YZ Systems NJEX 610G Parts list manual

NJEX 610G
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

NJEX 610G

Version: 06-2021

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page I NJEX 610G ver.06-2021
610G Table of Contents
610G Table of Contents......................................................................................................................I
Section 1: First Things To Know About The 610G ........................................................................1
How to Use this Manual.......................................................................................................................1
Operation Specications......................................................................................................................2
Theory of Operation.............................................................................................................................2
System Accessories ............................................................................................................................3
Section 2: System Installation.........................................................................................................4
Standard System Components............................................................................................................4
System Flow Schematic ......................................................................................................................5
Standard System Mounting .................................................................................................................6
Standard System Connections............................................................................................................7
 ......................................................................................8
Filling the Tank for the First Time.........................................................................................................8
Relling the Bulk Odorant Tank ...........................................................................................................9
Section 4: System Control & Electronics.....................................................................................10
Overview............................................................................................................................................10
....................................................11
Setting Operator Input Parameters (Z65/6.1 Controller Setup).........................................................11
....................................................13
Setting Operator Input Parameters (Z65/6.1 Controller Setup).........................................................13
 ......................................................................................................14
Overview............................................................................................................................................14
NJEX Gas Filter.................................................................................................................................15
Model 6000 pump and Actuation Gas Manifold.................................................................................16
....................................................................................................17
Preventative Maintenance Schedule.................................................................................................17
Recommended Spare Parts List........................................................................................................17
Section 9: 610G System TroubleShooting ...................................................................................18
How to Use This Section ...................................................................................................................18
Battery Test........................................................................................................................................19
Troubleshooting: Proportional-To-Time Mode ...................................................................................20
Troubleshooting: Proportional-To-Flow Mode....................................................................................22
Troubleshooting: Pump Performance................................................................................................23
 ...............................................................................................................25
NJEX Model 6000 Pump Assembled.................................................................................................26
NJEX Model 6000 Pump Actuation Assembly, Exploded View .........................................................27
NJEX Model 6000 Pump Check Valve Assemblies, and Seals, Exploded View ...............................28
NJEX Gas Filter.................................................................................................................................29
Controller (exploded).........................................................................................................................30
Wiring Control Document ..................................................................................................................31

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 1 NJEX 610G ver.06-2021
Section 1: First Things To Know About The 610G

The NJEX-610G Operations Manual is a stepby-
step guide containing the procedures needed to
work with the 610G System. The NJEX System
Series of odorizers implement the most advanced
technology available in the industry. It is recom-
mended that the technicians working with the
NJEX Odorization Systems study the manual
prior to initiating work on the system for the rst
time.
Typographic Conventions
To aid in readability, this manual uses sev-
eral typographic conventions. References to
illustrations, photographs, and other related
content will appear in italicized text along
with the location of where to nd the item in
the manual. Digital versions of the manual,
available in Adobe Acrobat™ PDF format,
will be highlighted further in blue italic text
indicating the copy retains a hyperlink to the
referenced item.
Measurement units are listed in italic pa-
renthesis text following their US standard
equivalent. As an example, for dening a
distance, 15’ (4.5 meters), is how the text will
appearthroughout the manual.
Items that require action, for example the
pressing of a key for programming the con-
troller, will feature the action item in sen-
tence case Bold Text followed in normal text
by the item such as, the Test key or Power
switch.
Starting with Section 4, System Control & Elec-
tronics, the manual will begin discussing the
in-depth operation of the electronic controller
where many of these typographic conven-
tions will be found. In the discussion about
the controller, the technician will learn about
the multiple switches used to program the
controller for operation. Further discussion
on the functions of the controller will take
place in Section 4, System Control and Elec-
tronics, on page 10.
Getting Help
This manual provides solutions to typical
questions about the 610G system. If the
answer can not be found within this manual,
contact YZ Systems at:
T: 1.281.362.6500
T: 1.800.653.9435
E: [email protected]
When calling, have this manual close at
hand. Whether calling or writing, please
include in your communique the following
information:
• The serial number of the NJEX System
and the version number of this manual.
The serial number is located inside the
enclosure door. The version number of
this manual located at the bottom of each
page.
• A description of the problem and, when
the problem occurred.

