Welker 4P Installation and operating instructions

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

TABLEOFCONTENTS
2IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Copyright © 2019 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks of Welker, Inc.
 SAFETY 3
1. PRODUCT INFORMATION 4
1.1 Introduction 4
1.2 Product Description 4
1.3 Power Supply to the 4P 4
1.4 Specifications 5
1.5 Equipment Diagrams 6
  
2. INSTALLATION & OPERATION 8
2.1 Before You Begin 8
2.2 Installation and Initial Wiring 8
2.3 Preparing for Timed Sampling 11
2.4 Preparing for Proportional to Flow Sampling 14
2.5 Setting the Sampling Frequency 24
  
3. CALIBRATION 31
3.1 Before You Begin 31
3.2 Adjusting Zero and Span 31
3.3 Adjusting Dwell Time 32
  
4. TROUBLESHOOTING 33
4.1 Troubleshooting 33
  
 APPENDICES 34
 A: Referenced or Attached Documents 34
 B: Settings at a Glance 35


IMPORTANTSAFETYINFORMATION
READALLINSTRUCTIONS
Notes emphasize information and/or provide additional information to assist the user.
Caution messages appear before procedures that could result in damage to equipment if not observed.
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.
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 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 completely and carefully.
IMPORTANT - Save these instructions for local inspector's use.
IMPORTANT - Observe all governing codes and ordinances.
Note to Installer - Leave these instructions with the end user.
Note to End User - Keep these instructions for future reference.
Installation of this Sample Frequency Controller is of a mechanical and electrical nature.
Proper installation is the responsibility of the installer. Product failure due to improper installation is not covered under the warranty.
If you received a damaged Sample Frequency Controller, please contact a Welker representative immediately.
Phone: 281.491.2331
Address: 13839 West Bellfort Street
Sugar Land, TX 77498
SAFETY
3IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.1 Introduction
We appreciate your business and your choice of Welker products. The installation, operation, and maintenance liability for this
equipment becomes that of the purchaser at the time of receipt. Reading the applicable Installation, Operation, and
Maintenance (IOM) Manuals prior to installation and operation of this equipment is required for a full understanding of its
application and performance prior to use.*
If you have any questions, please call Welker at 1-281-491-2331.
*The following procedures have been written for use with standard Welker parts and equipment. Assemblies that have been modified may have additional
requirements and specifications that are not listed in this manual.
1.2 Product Description
The Welker 4P Sample Frequency Controller is a simple, multi-function controller designed for use with sampling systems.
Once power is supplied to the 4P and solenoid, the 4P operates as a free-running timer that can be used to pulse a sample
pump. By setting the sampling frequency switch, the 4P can be set to practically any time period required.
The 4P is also capable of receiving digital, voltage pulse, or analog signals and can easily interface with a variety of devices, such
as transmitters, flow computers, and turbine meters. The timber board can be configured to operate based on time or
proportionality to the input signal.
Welker may custom design the 4P to suit the particular application and specifications of each customer.
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.
To determine whether to supply the timer with DC 12 or 24 V, refer to Table 1.
Table 1: Determining Necessary Power Supply
Solenoid Power &Watt Draw Power Supply to 4P
12 Volt, Draw ≤ 2 Watts DC 12 V
12 Volt, Draw > 2 Watts Install a Relay; Power Supply to 4P Dependent on Supply
Needed to Supply Relay (DC 12 or 24 V)
24 Volt, Draw ≤ 10 Watts DC 24 V
24 Volt, Draw > 10 Watts Install a Relay; Power Supply to 4P Dependent on Supply
Needed to Supply Relay (DC 12 or 24 V)
SECTION 1: PRODUCTINFORMATION
4IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

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
Applications Control of Sample Pumps
Timer
Temperature Range -40 °F to 160 °F (-40 °C to 71 °C)
Power DC 7–28 V
Current
2 W @ DC 12 V*
10 W @ DC 24 V*
*Solenoid Current Not Included
Analog Input DC 1–5 V
4–20 mA
Digital Input
Open Collector or Dry Contact
DC 1–5 V
Impedance: 10 kΩ
Maximum Frequency: 1 Hz
Digital Output PNP Transistors Sinking 600 mA
Switches Between Input and Ground
Mounting Bracket or Dome
Feature Adjustable Dwell Time
Options
AC/DC Converter
DC 12 V Power Supply
Enclosure
Relay
Scaler Card
5IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.5 Equipment Diagrams
Figure 1: Mounting Options
6IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 2: Timer Board Diagram
7IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

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.


All electrical connections must meet local and national electric codes, and excessive weight added to the conduit run must be
supported.
2.2 Installation and Initial Wiring

All terminations should be made on the terminal strip to the right of the timer board using fork terminals.


The timer board does not need to be removed from the enclosure to make terminations.


The terminations needed to power the timer are the same for all applications.

1. As necessary, mount the enclosure to the desired location. Ensure that there is sufficient clearance below the enclosure
for the cables and conduit to exit.

The enclosure can be mounted directly to the pump, on a nearby wall, or to a mounting bracket.

2. Open the enclosure door.
3. Locate the wiring terminal block on the timer board (Figure 2).
SECTION 2: INSTALLATION&OPERATION
8IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

4. Make the terminations for the power supply. Connect the positive lead of the power supply to (+) VOLTSIN and the
negative lead to (-) VOLTS IN (Figure 3).

Figure 3: Power Terminations

5. Make the terminations for the solenoid. Connect the positive lead of the solenoid to OUTPUT and the negative lead to
COMMON (Figure 4).

Figure 4: Solenoid Terminations

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).

9IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 5: Solenoid Terminations Through a Relay
10 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2.3 Preparing for Timed Sampling

If there are no incoming signals and the timer board will be used for timed applications, the basic wiring configuration of the
power and solenoid is sufficient for operation; no further wiring connections are required.


A summary of settings by application is provided in Appendix B, Settings at a Glance.

1. Slide the analog/digital switch to the left to the "A" position.

Figure 6: Analog/Digital Switch in "A" Position

11 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2. Slide switch 1 in the MODESELECT switch bank up to the ON position, and then slide switches 2, 3, and 4 in the
MODESELECT switch bank down to the OFF position (Figure 7).

Figure 7: Mode Select Switches Configured for Timed Sampling

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).

12 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 8: Divisor Switches Configured for Timed Sampling

4. Proceed to Section 2.5, Setting the Sampling Frequency.
13 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2.4 Preparing for Proportional to Flow Sampling

If there are incoming signals and the timer board will be used for proportional to flow applications, additional wiring
connections are required.


A summary of settings by application is provided in Appendix B, Settings at a Glance.


If the incoming signals are digital or voltage pulse, continue to step 1.
If the incoming signals are analog (mA), proceed to step 6.
If the incoming signals are analog and power needs to be supplied to the transmitter, proceed to step 11.

Digital or Voltage Pulse Signal
1. 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

14 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2. Slide the analog/digital switch to the right to the "D" position (Figure 10).

Figure 10: Analog/Digital Switch in "D" Position

15 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

3. Slide switch 4 in the MODESELECT switch bank up to the ONposition, and then slide switches 1, 2, and 3 in the
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

16 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

4. Slide switches 1–4 in the DIVISORSWITCH switch bank down to the OFF position (Figure 12).

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.
17 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Analog Signal (mA)
6. If the incoming signals are analog, the power may be looped if the signal is milliamps (mA) instead of watts (W).
Connect the positive side of the analog input to the ANALOGIN terminal and the negative side to the
COMMONterminal (Figure 13).

Figure 13: Terminations for Analog (mA) Signal

7. