YZ Systems NJEX ZEO 6400 Parts list manual

The NJEX ZEO
6400
7400
8400
9400
Instruction & Operating Manual
ZERO EMISSIONS ODORIZATION SYSTEM

Table of Contents
Section 1: Things to Know - NJEX ZEO.................................................................................. 3
How to Use this Manual ...................................................................................................... 3
Getting Help........................................................................................................................ 3
Warranty............................................................................................................................. 7
SAFETY NOTES –General System.................................................................................... 7
Theory of Operation............................................................................................................ 8
System Accessories...........................................................................................................10
Section 2: System Installation................................................................................................12
Standard System Components...........................................................................................12
System Flow Schematic.....................................................................................................14
Standard System Lifting and Mounting...............................................................................15
Standard System Connections...........................................................................................17
Standard Skid Connections................................................................................................22
Skid System Mounting .......................................................................................................25
Section 3: Filling the Bulk Odorant Tank................................................................................26
Filling the Tank for the First Time.......................................................................................26
Refilling the Bulk Odorant Tank..........................................................................................27
Section 4: System Operation.................................................................................................28
Starting the System............................................................................................................28
Stopping the System..........................................................................................................29
Section 5: System Control Electronics...................................................................................32
Controller Overview............................................................................................................32
To Power Up the System ...................................................................................................34
Communications Interface..................................................................................................34
Using the N-400 Home Screen...........................................................................................35
Using the N-400 Main Menu...............................................................................................39
Setting Operator Input Parameters.....................................................................................40
Section 6: Troubleshooting....................................................................................................63
How to Use This Section....................................................................................................63
Section 7: System Maintenance ............................................................................................75
Preventative Maintenance Schedule..................................................................................75
Appendix A: NJEX ZEO Response Forms.............................................................................79
Appendix B: Wiring Control Document...................................................................................81
Appendix C: N-400 Modbus Specifications............................................................................89
Appendix D: Controller Replacement Components................................................................95
Appendix E: Controller Mounting...........................................................................................96
Appendix F: Bulk Odorant Filter Replacement.......................................................................97
Appendix G: Injection Pump Oil Fill Startup Procedure..........................................................98
Appendix H: Injection Pump Diaphragm Replacement ........................................................100

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NJEX ZEO Version 04/13/2021 Page 3
How to Use this Manual
The NJEX ZEO Operations Manual is a step-by-step guide containing the procedures needed
to work with the NJEX ZEO System.
The NJEX ZEO Series of odorizers implement the most advanced technology available in the
industry. It is recommended that the technicians working with the NJEX ZEO Odorization
Systems study the manual prior to initiating work on the system for the first time.
Getting Help
This manual provides solutions to typical questions about the ZEO system. If the answer cannot
be found within this manual, contact YZ Systems at:
T: 1.281.362.6500
T: 1.800.653.9435 (800.NJEX.HELP)
F: 1.281.362.6513
E: [e-mail]
When calling, have this manual close at hand. Whether calling or writing, please include the
following information:
•The serial number and model number of the NJEX ZEO System. The serial and model
numbers are located on the nameplate located on the exterior of the front door of the
enclosure.
•A description of the problem and, if applicable the actions of the technical personnel when the
problem occurred.
•A listing of any messages that may have appeared in the LCD on the N-400 controller, please
include:
1. The exact wording of all alarm(s).
2. The version number of the Controller and IS Transition Board firmware.
3. The version number of the Sentry software used.
Section 1: Things to Know - NJEX ZEO

