Monitor PZP Guide

PZP Vibratory Level Sensor
BULLETIN
524A
I N S T A L L A T I O N & O P E A T I O N
®
Thank you for purchasing a quality product from Monitor Technologies
LLC. We realize that you do have a choice of vendors when procuring
vibratory level sensors and we sincerely appreciate your business!
This manual contains the information necessary to ensure a safe and
successful installation. Please read and comply with the section on page
6 of this manual pertaining to SAFETY. Doing so will ensure proper oper-
ation of the equipment and the safety of all personnel.
Before discarding shipping container, please inspect it thoroughly and
verify that all parts ordered are accounted for. Sometimes smaller parts
become stuck under carton flaps and other packaging materials.
In the event that information contained herein does not completely sat-
isfy your requirements or answer your questions, you may contact
Technical Support on our website www.monitortech.com, by telephone
at 800-766-6486 (630-365-9403), or by fax at 630-365-5646. If your
sensor ever requires service either in or out of warranty, please contact
us and obtain an RMA number prior to shipping the unit to us.
M o d e l P Z P
www.monitortech.com

PRE - I N S ALL A ION CON S I D E R A IONS
2
Choosing a Location: (See Figure 2)
1) Material Flow - When selecting a location for the PZP,
choose a point in the vessel where the probe will be out of
the direct flow of incoming and outgoing material to prevent
any mechanical damage that may be caused by the pres-
sure of the flow (see section regarding Protective Baffles).
The PZP must be positioned at a point where incoming
material will reach and cover the probe in its normal flow,
and when receding, will flow away from the probe in an even
manner. Choose a position where a majority of the probe
(not just the tip) will be covered. This is particularly important
when detecting materials with low densities.
2) Vessel Interference - Select an area where the probe will
not come in contact with internal structures of the vessel.
When using the flexible cable extension probe, consider the
angle of repose of the material. Insure that the swing of the
cable will not allow the probe to touch the vessel wall during
filling or emptying.
3) Pipe Extension einforcement - When top mounting a
probe with a pipe extension, select a location where it is fea-
sible to reinforce the extension to the vessel wall. See
Mechanical Installation for further details.
Probe Mounting: (See Figure 2)
1) Coupling Mount - Cut a hole into the vessel that corre-
sponds to the outer diameter of a 1-1/2" pipe coupling.Note 1
Position a half coupling flush with the inside of the vessel
and weld into place. Thread the PZP into the coupling and
tighten using the wrench flats provided on the probe. Do not
tighten by rotating the housing. Pipe joint sealant or Teflon®
tape may be used to achieve pressure sealing capability if
desired.
2) Probe Orientation - On side mount applications, tighten so
that the diamond shape is positioned vertically. This is
achieved when the two “grooves” in the hexagonal flats are
re-aligned vertically.
3) Housing Orientation - On side mount applications, if the
housing is positioned without the wire entrances in a down-
ward position, orientate the housing as follows:
-Remove cover. Loosen (do not remove) the screw that is
visible through the hole in the center of the circuit board.
-Rotate the housing to the desired position.
-Tighten the screw in the center of the circuit board.
Replace the cover.
MECH A N I C AL I N S ALL A ION
Protective Baffles: (See Figure 2)
The PZP is a sensitive level sensing instrument. Therefore,
particular attention should be given to assure that the mechan-
ical construction of the probe is not damaged by material.
Probe deflection (bending) as little as 1/16 inch (1.5mm) can
render the probe inoperative. Failure to properly protect the
probe will invalidate the warranty. Install a protective baffle
above side mounted probes. The baffle can be created using a
number of materials including angle irons, welded plates and
pipe sections. It should be securely mounted to the vessel wall
and should extend the full length of the probe. The lowest part
of the baffle should be 4 to 6 inches (101.6 to 152.4 mm) above
the upper edge of the probe.
