720G 08182003

NJEX 720 G
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
THE NJEX 720 G
INSTRUCTION & OPERATING MANUAL
Version: NJEX720G ver.08182003
720G TABLE OF CONTENTS
720G Table of Contents .................................................................................................................... I
Section 1: First Things To Know About The 720G .......................................................................1

How to Use this Manual .......................................................................................................................1
Typographic Conventions .................................................................................................................... 1
Getting Help ......................................................................................................................................... 1
Operation Specifications .....................................................................................................................2
Theory of Operation ............................................................................................................................3
Power Options .................................................................................................................................... 4
System Accessories ........................................................................................................................... 5
Section 2: System Installation .........................................................................................................7

Standard System Components ...........................................................................................................7
System Flow Schematic .....................................................................................................................8
Standard System Mounting ................................................................................................................. 9
Standard System Connections ......................................................................................................... 10
Standard System Optional Power Supplies ...................................................................................... 11
Skid System Components ................................................................................................................ 12
System Flow Schematic ................................................................................................................... 13
Skid System Mounting ....................................................................................................................... 14
Skid System Connections ................................................................................................................. 15
Skid System Optional Power Sapless .............................................................................................. 16
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
Optional: SPO-12V Power Supply ..................................................................................................... 20
Optional: EPO-120V Power Supply ................................................................................................... 20
Section 5: Programming for Proportional-to-Flow Operation ................................................... 21

Setting Operator Input Parameters ................................................................................................... 21
Section 6: Programming for Proportional-to-Time Operation .................................................. 27

Setting Operator Input Parameters ................................................................................................... 27
Section 7: Mechanical System ...................................................................................................... 29

Overview ........................................................................................................................................... 29
Bulk Odorant Filter Assembly ............................................................................................................ 30
NJEX Gas Filter ................................................................................................................................. 30
Model 7000 Pump ............................................................................................................................. 31
Pump Actuation Gas Solenoid ........................................................................................................... 31
Pump Actuation Pneumatic Relay ..................................................................................................... 32
YZ Systems, Inc. 3101 Pollok Drive Conroe, Texas USA 77303 P: 936.788.5593 F: 936.788.5720
NJEX 720G ver.08182003 Page I
720G TABLE OF CONTENTS
Section 8: System Maintenance ................................................................................................... 33

Preventative Maintenance Schedule ................................................................................................. 33
Weekly Schedule .............................................................................................................................. 33
Annual Inspection .............................................................................................................................. 33
Section 9: 720G System Troubleshooting ................................................................................... 35

How to Use This Section ................................................................................................................... 35
For Additional Help ....................................................................................................................... 35
Step-by-Step Resolution .............................................................................................................. 35
Battery Test ....................................................................................................................................... 36
Timer Mode Troubleshooting Steps ................................................................................................... 37
Proportional-To-Flow Troubleshooting Steps ..................................................................................... 38
LCD Stroke Indicator Test ............................................................................................................ 39
Non-Linear/Linear Flow Input ....................................................................................................... 40
Pump Performance Troubleshooting ................................................................................................ 41
Appendix A: Illustrations ................................................................................................................ 45

NJEX Model 7000 Pump Assembled ................................................................................................. 45
NJEX Model 7000 Pump Actuation Assembly, Exploded View........................................................... 46
NJEX Model 7000 Pump, Diaphragm Cartridge ................................................................................ 47
NJEX Model 7000 Pump, Check Valve Assemblies and Seals, Exploded View ................................ 48
Bulk Odorant Filter ............................................................................................................................ 49
NJEX Gas Filter ................................................................................................................................. 50
Pneumatic Relay................................................................................................................................ 51
Z-200 Electronics Assembly............................................................................................................... 52
Optional Rosemount DPT................................................................................................................... 53
SPO-12V (Optional) Power Supply ................................................................................................... 54
EPO-120V (Optional) Power Supply ................................................................................................. 55
Z-200 Wiring Control Document........................................................................................................ 56
Page II NJEX 720G ver.08182003
SECTION 1: FIRST THINGS TO KNOW ABOUT THE 720G
72
How to Use this Manual Getting Help
The NJEX-720G Operations Manual is a step-by- This manual provides solutions to typical questions
step guide containing the procedures needed to about the 720G system. If the answer can not be
work with the 720G System. found within this manual, contact YZ Systems at:
The NJEX System Series of odorizers implement the T: 1.936.788.5593

most advanced technology available in the industry. It is T: 1.800.653.9435 (800.NJEX.HELP)
recommended that the technicians working with the F: 1.936.788.5720
NJEX Odorization Systems study the manual prior to Em: Service@yzhq.com
initiating work on the system for the first time.
When calling, have this manual close at hand. Whether
Typographic Conventions calling or writing, please include in your communique the
following information:
To aide in readability, this manual uses several
typographic conventions. References to illustrations, The serial number of the NJEX System and the
photographs, and other related content will appear in version number of this manual. The serial number is
italicized text along with the location of where to find the located on the inside of the enclosure door. The
item in the manual. Digital versions of the manual, version number of this manual is located at the
available in Adobe Acrobat PDF format, will be bottom of each page.
highlighted further in blue italic text indicating the copy
retains a hyperlink to the referenced item. A description of the problem and, if applicable the
actions of the technical personnel when the problem
Measurement units are listed in italic parenthesis text occurred.
following their US standard equivalent. As an example,
for defining a distance, 15' (4.5 meters), is how the text
will appear throughout the manual.
Items that require action, for example the pressing of a

key for programming the controller, will feature the
action item in sentence case Bold Text followed in
normal text by the item such as, the Test key or Power
switch.
Starting with Section 4, System Control & Electron-

ics, the manual will begin discussing the in-depth
operation of the Z-200 electronic controller where
many of these typographic conventions will be
found. In the discussion about the controller, the
technician will learn about the multiple switches
used to program the Z-200 for operation. Further
discussion on the functions of the Z-200 controller
will take place in Section 4, System Control and
Electronics, on page 19.
Adobe Acrobat & Acrobat Reader are trademarks of Adobe Systems, Inc.
NJEX 720G ver.08182003 Page 1
Operation Specifications
Maximum Odorant Output: .38 gallons/day
(1.44 liters/day)
Maximum Operating Pressure: 1,440 psig
(99.28 Bar (g)
Operating Temp Range: 0 to 140 degrees F.
(17C to 60C)
Power Supply: LBP-14 Battery (std),
EPO-120V external
power supply (opt),
SPO-12V solar power
supply (opt)
Gas Flow Input Signal: 4-20mA or 1-5 VDC
Analog Signal
Note: at temperatures below 32 F (0 C), conditioning 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
filtration 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 affect 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
30 F (-1 C).
Page 2 NJEX 720G ver.08182003
72
Theory of Operation
Proportional-To-Time Operation: In this mode
of operation, the 720G injects odorant into the
pipeline at regular time intervals. The volume
injected per stroke is set by the operator using
volume adjustment spacers featured in the 7000
pump. The Z-200 operates as a recycling timer,
periodically energizing a low power solenoid
valve. Energizing the solenoid valve allows
actuation gas to stroke the 7000 pump. The rate
at which this occurs is set by the operator using
three 10-position switches on the Z-200. The
number of times the solenoid output is activated
is recorded by the onboard LCD indicator.
Proportional-To-Flow Operation: In this mode

of operation, the Z-200 operates as a recycling
timer with the exception that the off time is
adjusted to compensate for variations in pipeline
flow conditions. The injection rate is a function of
operator inputs and the flow signal voltage. The
volume injected per stroke is set by the operator
using volume adjustment spacers featured in the
7000 pump. Three 10 position switches and a
mode switch are used to set the flow param-
eters. The number of times the solenoid output
is actuated is recorded by an onboard LCD
indicator.
CAUTION:
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
1.936.788.5593.
Power Options:
Long-Life Battery: The Z-200 timer/counter

operates using a replaceable internal battery
pack. As the standard power source, the battery
pack condition is monitored by way of two indica-
tor LEDs. When the battery pack needs replace-
ment, 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.
AC Power Option: If conditions exist that make

replacement of the internal battery undesirable,
the External Power Option (Model EPO-120V)
can be used in lieu of the internal battery pack.
The EPO-120V consists of an AC-to-DC conver-
tor and intrinsically safe barrier that converts 120
VAC to 28 VDC to operate the Controller without
the use of an internal battery pack.
Solar Power Option: This power option may

also be used in lieu of the internal battery pack.
The Solar Power Option (Model SPO-12V)
consists of a 5 watt solar panel with RM-12
charger regulator module and internal 12V, 5
Amp hour battery pack.
72
System Accessories
Odorant Injection Probe, includes a 316
stainless steel probe, and isolation valve for
location at the pipeline. When ordering, please
specify pipeline connection required, 1/2" or 3/4".
Odorant Injection Probe with Sightglass, 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, odorant
discharge, and differential pressure switch
connections, (P/N A1-0182).
NJEX Scrubbers. These filters are designed to
scrub the exhaust gas vented from the pumps.
They are available by ordering P/N C4-0024,
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.
Notes
SECTION 2: SYSTEM INSTALLA
NSTALLATION
ALLATION
Standard System Components