SECTION 1: THINGS TO KNOW - NJEX ZEO
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Page 4 NJEX ZEO Version 04/13/2021
Table 1: Operation Specifications
Operation Specification
Model
6400
7400
8400
9400
Maximum odorant output at 1800 PSI (124 Bar)
MMCF/day @ 0.5 lb/mmcf
(m3/day) @ 8 mg/m3
60
(1.28M)
175
(5.12M)
515
(10.50M)
1000
(20.00M)
MMCF/day @ 1.0 lb/mmcf
(m3/day) @ 16 mg/m3
30
(0.64M)
88
(2.56M)
258
(5.25M)
500
(10.00M)
MMCF/day @ 1.5 lb/mmcf
(m3/day) @ 24 mg/m3
20
(0.43M)
58
(1.70M)
172
(3.50M)
333
(6.67M)
Maximum operating
pressure –psig (Bar)
1800 (124)
Operating Temp Range
-20° to +50°C
-4° to +122°F
Flow Rate Input Signal
4-20 mA, 1-5VDC, Pulse (PPS, PPM)

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NJEX ZEO Version 04/13/2021 Page 5
Table 2: Power Requirements
Each system will require the four power connections outlined below:
Power Requirements –Class 1, Division 1
Overall System
AC: 1 Ph. 115/230VAC, 15/8A, 60Hz
Injection Pump Power, C1D1
AC: 1 Ph. 115/230VAC, 6.6/3.3A, 60Hz
Transfer Pump Power, C1D1
AC: 1 Ph. 115/230VAC, 6.6/3.3A, 60Hz
ACC Power
AC: 85-260VAC, 1A Max, 50/60Hz
24V Power Supply
AC: 90-264VAC, 0.8/0.6A, 50/60 Hz
Power Requirements –Zone 1 ATEX and IECEx
Overall System
AC: 1 Ph. 115/230VAC, 8.2/5.2A, 50/60Hz
Injection Pump Power, Zone 1
AC: 1 Ph. 115/230VAC, 2.9/1.5A, 50Hz
1 Ph. 115/230VAC, 3.2/1.7A, 60 Hz
Transfer Pump Power, Zone 1
AC: 1 Ph. 115/230VAC, 2.9/1.5A, 50Hz
1 Ph. 115/230VAC, 3.2/1.7A, 60 Hz
ACC Power
AC: 85-260VAC, 1A Max, 50/60Hz
24V Power Supply
AC: 90-264VAC, 0.8/0.6A, 50/60 Hz
N-400 Controller Power
Consumption
DC: 24VDC, 250mA, 6W Max
AC: 90-250VAC RMS Max., 50/60Hz, <1A
*N-400 Controller power is intrinsically safe and supplied internally from the explosion proof or
flameproof enclosure.

SECTION 1: THINGS TO KNOW - NJEX ZEO
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Page 6 NJEX ZEO Version 04/13/2021
System Certifications
The NJEX ZEO System holds one of the following approvals and must be installed, grounded,
wired, and I.S. Barrier Protected in accordance with all applicable electrical codes:
In addition to local electrical codes for which the system is installed, the systems must also
comply with the Wiring Control Documents located in the appendix of this manual. For both
hazardous location listings, the N-400 Wiring Control Document 1E-0378 must be followed for
any connections to the N-400 controller. See the system level Wiring Control Documents 1E-
0384 or 1E-0385 for requirements for connecting incoming power per the hazardous location
listing.
North America, Class and Division Hazardous Location*
Class 1, Division 1, Groups C and D
Class 1, Zone 1, Group IIB
T3C
Type 3R
*WARNING: To comply with the North American hazardous location requirements and
to reduce the risk of ignition of hazardous atmospheres, conduit runs must have a
sealing fitting (not provided) connected within 18 inches of the enclosure.
ATEX, IECEx Zone Hazardous Location
IECEx ETL 20.0051X
Ex db ia [ia IIC Ga] IIB T4 Gb
ITS21UKEX0038X
ITS-I21ATEX29212X
II 2 G Ex db ia [ia IIC Ga] IIB T4 Gb
2812
0891
-20°C ≤ Ta ≤ + 50°C
IP43
Specific Conditions of Use
1. External non-metallic materials represent a potential electrostatic charging hazard. See
the safety notes in this manual for details.
2. The flameproof joints are not intended to be repaired in the Actuator Capacity Control
(ACC). For repair of flameproof joints, see the manufacturer for more information.
3. To guarantee the tensile strength of the screws of the flameproof junction box present in
the Actuator Capacity Control (ACC) and flameproof enclosure, the supplied screws have
a tensile strength of equal to or greater than 700 N/mm2. Fasteners are factory supplied.
4. The property class of the special fasteners used in the Elnor Motors (Transfer Pump and
Injection Pump Motors) must be at least: Hexagon cap screws [4.6], Hexagon nut [5] (if
used), Socket Cap Screws [8.8]. Fasteners are factory supplied.

