlarm Troubleshooting Steps.........................................................90
Verometer Expansion Tank CableAlarm Troubleshooting Steps..............................................90
Verometer Expansion Tank LowAlarm Troubleshooting Steps.................................................90
Verometer ExpansionTank HighAlarm Troubleshooting Steps ................................................91
Verometer Overfill Non-Alarm Indicator Troubleshooting Steps ................................................91
Verometer Fill Rate Non-Alarm Indicator Troubleshooting Steps ..............................................91

YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
Page VNJEX 6300G ver.092001 • pub. no. 37300
6300G T6300G T
6300G T6300G T
6300G TABLEABLE
ABLEABLE
ABLE
OFOF
OFOF
OF CC
CC
C
ONTENTSONTENTS
ONTENTSONTENTS
ONTENTS
Section 13: 6300G System Troubleshooting continued
Pump Alarms.....................................................................................................................................91
Pump Over Pumping Alarm Troubleshooting Steps .................................................................92
Pump Under PumpingAlarm Troubleshooting Steps ...............................................................92
Pump FailureAlarm Troubleshooting Steps .............................................................................93
AppendixA: Illustrations................................................................................................................95
NJEX Model 6000 PumpAssembled.................................................................................................95
NJEX Model 6000 PumpActuationAssembly, Exploded View...........................................................96
NJEX Model 6000 Pump, Check ValveAssemblies and Seals, Exploded View ................................97
FillValve,ExplodedView ...................................................................................................................98
VM-1000 Verometer, with FilterAssembly, Exploded View ................................................................99
Bulk Odorant Filter ..........................................................................................................................100
NJEXGasFilter...............................................................................................................................101
Electronics Assembly......................................................................................................................102
SPS-12 Solar Power Supply Unit ....................................................................................................103
LPS-120/240 Charger Supply Unit ..................................................................................................104
Heater Wiring Diagrahm (Optional).................................................................................................105
Appendix B: N-300 Modbus Specifications ...............................................................................107
Communications Settings...............................................................................................................107
N300 Modbus Function Support ................................................................................................107
Boolean Registers.....................................................................................................................107
Control Functions ......................................................................................................................107
Status Functions .......................................................................................................................108
Alarm Functions ........................................................................................................................109
Integer Registers .......................................................................................................................110
Result Data Functions............................................................................................................110
Parameter functions..................................................................................................................112
Exception Responses ............................................................................................................... 112
Appendix C: Response Forms.....................................................................................................113
For the Reocrd Form ......................................................................................................................113
NJEX Trouble Shooting Form ..........................................................................................................114
Appendix D: Documents............................................................................................................... 115
N-300 Controller Display Diagram................................................................................................... 115
Wiring Control Document................................................................................................................116