Standard primary components of the NJEX-720G
include the following:
System Controller. The Z-200 Controller with

internal battery assembly.
Odorant Injection Pump. The NJEX 7000 is

a pneumatically actuated, positive displacement,
reciprocating style plunger pump.
Bulk Odorant Filter. Provides primary odor-

ant filtration between the storage tank and the
NJEX-720G. The Bulk odorant filter is equipped
with 1/4" FNPT connections.
System Enclosure. Houses the Model 7000

pump, the Z-200 Controller, and the actuation
gas manifolds.
NJEX Gas Filter. Installed before the actua-

tion gas regulator, this filter provides a 25 micron
coalescent filtration to insure a clean pneumatic
supply.
Pump Actuation Model 7000F

Solenoid Metering Pump
System Enclosure
Figure 1 Z-200 Controller 4-20 mA or 1-5VDC
Analog Flow Signal
Odorant From
Bulk Filter
Odorant to
Pipeline
Actuation Gas Out
To Regulator Odorant To 720G
Regulated
Actuation Gas In NJEX Gas Filter Odorant
Inlet
NJEX Gas Filter Bulk Odorant

Filter Assembly
NSTALLATION
ALLATION
System Flow Schematic

Figure 2
720G ENCLOSURE OPTIONAL SYSTEM POWER

Z-200
Timer/Controller
EPO-120 Power Option
(120 VAC By Customer)
4-20 mA or 1-5VDC
Analog Flow Signal - Or -
By Customer (CEVQT[
/WVWCN
5[UVGO
4463:/.
SPO-12 Power Option
NJEX Gas
Gas Supply Filter
50-60 psi
(3.45-4.15 Bar)
By Customer
7000F
Pump
V18
V17
Bulk
Odorant
Filter
From Odorant
Supply
25 psi Min.
ODORANT SIGHTGLASS/ (1.72 Bar Min.)
PROBE ASSEMBLY
(Option)
V8
Pipeline
Legend
Actuation Gas Pneumatic Relay Pressure Regulator w/Gauge
Odorant Normally Open Valve Solenoid Valve
Electrical Check Valve
NSTALLATION
ALLATION
Standard System Mounting
1. Securely attach a section of 2 pipe in a vertical

configuration at the location where the NJEX
720G is to be installed. Using the mounting
clamps provided with the NJEX 720G System,
attach the system to the pipe.
2. Connect a ground wire from the 2 pipe to a properly

installed ground rod, located adjacent to the pipe.
Figure 3
ODORANT
OUT ODORANT
OUT
ODORANT SUPPLY IN
ODORANT FILTER ACTUATION
GAS IN NJEX Gas Filter
ACTUATION
GAS FILTER
GROUNDING ROD
NSTALLATION
ALLATION
Standard System Connections

Required field connections to place the 720G into Figure 4
operation are as follows: 4
1. Connect the odorant supply source to the bulk

odorant filter inlet (1/4 or 3/8" stainless steel
tubing is recommended).
5
2. Connect the bulk odorant filter discharge to
the pump inlet isolation valve fitting (1/4" stain-
less steel tubing is required).
3. Connect the regulated actuation gas source

(50-60 psi, 3.45-4.15 Bar, by customer) to the 2
NJEX gas filter inlet.

1
NOTE: In applications where the actuation gas

supply has a high water content and/or a low
hydrocarbon dew point, additional actual gas
filtration or heating of the 720G system may be
necessary. Bottled nitrogen can also be used
during cold operating conditions to avoid conden-
sation in the actuation gas supply line. Also, an 3 NJEX Gas Filter
4
actuation gas source pressure of 50 psi
(3.45 Bar) should be adequate in most installations.
4. Connect the NJEX gas filter outlet to the

upper port on the actuation gas regulator tee
located on the right side of the enclosure.
5. Connect the pump discharge valve fitting to

the pipeline connection.
7. Connect the flow signal device to the termina-

tion strip located in the system control enclosure
(see Wiring Control Document, page 56).
CAUTION:
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 1.936.788.5593.
NSTALLATION
ALLATION
Optional Power Supply: Figure 5

Connect the yellow SPO-12V power cable,
Figure 5, or the EPO-120V yellow power cable,
Figure 6, to the system control enclosure.
NOTE: the solar panel should be mounted free

of obstructing shade and should be facing South
in the Northern Hemisphere, and facing North in
the Southern Hemisphere.
Figure 6
NSTALLATION
ALLATION
OPTIONAL
Skid System Components SOLAR PANEL
Figure 7
Introduction
The NJEX SkidMount Series of odorization systems
is a total system approach to odorization. These
systems are completely factory assembled, tested,
and delivered requiring only three field connections
SYSTEM
to be fully operational. The NJEX SkidMount ENCLOSURE
Systems offer all the advantages of our standard BULK ODORANT
720G Systems plus the added benefit of an FILTER
onboard odorant storage tank. The configuration BULK ODORANT
TANK
allows for a total systems approach to odorization.
The Systems are available with 20, 60, 120, 250,

500 and 1000 gallon tank sizes. Additional optional
size tanks are available on request.
Skid system primary components of the NJEX-720G

include the following:
Skid Mounted Tank a pre-assembled, and tested

Structural steel skid with odorant tank, valve
package, skid piping, and system enclosure.
System Controller. The Z-200 Controller

with internal battery assembly.
Figure 8
Odorant Injection Pump. The NJEX 7000 is
a pneumatically actuated, positive displacement
pump.
Bulk Odorant Filter. Provides primary

odorant filtration between the storage tank and
the NJEX-720G. The Bulk odorant filter is
equipped with 1/4" FNPT connections.
System Enclosure. Houses the Model 7000F

pump, the Z-200 Controller, and the actuation
X GAS FILTER
gas manifolds.
NJEX Gas Filter. Installed before the actua-

tion gas regulator, this filter provides a 25 micron
coalescent filtration to insure a clean pneumatic
supply.
NSTALLATION
ALLATION
System Flow Schematic

Figure 9
720G ENCLOSURE OPTIONAL SYSTEM POWER

Z-200
Timer/Controller
EPO-120 Power Option
(120 VAC By Customer)
4-20 mA or 1-5VDC
Analog Flow Signal - Or -
By Customer ( CEVQ T[
/ WVWCN
5 [UVG O
4463 :/.
SPO-12 Power Option
Gas Supply
50-60 psi
(3.45-4.15 Bar) NJEX Gas
By Customer Filter
7000F
Pump
V18
V17
Bulk
Odorant
Filter
From Odorant
Supply
25 psi Min.
PROBE ASSEMBLY
(Option)
V8
30 psi
Pipeline NJEX STORAGE TANK
LI
V15 V13 V12 V11 V10

Min. 25 psi
(1.72 Bar)
Legend
Actuation Gas Normally Closed Valve LI Level Indicator Pneumatic Relay
Odorant Normally Open Valve Pressure Regulator w/Gauge

Electrical Check Valve Pressure Relief Valve
Solenoid Valve
V8 Injection Probe Pipeline V12 RV Isolation Valve V15 Odorant Supply

Isolation Valve Note: V12 not installed on Isolation Valve
V10 Odorant Storage 20 & 60 gal. Tanks. V17 Odorant Inlet
V13 Odorant Storage Tank Isolation Valve
Tank Fill Valve
Blanket Gas Isolation Valve V18 Odorant Discharge Line
V11 Odorant Storage Tank
Isolation Valve
Vapor Return Valve
NSTALLATION
ALLATION
Skid System Mounting:

1. Bolt down the system to a concrete slab using
the mounting holes 3/4" (19 mm) provided in the
skid. Recommended slab size is 12" (30.5 mm)
wider and longer than the skid. Recommended
bolt/stud sizes for mounting the skid are either
11/16" or 5/8".
2. Connect a ground wire to one of the grounding
lugs located on the skid.
Sample Skid Dimensions

Model C D App. Weight
720G-20 96"(244 cm) 26"(66 cm) 850 lbs.(386 kg)
720G-60 122"(310 cm) 32"(81 cm) 1200 lbs.(544 kg)
720G-120 147"(373 cm) 39"(99 cm) 1700 lbs.(771 kg)
Figure 10
C
1"
1"
FILL VALVE
VAPOR RETURN
RELIEF VALVE
LEVEL INDICATOR
BLANKET GAS
ODORANT SUPPLY
D
3/4" Holes
(4 Places)
NSTALLATION
ALLATION
Skid System Connections
Required field connections to place the 720G into Figure 12

operation are as follows:
1. Connect the regulated actuation gas source

(50-60 psi, 3.44 - 4.15 Bar, by customer) to the 3
NJEX gas filter inlet.
NOTE: In applications where the actuation gas

supply has a high water content and/or a low
hydrocarbon dew point, additional actual gas
filtration or heating of the 720G system may be
necessary. Bottled nitrogen can also be used 2
during cold operating conditions to avoid conden-
sation in the actuation gas supply line. Also, an
actuation gas source pressure of 50 psi (3.45
Bar) should be adequate in most installations.
ODORANT FILTER
2. Connect the pump discharge valve fitting to

the pipeline connection.
1
3. Connect the flow signal device to the termina-
tion strip located in the system control enclosure
(see Wiring Control Diagram, page 56).
CAUTION:
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 1.936.788.5593.
NSTALLATION
ALLATION
Optional Power Supply:

Connect the yellow SPO-12V power cable, Figure 13
Figure 13, or the EPO-120V yellow power cable,
Figure 14, to the system control enclosure.
NOTE: the solar panel should be mounted free

of obstructing shade and should be facing South
in the Northern Hemisphere, and facing North in
the Southern Hemisphere.
Figure 14
SECTION 3: FILLING THE BULK ODORANT TANK
3. To purge the tank open valve V10 to introduce
Filling the Tank for the First Time inert or natural gas to the tank to begin displac-
ing any ambient air from the empty tank. Con-
CAUTION:
CAUTION: tinue until pressure on the gage located directly
Odorant has a very strong odor, which if allowed to above V13 is observed, then partially open V11
escape to the atmosphere, may cause problems in the to allow ambient air from the tank to begin
local community. Take necessary precautions when flowing out. Allow this process to continue until
filling an odorant storage tank to assure that the local all ambient air from the tank is purged, and only
community is not disrupted during the filling process. inert gas or natural gas is emitting from this
Verify that the entire system has no pressure in it before valve, then close V11 and V10. The time required
beginning. Additionally, all personnel should wear to accomplish this task will vary with the tank
protective clothing, and use equipment as recom- size.
mended by the chemical manufacturer during this time.
If you are uncertain about any aspect of the odorant 4. Vent purge gas by opening V11 partially until tank
itself, you should contact the manufacturer of your pressure just reaches zero, and then close V11.
chemical prior to proceeding.
5. Attach odorant supply to V10, open V10, and begin
1. Verify correct position of valves before begin- transferring odorant to the bulk tank.
ning, Figure 15
6. Connect a line from V11 to a flare or vapor recovery
Open: V12, and V13* device, and open V11.
Closed: V10, V11, and V15 CAUTION:

CAUTION:
*Note Gas Supply to V13 should NOT be turned on Fill tank to a maximum level of 80% of the tank capacity.
during this procedure.
7. Close V10 and V11, and remove odorant transfer
2. Attach inert or natural gas supply to V10. equipment, and line to flare or vapor recovery
Gas Supply
50-60 psi
device.
By Customer Filter
8. Continue through the remaining procedures in this

7000F
manual.
Pump
V18
V17
Figure 15 Bulk
Odorant
Filter
From Odorant
Supply
25 psi Min.
PROBE ASSEMBLY
(Option)
V8
30 psi
LI
V15 V13 V12 V11 V10

Min. 25 psi
(1.72 Bar)
Legend
Actuation Gas Normally Closed Valve LI Level Indicator V8 Injection Probe Pipeline V12 RV Isolation Valve V15 Odorant Supply
Odorant Normally Open Valve Pressure Regulator w/Gauge V10 Odorant Storage 20 & 60 gal. Tanks. V17 Odorant Inlet
Electrical Check Valve Pressure Relief Valve Tank Fill Valve
Solenoid Valve Isolation Valve
Vapor Return Valve
SECTION 3: FILLING THE BULK ODORANT TANK
Refilling the Bulk Odorant Tank
CAUTION:
CAUTION: 3. Connect a line from V11 to a flare or vapor
recovery device, and open V11.
Odorant has a very strong odor, which if allowed to
escape to the atmosphere, may cause problems in the
4. Attach odorant supply to V10, open V10, and begin
local community. Take necessary precautions when
transferring odorant to the bulk tank.
filling an odorant storage tank to assure that the local
community is not disrupted during the filling process.
Verify that the entire system has no pressure in it before CAUTION:
CAUTION:
beginning. Additionally all personnel should wear Fill tank to a maximum level of 80% of the tank capacity.
protective clothing, and use equipment as recommended
by the chemical manufacturer during this time. If you are 5. Close V10 and V11, and remove odorant transfer
uncertain about any aspect of the odorant itself, you equipment, and line to flare or vapor recovery
should contact the manufacturer of your chemical prior device.
to proceeding.
6. Open V13 and V15.
1. Place the Z-200 controller in the OFF Mode by
placing Mode Switch #1 in the Down position. 7. Place the Z-200 controller in a Running Mode by
placing the Mode Switch in the appropriate
2. Verify correct position of valves before begin- position. (Refer to Section 5 for Proportional-To-
ning, Figure 16. Flow operation, or Section 6 for Proportional-To-
Time operation).
Open: V12
Closed: V10, V11, V13, V15
Gas Supply
50-60 psi
By Customer Filter
7000F
Pump
V18
V17
Bulk
Odorant
Filter
Figure 16 From Odorant
Supply
25 psi Min.
PROBE ASSEMBLY
(Option)
V8
30 psi
LI
V15 V13 V12 V11 V10

Min. 25 psi
(1.72 Bar)
Legend
Actuation Gas Normally Closed Valve LI Level Indicator V8 Injection Probe Pipeline V12 RV Isolation Valve V15 Odorant Supply
Odorant Normally Open Valve Pressure Regulator w/Gauge V10 Odorant Storage 20 & 60 gal. Tanks. V17 Odorant Inlet
Electrical Check Valve Pressure Relief Valve Tank Fill Valve
Solenoid Valve Isolation Valve
Vapor Return Valve
SECTION 4: SYSTEM CONTROL & ELECTR
ONTROL ONICS
LECTRONICS
Overview Figure 17
The 720G control/electronics system is composed of

the system control enclosure, which may be pow-
ered off the LBP-14 internal battery, or may have
the SPO-12 solar charged power supply, or an
EPO-120 power supply, Figure 17. Individual OPTIONAL SPO-12
components of the system are shown below and are
described in the following pages.
The electronic control package provided with

your 720G odorizing system consists of a solid
state Z-200 Controller, and a Low Powered Z-200 Controller
Z-65/3.10 Controller
Solenoid. The Z-200 energizes the solenoid Mode Switch

