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Welker 4P Installation, Operation And Maintenance Manual

Sample frequency controller
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INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
WELKER SAMPLE FREQUENCY CONTROLLER
MODEL
4P
 
DRAWING NUMBERS
EL482.1
EL820
EL862
EL867
 
MANUAL NUMBER
IOM-001
 
REVISION
Rev. F, 2/12/2019

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  • Page 1 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WELKER SAMPLE FREQUENCY CONTROLLER MODEL   DRAWING NUMBERS EL482.1 EL820 EL862 EL867   MANUAL NUMBER IOM-001   REVISION Rev. F, 2/12/2019...

  • Page 2: Table Of Contents

    A: Referenced or Attached Documents   B: Settings at a Glance Copyright © 2019 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks of Welker, Inc. IOM-001 MODEL: 4P REV: F 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 Sample Frequency Controller, 4P. For comprehensive instructions, please refer to the IOM Manuals for each individual component. A list of relevant component IOM Manuals is provided in Appendix A of this manual.

  • Page 4: Product Information

    1.3 Power Supply to the 4P The 4P can operate with a DC 12 or 24 V power supply. If the power supply is greater than DC 24 V, a power converter must be used to convert the power to DC 12 or 24 V.

  • 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 2: 4P Specifications...

  • Page 6: Equipment Diagrams

    1.5 Equipment Diagrams Figure 1: Mounting Options IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 7 Figure 2: Timer Board Diagram IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...

  • Page 8: Installation & Operation

    SECTION 2: INSTALLATION & OPERATION 2.1 Before You Begin After unpacking the unit, check the equipment for compliance and any damage that may have occurred during shipment. Immediately contact a Welker representative if you received damaged equipment.     When sealing fittings with PTFE tape, refer to the proper sealing instructions for the brand used.
  • Page 9  6. If connecting the solenoid through a relay, connect the positive side of the relay to the OUTPUT terminal and the common side to the COMMON terminal (Figure 5).   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...
  • Page 10 Figure 5: Solenoid Terminations Through a Relay IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...

  • Page 11: Preparing For Timed Sampling

         1. Slide the analog/digital switch to the left to the "A" position.   Figure 6: Analog/Digital Switch in "A" Position   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 12  3. Slide switch 4 in the DIVISOR SWITCH bank up to the ON position, and then slide switches 1, 2, and 3 in the DIVISOR SWITCH switch bank down to the OFF position (Figure 8).   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...
  • Page 13 Figure 8: Divisor Switches Configured for Timed Sampling    4. Proceed to Section 2.5, Setting the Sampling Frequency. IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...

  • Page 14: Preparing For Proportional To Flow Sampling

    If the incoming signals are digital or voltage pulse, connect the positive side of the voltage pulse to the DIGITAL IN terminal and the common side to the COMMON terminal (Figure 9).   Figure 9: Terminations for Digital or Voltage Pulse Signal   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 15  2. Slide the analog/digital switch to the right to the "D" position (Figure 10).   Figure 10: Analog/Digital Switch in "D" Position   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 16 MODE SELECT switch bank down to the OFF position (Figure 11).   Figure 11: Mode Select Switches Configured for Proportional to Flow Sampling With Digital or Voltage Pulse Signal   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 17 Figure 12: Divisor Switches Configured for Proportional to Flow Sampling With Digital or Voltage Pulse Signal    5. Proceed to Section 2.5, Setting the Sampling Frequency. IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 18   Figure 13: Terminations for Analog (mA) Signal    7. Slide the analog/digital switch to the left to the "A" position (Figure 6). IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 19 MODE SELECT switch bank down to the OFF position (Figure 14).   Figure 14: Mode Select Switches Configured for Proportional to Flow Sampling With Analog (mA) Signal   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 20 Figure 15: Divisor Switches Configured for Proportional to Flow Sampling With Analog (mA) Signal    10. Proceed to Section 2.5, Setting the Sampling Frequency. IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 21 If the transmitter signal is in watts (W), slide switch 3 in the MODE SELECT switch bank up to the ON position, and then slide switches 1, 2, and 4 in the MODE SELECT switch bank down to the OFF position (Figure 17).   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...
  • Page 22 Figure 17: Mode Select Switches Configured for Proportional to Slow Sampling With Analog (W) Signal   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 23 1, 2, and 3 in the DIVISOR SWITCH switch bank down to the OFF position (Figure 18).   Figure 18: Divisor Switches Configured for Proportional to Flow Sampling With Analog (W) Signal IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...