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NJEX ZEO Version 04/13/2021 Page 7
Warranty
Please visit our web site www.yzsystems.com for a complete copy of our warranty contained in
our Terms and Agreement document.
SAFETY NOTES –General System
•Always use extreme care when performing maintenance on an odorization system. Check to
ensure the removal of liquid odorant and pressure from the portion of the system on which work
will be performed prior to removing components or fittings.
•Inspect all tube fittings and valve packing semiannually to ensure that liquid odorant remains
within the system.
•Systems must be installed per local electrical codes for which it is located.
•All mechanical and electrical work on NJEX ZEO Systems must be performed by trained
professionals.
•Proper personal protection equipment (PPE) such as protective eyewear and gloves should be
worn while installing or servicing this equipment.
WARNING: POTENTIAL STATIC CHARGING HAZARD - To avoid static buildup, use a
damp cloth to clean all painted or other non-metallic surfaces.
WARNING: MATERIALS USED IN THE CONSTRUCTION OF GROUP II ENCLOSURES
FOR EPL Ga EXCEEDS 10% IN TOTAL OF ALUMINUM, MAGNESIUM, TITANIUM AND
ZIRCONIUM –Non-sparking tools must be used while servicing the ZEO System and N-
400 controller to avoid an ignition hazard due to impact or friction.
WARNING: Power must be disconnected or locked out from the NJEX ZEO system before
performing any troubleshooting or repair to electrical components.
CAUTION: Vent Valve must be closed in all operations excluding venting. Failure to close
V5 during other operations will result in spilled odorant.

SECTION 1: THINGS TO KNOW - NJEX ZEO
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Page 8 NJEX ZEO Version 04/13/2021
Theory of Operation
The NJEX ZEO brings a change to how we odorize gas. With the legacy NJEX systems, gas is
odorized by running a pneumatically driven pump at a varying stroke rate with a fixed pump
displacement. The NJEX ZEO odorizes gas by running an electrically driven pump at a constant
stroke rate and varying the pump displacement. The advantage of the ZEO system is you are
always odorizing with each stroke (at least 24 times per minute) and only the amount changes
to maintain the injection rate.
Operation of the NJEX ZEO centers around four primary components: the transfer pump,
verometer, injection pump with actuator, and the N-400 controller.
During normal operation, the injection pump injects odorant into the system at a rate determined
by the N-400 controller. The injection pump runs at a fixed stroke rate and the amount of odorant
injected is controlled by the actuator (ACC) which adjusts diaphragm displacement by controlling
the amount of hydraulic fluid pushed against the diaphragm.
The verometer serves as a temperature compensated meter, which verifies the amount of
odorant injected by the injection pump. The N-400 controller uses an input signal from the
verometer to determine the amount of odorant that has been injected, as well as the odorant level
within the verometer. Once theodorant level fallsto 0%, the N-400controller prompts the transfer
pump to fill the verometer. Once the verometer is filled, the N-400 controller stops the transfer
pump.
The N-400 controller allows the ZEO system to operate in either a proportional-to-time or a
proportional-to-flow mode. In the proportional-to-time mode of operation, the user inputs the
target lb/hr or kg/hr rate. The ACC adjusts the injection pump capacity to maintain this target.
In the proportional-to-flow mode of operation, the N-400 controller uses a customer provided gas
flow rate input signal and several operator input values to maintain the injection rate setpoint per
the measured flow signal. These operator input values include the odorant injection rate
(lb/MMCF or mg/m3) and the odorant density (lbs/gal or g/cc). The flow input signal is customer
provided by either a flow computer or other flow monitoring devices. In this mode, the controller
has the capability to distinguish between a low flow situation and a loss of flow input signal. For
systems with analog inputs, if a loss of flow signal occurs, and if programmed, the controller
automatically defaults back to a pre-selected percentage of the flow input.
If system redundancy is required, the NJEX ZEO system has two main options for the backup
system, NBS Output (Default) or Redundancy.
For NBS Output, the NBS output terminal can be connected to another YZ system such as the
N-300 Controller in a pneumatic NJEX unit or the Z-65 Controller in an LVO unit. In the instance
of power loss or injection pump diaphragm failure, the unit will be put into standby mode and will
signal the backup system to run.
For Redundancy, dual ZEO systems can be configured as Primary or Secondary on the N-400
controller and wired together to send a signal in the occurrence of a failure. The primary cabinet
will inject odorant and in the case of power loss, a low injection rate alarm, or pump failure, the
backup system will be started. During normal operation, the backup system will be held in
Standby mode. If the backup system fails due to an injection rate low alarm or pump failure, both
the primary and backup units will run until the systems are stopped and serviced.