Mode Switch
which in turn sends a pneumatic actuation signal

via a pneumatic relay, to the Sample Pump,
every time a sample is required either Propor-
tional-To-Flow, or Time.
(CEVQT[
/WVWCN
5[UVGO
4463:/.
SAFETY NOTES
(CEVQT[
NOTES
/WVWCN
5[UVGO
4463:/.
Always use extreme care when performing mainte-

nance on Sampling Systems. Always take necessary OPTIONAL EPO-120
measures to assure that electrical classification in the
area is considered, before, and during all repairs, and
that necessary steps are taken to maintain proper
electrical procedures for the classification of the area.
The control package requires you to configure

the Z-200 controller to operate in a Proportional-
To-Flow mode, refer Section 5, to page 21, or a
Proportional-To-Time mode, refer toSection 6,
page 23. All wiring connected to the Z-200
controller must be done in accordance with the
Wiring Control Document, refer to Appendix A,
page 56. NJEX 720G electronics are rated for
use in Class I, Division 1, Groups C and D
hazardous locations.
SECTION 4: SYSTEM CONTROL & ELECTR
ONTROL ONICS
LECTRONICS
Optional:
SPO-12V Power Supply
Figure 18
In lieu of using the standard LBP-14 internal battery of
the Z-200 controller as a power source, an SPO-12V
intrinsically safe power supply may have been or-
dered, with your 720G system. An SPO-12V intrinsi-
cally safe power supply consists of a solar panel
assembly as shown in Figure 18, which includes a
solar panel, rechargable battery, and circuit protection.
The SPO-12V must be mounted in such a manner as
to provide direct sunlight to the panel. In the Norther
Hemisphere the panel should be mounted facing
south, and in the Southern Hemisphere the panel
should be mounted facing North. The 720G will
operate on the battery for approximately 30 days
without additional power generated by the solar panel.
The yellow power cable from the Z-200 controller must
be connected to the cable connector located on the
bottom of the SPO-12V.
Optional:
EPO-120V Power Supply
In lieu of using the standard LBP-14 internal battery of

the Z-200 controller as a power source, or an SPO-
12V intrinsically safe power supply, your 720G system Figure 19
may have been ordered, with an EPO-120V external
power supply . An EPO-120V external power supply
consists of an explosion proof enclosure containing a
120 VAC to DC power supply, Intrinsically Safe Barrier,
and a cable to connect to the Z-65, as shown in Figure
19. All wiring connected to the Z-65 controller must be
done in accordance with the Wiring Control Document,
refer to Appendix A, page 56. NJEX 720G electronics
are rated for use in Class I, Division 1, Groups C and
D hazardous locations.
SAFETY NOTES
NOTES
nance on Sampling Systems. Always take necessary
measures to assure that electrical classification in the
area is considered, before, and during all repairs, and
that necessary steps are taken to maintain proper
electrical procedures for the classification of the area.
SECTION 5: PROGRAMMING FOR PROPORTION
OPORTIONAL-TO-FLOW OPERA
TIONAL TION
PERATION
Z-200 Controller Setup:

Proportional-To-Flow Operation
In this mode of operation, the Z-200 uses operator

inputs in conjunction with the 4-20mA or 1 - 5 VDC
flow input to vary the time that will transpire between
pump strokes. Use the example below to calculate
initial flow percentage and initial stroke rate settings,
given the values shown.
Figure 20
1. Pump displacement (0.2 to 1.0 cc) = a

2. Odorant density (lb/gal or g/cc) = b
3. Desired injection rate (lb/MMCF or mg/m3) = c
4. Average flow rate (MCF/hr or m3/hr) = d
5. Maximum flow rate (MCF/hr or m3/hr) = e
6. Initial percentage flow (mode 2 - xx.x%) = d/e x 100%
7. Initial stroke rate (mode 1 - x.xx minutes)
a. English = a x b x 15.8503*
cxd
b. Metric = a x b x 60000*
cxd
Example #1 Example #2
English Gas Flow Metric Gas Flow
pump displacement (a) = .5 cc .5 cc
odorant density (b) = 6.80 lb/gal .815 g/cc
injection rate (c) = .5 lb/MMCF 8 mg/m3
average flow rate (d) = 60.00 MCF/hr 1700 m3/hr
maximum flow rate (e) = 120.0 MCF/hr 3400 m3/hr
Initial stroke rate setting (Mode 1)

Example #1 .5cc x 6.8 lb/gal x 15.8503*
Time = .5 lb/MMCF x 60 MCF/hr = 1.8 minutes
Example #2 .5 cc x .815 g/cc x 60000*

Time = 8 mg/m3 x 1700 m3/hr = 1.8 minutes
*conversion constant
Initial % Flow setting (Mode 2) 60/120 x 100% = 50.0% 1700/3400 x 100% = 50.0%
NOTE: To obtain maximum battery life, choose the longest time interval and the largest pump dis-
placement setting possible.
TIONAL TION
PERATION
Setting Operator Input Parameters Figure 21
In order for the Z-200 Controller to operate in the

proportional-to-flow mode of operation it will be
necessary to enter all of the following param-
eters:
Loss of flow input: (CEVQT[

/WVWCN
5[UVGO
(X.XX min) Mode #7 Default 2.00 min 4463:/.
The loss of flow input setting is a predetermined

amount of time that the operator would like to see
transpire between pump strokes in the event that
the 1 - 5 VDC flow input signal is lost.
Figure 22
To set the loss of flow input:
1. Set the mode switch to position #7.
2. Set the data switches to the desired
time (X.XX minutes).
Ex: 2 minutes = 2.00
3. Depress the enter switch to load the
value into memory.
NOTE: the green LED will flash if entry is

accepted; the red LED will flash if not accepted.
Low flow shut-off:

(XX.X%) Mode #6 Default 2.0%
The low flow shut-off setting allows a preset point
in % of flow to be set that the operator would like
the Z-200 to stop operating. This allows the
Controller to sense low flow conditions that might
exist in the pipeline where operation of the Z-200
Controller is not wanted. When flow again Figure 23
increases above this point the Z-200 will again
resume operation.
To set the low flow shut-off:

% flow (XX.X%).
Ex: 2% = 02.0
value into memory.

TIONAL TION
PERATION
Figure 24
Zero calibration:
Mode #4 (1.00VDC @ 0% of metered flow)
The zero calibration adjustment is used to

calibrate the Z-200 Controller for 0% of metered
flow in the pipeline (1 VDC). The Z-200 Control-
ler is calibrated at the factory for 0% of flow to
directly correspond to 1.00 VDC at the flow input
terminals #4 and #5. (CEVQT[
/WVWCN
5[UVGO
4463:/.
To set zero calibration:

2. Apply 1.00 VDC to the terminal strip
terminal #4 (+signal input); terminal #5 Figure 25
(-signal input). If a DPT is being used,
output from the transmitter should be
1.00 VDC @ 0" (0 cm) differential
pressure (See DPT calibration pages 53).
zero setting into memory.

Span calibration:
Mode #3 (5.00VDC @ 100% of metered flow)
The span calibration adjustment is used to

calibrate the Z-200 Controller for 100% of me-
tered flow in the pipeline (5 VDC). The Z-200
Controller is calibrated at the factory for 100%
flow to directly correspond to 5.00VDC at the
flow input terminals #4 and #5. Figure 26
To set the span calibration:

2. Apply 5.00 VDC to the terminal strip
terminal #4 (+signal input); terminal #5
(-signal input). If a DPT is being used,
output from the transmitter should be
5.00 VDC @ maximum range of meter.
Ex.: 5.00 VDC @ 100" (254 cm) water
differential pressure
(See DPT calibration pages 53).
3. Depress the enter switch to load the NOTE: for maximum accuracy, after setting the
span setting into memory. span, return to the zero calibration section and
repeat both zero and span procedures in that
NOTE: the green LED will flash if entry is order.
TIONAL TION
PERATION
Figure 27
Initial percentage flow:
(XX.X%) Mode #2 Default 50.0%
The initial percentage flow should be set by the

operator to the typical or average % of metered
flow that exists in the pipeline. This should be
based upon historical flow measurement records
from the metering device being used. If the (CEVQT[
/WVWCN
5[UVGO
history is not known, use an anticipated value. 4463:/.
To set initial percentage flow:

Figure 28
2. Set the data switches to the desired %
of flow (X.XX%).
Ex.: 50% = 50.0
value into memory.

Initial stroke rate:

(X.XX min) Mode #1 Default 2.00 min
NOTE: To obtain maximum battery life, choose
The initial stroke rate is set by the operator to the the longest time interval and the largest pump
amount of time that would be desired to transpire displacement setting possible.
between pump strokes if the % of flow measured
in the pipeline was equal to that set in mode
position #2 (initial percentage flow). Figure 29
To set the initial stroke rate:

time (X.XX minutes).
Ex.: 2 minutes = 2.00
value into memory.

