BULLETIN

524A
INSTALLATION & OPERATION

PZP Vibratory Level Sensor

Model PZP

Thank you for purchasing a quality product from Monitor Technologies

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

www.monitortech.com
 Protective Baffles: (See Figure 2)
PRE-INSTALL ATION CONSIDERATIONS The PZP is a sensitive level sensing instrument. Therefore,
Choosing a Location: (See Figure 2) particular attention should be given to assure that the mechan-
1) Material Flow - When selecting a location for the PZP, ical construction of the probe is not damaged by material.
choose a point in the vessel where the probe will be out of Probe deflection (bending) as little as 1/16 inch (1.5mm) can
the direct flow of incoming and outgoing material to prevent render the probe inoperative. Failure to properly protect the
any mechanical damage that may be caused by the pres- probe will invalidate the warranty. Install a protective baffle
sure of the flow (see section regarding Protective Baffles). above side mounted probes. The baffle can be created using a
The PZP must be positioned at a point where incoming number of materials including angle irons, welded plates and
material will reach and cover the probe in its normal flow, pipe sections. It should be securely mounted to the vessel wall
and when receding, will flow away from the probe in an even and should extend the full length of the probe. The lowest part
manner. Choose a position where a majority of the probe of the baffle should be 4 to 6 inches (101.6 to 152.4 mm) above
(not just the tip) will be covered. This is particularly important the upper edge of the probe.
when detecting materials with low densities.
2) Vessel Interference - Select an area where the probe will
DIMENSIONS ARE SHOWN IN INCHES WITH MILLIMETER EQUIVALENT IN BRACKETS

not come in contact with internal structures of the vessel.

When using the flexible cable extension probe, consider the
angle of repose of the material. Insure that the swing of the
cable will not allow the probe to touch the vessel wall during
filling or emptying.
3) Pipe Extension Reinforcement - When top mounting a
probe with a pipe extension, select a location where it is fea-
sible to reinforce the extension to the vessel wall. See
Mechanical Installation for further details.

Figure 2

MECHANIC AL INSTALL ATION

Probe Mounting: (See Figure 2)
1) Coupling Mount - Cut a hole into the vessel that corre-
sponds to the outer diameter of a 1-1/2" pipe coupling.Note 1
Position a half coupling flush with the inside of the vessel
and weld into place. Thread the PZP into the coupling and
tighten using the wrench flats provided on the probe. Do not
tighten by rotating the housing. Pipe joint sealant or Teflon®
tape may be used to achieve pressure sealing capability if
desired.
2) Probe Orientation - On side mount applications, tighten so
that the diamond shape is positioned vertically. This is
achieved when the two “grooves” in the hexagonal flats are
re-aligned vertically.
3) Housing Orientation - On side mount applications, if the
housing is positioned without the wire entrances in a down-
ward position, orientate the housing as follows:
-Remove cover. Loosen (do not remove) the screw that is
Figure 1
visible through the hole in the center of the circuit board.
-Rotate the housing to the desired position.
-Tighten the screw in the center of the circuit board.
Replace the cover.
Note 1: Mounting should be a 1-1/2” NPSC pipe coupling (which is a
straight thread coupling) and mounted per the illustration. Use of an
NPT (tapered pipe thread) type coupling or flange is not recommended
2 unless the minimum inside diameter is greater than 1.734”.
Pipe Extension Reinforcement: (See Figure 3)
Mechanical reinforcement of the pipe extension should be con-
ELECTRIC AL INSTALL ATION
sidered whenever installing a probe length greater than 72 Remove the housing cover to access all electronics. All wires
inches (1829 mm). The pipe extension should be anchored to shall be routed through the cord connector provided. If neces-
the side wall with braces to reduce mechanical stress at the sary, refit the connection with a 1/2" NPT fitting (steel is rec-
connection point of the extension and to protect the PZP from ommended since minor rethreading is required).
damage. When bracing, never weld or drill into the pipe exten-
sion since the electrical wires within the extension may be dam- Factory Wiring:
aged. Use mechanical clamping techniques. The PZP probe wires are connected to the frontside of the
PCB. DO NOT alter this connection. Doing will likely cause
improper operation of the sensor.

Permanently Connected Equipment:

Disconnecting devices shall by included in the system installa-
tion. In installations were multiple circuits are used (i.e. inde-
pendent circuits for power input and output relay), individual
disconnects are required. The disconnects shall be within
close proximity of the equipment, accessible to operators, and
marked appropriately as the disconnect for the associated cir-
cuit. Assure the disconnect ratings are appropriately sized for
the circuit protected (See Specifications).

Protective Earthing:
Each PZP is provided with a "protective conductor terminal"
which shall be terminated to the local earth ground potential to
eliminate shock hazard in the unlikely event of internal insula-
tion breakdown. Select wire size that can carry in excess of the
sum of all circuit's maximum amperage.