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NJEX ZEO Version 04/13/2021 Page 9
During operation, the N-400 controller will record the injection rate and log this data and any
active alarms to the MM-400 Memory Module. The MM-400 Memory Module can be removed
from the N-400 controller so the data can be retrieved using YZ System’s Sentry Utility Software
for future reference.
CAUTION: Excessive tubing lengths should be avoided. Installation of the NJEX ZEO
Odorization system should be as close to the point of injection and Odorant Storage Tank
as possible. Tubing length from the Odorant StorageTank to the system should not exceed
15 feet (4.5 meters). Discharge tubing length should not exceed 50 feet (15 meters). The
tubing size should be 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.

SECTION 1: THINGS TO KNOW - NJEX ZEO
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Page 10 NJEX ZEO Version 04/13/2021
System Accessories
•Odorant Injection Probe - includes a 316 stainless steel probe, andisolation valve for location
at the pipeline. When ordering, please specify pipeline connection required, 1/2” or 3/4”.
•Odorant Injection Probe with Sight Glass - 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, 1/2” or 3/4”.
•1/4” stainless steel discharge tubing In-line Check Valve - For placement in the odorant
discharged tubing line immediately preceding the probe assembly. (P/N A3-0024).
•1/4” stainless steel tubing Dielectric Isolator Union - These should be installed in every
tubing line that attaches the odorizer to the pipeline in any manner. For example the supply gas
and odorant discharge. (P/N A1-0182).
•NJEX ZEO Scrubbers - These filters are designed to scrub vented gas from the system. They
are available by ordering P/N C4-0018, 15 gallon scrubber.
•Back Pressure Regulator - If the pipeline pressure is below 250psig (17.2 Bar), a back
pressure regulator is required to be installed on the discharge tubing line prior to the isolator
union charged to a minimum 300psig (20.7 Bar). (P/N 59207)
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 Systems toll free
at 800.344.5399. For technical support, call 800.653.9435.

YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, PA • USA • 18974 • P: 281.362.6500 • www.yzsystems.com
NJEX ZEO Version 04/13/2021 Page 11
Notes

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NJEX ZEO Version 04/13/2021 Page 12
NJEX ZEO systems can be installed outdoors or indoors. The ambient temperature year-round
must be within the system limits. If a system is installed outdoors in a location with higher
ambient temperature and direct sunlight during warmer months, a shaded structure over the
cabinet is recommended. If the system is installed outdoors in a colder climate close to the
lower limits, a climate-controlled building is recommended. NJEX ZEO systems must be
installed per this manual and all local electrical regulations for which it is located.
Standard System Components
Standard primary components of the NJEX ZEO include the following:
1. System Enclosure upper cabinet. The System
Enclosure houses the mROY injection pump with
ACC, the verometer integrated with the bulk
odorant filter and suction and discharge manifold,
and the N-400 intrinsically safe system controller.
The upper cabinet has an integrated solar shield
to reduce internal temperatures in the cabinet from
solar exposure.
2. System Enclosure lower cabinet. The System
Enclosure lower cabinet houses the magnetic
drive transfer pump and Explosion Proof
Enclosure.
3. N-400 Intrinsically Safe Controller. Intrinsically
safe system controller.
4. Explosion Proof or Flameproof Electrical
Housing. Houses the intrinsically safe transition
board, bridging the non-intrinsically safe and
intrinsically safe electrical connections. Customer
supplied AC power routes through the explosion
proof box.
5. mROY injection pump with ACC. The injection
pump is housed in the System Enclosure upper
cabinet. The injection pump stroke rate will vary
for each system size. The injection pump runs at
a fixed stroke rate and the amount of odorant
injected is controlled by the actuator which adjusts
stroke length of the diaphragm by controlling the
amount of hydraulic fluid pushed against the
diaphragm.
6. Verometer assembly. The verometer assembly verifies the volume of odorant injected while
compensating for odorant temperature. The verometer, bulk odorant filter, and odorant manifold
are integrated into a single assembly.
Section 2: System Installation
Figure 1 NJEX ZEO Cabinet subsystems,
open doors
1
2
3
5
6
7
8
4

SECTION 2: SYSTEM INSTALLATION
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NJEX ZEO Version 04/13/2021 Page 13
7. Bulk Odorant Filter. Provides primary odorant filtration between the storage tank and the NJEX
ZEO system. The Bulk Odorant Filter is integrated into the verometer assembly in the System
Enclosure and is field replaceable.
8. Transfer Pump Assembly. Transfers odorant from bulk odorant tank through the bulk odorant
filter and into the verometer.

SECTION 2: SYSTEM INSTALLATION
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Page 14 NJEX ZEO Version 04/13/2021
System Flow Schematic
Figure 2 NJEX ZEO SYSTEM P&ID

SECTION 2: SYSTEM INSTALLATION
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NJEX ZEO Version 04/13/2021 Page 15
Standard System Lifting and Mounting
The cabinets are provided with three 1.25” (31.8mm) lifting eyes. The cabinet should be lifted
from these lifting eyes with a suitable device. The lifting eyes can be removed after the system
is installed if so desired.
WARNING: While lifting, all personnel should stand clear of the cabinet. Keep all hands,
fingers, etc. free from under the cabinet while setting down. Lifting must be performed
with an adequate lifting system.
Bolt down the system enclosure to a concrete slab using the four mounting slots (5/8”) provided
in the bottom of each leg of the enclosure. Recommended bolt or stud size for mounting the
enclosure is 1/2”. See Figure 3 for mounting dimensions. Cabinets will be supplied with either
tapered or straight legs depending on the application. Please see the model code of the NJEX
ZEO system to determine which leg type your system has. If you have additional questions,
contact your local YZ Systems sales representative.
NOTE: It is recommended to leave a 2 foot (0.6 meter) clearance around the NJEX ZEO
cabinet to provide ample access when maintenance is required.
WARNING: If the cabinets are installed within a skid system, do not lift the assembled
skids by the cabinet lifting eyes. The cabinet lifting eyes are sized to lift the cabinet and
its contents only.

SECTION 2: SYSTEM INSTALLATION
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Page 16 NJEX ZEO Version 04/13/2021
Figure 3 NJEX ZEO Cabinet Footprint –Dimensions mm[in]. Dotted lines in cabinet front and side view
represent straight leg width and depth. Reference the ZEO Model Code to determine if your cabinet has
straight or tapered legs.

