Welker OdorEyes ECOsystem, Installation, Operation And Maintenance Manual

Page 1: ...RATION 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: ...LLATION OPERATION 16 2 1 Before You Begin 16 2 2 Installation 16 2 3 Start Up Procedures 18 3 XLT TOUCH SCREEN CONTROLLER 20 3 1 Understanding the Display 20 3 2 Navigating the Monitor Screens 21 3 3 Navigating the Setup Screens 28 4 MAINTENANCE 46 4 1 Before You Begin 46 4 2 Maintenance 46 APPENDICES 47 A Referenced or Attached Documents 47 B Maintenance Schedule 48 Copyright 2019 Welker Inc All ...

Page 3: ... accuracy and is intended to be used as a guide for the installation operation and maintenance of the Welker OdorEyes equipment described in this manual Correct installation and operation however are the responsibility of the end user Welker reserves the right to make changes to this manual and all products in order to improve performance and reliability BEFORE YOU BEGIN Read these instructions co...

Page 4: ...ystem continues infusing proportional to flow On site and remote troubleshooting and monitoring are made easier by time and date stamped audit data detailing system performance alarm history and odorant tank level An optional solar panel generates renewable energy to power the system when an electrical source is unavailable The valve section contains one 1 two 2 or three 3 solenoids which control ...

Page 5: ...50 US Gallons 189 L 60 US Gallons 227 L 100 US Gallons 378 L 120 US Gallons 454 L 250 US Gallons 946 L 500 US Gallons 1892 L Others Available Features Odorant Tank Level Gauge Skid With 110 Containment Temperature Transmitter Touch Screen Controller Valve Section See Table 2 Options Flag Tracker Level Indicator Heater for Controller Enclosure NEMA 4 or NEMA 7 Enclosure for Controller Solar Panel S...

Page 6: ...1 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 1 5 Equipment Diagrams Figure 1 General Arrangement Horizontal Odorant Tank ...

Page 7: ...7 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 2 General Arrangement Vertical Odorant Tank ...

Page 8: ...8 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 3 Valve Section Single Solenoid 8 Tubing ...

Page 9: ...9 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 4 Valve Section Dual Solenoid 8 Tubing ...

Page 10: ...10 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 5 Valve Section Dual Solenoid With Heater 8 Tubing ...

Page 11: ...11 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 6 Valve Section Single Solenoid Tubing ...

Page 12: ...12 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 7 Valve Section Dual Solenoid Tubing ...

Page 13: ...13 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 8 Valve Section Dual Solenoid With Heater Tubing ...

Page 14: ... IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 9 Valve Section Triple Solenoid With Heater and 8 Tubing ...

Page 15: ...STEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 10 Pneumatic Filter Figure 11 Volume Bottle Diagram Applicable for Valve Sections With 8 Tubing ...

Page 16: ... or gate station All electrical connections must meet local and national electric codes and excessive weight added to the conduit run must be supported 2 2 Installation System Skid 1 Mount the skid to a flat level surface such as a concrete slab 2 Connect a grounding wire to each grounding lug on the skid to safely ground the system 3 Connect the skid drain port s to an appropriate draining locati...

Page 17: ... with the optional flag tracker level indicator installation is now complete proceed to Section 2 3 Start Up Procedures If the ECOsystem is equipped with the optional flag tracker level indicator continue to step 11 Flag Tracker Level Indicator Optional The float and gasket must be installed to the flag tracker level indicator prior to filling the odorant supply tank The float and gasket are packa...

Page 18: ...ure 10 7 Apply natural gas to the valve section to pressurize the natural gas supply regulator Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 or Figure 9 The pneumatic supply regulator comes factory set to the setting required to operate the solenoid s 8 If applicable open regulator outlet valve C Figure 8 or Figure 9 9 If applicable open volume bottle valve D Figure 11 The volume bottle wi...

Page 19: ...eration 14 From the controller verify the correct operation of the solenoid and flow switch From the Main Menu select Setup Odorizer Figure 23 From the Setup Odorizer menu select View I O Figure 41 15 As the controller opens the solenoid verify that FlowSw and Sol 1 darken simultaneously 16 As the controller closes the solenoid verify that FlowSw and Sol 1 clear simultaneously 17 Once the correct ...

Page 20: ...331 SECTION 3 XLT TOUCH SCREEN CONTROLLER 3 1 Understanding the Display The touch screen controller is used to modify system parameters and view current system information and current alarm status 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 ...

Page 21: ...ion Keys 3 2 Navigating the Monitor Screens Through the monitor screens the user can access the System Status Solenoid Stats Odorant Tank Level Current Alarms Audit Trail 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 ...

Page 22: ...he System Status submenus provide the user with an overview of system performance Figure 15 System Status Submenu 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 ...