TIONAL TION
PERATION
Figure 30
Run Mode: the run mode position is the position
that the mode switch should be in to start the
Z-200 Controller in the proportional-to-flow mode
of operation. When in this mode of operation the
Z-200 Controller will monitor the flow input and
adjust the time interval between pump strokes to
be proportional to the % of flow measured in the
pipeline.
(CEVQT[
/WVWCN
5[UVGO
4463:/.
To start the Z-200/3.10 Controller:

2. Depress the enter switch to begin Figure 31
operation.
NOTE: If all parameters (mode #'s 7, 6, 4, 3, 2,

1) have not been entered properly, a red LED will
illuminate and stay on and the Controller will not
start in the run mode position #0 when the enter
switch is depressed. See the LED indicator
chart in the trouble shooting section of the
manual if the Z-200Controller does not seem to
operate properly.
TIONAL TION
PERATION
Notes
OPORTIONAL-TO-TIME OPERA
TIONAL TION
PERATION
Setting Operator Input Parameters Figure 32

Z-200 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 examples below to calculate the timer setting
needed.
(CEVQT[
/WVWCN
5[UVGO
4463:/.
Figure 33
1. Pump displacement (0.2 to 1.0 cc) = a

2. Odorant density (lb/gal or g/cc) = b
3. Desired injection rate (lb/MMCF or mg/m3) = c
4. Average flow rate (MCF/hr or m3/hr) = d
5. Timer setting
a. English = a x b x 15.8503*
cxd
b. Metric = a x b x 60000*
cxd
Example #1 Example #2
English Gas Flow Metric Gas Flow
pump displacement (a) = 0.5 cc 0.5 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 timer setting = 0.5cc x 6.8 lb/gal x 15.8503*

.5 lb/MMCF x 6 MCF/hr = 18 minutes
Example #2 timer setting = 0.5 cc x .815 g/cc x 60000*

8 mg/m3 x 170 m3/hr =18 minutes
*conversion constant
OPORTIONAL-TO-TIME OPERA
TIONAL TION
PERATION
NOTE: To obtain maximum battery life, choose

the longest time interval and the largest pump Figure 34
displacement setting possible.
1. Adjust the pump volume adjustment

knob to the value used in the calcula-
tions in example 1 or 2.
time in minutes XX.X minutes.
Ex.: 18 minutes = 18.0
time into memory to start operation.
NOTE: see the LED indicator chart in the trouble

shooting section of the manual if the Z-200
controller does not seem to operate properly.
NOTE: Time (18.0 minutes) above corresponds to dial setting

shown for the Z-200.1 model. (For the Z-200.10, the time would
be 1.80 minutes - the decimal moves one place to the left).
SECTION 7: MECHANICAL SYSTEM
Overview:
The 720G mechanical system is composed of
the mechanical/electrical enclosure. Individual
components of the system are shown below and
described in the following pages.
Figure 35
Pump Actuation Model 7000F

Solenoid Metering Pump
Z-200 Controller 4-20 mA or 1-5VDC System Enclosure

Analog Flow Signal
Odorant From
Bulk Filter
Odorant to
Pipeline
Actuation Gas Out
To Regulator Odorant To 720G
Regulated
Actuation Gas In NJEX Gas Filter Odorant
Inlet
NJEX Gas Filter Bulk Odorant

Filter Assembly
Bulk Odorant Filter Assembly:
The bulk odorant filter assembly should be Figure 36

located just below the mechanical enclosure and
performs the following functions:
provides the system's odorant supply

connection by means of a 1/4" FNPT
connection.
houses the odorant filter system within the
720G System
In the event that the internal filter elements

become dirty, a bulk odorant filter repair kit is
available.
Figure 37
NJEX Gas Filter
A 25 micron coalescent filter is provided with each
6300G This filter, Figure 37, is installed on the back
outside of the enclosure and should be connected
to the regulated (50-60 psi / 3.45-4.15 Bar) actua-
tion 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 filtration and
heating of the actuation gas supply may be neces-
sary. Bottled nitrogen can also be used as an
alternate gas supply source if gas conditioning is a
problem.
Model 7000 pump
Figure 38
The NJEX 7000F pump, figure 175, is a pneumati-
cally actuated, positive displacement, reciprocating
plunger pump. The 7000F is actuated with com-
pressed air or pipeline gas at a pressure of 30 - 60
psi (2.07 - 4.14 Bar), refer to Section 2, the System
Flow Schematic, illustration 2, on page 8. The pump
has an adjustable displacement of 1.0cc, 0.8cc,
0.7cc, 0.6cc, 0.5cc, 0.4cc, 0.3cc or 0.2cc. It
achieves proportional-to-flow injection through
adjustment of the stroke rate. The 7000F is rated for
a maximum stroke rate of 46 strokes per minute.
Each time the pump strokes, the plunger displaces

hydraulic fluid against the pump diaphragm, which
in turn displaces odorant through the discharge
check valve. The pump diaphragm acts as an
isolation device between the hydraulic fluid and the
odorant, minimizing the risk of odorant escape into
the atmosphere. Each time the plunger returns, it
completely removes itself from the plunger seal.
This allows any air trapped in the hydraulic system
to be vented.
The 7000F incorporates a cartridge design in the

four areas that are most likely to require mainte-
nance. They are: the diaphragm assembly, 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.
Figure 39
Pump Actuation Solenoid:
Actuation Gas
Supply
This actuation gas manifold houses the actuation
Solenoid
gas solenoid and the pneumatic exhaust connec-
tion for solenoid. 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.
Exhaust
Muffler
Pump Actuation
Pneumatic Relay:
Figure 40
This actuation gas manifold houses the pump
actuation pneumatic relay and the pneumatic
exhaust connection for the relay. These openings
are located on the right side of the mechanical
enclosure and are ported through the enclosure
wall. The upper manifold connection is for the
exhaust connection, while the lower connection
is for the actuation gas supply. A pneumatic
realay is required to provide sufficient volumn of
gas to stroke the pump in a timely fashion. This
would not be possible directly though the tiny
orfice of the solenoid.
SECTION 8: SYSTEM MAINTENANCE
AINTENANCE
Preventative Maintenance
Schedule
Recommended Spare Parts List
A preventative maintenance program serves to antici-
pate maintenance issues prior to waiting until the system Part # Description Recommended
requires service. Like changing the oil & filters in an Quantity
automobile, by choosing to service the various parts and A4-0003 3-way solenoid valve 1
operation in the NJEX System at regular intervals, the C4-0133 NJEX gas filter replacement
technician can perform the maintenance service when filter element 1
desired, rather than when required, such as in the D3-0103 Bulk odorant filter element
middle of night. replacement kit 1
D3-0131 Model 7000F pump seal
The key is to perform maintenance before it is required. replacement kit 1
The preventative maintenance schedule implemented D3-0142 Z-65/200 fuse replacement kit 1
should consider the application of the odorizer. Many of E3-2001 LBP-14 internal Z-65 battery 1
these considerations include: the weather environment;
the condition of, the actuation gas, the odorant and the
odorant bulk storage tank, and the pump stroke fre-
quency. All of these issues must be considered when
establishing a preventative maintenance schedule.
Recommended Maintenance Schedule

Weekly Inspection
1. Verify gas pressures
2. Check for gas and odorant leaks
3. Visually inspect for obvious external problems
Annual Inspection
1. Change filters
2. Rebuild pump
3. Replace solenoid
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)
SECTION 8: SYSTEM MAINTENANCE
AINTENANCE
Notes
SECTION 9: 720G SYSTEM TROUBLESHOOTING
OUBLESHOOTING
How to Use This Section Step-by-Step Resolution

The recommendations contained in this section should be Using a step-by-step method to resolve issues on the
used as a preliminary information resource to remedy opera- NJEX System will reduce maintenance time and assit in
tional issues with the NJEX System. It is important to read all of returning the odorization system to service quicker.
the definitions and notes prior to initiating work.
The following repesent the recommended chronology to
Each sub-section contains a description of the alarm resolve issues:
and non-alarm indicators followed by a step-by-step
trouble shooting proceedure. 1. Re-establish the correct pressures.
a. Bulk Storage Tank, 25psi (2.07-2.41 Bar)
b. Actuation Supply, 50-60 psi (3.45-4.13 Bar)
For Additional Help 2. Verify that the odorant storage tank has suffi-
cient odorant in it to supply the NJEX 720G
Any issue that can not be resolved through the use of with odorant.
this reference, please contact YZ Technical Service at:
3. Proceed to applicable troubleshooting aids on
T: 1.800.653.9435 (1.800.NJEX-HELP) the following pages.
T: 1.936.788.5526, International Calls
F: 1.936.788.5720
Em: Service@yzhq.com
Assistance is available 24 hours a day, 7 days a week,