Figure 2
Figure 1
DIMENSIONS A E SHOWN IN INCHES WITH MILLIMETE EQUIVALENT IN B ACKETS
Note 1: Mounting should be a 1-1/2” NPSC pipe coupling (which is a
straight thread coupling) and mounted per the illustration. Use of an
NPT (tapered pipe thread) type coupling or flange is not recommended
unless the minimum inside diameter is greater than 1.734”.

3
Pipe Extension einforcement: (See Figure 3)
Mechanical reinforcement of the pipe extension should be con-
sidered whenever installing a probe length greater than 72
inches (1829 mm). The pipe extension should be anchored to
the side wall with braces to reduce mechanical stress at the
connection point of the extension and to protect the PZP from
damage. When bracing, never weld or drill into the pipe exten-
sion since the electrical wires within the extension may be dam-
aged. Use mechanical clamping techniques.
Figure 3
Hi-Temp/ emote Electronics Models: (See Figure 4)
1) Probe Mounting - Follow instructions as earlier stated in
this section. Note that the hi-temperature/remote electronics
PZP has been completely assembled at the factory to insure
performance and assembly integrity. This may cause some
installation inconveniences as the electronic portion of the
assembly will require simultaneous rotation as the probe is
installed.
2) emote Electronics - This portion is connected to the
probe via a 6 foot (1829 mm) flexible conduit. Mount the
remote electronics to a structure away from the heat or
vibration being avoided. Position the wire entrances such
that the risk of moisture infiltration is minimized. Reference
the hole pattern of the mounting plate and securely fasten
into place.
Figure 4
Remove the housing cover to access all electronics. All wires
shall be routed through the cord connector provided. If neces-
sary, refit the connection with a 1/2" NPT fitting (steel is rec-
ommended since minor rethreading is required).
Factory Wiring:
The PZP probe wires are connected to the frontside of the
PCB. DO NOT alter this connection. Doing will likely cause
improper operation of the sensor.
Permanently Connected Equipment:
Disconnecting devices shall by included in the system installa-
tion. In installations were multiple circuits are used (i.e. inde-
pendent circuits for power input and output relay), individual
disconnects are required. The disconnects shall be within
close proximity of the equipment, accessible to operators, and
marked appropriately as the disconnect for the associated cir-
cuit. Assure the disconnect ratings are appropriately sized for
the circuit protected (See Specifications).
Protective Earthing:
Each PZP is provided with a "protective conductor terminal"
which shall be terminated to the local earth ground potential to
eliminate shock hazard in the unlikely event of internal insula-
tion breakdown. Select wire size that can carry in excess of the
sum of all circuit's maximum amperage.
Power Input: (See Figure 5)
The PZP is designed with a universal power supply that can
accept a wide range of AC and DC voltages (see Specifications
to insure compatibility). Select wire size that can deliver suit-
able voltage and current for the application. Connect power as
shown in Figure 5.
Output Contact Connections:
The PZP is equipped with two sets of isolated contacts (DPDT)
which indicates whether or not material is being detected within
the vessel. This output is also influenced by the selection of the
"fail-safe" jumper as described in the "Setup" section of this
manual. The designations on the circuit board relate to the
contact status when the material is "not" sensed and the fail-
safe jumper is in the "low" (FL) mode. These contacts can be
connected to any type of control device, provided that ratings
are observed (See Specifications). Select wire size that can
deliver suitable voltage and current for the application.
ELEC RIC A L I N S AL L A IO N
Figure 5

4
Figure 6
Figure 7
Complete set-up of the PZP is accomplished by two functions:
sensitivity and fail-safe. Each application can be adjusted inde-
pendently for optimum operation.
Sensitivity: (See Figure 6)
Select sensitivity based on application as shown below.
