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Welker OdorEyes OdorEyes Liquid Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
WELKER
ECOSYSTEM LIQUID WITH XL4 CONTROLLER
®
DRAWING NUMBER
OE500VS.1
BSYS0157
MANUAL NUMBER
IOM-243
REVISION
Rev. A, 08/14/2024

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  • Page 1 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WELKER ECOSYSTEM LIQUID WITH XL4 CONTROLLER ® DRAWING NUMBER OE500VS.1 BSYS0157 MANUAL NUMBER IOM-243 REVISION Rev. A, 08/14/2024...

  • Page 2: Table Of Contents

    Before You Begin Maintenance Alarm and Flow Meter Check Procedures Troubleshooting Guidelines APPENDICES A: Referenced or Attached Documents B: Maintenance Schedule IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 3: Safety

    IOM Manuals for each individual component. A list of relevant component IOM Manuals is provided in Appendix A of this manual. The information in this manual has been carefully checked for accuracy and is intended to be used as a guide for the installation, operation, and maintenance of the Welker®...

  • 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 Liquid Specifications...

  • Page 6: Equipment Diagrams

    1.5 Equipment Diagrams Figure 1: ECOsystem Liquid Solenoid Cabinet Schematic IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 7 Figure 2: Odorant Supply Tank General Arrangement IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 8 Figure 3: ECOsystem Liquid Solenoid Cabinet Connections Diagram IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 9 Figure 4: ECOsystem Liquid Solenoid Cabinet Diagram Figure 5: ECOsystem Liquid Solenoid Cabinet Valve Diagram IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 10 Figure 6A: Odorant Filter Diagram Figure 6B: Pneumatic Supply Filter Dryer Diagram IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 11: Installation & Operation

    Connect the skid drain port to an appropriate draining location (Figure 2). System Connections 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 12: Electrical Connections

    Replace the shipping gasket with the provided gasket. Install the bottom drain flange with the float to the level indicator. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 13: Start-Up Procedures

    Open tank blanket pressure outlet valve Q (Figure 5). Check the tank blanket pressure connections for leaks, and repair as necessary. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 14: Controller Configuration

    Valves Open; hold for 2 to 3 seconds (Figure 36). Alternate pressing Force Bank 1 Valves Open and Force Bank 2 Valves Open until liquid is observed at the sight glass mounted at the injection point. Welker® recommends forcing the injection cycle a minimum of three times (3x) per bank. Note that the forced injection cycle will automatically alternate between both banks.

  • Page 15: Xl4 Touch Screen Controller

    Setup From this type of screen, numeric and/or text values that affect the setup of the odorizer can be changed. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 16: Navigating The Display

    If nothing on the screen is pressed for a certain amount of time, the sleep function will cause the backlight on the screen to turn off. To wake up the controller, press anywhere on the screen or press one of the function keys. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 17 Tank Level Low Active if the flow meter is disabled or turned off; must be manually disabled/re-enabled Odor Flowmeter Disabled IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 18: Navigating The Monitor Menus

    Log to view current information for the odorizer. Monitor screens are information screens: no values can be changed from these screens. Figure 10: Monitor Menu Submenus IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 19 If the system status totals are used to track system performance, they should be periodically reset through the System Control submenu (Figure 19). IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 20 Injection Stats Figure 12: Monitor Menu Injection Stats IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 21 Odorant Tank Level Figure 13: Monitor Menu - Tank Level IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 22 The System 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 14: Monitor Menu System I/O, 1 of 2 IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 23 Figure 15: System I/O, 2 of 2 IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 24: Current Alarms

    The Current Alarms submenu provides the user with an overview of the current alarm status and allows the user to clear alarms that do not require certain actions. Figure 16: Monitor Menu Current Alarms IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 25: Alarms Log

    If SD Card Data Logging is enabled, the alarm logs will also be stored on the installed micro-SD card. The micro-SD card is equipped with 8 GB of storage. Figure 17: Monitor Menu Alarms Log IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 26: Navigating The Setup Menus

    Changing numeric and/or text values in the Setup submenus will alter how the system operates. Figure 18: Setup Menu Submenus IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 27: Numeric Values

    If a mistake is made while entering the new value or if the value does not need to be changed, press the home button to discard the changes and return to the Home screen. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 28: System Control

    Through the System Control submenu, the user can set the general parameters for the odorizer. Figure 19: Setup Menu System Control IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 29 Through the Odorant Inject submenus, the user can input information for bank 1 and bank 2. Figure 20: Setup Menu Odorant Inject IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 30 Figure 21: Setup Menu Odorant Inject Submenu IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 31 Figure 22: Odorant Inject Advanced Setup Advanced Setup screens should only be adjusted under the guidance of Welker® technical support. Contact Welker® if adjustments to the Advanced Setup screens are necessary. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com...

