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Welker OdorEyes ECOsystem Pulse Bypass System Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
WELKER ECOSYSTEM™ PULSE BYPASS SYSTEM
WITH XLT CONTROLLER
DRAWING NUMBERS
OE153VS
OE180VS.1
OE181VS
OE181VS.3E
OE183VS.1E
OE190VS
OE220VS.1E
MANUAL NUMBER
IOM-181
REVISION
Rev. C, 06/25/2019

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Summary of Contents for Welker OdorEyes ECOsystem Pulse Bypass System

  • Page 1 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WELKER ECOSYSTEM™ PULSE BYPASS SYSTEM WITH XLT CONTROLLER DRAWING NUMBERS OE153VS OE180VS.1 OE181VS OE181VS.3E OE183VS.1E OE190VS OE220VS.1E MANUAL NUMBER IOM-181 REVISION Rev. C, 06/25/2019...

  • Page 2: Table Of Contents

    APPENDICES A: Referenced or Attached Documents B: Maintenance Schedule Copyright © 2019 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks of Welker, Inc. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...

  • Page 3: Safety

    Warning messages appear before procedures that could result in personal injury if not observed. This manual is intended to be used as a basic installation and operation guide for the Welker OdorEyes ECOsystem™ Pulse Bypass System With XLt Controller. For comprehensive instructions, please refer to the IOM Manuals for each individual component.

  • Page 4: Product Information

    If you have any questions, please call Welker at 1-281-491-2331. *The following procedures have been written for use with standard Welker OdorEyes parts and equipment. Assemblies that have been modified may have additional requirements and specifications that are not listed in this manual.

  • Page 5: Specifications

    1.4 Specifications The specifications listed in this section are generalized for this equipment. Welker can modify the equipment according to your company's needs. Please note that the specifications may vary depending on the customization of your equipment. Table 1: ECOsystem™ Specifications...

  • Page 6: Equipment Diagrams

    1.5 Equipment Diagrams Figure 1: General Arrangement – Horizontal Odorant Tank IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 7 Figure 2: General Arrangement – Vertical Odorant Tank IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 8 Figure 3: Valve Section – Single Solenoid, ³ " Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 9 Figure 4: Valve Section – Dual Solenoid, ³ " Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 10 Figure 5: Valve Section – Dual Solenoid With Heater, ³ " Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 11 Figure 6: Valve Section – Single Solenoid, ¼" Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 12 Figure 7: Valve Section – Dual Solenoid, ¼" Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 13 Figure 8: Valve Section – Dual Solenoid With Heater, ¼" Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 14 Figure 9: Valve Section – Triple Solenoid With Heater, ¼" and ³ " Tubing IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 15 Figure 10: Pneumatic Filter Figure 11: Volume Bottle Diagram (Applicable for Valve Sections With ³ " Tubing) IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 16: Installation & Operation

    Connect from odorized gas outlet valve K2 to an unused valve on the natural gas pipeline downstream of the regulated pressure drop (Figure 1 or Figure 2). Welker recommends using stainless steel tubing for all natural gas process lines, as plastic tubing can absorb odorant from the gas. Ensure that all valves on the system are closed.
  • Page 17 The spring attached to the bottom drain flange cushions the float when the odorant supply tank is empty. Replace the shipping gasket with the provided gasket. Install the bottom drain flange with float to the level indicator. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 18: Start-Up Procedures

    If applicable, slowly open any valves between the odorized gas outlet on the odorant supply tank and the pipeline. Check for leaks and repair as necessary. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 19 As the controller closes the solenoid, verify that FlowSw and Sol 1 clear simultaneously. Once the correct operation of the solenoid and flow switch has been confirmed, the ECOsystem™ is operational. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 20: Xlt Touch Screen Controller

    The touch screen controller is a menu-driven system. The Home screen is the top screen in the menu tree (Figure 12). Figure 12: Controller Menu Tree IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 21: Navigating The Monitor Screens