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 2 NJEX 610G ver.06-2021
Section 1: First Things To Know About The 610G

Maximum recommended
Odorant Output: 0.5 gallons/day
(200 cc/day)
Maximum Operating
Pressure: 1,440 psig
(99.28 Bar (g)
Operating Temp Range: 0 to 140° F.
(-17° C to 60° C)
Power Supply: LBP-14 Battery
Gas Flow Input Signal: Pulse (Dry contact
or voltage pulse)

In this mode
of operation, the 610G injects odorant into the
pipeline at regular time intervals. The volume
injected per stroke is set by inserting a stroke
spacer into the actuation plug of the 6000B pump.
The Z-65 controller operates as a recycling timer,
periodically energizing a low power solenoid
valve. Energizing the solenoid valve allows actua-
tion gas to stroke the 6000B pump. The rate
at which this occurs is set by the operator using
two 10-position switches on the controller. The
number of times the solenoid output is activated
is recorded by the onboard LCD indicator.
 In this mode
of operation, the controller operates as a dividing
counter. The counter periodically energizes
a low power solenoid valve. The rate at which
this occurs is a function of operator input as well
as the host computer or other device that inputs
pulses per volume metered. The volume injected
per stroke is set by inserting a stroke spacer into
the actuation plug of the 6000B pump. The two
10-position switches are used to set the number
of pulses the counter will count before activating
the solenoid output. The number of times the
solenoid output is activated is recorded by the
onboard LCD stroke indicator.

Long-Life Battery: The controller timer/counter
operates using a replaceable internal battery
pack. As the standard power source, the battery
pack condition is monitored by way of two
indicator LEDs. When the battery pack needs
replacement, the red LED will illuminate when the
solenoid output is activated. If the battery pack
is good, the green LED will illuminate when the
solenoid is activated. Typical battery life is one
year based on a two minute/stroke rate.

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 3NJEX 610G ver. 06-2021
Section 1: First Things To Know About The 610G
System Accessories
•  includes a 316
stainless steel probe and isolation valve for lo-
cation at the pipeline. When ordering, please
specify pipeline connection required, ½″ or
¾″ .
• 
(P/N A1-0238) 1/8” drop adapter includes a
316 stainless steel probe, visual odorant sight
indicator, and an isolation valve for location at
the pipeline. When ordering, please specify
pipeline connection required, ½″ or ¾″.
• 
Check Valve. For placement in the odorant
discharged tubing line immediately preceding
the probe assembly, (P/N A3-0438) .
• -
tor Union. These should be installed in every
tubing line that attaches the odorizer to the
pipeline in any manner. For example the sup-
ply gas, odorant discharge, and di󰀨erential
pressure switch connections, (P/N A1-0182) .
• NJEX Scrubbers. These lters are designed
to scrub the exhaust gas vented from the
pumps. They are available by ordering P/N
C4-0018, 15 gallon scrubber.
A complete line of odorization accessories
ranging from pre-odorized gas scrubbers to
injection probes is available through YZ. Please
contact your local representative or YZ toll free
at 800.344.5399. For technical support call
800.653.9435.
Application Notes
• When installed and operated properly we can
consistently perform at the smallest pump
displacement of 0.02 cc/stroke with as much
as 30 minutes between strokes; therefore time
intervals will be approved between 6 secand
30 minutes.
• Keep in mind that with the LVO there is
no internal microprocessor to do calcula-
tions, or make adjustments; therefore,
the LVO must be operated in Proportional
to Time mode (0.1 min., to 30 min.), or
in the Flow mode as a slave to counting
“XX” number of pulses. The pulses can-
not come faster than 1.5 Hz or approxi-
mately 670 ms between pulses, and each
pulse must have a minimum dwell time of
21 ms, and you cannot count more than
99 pulses before stroking the pump.
• Finally remember the battery life on the
LVO will be limited by stroke frequency
and temperatures. The faster it runs and
the colder it gets, the shorter the battery
life will be.