365 days a year, via the telephone numbers listed above.
SAFETY NOTES
NOTES
nance 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 packings semi-

annually to ensure that liquid odorant remains within
the system.
OUBLESHOOTING
Battery Test:
A. Set the mode switch in the mode position #5. NOTE: the solenoid must be connected to test
B. Depress the test switch. the battery condition. Battery condition cannot
C. When the solenoid fires: be tested with a volt meter.
A green LED signifies a good battery.
A red LED signifies a depleted battery.
Replacing a Depleted Battery

1. Remove the four thumb screws, cover plate
and terminal strip.
Figure 41
2. The battery is located in the lower left hand
corner of the Z-200 controller assembly.
3. Unclip the battery plug from the battery

receptacle.
4. Replace the depleted battery with a fresh Battery Pack
battery pack (part No. E3-2001).
NOTE: follow the illustration to assure proper

battery wire placement in the Z-200 enclosure.
5. Return the mode switches to their original

positions.
6. Dispose of your old battery through a local

battery disposal service, or send your depleted
battery to:
YZ Systems Inc.
206 Lubbock Hwy.
Snyder, TX 79549 USA
OUBLESHOOTING
Troubleshooting: Timer Mode #5

Figure 42
Proportional-to-Time
A. Set the mode switch to position #5.
B. Set the data switches to 00.0 to enter the

Figure 43
diagnostic mode of operation.
C. Depress the enter switch to load the value

into the memory.
D. This mode of operation enables the operator

to increase the solenoid output rate to one
actuation every two seconds.
NOTE: the LCD stroke indicator should incre-

ment each time the solenoid actuates.
LED Indicator Chart (proportional-to-time only)
green red condition
on off solenoid on, good battery

off on solenoid on, low battery
NOTE: on means for approximately one half

second.
To test the LED indicators, depress the test

switch located on the front of the controller.
Timer Setting
A. Z-200/6.1 - all time settings are xx.x minutes
B. Z-200/6.10 - all time settings are x.xx minutes.
OUBLESHOOTING
Troubleshooting: Run Mode #0

Proportional-to-Flow
A. Refer to the controller set-up section in the

manual and make sure the following
parameters have been set:
1. mode #7 loss of flow input (XX.X min)
(X.XX min for Z-200.10)
2. mode #6 low flow shut off (XX.X%)
3. mode #4 zero calibration
(1.0V @ 0% flow)
4. mode #3 span calibration
(5.0V @ 100% flow)
5. mode #2 initial percentage flow
(XX.X%)
6. mode #1 initial stroke rate (XX.X min)
(X.XX min for Z-200.10)
NOTE: if all parameters have not been entered

properly, a red LED will illuminate and stay on
and the controller will not start in run mode
position #0 when the enter switch is depressed.
B. After these inputs have been re-entered,

depress enter switch to start operation.
LED indicator chart (proportional-to-flow mode only)

Green Red Condition
on off solenoid on, good battery
off on solenoid on, low battery
blink off lowflow shut off imposed
off blink loss of flow input alarm
NOTE: on means for approximately one half

second. Blink means on for approximately 20
milliseconds.
To test the LED indicators, depress the test

switch located on the front of the controller.
OUBLESHOOTING
Troubleshooting:
LCD stroke indicator test
Figure 44
A. Set the mode switch to position #5.
B. Set the data switches to 00.0 to enter the

diagnostics mode of operation.
C. Depress the enter switch to load the value Figure 45

into memory.
D. This mode of operation enables the operator

to increase the solenoid output rate to one
stroke every two seconds.
Figure 46
E. Unscrew the thumb screws and remove the
eight position terminal strip and cover. This
will expose the battery pack and three position
configuration jumper (located in the lower right
hand corner of the Z-200 controller assembly).
F. Set the configuration jumper to the far right

position marked stroke indicator test.
(CEVQT[
/WVWCN
G. This will cause all six digits to become active 5[UVGO
4463:/.
or display. Press reset and a display should

Factory setting for
increment 000000,111111, ets., up to configuration jumper
999999 each time the solenoid actuates.
When the display reads 999999, the test is Figure 47
complete.
NOTE: when the test is complete, move the

jumper back to the factory position (far left).
(CEVQT[
/WVWCN
5[UVGO
4463:/.
Setting for stroke indicator test

configuration jumper
OUBLESHOOTING
Troubleshooting:
Non-linear/linear flow input Figure 48
The Z-200 controller is capable of receiving two

types of flow outputs: non-linear and linear.
A. Non-Linear: when using differential pres-

sure transmitter inputs that are not linear with
respect to flow, the configuration jumper should
be in the factory setting to the far left position
(CEVQT[
marked non-linear. /WVWCN
5[UVGO
4463:/.
Factory setting for non-linear

flow input using the DPT
Figure 49
B. Linear: when using flow computer type flow
inputs that are linear with respect to flow, the
configuration jumper should be in the middle
position marked linear.
(CEVQT[
/WVWCN
5[UVGO
4463:/.
Setting for linear flow input
OUBLESHOOTING
Troubleshooting:
Pump Performance
1. Verify operating conditions. Correct as needed. pipeline, for pressures less than 250 psi
(17.24 Bar). If a back pressure regulating
2. Check to see if the pump operation sounds the device is not installed as described above,
same as previously. A distinct bottoming of the install the device before proceeding.
plunger piston and a return to the top of the
plunger piston housing should be audible with e. If line pressure is less than 250 psi (17.24
each actuation. If not, remove the actuation Bar) and a back pressure regulating device
cylinder. Inspect for a broken return spring, is installed on the odorant injection line,
proper oil level,or a stuck / sticking actuator inspect the back pressure regulating device
piston or plunger. Replace the spring if broken. for proper operation, and installation as
Clean and Lubricate the actuation cylinder and described above.
actuation piston assembly. Manually push the
plunger into the seal assembly and ensure it 4. Verify that the actuation pressure remains un-
returns completely and freely. If sticking contin- changed from previous setting.
ues to occur, the seals should be replaced.
Reassemble and see if alarm reoccurs after a 5. Verify that all valves and check valves are properly
system restart. If oil loss is noted, pump should set system operation. Inspect for valve settings that
be completely rebuilt. can restrict pump displacement.
3. If pump actuation is normal: 6. Check the actuation gas filter for flow resriction or
closure.
a. Inspect the discharge lines and valves for a restriction.
7. Ascertain whether the pump is properly stroking.
b. Inspect all the check valves on the discharge
side of the pump, from the NJEX System to the a. If pump actuation does not occur as the Test
pipeline, for proper operation. key is pressed, remove the actuation gas line at
the top of the pump and test the pump stroke
c. Verify that the operating conditions remain again. As the Test key is pressed, there should
unchanged and correct as needed. The pipeline be a burst of gas at the open actuation supply
pressure should be at least 250 psi (17.24 Bar). connection. If gas is released from the open
actuation supply line skip to subsection 7.e. ,
d. Inspect the installation for the use of a back otherwise continue to 7.b.
pressure regulating device. For pipeline
pressures less than 250 psi (17.24 Bar) a b. If solenoid discharge to the pump connection
back pressure regulating device must be does not release gas, remove the pump
installed immediately outside the NJEX solenoid wiring cable. Next, connect a volt
enclosure on the odorant line leading to the meter to the two parallel posts of the solenoid
pipeline injection point. A back pressure cable. As the Test key is pressed, obseve if a
regulating device can aliviate the over 12VDC current becomes present.
pumping conditions that can result by the If a voltage is detected the solenoid should be
varying pressures and temperatures in the replaced.
OUBLESHOOTING
c. If the above test indicates the solenoid is

functioning, next determine if the signal is
being sent by the controller, or lost in the
cabling and connections. Connect your
volt meter to terminals 1 and 2, with 1 being
the positive and 2 being the negative. Now,
test fire the pump with the test switch. A
momentatry voltage pulse, aproximately .2
seconds in duration, should be observed.
This will be a DC voltage pulse not exceed-
ing 12VDC. If the pulse is at the termina-
tion panel next check the polarity of
connections of the wiring. The terminal 1
should have a red wire attached and, the
terminal 2 should have a black wire at-
tached. If the polarity is correct, on the
wiring, the cable assembly to the sole-
noid should be replaced.
d. If no voltage is detected, check and

replace the fuse under the N-200 controller
cover. If there is still no voltage detected,
contact the technical service department at
the factory.
e. With the actuation gas line reconnected to the

pump, test stroke the pump. Observe if there is
an audible pump stroke with the piston bottom-
ing out and returning to the top of the pump
housing. If an audible pump actuation is not
present , remove the actuation cylinder and
inspect for a broken return spring, or a stuck /
sticking plunger assembly. Replace the spring if
broken, clean and relubricate the plunger
assembly and actuation cylinder. Make certain
the seals are not sticking to the plunger assem-
bly.
8. If problems persist, contact YZ technical service for

additional assistance.
OUBLESHOOTING
Notes
OUBLESHOOTING
Notes
APPENDIX A: ILLUSTRA
LLUSTRATIONS
USTRATIONS
NJEX Model 7000 pump