  • Page 24: Setting The Sampling Frequency

    2.5 Setting the Sampling Frequency The 4P is programmed by setting the SAMPLING FREQUENCY SWITCH on the timer board. Sampling frequency equations based on the application (i.e., timed or proportional to flow) are used to calculate the switch factor, which determines the switch setting.
  • Page 25 Timed Collection  1. Calculate the desired sampling frequency using the provided equations (Figure 20).   Figure 20: Sampling Actuation Equations for Timed Collection   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 26 Set the SAMPLING FREQUENCY SWITCH to the desired switch factor based on the equations (Figure 21).   Figure 21: Example – Timed Collection Setting, Liquid IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 27 Set the SAMPLING FREQUENCY SWITCH to the desired switch factor based on the equation (Figure 23 or Figure 24).   Figure 23: Example – Proportional to Flow Collection (Digital), Gas   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 28 Figure 24: Example – Proportional to Flow Collection (Digital), Liquid IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 29 Calculate the desired sampling frequency using the provided equations (Figure 25).   Figure 25: Sampling Actuation Equations for Proportional to Flow Collection (Analog)   IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 30 Set the SAMPLING FREQUENCY SWITCH to the desired switch factor based on the equations (Figure 26).   Figure 26: Example – Proportional to Flow Collection (Analog), Gas IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...

  • Page 31: Calibration

    Locate the eight-pin chip on the rear of the timer board. The chip is labeled U2. 3.2 Adjusting Zero and Span A 4–20 mA or DC 1–5 V source, frequency counter, and small blade screwdriver are needed to adjust the calibration of the 4P.  ...

  • Page 32: Adjusting Dwell Time

     3. As necessary, adjust the dwell time. To increase the dwell time, adjust R31 clockwise. To decrease the dwell time, adjust R31 counterclockwise. IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...

  • Page 33: Troubleshooting

    SECTION 4: TROUBLESHOOTING 4.1 Troubleshooting The most common issues for the 4P are described in Table 3. If an issue is encountered that is not described below, contact Welker for service options.   Table 3: 4P Troubleshooting Issues Possible Solutions Use a voltmeter to ensure that a minimum of DC 7 V and a maximum of DC 28 V is across (+) VOLTS IN and (-) VOLTS IN.

  • Page 34: Appendices

    APPENDIX A: REFERENCED OR ATTACHED DOCUMENTS Welker Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:   None Other Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:   ASCO Valve, Inc. General Service Solenoid Valves Series 8345 (Welker IOM-V387)  ...

  • Page 35: B: Settings At A Glance

    ON position; all other switches down to OFF position (Figure B1 and Figure B2) Figure B1: Frequency Switch Values Figure B2: Sampling Actuation Equations for Timed Collection IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...
  • Page 36 SAMPLING FREQUENCY SWITCH: Switches whose binary values equal the switch factor when added together up to ON position; all other switches down to OFF position (Figure B1 and Figure B3) Figure B3: Sampling Actuation Equations for Proportional to Flow Collection (Digital) IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...
  • Page 37 SAMPLING FREQUENCY SWITCH: Switches whose binary values equal the switch factor when added together up to ON position; all other switches down to OFF position (Figure B1 and Figure B4) IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...
  • Page 38 ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________   13839 West Bellfort Street Sugar Land, TX  77498 Phone: 281.491.2331 welker.com IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331...

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