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 4 NJEX 610G ver.06-2021
Section 2: System Installation

Standard primary components of the NJEX-610G
include the following:
A. System Odorant Tank. The odorant tank is
tested and pre-assembled with a valve
package including a visual level indicator.
B. System Controller. Controller with internal
battery assembly.
C. Odorant Injection Pump. The NJEX 6000 is a
pneumatically actuated, positive displace-
ment plunger pump.
D. System Enclosure. Houses the Model 6000B
pump, the Z-65 Controller, the actuation gas
manifold and the odorant discharge
manifold. NEMA rating 4X.
E. NJEX Gas Filter. Installed between the
actuation gas regulator and the actuation
gas manifold, this lter provides a 25 micron
coalescent ltration to insure a clean
pneumatic supply.
Figure 1
A
B
C

E

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 5NJEX 610G ver.06-2021
Section 2: System Installation
System Flow Schematic
Figure 2
30-60 psi
(207-414 kPa)
By Customer
Table 1
TABLE 1
Pipeline Pressure Actuation Pressure
100-200 psi (6.89-13.8 bar) 30 psi (2.07 bar)
200-500 psi (13.89-34.5 bar) 40 psi (2.76 bar)
500-900 psi (34.5-62.1 bar) 50 psi (3.45 bar)
900-1400 psi (62.1-96.5 bar) 60 psi (4.14 bar)
Z - 65 / 6.1

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 6 NJEX 610G ver.06-2021
Section 2: System Installation

1. Securely attach a section of 2″ pipe in a
vertical conguration at the location where
the NJEX 610G is to be installed. Using the
mounting clamps provided with the NJEX
610G system, attach the system to the pipe.
2. Connect a ground wire from the 2″ pipe to a
properly installed ground rod, located adja-
cent to the pipe.
Figure 3

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 7NJEX 610G ver.06-2021
Section 2: System Installation

Required eld connections to place the 610G into
operation are as follows:
1. Connect the regulated actuation gas source
(30-60 psi, 2.1-4.1 bar, by customer, refer
Table 1, Page 5) to the NJEX gas lter inlet.
NOTE: At temperatures below 32ºF (0°C), con-
ditioning of the actuation gas supply may be
required. Where the actuation gas supply has a
high water content and/or a low hydrocarbon dew
point, additional actuation gas ltration or heating
of the actuation gas supply may be necessary.
Bottled nitrogen can also be used during cold
operating conditions to avoid condensation in the
actuation gas supply line. In addition, operation at
extreme temperatures will a󰀨ect seal and o-ring
performance. To prolong the service of seals and
o-rings, adequate heat should be provided to
maintain an operating environment above 32ºF
(0°C).
2. Connect the pump discharge valve tting to
the pipeline connection.
3. Connect the ow signal device to the termina-
tion strip located in the system control enclo-
sure (see Wiring Control Document, page 32).
Installation Guidelines
• We recommend that the tubing from the
610 LVO be adapted to 1/8” tubing before it
reaches the sight glass.
• A 50 lb. in-line check valve should be located
just before the sight glass. (1/8” in-line C.V.
P/N A3-0438)
• The sight glass should be tted with a 1/4”
MNPT x 1/8”t bore through tting (P/N A1-
0283) and 1/8” S.S. tubing extending through
the bore of the sight glass tting until it just
protrudes from the 1/4” dripper point.
Figure 4
CAUTION:
Excessive tubing lengths should be avoided.
Installation of the NJEX Odorization system
should be as close to the point of injection and
Odorant Storage Tank as possible. Maximum
tubing length should not exceed 15’ (4.5 meters)
with the tubing size maintained as indicated in
this manual. If longer tubing lengths are required
consult YZ Systems Technical Services at
800.653.9435 or 1.281.362.6500