Page 23: ...STEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Solenoid Stats Figure 16 Solenoid Stats Submenu Odorant Tank Level Figure 17 Odorant Tank Level Submenu ...

Page 24: ...any other input parameters The Fixed Rate Alarm will not clear until Fixed Mode is disabled Analog Temperature Can only be active if Transmitter is set as the RTD setup method NOTE If this alarm is active verify that a 4 20 mA signal is being received from the temperature transmitter If this alarm is active the system will use the manually entered temperature therefore Welker recommends regularly ...

Page 25: ...t Street Sugar Land TX 77498 welker com Service Department 281 491 2331 View Audit Trail 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 ...

Page 26: ...llfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 View Audit Trail 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 ...

Page 27: ...OSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Controller Version Figure 21 Controller Version MicroSD Card Access Figure 22 MicroSD Card Access ...

Page 28: ...u the user can access the Controller Setup Odorant Tank Setup Gas Flow Signal Fixed Rate Setup Auto Scroll Setup MODBUS Setup Local Audit Trail Local Alarms Log and View I O submenus and change numeric and or text values that alter the parameters and features of the odorizer Changing numeric and or text values in the Setup Odorizer submenus will alter how the system operates Figure 23 Setup Odoriz...

Page 29: ...red press ENTER to save the changes If the new value entered is outside the range of allowable values the value will revert back to the previous value once ENTER is pressed The keypad will stay active allowing another value to be entered Text Values 4 To change a text value press on the value to be changed A dropdown menu will appear on the screen 5 Scroll through the value s options using the arr...

Page 30: ...h the Controller Setup submenu the user can set the general parameters for the odorizer Figure 24 Controller Setup Submenu 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 ...

Page 31: ...treet Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 25 Dual Solenoid Setup Odorant Tank Setup Through the Odorant Tank Setup submenus the user can input information for the odorant tank and temperature transmitter Figure 26 Odorant Tank Setup Submenus ...

Page 32: ...tead the user must enter a value in the Adjust Level field to increase or decrease the Current Level by the specified amount To decrease the Current Level enter the volume to be subtracted from the current level as a negative number in the Adjust Level field and then press ENTER to save the changes The Current Level should have decreased by the amount entered and the Adjust Level should have rever...

Page 33: ...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 Figure 28 Strapping Tables ...

Page 34: ... is no device tracking the temperature in the odorant tank the Method should be set to Manual Entry Setting an accurate manual temperature is necessary even when using a temperature transmitter The temperature of the odorant supply tank is key to system operation correct odorization is not possible without this value Odorant Type Setup Figure 30 Odorant Type Setup If the type of odorant used is ch...

Page 35: ... C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Gas Flow Signal 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 ...

Page 36: ...1 491 2331 Figure 32 Gas Flow Signal Input Signal Setup If the gas flow signal will be analog the analog signal must be 4 20 mA powered by the user 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 ...

Page 37: ...own will halt odorization until the alarm is cleared Setting the Fail Mode to Constant Rate will allow odorization to continue at the specified rate If the gas flow value does not change during the Pulse Input Cutoff time the system will alarm for loss of flow and will enter the specified Fail Mode The alarm will clear on the next pulse input or change in Modbus gas flow and the system will resume...

Page 38: ...38 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Fixed Rate Setup Figure 34 Fixed Rate Setup ...

Page 39: ...ODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Auto Scroll Setup Figure 35 Auto Scroll Setup Figure 36 Auto Scroll Pre Set Screens ...

Page 40: ...40 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Modbus Setup Figure 37 Modbus Setup ...

Page 41: ...fort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Audit Trail and Alarms Log Setup 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 ...

Page 42: ...42 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 SD Card Logging Figure 39 SD Card Logging ...

Page 43: ...est Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 View I O 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 ...

Page 44: ...44 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Figure 41 View I O 2 of 2 ...

Page 45: ...45 IOM 181 MODEL ECOSYSTEM WITH XLT CONTROLLER REV C 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 Date and Time Figure 42 Date and Time ...

Page 46: ... be lubricated to allow smooth transition of parts 3 All maintenance and cleaning of the unit should be performed on a smooth clean surface 4 2 Maintenance 1 During operation monitor the system for leaks If leaks are present halt operation and repair as necessary 2 Occasionally a system component may need to be repaired or replaced for manufacturer recommended maintenance To perform maintenance on...

Page 47: ...ITHERM C Electric Heater Welker IOM V104 INTERTEC Instrumentation Ltd TS Thermostat Welker IOM V105 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 IO...

Page 48: ...structions Table B1 ECOsystem Maintenance Schedule Action Weekly Every 12 Months As Necessary If applicable confirm proper functioning of the heater X Open F 5 drain valve G to allow moisture to drain from the filter X Verify the pneumatic supply pressure X Rebuild the F 5 using a Welker repair kit Replace the O rings and filter cartridge X View the controller s current alarms X Inspect the tubing...

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