1) Position A - For materials ≥ 1.5 lb/ft3 (24 kg/m3)
2) Position B - For materials ≥ 10 lb/ft3 (160 kg/m3)
3) Position C - For materials that have caused false signals
due to probe coating in Position B. Use only as a last resort.
ed LED: (See Figure 7)
The red LED indicates the status of the output relay which is
dependent on material sensing and fail-safe selection. Refer to
Figue 7.
Fail-Safe: (See Figure 7)
Selection of the fail-safe mode will permit the output contacts to
be signaled in a manner which assures proper control of loads
in the event of power failure. Select fail-safe mode based on
which condition is most critical to signal (high level or low level).
1) FH - When no material is sensed, the relay will be ener-
gized. The relay will de-energize when material is sensed, or
if power failure occurs.
2) FL - When material is sensed, the relay will be energized.
The relay will de-energize when no material is sensed, or if
power failure occurs.
P OBLEM: Sensor will not sense material.
CAUSE/SOLUTION:
1) Verify power is applied to the sensor.
2) Verify sensitivity setting. Position sensitivity switch in posi-
tion “A” therefore making the probe more sensitive to “diffi-
cult to sense” materials.
SE UP
RO U BLES H O O I N G
3) Verify probe coverage when sensing is expected. The sen-
sor is not designed to be “tip sensitive”. Permit significant
probe coverage before expecting material sensing.
4) Verify electrical connection between the probe and circuit
board. The red wires should be connected to the “T” and “R”
terminals. The black wire should be connected to the GND
terminal.
P OBLEM: Sensor remains in “DETECT” mode even when
material is absent.
CAUSE/SOLUTION:
1) Verify the probe is not in direct contact with any internal ves-
sel structure. If so reposition sensor.
2) Verify sensitivity setting. Position sensitivity switch in posi-
tion “B” therefore making the probe less sensitive to “easy to
sense” materials and more immune to material buildup. If
problems continue, select Position C.
3) Verify material buildup on probe. Product buildup across the
probe surface or between the probe and vessel wall may
create false detection. Clean probe if necessary.
P OBLEM: Output contacts perform opposite of designa-
tions (N/O, N/C).
CAUSE/SOLUTION:
1) Designations on the PCB relate to relay status when in “Fail-
safe Low” (FL) mode and when no material is sensed. When
in “Fail-safe igh” (F ) mode and when no material is
sensed, the designations are reversed. Swap wire termina-
tions of N/O and N/C if necessary. Changing the fail-safe
selection is not recommended unless fail-safe feature is not
a concern to the application.

5
M EC H A NI C A L S
DIMENSIONS A E SHOWN IN INCHES WITH MILLIMETE EQUIVALENT IN B ACKETS
Standard Probe
Pipe Extension Probe
Flexible Cable Extension Probe
Hi-Temp/ emote Electronics Probe
Hi-Temp/ emote Electronics Probe With Pipe Extension
The PZP is a maintenance-free product and should be serviced
by Monitor Technologies LLC only. If operation appears inap-
propriate, refer to the Troubleshooting section of this bulletin. If
proper operation is not achievable, consult the factory.
M AI N E N A NC E
1 1/2” NPT

BULLETIN
524
Monitor Technologies LLC
44W320 Keslinger Rd.
t
Elburn, IL 60119
t
630-365-9403
t
800-766-6486
t
Fax: [phone]
t
www.monitortech.com
S A FE Y
General Safety
CAUTION: It is essential that all instructions in this manual be
followed to ensure proper operation of the equipment and safe-
ty of operating personnel. The use of this symbol is used
throughout manual to highlight important safety issues. Please
pay particular attention to these items.
Electrical Shock Caution
Certain PZPs are powered with IG VOLTAGE. No operator
serviceable parts are inside. All servicing is to be performed by
qualified personnel. Each PZP is provided with a "protective
conductor terminal" ddwhich shall be terminated to earth
ground potential (See Electrical Installation). This product's
design complies with EN61010-1 installation category II and
pollution degree 2.