Power Input: (See Figure 5)

Figure 3 The PZP is designed with a universal power supply that can
Hi-Temp/Remote Electronics Models: (See Figure 4) accept a wide range of AC and DC voltages (see Specifications
1) Probe Mounting - Follow instructions as earlier stated in to insure compatibility). Select wire size that can deliver suit-
this section. Note that the hi-temperature/remote electronics able voltage and current for the application. Connect power as
PZP has been completely assembled at the factory to insure shown in Figure 5.
performance and assembly integrity. This may cause some
installation inconveniences as the electronic portion of the Output Contact Connections:
assembly will require simultaneous rotation as the probe is The PZP is equipped with two sets of isolated contacts (DPDT)
installed. which indicates whether or not material is being detected within
2) Remote Electronics - This portion is connected to the the vessel. This output is also influenced by the selection of the
probe via a 6 foot (1829 mm) flexible conduit. Mount the "fail-safe" jumper as described in the "Setup" section of this
remote electronics to a structure away from the heat or manual. The designations on the circuit board relate to the
vibration being avoided. Position the wire entrances such contact status when the material is "not" sensed and the fail-
that the risk of moisture infiltration is minimized. Reference safe jumper is in the "low" (FL) mode. These contacts can be
the hole pattern of the mounting plate and securely fasten connected to any type of control device, provided that ratings
into place. are observed (See Specifications). Select wire size that can
deliver suitable voltage and current for the application.

Figure 4
Figure 5

3
 SETUP
Complete set-up of the PZP is accomplished by two functions:
sensitivity and fail-safe. Each application can be adjusted inde-
pendently for optimum operation.

Sensitivity: (See Figure 6)

Select sensitivity based on application as shown below.

1) Position A - For materials ≥ 1.5 lb/ft3 (24 kg/m3)

2) Position B - For materials ≥ 10 lb/ft3 (160 kg/m3)
3) Position C - For materials that have caused false signals
due to probe coating in Position B. Use only as a last resort.
Figure 7
Red LED: (See Figure 7)
The red LED indicates the status of the output relay which is
TROUBLESHOOTING
dependent on material sensing and fail-safe selection. Refer to 3) Verify probe coverage when sensing is expected. The sen-
Figue 7. sor is not designed to be “tip sensitive”. Permit significant
probe coverage before expecting material sensing.
Fail-Safe: (See Figure 7) 4) Verify electrical connection between the probe and circuit
Selection of the fail-safe mode will permit the output contacts to board. The red wires should be connected to the “T” and “R”
be signaled in a manner which assures proper control of loads terminals. The black wire should be connected to the GND
in the event of power failure. Select fail-safe mode based on terminal.
which condition is most critical to signal (high level or low level).
1) FH - When no material is sensed, the relay will be ener- PROBLEM: Sensor remains in “DETECT” mode even when
gized. The relay will de-energize when material is sensed, or material is absent.
if power failure occurs. CAUSE/SOLUTION:
2) FL - When material is sensed, the relay will be energized. 1) Verify the probe is not in direct contact with any internal ves-
The relay will de-energize when no material is sensed, or if sel structure. If so reposition sensor.
power failure occurs. 2) Verify sensitivity setting. Position sensitivity switch in posi-
PROBLEM: Sensor will not sense material. tion “B” therefore making the probe less sensitive to “easy to
CAUSE/SOLUTION: sense” materials and more immune to material buildup. If
1) Verify power is applied to the sensor. problems continue, select Position C.
2) Verify sensitivity setting. Position sensitivity switch in posi- 3) Verify material buildup on probe. Product buildup across the
tion “A” therefore making the probe more sensitive to “diffi- probe surface or between the probe and vessel wall may
cult to sense” materials. create false detection. Clean probe if necessary.

PROBLEM: Output contacts perform opposite of designa-

tions (N/O, N/C).
CAUSE/SOLUTION:
1) Designations on the PCB relate to relay status when in “Fail-
safe Low” (FL) mode and when no material is sensed. When
in “Fail-safe High” (FH) mode and when no material is
sensed, the designations are reversed. Swap wire termina-
tions of N/O and N/C if necessary. Changing the fail-safe
selection is not recommended unless fail-safe feature is not
a concern to the application.

Figure 6

4
 MECHANICALS
DIMENSIONS ARE SHOWN IN INCHES WITH MILLIMETER EQUIVALENT IN BRACKETS

1 1/2” NPT

Standard Probe

Hi-Temp/Remote Electronics Probe

Pipe Extension Probe

Hi-Temp/Remote Electronics Probe With Pipe Extension

MAINTENANCE
The PZP is a maintenance-free product and should be serviced
by Monitor Technologies LLC only. If operation appears inap-
propriate, refer to the Troubleshooting section of this bulletin. If
proper operation is not achievable, consult the factory.

Flexible Cable Extension Probe

5
B U L L E T I N
SPECIFIC ATIONS

524 Power Requirements:

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

Monitor Technologies LLC

44W320 Keslinger Rd. t Elburn, IL 60119 t 630-365-9403 t 800-766-6486 t Fax: 630-365-5646 t www.monitortech.com
GDR JSC SEP 30 2016 DOC-001-524A 12