    Alarms Log, Controller Version, and MicroSD Card to view current information for the odorizer. Monitor screens are informational screens: no values can be changed from these screens. Figure 14: Monitor Odorizer Submenus IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 22 If the system status totals are used to track system performance, they should be periodically reset through the Controller Setup submenu (Figure 24). As the total values increase, they will begin to lose accuracy and will eventually stop accumulating. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 23 Solenoid Stats Figure 16: Solenoid Stats Submenu Odorant Tank Level Figure 17: Odorant Tank Level Submenu IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 24 Pulse Gas Flow received from the flow meter. If this alarm is active when the controller is receiving pulse input from the flow meter, Welker recommends increasing the pulse input cutoff time to prevent the alarm from becoming active prematurely.
  • Page 25 From the View Audit Tail submenu, the user can access the audit tail records stored on internal memory. Up to 600 audit trail records can be stored and viewed. Figure 19: View Audit Trail IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 26 From the View Alarms Log submenu, the user can access the alarms log stored on internal memory. Up to 428 alarms log records can be stored and viewed. Figure 20: View Alarms Log IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 27 Controller Version Figure 21: Controller Version MicroSD Card Access Figure 22: MicroSD Card Access IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 28: Navigating The Setup Screens

    Changing numeric and/or text values in the Setup Odorizer submenus will alter how the system operates. Figure 23: Setup Odorizer Submenus IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 29 If a mistake is made while entering the new value or if the value does not need to be changed, press ESC to discard the changes. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 30 If the system status totals are used to track system performance, they should be periodically reset through the Controller Setup submenu (Figure 24). As the total values increase, they will begin to lose accuracy and will eventually stop accumulating. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 31 Through the Odorant Tank Setup submenus, the user can input information for the odorant tank and temperature transmitter. Figure 26: Odorant Tank Setup Submenus IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 32 ENTER to save the changes. The Current Level should have increased by the amount entered, and the Adjust Level should have reverted to 0.0. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 33 Figure 28: Strapping Tables IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 34 Odorant Type Setup Figure 30: Odorant Type Setup If the type of odorant used is changed, please contact Welker® OdorEyes® personnel for new absorption values and/or pressure regulator setting. IOM-181 MODEL: ECOSYSTEM™...
  • Page 35 Through the Gas Flow Signal submenus, the user can set up the parameters of the odorant gas flow input signal. Figure 31: Gas Flow Signal Submenus IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 36 If the gas flow signal will be a pulse, the pulse will be a digital pulse powered by the controller. If the pulse input method is selected, the Pulse Input Cutoff must also be set (Figure 33). IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 37 Fail Mode. The alarm will clear on the next pulse input or change in Modbus gas flow, and the system will resume normal operation. IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 38 Fixed Rate Setup Figure 34: Fixed Rate Setup IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 39 Auto Scroll Setup Figure 35: Auto Scroll Setup Figure 36: Auto Scroll Pre-Set Screens IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 40 Modbus Setup Figure 37: Modbus Setup IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 41 Through the Local Audit Trail and Local Alarms Log submenus, the user can set up and reset the data logs stored locally. Figure 38: Audit Trail and Alarms Log Setup IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 42 SD Card Logging Figure 39: SD Card Logging IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 43 The View I/O submenu provides the user with an overview of the current status of digital inputs, digital outputs, and analog inputs in the system. Figure 40: View I/O, 1 of 2 IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 44 Figure 41: View I/O, 2 of 2 IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 45 Date and Time Figure 42: Date and Time IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 46: Maintenance

    SECTION 4: MAINTENANCE 4.1 Before You Begin Refer to Appendix B, Maintenance Schedule, for the itemized Welker recommended maintenance schedule for the ECOsystem™. Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit available for repairs of the system in case of unexpected wear or faulty seals.

  • Page 47: Appendices

    MTS Systems Corporation Level Plus® Liquid-Level Sensors With Temposonics® Technology M-Series Model MR Analog • Transmitter (Welker IOM-V036) Power-Sonic Corporation PS-1270 12 Volt 7.0 AH Rechargeable Sealed Lead Acid Battery (Welker IOM-V223) • PR electronics 5333D 2-Wire Programmable Transmitter (Welker IOM-V270) •...

  • Page 48: B: Maintenance Schedule

    APPENDIX B: MAINTENANCE SCHEDULE Welker recommends keeping high-wear parts on hand and replacing these parts immediately when worn or damaged. Refer to the Installation, Operation, and Maintenance (IOM) Manual for each component for maintenance instructions. Table B1: ECOsystem™ Maintenance Schedule...
  • Page 49 _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ 13839 West Bellfort Street Sugar Land, TX 77498 Phone: 281.491.2331 welker.com IOM-181 MODEL: ECOSYSTEM™ WITH XLT CONTROLLER REV: C 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

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