SECTION 2: SYSTEM INSTALLATION
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NJEX ZEO Version 04/13/2021 Page 17
Standard System Connections
Required field connections to place the NJEX ZEO system into operation are as follows:
1. AC Power Connections - There are two possible AC power connections configurations
depending on the cabinet installation location.
a For cabinets in North America with a Class 1, Division 1 hazardous location
certification, there are four AC power connections that share a common ground that
route through the explosion proof box located in the lower cabinet of the system
enclosure for a total of nine wires. A ¾” conduit fitting is provided at the back of the
cabinet for connection.
b For cabinets outside of North America with a Zone 1 hazardous location certification,
there is a 12 conductor 14AWG power cable that is supplied through a grommet and
out the back of the cabinet. There are four pairs with individual grounds that are
connected in the flameproof enclosure located in the lower cabinet of the system
enclosure.
2. See Power Requirements in Section 1 for the required specifications on the incoming power
connections. The incoming power connections shall be terminated in a junction box (not
provided) in accordance with local codes and regulations for the area in which the system is
installed.
IMPORTANT: Suitably rated overcurrent protection must be applied to the AC wiring for
both the Injection Pump motor and Transfer Pump motor in accordance with local codes
and regulations.
3. Connect the analog flow signal device to the termination block (TB8) located in the N-400
Controller ORthe pulsed flow input to the termination block (TB2). Note the jumper placement
(JP4) for each analog flow signal type and adjust if necessary. If using a pulsed flow input,
the jumper position (JP4) is inconsequential. Refer to the Wiring Control Document in
Appendix B and the Wiring Diagram reference label located inside the N-400 Controller Door
or below in Figure 4.
4. For cabinet only systems, connect the tank level device to the termination block (TB11)
located in the N-400 Controller. For skid mount systems, the tank level device will be factory
wired to the N-400 Controller. In the instance of a dual cabinet skid mounted unit, the tank
level will only be wired toone controller. Note thejumper placement (JP7) for tank level signal
type and adjust if necessary. Refer to the Wiring Control Document in Appendix B and the
Wiring Diagram reference label located inside the N-400 Controller Door or below in Figure 4.
5. If used, connect the optional Remote Inhibit Input signal to the termination block (TB2) located
in the N-400 Controller. Refer to the Wiring Control Document in Appendix B and the Wiring
Diagram reference label located inside the N-400 Controller Door or below in Figure 4.
IMPORTANT: In a system with two cabinets wired for redundancy, the Remote Inhibit input
is used to connect the primary and backup systems. Remote Inhibit will not be available
for use. See Step 7 below for wiring for redundancy.
6. If used, connect the RS-485 communication wiring as required to the termination block (TB16)
located in the N-400 Controller. Refer to the Wiring Control Document in Appendix B and the
Wiring Diagram reference label located inside the N-400 Controller Door or below in Figure 4.

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Page 18 NJEX ZEO Version 04/13/2021
7. If applicable, to wire two cabinets for redundancy, connect the NBS output termination block
(TB14) of the primary system to the Inhibit Input of the backup system (TB2 Pins 3 and 4)
located in the N-400 Controller. Mirror the connection from the backup to the primary system
by connecting the NBS output termination block (TB14) of the backup system to the Inhibit
Input of the primary system (TB2 Pins 3 and 4). Refer to the Wiring Control Document in
Appendix B, the Wiring Diagram reference label located inside the N-400 Controller Door or
below in Figure 4, and the Redundancy Wiring Diagram in Figure 5 if needed.
a On both the primary and backup system, remove the shunt across jumper JP11 and
replace the shunt covering pins 2 and 3. For standard remote inhibit operation without
a backup system, JP11 should be shunted as supplied from the factory across pins 1
and 2.
Figure 4 N-400 Controller Wiring Diagram Label