  • Page 32: Controller Options

    Through the Controller Options submenus, the user can customize the screen operation and set up communication for the controller. Figure 23: Setup Menu Controller Options IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 33 Figure 24: Controller Options Auto Scroll Setup The Auto Scroll behavior can also be started by pressing the F4 function key. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 34 Figure 25: Auto Scroll Pre-Set Screens IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 35: Date/Time Setup

    Figure 26: Controller Options Date/Time Setup The date and time can also be edited by selecting the current date and time on any screen. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 36 Modbus Setup Figure 27: Controller Options Modbus Setup IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 37 Ethernet Setup Figure 28: Controller Options Ethernet Setup IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 38 Through the Gas Flow Signal submenus, the user can set up the parameters of the odorant gas flow input signal. Figure 29: Setup Menu Gas Flow Signal IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 39 If the gas flow signal will be pulse, the pulse will be a digital pulse powered by the controller. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 40 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-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 41 When using an electronic level transmitter to track the odorant tank level, the Method should be set to Transmitter. When estimating the odorant tank level based on odorant usage, the Method should be set to Calculated. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 42 ENTER to save the changes. The Current Level should have increased by the amount entered, and the Odorant Flow Adjust Level should have reverted to 0.0 gallons. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 43 Figure 34: Odorant Tank Tank Volume Setup IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 44 Figure 35: Tank Volume Setup Strapping Tables If the odorant tank is horizontal, the strapping points will be calculated and entered at the factory. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 45: Troubleshooting

    Through the Troubleshooting submenu, the user can access troubleshooting options for bank 1 and bank 2. Figure 36: Setup Menu Troubleshooting IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 46: Maintenance

    After the seals are installed, the outer diameter of shafts and inner diameter of cylinders may be lubricated to allow smooth transition of parts. All maintenance and cleaning of the unit should be performed on a smooth, clean surface. Welker® recommends having the following tools available for maintenance. Please note that the exact tools required may vary by model. Adjustable Wrenches b.

  • Page 47: Maintenance

    After performing necessary maintenance on system components, reconnect all instrument tubing. g. Reinstall the system according to the instructions in Section 2.2, Installation, and Section 2.3, Start-Up Procedures. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 48: Alarm And Flow Meter Check Procedures

    Check the wiring on the magnetostrictive level indicator to ensure proper operation (Figure 2). Refer to the Installation, Operation, and Maintenance (IOM) Manual for the magnetostrictive level indicator for instructions on wiring the magnetostrictive level indicator. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 49: Return To Operation

    Set Odor Rate Required to the previous value that was recorded before the Troubleshooting procedures. The ECOsystem Liquid is now operational. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

  • Page 50: Troubleshooting Guidelines

    If the alarm returns, there may be some obstruction to the flow. Perform maintenance on the odorant filter and continue troubleshooting. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...
  • Page 51 N and odorant flow meter outlet valve P, and then open odorant flow meter bypass valve O. Force the solenoids open. If odorant is still not flowing, contact Welker® for additional support. IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER...

  • Page 52: Appendices

    INTERTEC Instrumentation Ltd. TS Thermostat (Welker® IOM-V105) • Max Machinery, Inc. Positive Displacement Flowmeters Models P001, P002, 213, 214, and 215 (Welker® IOM-V106) • Peter Paul Electronics Co., Inc. Series 20 Hazardous Location High Pressure 2-Way Solenoid Valves Model EH22 (Welker®...

  • Page 53: Appendix 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 Liquid Maintenance Schedule...
  • Page 54 _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ 13839 West Bellfort Street Sugar Land, TX 77498 Phone: 281.491.2331 welker.com IOM-243 MODEL: ECOSYSTEM LIQUID WITH XL4 CONTROLLER REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331...

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