Assembled, Figure 50
Actuation Gas
Replacement Pump Seal Kit

P/N D3-0131
Odorant
Actuation Gas
Hydraulic Oil
LLUSTRATIONS
USTRATIONS
NJEX Model 7000F Pump

Actuation Assembly,
Exploded View, Figure 51
Stroke Spacers
Part
Actuation Cylinder Volume Color Number
PN: B0-0078 100% Red B0-1061
80% Green B0-0103
70% Yellow B0-0104
60% Black B0-0062
50% Purple B0-0102
40% Silver B0-0101
30% Blue B0-0100
20% Gold B0-0063
Cartridge Nut
PN: B0-0083
Plunger Seal
Piston Seal PN: A6-0018
PN: A6-0084
Plunger Guide Bushing
PN: B0-0084
Actuation Piston Assembly
PN: B0-0087
Cartridge Body
PN: B0-0085
O-Ring
PN: A5-2016
O-Ring
PN: A5-2023
Plunger Seal
Actuation Spring PN: A6-0018
PN: C3-0043
O-Ring
PN: A5-2115
Oil Reservoir Cap

Actuation Spring Dampener PN: B0-0068
PN: B0-0095
Drain Plug
PN: A2-0177
Pump Housing
PN: B0-0069
LLUSTRATIONS
USTRATIONS

Diaphragm Cartridge,
Pump Housing
PN: B0-0069
O-Ring
PN: A5-2115
O-Ring
PN: A5-1121
Cap
PN: B0-0072
O-Ring
PN: A5-2023
O-Ring
PN: A5-1027
Diaphragm
PN: A6-0087
Cartridge Piston
PN: B0-0070 PN: B0-0071
Spring
PN: C3-0002
O-ring
PN: A5-1129
O-Ring
PN: A5-1131
LLUSTRATIONS
USTRATIONS

Check Valve Assembly,
O-ring
Discharge Check Cartridge PN: A5-1115A5-
PN: B0-00756 1129
Check Wafer
PN: B0-0074
Sleeve O-Ring
PN: B0-0076 PN: A5-1012
Check Wafer
PN: B0-0074
O-Ring
Seal Nut PN: A5-1016
PN: B0-0074
Backup O-Ring
PN: A5-0093
O-Ring
PN: A5-1014
Pump Housing
PN: B0-0069
Check Wafer
PN: B0-0074
Inlet Check Cartridge

O-Ring
PN: B0-0073
PN: A5-1115
Backup O-Ring
O-Ring
PN: A5-0093
PN: A5-1115
LLUSTRATIONS
USTRATIONS
Bulk Odorant Filter

Figure 54
Odorant Filter Cap
Bypass Line *O-Ring

Odorant From
From Odorant Odorant Storage Tank
P.N A5-1334
Discharge Manifold
* O-Ring
P/N A5-1334
* Odorant Filter Elements (12 Ea.)

P/N C4-0103
Odorant Filter Tube

P/N C4-0108
Odorant Filter Support

P/N C4-0104
1/4"-20 ss Nut
P/N C0-0095
Washer Suspension Rod

P/N C4-0109
Odorant Filter Body

P/N C4-0100
Washer Retainer
P/N C4-0102
1/4"-20 ss Nut
P/N C0-0095
*Bulk Odorant Filter Element Replacement Kit (P/N D3-0103)
LLUSTRATIONS
USTRATIONS
NJEX Gas Filter

Figure 55
Gas Filter Label In Out

PN: D5-0074 Gas Filter Cap
PN: C4-0130
O-Ring 334 Viton

PN: A5-1334
Filter Suspension Rod

PN: C4-0109
Coalescing Filter Element1

PN: C4-0133
Filter Locator Bushing

PN: C4-0132
Filter Retainer Washer

PN: C4-0102
1/4 - 20 SS Hex Nut

PN: C0-0095
Filter Bowl
PN: C4-0131
1/4 NPT Drain Cock

1
PN: A3-0044
NJEX Gas Filter Replacement Element
PN: C4-0133
LLUSTRATIONS
USTRATIONS
Pneumatic Relay
Figure 56
BILL OF MATERIALS
REF. PART NO. DESCRIPTION QTY.
1 B0-0111 PNEUMATIC RELAY TOP PLUG 1
2 A5-2020 OR -020 NITRILE 1
3 C0-0350 10-32 HEX NY-LOCK NUT 1
4 B0-0112 PNEUMATIC RELAY PISTON 1
5 B0-0074 CV WAFER - 1/2" STD. 1
6 A6-0113 PNEUMATIC RELAY PUSHROD 1
7 A3-0291 PNEUMATIC RELAY BODY 1
8 C3-0048 FV-3 SPRING 1
9 A5-2016 OR -016 NITRILE 1
10 B0-0113 PNEUMATIC RELAY BOTTOM PLUG 1
11 A6-0099 'K' SEAL, 1" #KP-125-01.000 C-44 ACT. 1
12 B0-0115 NJEX RELAY VALVE WAFER 1
13 A1-0236 MELBOW 5/32T x #10-32 1
LLUSTRATIONS
USTRATIONS
Diagram:
Z-200 Controller
Ref. No. Description Part No. Qty.
Figure 57
1 Z-200/6 Controller Assembly 1
8 Model Z-200/6.1 F2-0002
Model Z-200/6.10 F2-0020
2 Battery Pack E3-2001 1
3* Stroke Counter Assembly G1-0001 1
4* Terminal Strip, 6 Position H1-0001 1
5* BCD Switch E1-0001 4
6 Face Plate 1
Model Z-200/6.1 A9-3002
Model Z-200/6.10 A9-3031
7 Thumb Screw A9-1001 4
8 Cable Assembly G2-0001 1
9 9 Solenoid Valve A4-0003
A4-0001 1
10 Repair Kit* D3-0006 1
11 Z-65/200 Fuse Replacement Kit D3-0142 1
(2 Fuses Per Kit)
11
LLUSTRATIONS
USTRATIONS
Rosemount Differential
Pressure Transmitter (DPT):
Theory of Operation: Figure 58
The Rosemount Model 2024 Transmitter is a low
power differential pressure measuring device
Black
capable of measuring differential pressures from Green
0 - 250 inches (635 cm) of water and delivering a SHD
proportional 1 - 5 volt output. The YZ Model
Z-200 controller is designed to operate the
White
Rosemount 2024 DPT. Both units are Factory (CEVQT[
/WVWCN
5[UVGO
4463:/. Red
Mutual (FM) approved for intrinsically safe Class
I, Division 1, Groups C, D operation. This allows
for the transmitter to be directly powered by the
controller, without the use of barriers, when used
in accordance with YZ Systems Wiring Control
Document # 103-0431.
Installation
a. Locate the DPT in an area where vibration, Differential
Pressure
shock, and temperature fluctuation effects are Transmitter
(DPT)
minimal. SlimLine
Manifold
b. Mount the DPT directly to the measurement Low Pressure

Isolation Valve
High Pressure
Isolation Valve
taps or use the mounting bracket shipped with
the transmitter (see diagram below). In either Equalization
case, mount the DPT at an elevation above or Valve
equal to the pipeline measurement taps.
c. Connect the DPT to the Z-200 controller using Orifice Connection
the wiring kit included with the transmitter.