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 8 NJEX 610G ver.06-2021
Section 3: Filling the Bulk Odorant Tank
Filling the Tank for the First Time
CAUTION:
Odorant has a very strong odor, which if allowed
to escape to the atmosphere, may cause
problems in the local community. Take necessary
precautions when lling an odorant storage tank
to assure that the local community is not
disrupted during the lling process. Verify that
the entire system has no pressure in it before
beginning. Additionally, all personnel should
wear protective clothing, and use equipment as
recommended by the chemical manufacturer
during this time. If you are uncertain about any
aspect of the odorant itself, you should contact
the manufacturer of your chemical prior to
proceeding. The MAXIMUM amount of odorant
in the standard tank should never exceed 4
gallons.
1. Verify correct position of valves before begin-
ning, gure 5.
Closed: V10, V11 and V13
2. Attach inert or natural gas supply to V10.
3. To purge the tank open valve V10 to introduce
inert or natural gas to the tank to begin dis-
placing any ambient air from the empty tank.
Continue until pressure on the gage located
directly below V10 is observed, then partially
open V11 to allow ambient air from the tank
to begin owing out. Allow this process to
continue until all ambient air from the tank is
purged, and only inert gas or natural gas is
emitting from this valve, then close V11 and
V10. The time required to accomplish this
task will vary with the tank size.
4. Vent purge gas by opening V11 partially until
tank pressure just reaches zero, and then
close V11.
5. Attach odorant supply to V10, open V10, and
begin transferring odorant to the bulk tank.
• The tank level indicator will not start to
rise until approximately 0.5 gallons of
odorant is in the tank.
• 1 gallon is approximately the thin line
above the tting.
• 2.5 gallons is approximately the next thick
line below the red keep-out.
• 4 gallons is about where the red diagonal
keep-out mark starts.
6. Connect a line from V11 to a are or vapor
recovery device, and open V11.
CAUTION:
Fill tank to a maximum level of 80% of the tank
capacity (4 gallons). Stay below the red-diagonal
keep-out.
7. Close V10 and V11, and remove odorant
transfer equipment, and line to are or vapor
recovery device.
8. Continue through the remaining procedures in
this manual.
Figure 5
30-60 psi
(207-414 kPa)
per Table 1 by
customer
Z-65/6.1

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 9NJEX 610G ver.06-2021
Section 3: Filling the Bulk Odorant Tank

CAUTION:
Odorant has a very strong odor, which if allowed
to escape to the atmosphere, may cause
problems in the local community. Take necessary
precautions when lling an odorant storage tank
to assure that the local community is not
disrupted during the lling process. Verify that
the entire system has no pressure in it before
beginning. Additionally all personnel should wear
protective clothing, and use equipment as
recommended by the chemical manufacturer
during this time. If you are uncertain about any
aspect of the odorant itself, you should contact
the manufacturer of your chemical prior to
proceeding.
1. Place the Z-65 controller in the OFF Mode by
placing Mode Switch #1 in the Down position.
2. Verify correct position of valves before begin-
ning, Figure 6.
Closed: V10, V11, V13
3. Connect a line from V11 to a are or vapor
recovery device, and open V11.
4. Attach odorant supply to V10, open V10, and
begin transferring odorant to the bulk tank.
CAUTION:
Fill tank to a maximum level of 80% of the tank
capacity. Stay below red keep-out zone.
• The tank level indicator will not start to rise
until approximately 0.5 gallons of odorant is in
the tank.
• 1 gallon is approximately the thin line above
the tting.
• 2.5 gallons is approximately the next thick
line below the red keep-out.
• 4 gallons is about where the red diagonal
keep-out mark starts.
5. Close V10 and V11, and remove odorant
transfer equipment, and line to are or vapor
recovery device
6. Open V13 until the storage tank pressure is
10 psig.
7. Place the Z-65 controller in the ON Mode by
placing Mode Switch #1 in the Up position.
Figure 6
30-60 psi
(207-414 kPa)
per Table 1 by
customer
Z-65/6.1