Electromagnetic Compatibility (EMC)
The PZP was tested and found to comply with the standards listed below.
The PZP should not be used in residential or commercial environments.
Compliance to EMC standards was demonstrated by means of a test
setup using the following installation methods.
1) PZP enclosure was connected to earth ground (protective earth).
2) No specific wiring convention was used to supply power or
to retrieve output signal from the PZP.
EMC Emissions:
Meets EN 61326-1 Electrical Equipment for Control Use, EMC
EN 55011 Radiated and conducted emissions
(Class A- industrial)
EN 61000-3 Fluctuations/Flicker
Meets FCC Part 15B: RF Devices, Unintentional Radiators
CISPR 11 Radiated and conducted emissions
(Class A- industrial)
EMC Immunity:
Meets EN 61326-1 Electrical Equipment for Control Use,
EMC
IEC 1000-4-2 Electrostatic discharge (industrial)
IEC 1000-4-3 RF radiated EM fields (industrial)
IEC 1000-4-4 Electrical fast transients (industrial)
IEC 1000-4-5 Electrical surges (industrial)
IEC 1000-4-6 RF conducted EM energy (industrial)
IEC 1000-4-8 Power frequency magnetic fields
(industrial)
IEC 1000-4-11 Source voltage deviation
Power Requirements: Universal 20 – 250 VAC 50/60 z
20 – 250 VDC
Power Consumption: 3 VA max.
Ambient Temp. Electronics: -22˚ F to 140˚ F (-30˚ C to 60˚ C)
Internal Bin Temperature:
Standard models: -22˚ F to 176˚ F (-30˚ C to 80˚ C)
igh Temp. models: -22˚ F to 302˚ F (-30˚ C to 150˚ C)
Output Relay: DPDT dry contact;
5 amps @ 250VAC max
Sensitivity: 1.25 lb/ft3(20 kg/m3)
minimum material density
Jumper selectable -
A ( igh >1.25 lb/ft3) (20 kg/m3)
B (Medium >10 lb/ft3)(160 kg/m3) or
C (Low, product build-up applications)
Time Delay: old-off, fixed delay of 1 second
old-on, fixed delay of 2-5 seconds
Fail-Safe: Jumper selectable
(high - F , low - FL)
Operating Frequency: 280 z
Enclosure: Die cast alum. beige powder coat;
NEMA 4; IP65
Probe/Gland Material: 304 stainless steel
Process Connection: 1-1/2" NPT (PZP); 1-1/2” NPSC (Vessel)
Pressure Rating: 150 PSI (10.4 bar)
Wire Entry: M20 x 1.5 cablegland,
remove for 1/2" NPT
Indicator: Red LED – Status dependent on material
sensing and fail-safe selection.
Solid Extension: 1" pipe, 304ss, 12' (3.6m) length max.
(customer specified length)
Cable Extension: Polyurethane sheathed,
steel rope reinforced; 20' (6.1m)
length max. (customer specified length)
Interconnection Distance: 6' (1.8m factory installed flexible conduit
(high temp models)
Weight: 4.5 lb (2 kg) (standard model only)
Approvals:
Monitor Technologies LLC warrants each PZP vibratory point
level sensor it manufactures to be free from defects in material
and workmanship under normal use and service within two (2)
years from the date of purchase. The purchaser must give
notice of any defect to Monitor within the warranty period,
return the product intact and prepay transportation charges.
The obligation of Monitor Technologies LLC under this warran-
ty is limited to repair or replacement at its factory. This warranty
shall not apply to any product which is repaired or altered out-
side of the Monitor Technologies LLC factory, or which has
been subject to misuse, negligence, accident, incorrect wiring
by others or improper installation. Monitor Technologies LLC
reserves the right to change the design and/or specifications
without prior notice.
SPECIFICA IONS
WARRAN Y
GDR JSC SEP 30 2016 DOC-001-524A 12
C INA Ro S 2