This kit includes YZ's drawing #03-0467 which
indicates how to connect the DPT and the FLOW
Z-200.
NOTE: it is recommended that the cable length

between the Z-200 and the DPT not exceed 25
feet (7.5 meters).
LLUSTRATIONS
USTRATIONS
Rosemount Differential
Pressure Transmitter (DPT): Figure 59
Common
Calibration:
Calibration of the DPT requires the use of an
accurate pressure source and a voltmeter. Signal
a. Check the wiring between the 2024 DPT and

the Z-200 controller to ensure it is connected
correctly. Rosemount
2024 DPT
b. Connect the pressure source to the DPT high
pressure port.
c. Connect the voltmeter positive lead to the DPT

signal terminal and the voltmeter negative lead
to the DPT common terminal.
NOTE: mode switch must be in
d. Turn the mode switch on the Z-200 controller position 3 or 4 to read transmitter
to position 4. output voltage.
e. While applying the equivalent of 0" (0 cm)

differential pressure to the transmitter, turn the
DPT "Zero" adjustment screw until the trans-
mitter output reads 1.00 volts.
f. Press the test/enter button on the Z-200 to set

the controller's zero reference.
Voltmeter
g. Turn the mode switch on the Z-200 controller
to position 3.
h. While applying the equivalent of maximum flow

differential pressure to the transmitter, example
100" (254 cm) water differential, turn the span
adjustment screw until the output reads 5.00
volts.
i. Press the test/enter button on the Z-200 to set

the controller's span reference.
j. Repeat steps d. through j., readjusting the DPT

zero and span as necessary.
k. Return the mode switch on the Z-200

controller to position 9. Refer to Section 5 to
set the system input parameters before start-
ing system operation.
LLUSTRATIONS
USTRATIONS
SPO-12V (optional)
Figure 60
NJEX 720
LLUSTRATIONS
USTRATIONS
EPO-120V (optional)
Figure 61
LLUSTRATIONS
USTRATIONS
Z-200 Wiring Control Document

Figure 62
System Installation Notes and Recommendations

The manufacturer's system installtion instructions and the National Electric Code, Canadian Electrical Code where applicable, must be followed
when installing this equipment. Tampering or replacement with non-factory components may adversely effect the safe use of the system.
Only the specified batteries should be used with this apparatus.
For guidance on installation see ANSI/ISA 12.6 Installation of Intrinsically Safe Instrument Systems in Class Hazardous Locations.
3101 POLLOK CONROE, TEXAS 77303
LLUSTRATIONS
USTRATIONS
Notes
3101 Pollok Drive
Conroe, Texas 77303
800.653.9435
P: 936.788.5593
F: 936.788.5698
Em: Service@yzhq.com
Web: www.yzsystems.com
YZ Systems, Inc. represents and warrants that for a period of 3 years from receipt of the product: (1) the product will be free from defects in materials and
YZ Systems, Inc.and
workmanship; (2) the product
represents will perform
and warrants that forsubstantially in accordance
a period of 1 year from receipt with product
of the manuals,
product: (1) theliterature,
product willor documentation.
be free from defectsAnyin written or oral
materials andinformation
workmanship;orand (2)
advice given
the product willbyperform
YZ representatives,
substantially in agents, or employees
accordance with product will in no way
manuals, increase
literature, orthe scope of this
documentation. Anywarranty.
written orIforal
the information
product fails orto comply
advice givenwith therepresentatives,
by YZ warranty
set forthorherein,
agents, employeesYZ's entire
will in noliability and the
way increase thecustomer's exclusive
scope of this warranty. remedy will be replacement
If the product fails to comply ofwith
the product(s)
the warrantyor,setatforth
YZ'sherein,
option,YZ's
YZ'sentire
reasonable
liability effort
andto make
the customer's
the product
exclusive meet
remedy thebewarranty
will replacement setof forth herein. YZ
the product(s) or,disclaims all other
at YZ's option, warranties,
YZ's reasonable either
effort expressed
to make or meet
the product implied, including
the warranty but not
set forth limited
herein. to, implied
YZ disclaims all other
warranties or merchantability
warranties, either and fitness
expressed or implied, including forbut
a not
particular
limited to, purpose,
impliedwith respect
warranties to the product.
or merchantability andThis limited
fitness for awarranty
particular gives you with
purpose, specific legal
respect torights.
the product.
You limited
This may have others,
warranty which
gives youvary fromlegal
specific to state.YouThese
staterights. may have remedies are not
others, which varyavailable
from stateoutside
to state.ofThese
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remedies States
are notand Canada.
available In no
outside ofevent shallStates
the United YZ and
or its suppliers
Canada. be liable
In no event shallfor
YZany
or itsdamages
suppliers whatsoever (including,
be liable for any damages without limitation,
whatsoever damages
(including, for loss
without of profits,damages
limitation, business forinterruption, lossbusiness
loss of profits, of information, or otherloss of
interruption,
pecuniary
information, loss) arising
or other out ofloss)
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arising inability
of the to
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of orthe product,
inability toeven
use theif YZ has been
product, even ifadvised of the
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advised of theof such damages.
possibility Information
of such damages. contained
Information contained
in this
in thisdocument
document isissubject
subject
toto change
change without
without notice
notice andnot
and does does not represent
represent a commitment
a commitment on the partonof YZtheSystems,
part of Inc.
YZ Systems,
All prices Inc. All prices
quoted quoted
are in U.S. are inF.O.B.
dollars, U.S. Snyder,
dollars,Texas.
F.O.B.LINC
LINC, Snyder, Texas.
Chemical LINC,
Pumps, LINCLevel
and LINC Chemical Pumps, and
& Flow Switches LINC Level
are trademarks of&YZFlow
Systems,Switches are other
Inc. All trademarks
productofnames
YZ Systems, Inc. All trademarks
and/or registered other product names
are the and/or
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services areof their to
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YZ's then-current YZ support
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prices which
and specifications, if
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change without All prices and specifications, if published, are subject to change without notice.

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NJEX 720 G

Section 1: First Things To Know About The 720G .......................................................................1

Section 2: System Installation .........................................................................................................7

Section 3: Filling the Bulk Odorant Tank .................................................................................... 17

Section 4: System Control & Electronics .................................................................................... 19

Section 5: Programming for Proportional-to-Flow Operation ................................................... 21

Section 6: Programming for Proportional-to-Time Operation .................................................. 27

Section 7: Mechanical System ...................................................................................................... 29

Section 8: System Maintenance ................................................................................................... 33

Section 9: 720G System Troubleshooting ................................................................................... 35

Appendix A: Illustrations ................................................................................................................ 45

The NJEX System Series of odorizers implement the T: 1.936.788.5593

Items that require action, for example the pressing of a

Starting with Section 4, System Control & Electron-

Note: at temperatures below 32 F (0 C), conditioning of

Proportional-To-Flow Operation: In this mode

Long-Life Battery: The Z-200 timer/counter

AC Power Option: If conditions exist that make

Solar Power Option: This power option may

Standard System Components

System Controller. The Z-200 Controller with

Odorant Injection Pump. The NJEX 7000 is

Bulk Odorant Filter. Provides primary odor-

System Enclosure. Houses the Model 7000

NJEX Gas Filter. Installed before the actua-

Pump Actuation Model 7000F

NJEX Gas Filter Bulk Odorant

System Flow Schematic

720G ENCLOSURE OPTIONAL SYSTEM POWER

SPO-12 Power Option

Actuation Gas Pneumatic Relay Pressure Regulator w/Gauge

Odorant Normally Open Valve Solenoid Valve

Electrical Check Valve

Standard System Mounting

1. Securely attach a section of 2 pipe in a vertical

2. Connect a ground wire from the 2 pipe to a properly

Standard System Connections

1. Connect the odorant supply source to the bulk

3. Connect the regulated actuation gas source

NJEX gas filter inlet.

NOTE: In applications where the actuation gas

4. Connect the NJEX gas filter outlet to the

5. Connect the pump discharge valve fitting to

7. Connect the flow signal device to the termina-

Optional Power Supply: Figure 5

NOTE: the solar panel should be mounted free

Skid System Components SOLAR PANEL

The Systems are available with 20, 60, 120, 250,

Skid system primary components of the NJEX-720G

Skid Mounted Tank a pre-assembled, and tested

System Controller. The Z-200 Controller

Bulk Odorant Filter. Provides primary

System Enclosure. Houses the Model 7000F

NJEX Gas Filter. Installed before the actua-

System Flow Schematic

720G ENCLOSURE OPTIONAL SYSTEM POWER

SPO-12 Power Option

Pipeline NJEX STORAGE TANK

V15 V13 V12 V11 V10

Actuation Gas Normally Closed Valve LI Level Indicator Pneumatic Relay

Odorant Normally Open Valve Pressure Regulator w/Gauge

V8 Injection Probe Pipeline V12 RV Isolation Valve V15 Odorant Supply

Skid System Mounting:

Sample Skid Dimensions