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsyvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 10 NJEX 610G ver.06-2021
Section 4: System Control & Electronics

The electronic control package provided with
your 610G odorizing system consists of a
solid state Z-65 Controller and a Low Powered
Solenoid powered by an internal battery. The
Z-65 energizes the solenoid which in turn sends
a pneumatic actuation signal to the Odorizer
Pump, every time a sample is required either
Proportional-To-Flow, or Time.
SAFETY NOTES:
Always use extreme care when performing
maintenance on the odorization system. Always
take necessary measures to assure that electrical
classication in the area is considered, before,
and during all repairs, and that necessary
steps are taken to maintain proper electrical
procedures for the classication of the area.
The control package requires you to congure the
Z-65 controller to operate in a Proportional
To-Flow mode, refer Section 5, to page 11, or a
Proportional-To-Time mode refer Section 6, page
13.
All wiring connected to the Z-65 controller
must be done in accordance with the Wiring
Control Document, refer to Appendix A, page
30. NJEX 610G electronics are rated for use in
Class I, Division 1, Groups C and D hazardous
locations.


 

Mode Switch
Z-65/3.10 Controller
Figure 7
WARNING:
• Electrostatic Discharge Hazard – Wipe with a
damp cloth only.
• System is top-heavy. Lift cabinet with rigging
to support weight and prevent it from tipping.
• The Z-65 controller is in a housing with more
than 10% aluminum. Non-sparking tools
must be used while servicing the Z-65 control-
ler to avoid an ignition hazard due to impact
or friction.
• Customer to ensure inlet actuation supply
pressure does not exceed 90 psi (6.2 bar).
APPROVALS:
Exia T3C
II 1/(1) SYST G
EEx ia IIB T4
LCIE 03 ATEX 6367X
Intrinsically safe Class 1, Division 1, Groups C, D
in accordance with YZ Systems Doc. No. 103-430
MODEL Z-65/6.1
YZ Industries, 201 Ivyland Road, Ivyland, PA 18974 215-441-0800 www.yzsystems.com
Z-65/6.1

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 11 NJEX 610G ver.06-2021
Section 5: Programming for Proportional-to-Flow Operation
Z-65/6.1 Controller Setup:
In this mode, the Z-65/6.1 controller is used as a
dividing counter to control the rate at which the
solenoid output is activated. The desired time be-
tween solenoid activation is controlled by the host
computer or other device that will give an input
pulse to the count input terminals #3 (+) input and
#5 (-) input. Use the chart below to calculate the
counter setting needed.
NOTE: If the calculated counter setting is less
than 1 or greater than 99, the pulses per volume
metered will need to be adjusted. This can be
programmed in most ow meters to the desired
rate. If the calculated counter setting is less than
1, increase the pulses per volume metered. If
the calculated counter setting is greater than 99,
decrease the pulses per volume metered.
Figure 8
Figure shown below reects Example # 1 setting
of 18 pulses counted before stroking the pump
Figure 9








Z-65/6.1
1. Pump displacement (from .02 to .1 cc) = a
2. Odorant density (lb/gal or g/cc) = b
3. Pulse/Volume metered (pulses/MCF or pulses/m³) = c
4. Desired Injection rate (lb/MMCF or mg/m³) = d
5. Counter setting
a. English = a x b x c x .264172*
d
a. Metric = a x b x c x 1000*
d
 
English Gas Flow Metric Gas Flow
Pump displacement (a) = .05 cc .05 cc
Odorant density (b) = 6.80 lb/gal .815 g/cc
Pulses/volume metered (c) = 100 pulses/MCF 10 pulses/m³
Injection rate (d) = .5 lb/MMCF 8 mg/m³
Example #1 Counter setting = .05cc x 6.80 lb/gal x 100 pulses/MCF x .264172* = 18 pulses
.5 lb/MMCF
Example #2 Counter setting = .05cc x .815 g/cc x 10 pulses/m³ x 1000* = 51 pulses
8 mg/m³
* conversion constant

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 12NJEX 610G ver.06-2021
Section 5: Programming for Proportional-to-Flow Operation
Z-65/6.1 Controller Setup:
A. Determine if the incoming input is either a
dry contact or voltage pulse.
1. 
a. Terminate the incoming connections to the
Z-65/6.1 terminal strip (see Figure 10).
b. Turn mode switch #1 to on.
c. Turn mode switch #2 to o󰀨.
d. Turn mode switch #3 to on.
e. Turn mode switch #4 to o󰀨.
2. If the input is a voltage pulse:
a. Terminate the incoming connections to the
Z-65/6.1 terminal strip (see Figure 12).
b. Turn mode switch #1 to on.
c. Turn mode switch #2 to o󰀨.
d. Turn mode switch #3 to on.
e. Turn mode switch #4 to on.

(setting the counter)
A. Once you have determined your incoming
input as either being a dry contact or voltage
pulse, turn the count dials to the appropriate
number of pulses you want to count before
activating the solenoid output. (Example: 18
pulses, turn the dials to 18).
1. Press the test button once to load the value
into memory.
Z-65/6.1
Figure 10
Figure 11
Figure 12
Z-65/6.1
Figure 13
Figure 14

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 13 NJEX 610G ver.06-2021
Section 6: Programming for Proportional-to-Time Operation
-
eters: Z65/6.1 Controller Setup
The rate at which the solenoid output is activated
is controlled by selecting the appropriate time
input. This determines the amount of time that will
transpire between solenoid actuations. Use the
chart below to actuate the timer setting needed.
1. Pump displacement (from .02 to .1 cc) = a
2. Odorant density (lb/gal or g/cc) = b
3. Desired injection rate (lb/MMCF or mg/m³) = c
4. Average ow rate (MCF/hr or m³/hr) = d
5. Timer setting
a. English = a x b x 15.8503*
c x d
a. Metric = a x b x 60000*
c x d
 
English Gas Flow Metric Gas Flow
Pump displacement (a) = .05 cc .05 cc
Odorant density (b) = 6.80 lb/gal .815 g/cc
Injection rate (c) = .5 lb/MMCF 8 mg/m³
Flow rate (d) = 6.00 MCF/hr 170 m³/hr
Example #1 Time setting = .05cc x 6.80 lb/gal x 15.8503* = 1.80 minutes
.5 lb/MMCF x 6.00 MCF/hr
Example #2 Timer setting = .05cc x .815 g/cc x 60000* = 1.80 minutes
8 mg/m³ x 170 m³/hr
* conversion constant








NOTE: To obtain maximum battery life, choose
the longest time interval and the largest pump
displacement setting possible.

timer)
1. Set the timer dials to the desired time.
2. Turn mode switch #1 to on.
3. Turn mode switch #2 to on.
4. Turn mode switch #3 to on.
5. Turn mode switch #4 to o󰀨.
6. Press the test button once to intiate the timer
sequence.
Figure 16
Figure 15
NOTE: The time (1.8 minutes from Example #1)
shown corresponds to the factory set timing
range. See Section 9 / Troubleshooting: Timer
Mode, Timer Range setting, Page 21.
Z-65/6.1

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 14 NJEX 610G ver.06-2021
Section 7: Mechanical System

The 610G mechanical system is composed
of the mechanical/electrical enclosure.
Individual components of the system are
shown below and described in the following
pages.
NJEX Gas Filter
NJEX Gas Filter
Manifold

Actuation
Metering Pump
Model 6000B
 



Figure 17
Z-65/6.1

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 15NJEX 610G ver.06-2021
Section 7: Mechanical System
NJEX Gas Filter
A 25 micron coalescent lter is provided with
each 610G. This lter, as shown, is installed on
the back outside of the enclosure and should be
connected to the regulated (30-60 psi / 2.1-4.1
bar, per Table 1, Page 5) actuation gas supply
provided by the system operator. By conditioning
the incoming actuation gas, a clean pneumatic
supply will be provided to the solenoid valves.
This will ensure a longer operational life for the
pneumatic control system. If the actuation gas
supply has a high water content and / or a low
hydrocarbon dew point, additional ltration and
heating of the actuation gas supply may be nec-
essary. Bottled nitrogen can also be used as an
alternate gas supply source if gas conditioning is
a problem.
Figure 18

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 16 NJEX 610G ver.06-2021
Section 7: Mechanical System

The NJEX 6000 pump, as shown, is a pneumati-
cally actuated, positive displacement, plunger
pump. The 6000 is actuated with compressed air
or pipeline gas at a pressure of 30-60 psi (2.1
– 4.1 Bar) - refer Table 1, page 5, refer to Sec-
tion 2, the System Flow Schematic, Figure 2. The
pump has an adjustable displacement of 0.1cc to
0.02cc. It achieves proportional-to-ow injection
through adjustment of the stroke rate. The 6000 is
rated for a maximum stroke rate of 60 strokes per
minute. Each time the pump strokes, the plunger
displaces odorant through the discharge check
valve. The pump is congured with two sets of
plunger seals, segregated from each other with a
trapped air space, minimizing the risk of odorant
escape into the atmosphere.
The 6000 incorporates a cartridge design in key
areas that may require maintenance.
They are: the inlet check valve, the discharge
check valve, and the plunger bushing / seal
assembly. The cartridge design provides easier
maintenance resulting in less down-time.
The gage on the front of the pump reects any
pressure between the two sets of seals in the
pump in case of primary seal failure. Normally
this gage should be reading “0 psi” and should
show no movement. If the gage shows a sudden
swing upward in pressure with each stroke of the
pump, this is an indication that the pump should
be rebuilt due to primary seal damage.

The actuation gas manifold houses the actuation
gas supply connection and the pneumatic
exhaust connection for the 610G system. These
openings are located on the left side of the
mechanical enclosure and are ported through the
enclosure wall. The upper manifold connection
is for the actuation gas supply, while the lower
connection is for the exhaust connection. The
actuation gas manifold also serves as the
mounting location for the solenoid valve.
Solenoid
Actuation Gas
Supply
Exhaust
Muffler
Figure 19
Figure 20

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
Page 17 NJEX 610G ver.06-2021
Section 8: System Maintenance

A preventative maintenance program serves to
anticipate maintenance issues prior to waiting
until the system requires service. Like changing
the oil & lters in an automobile, by choosing to
service the various parts and operation in the
NJEX System at regular intervals, the technician
can perform the maintenance service when
desired, rather than when required, such as in the
middle of night.
The key is to perform maintenance before it is
required. The preventive maintenance schedule
implemented should consider the application
of the odorizer. Many of these considerations
include: the weather environment, the condition
of, the actuation gas, the odorant and the
odorant bulk storage tank, and the pump stroke
frequency. All of these issues must be considered
when establishing a preventative maintenance
schedule.

Weekly Inspection
1. Verify gas pressures
2. Check for gas and odorant leaks
3. Visually inspect for obvious external problems
Semi-Annual Inspection
1. Inspect overow protector and service as needed
2. Inspect tube ttings and valve packings for leaks.
Annual Inspection
1. Change lters
2. Rebuild pump
3. Replace solenoids
4. Test regulators and service, as needed
5. Condition the odorant, as needed
6. Test the NJEX System performance.
7. Replace the battery (More frequent replacement
may be required if the odorizer strokes more than
5 times per hour)

 
Quantity
A4-0003 3-way solenoid valve 1
C4-0133 NJEX gas lter replacement
lter element 1
D3-0140 Model 6000B pump seal
replacement kit 1
D3-0142 Z-65/200 fuse replacement kit 1
E3-2001 LBP-14 internal Z-65 battery 1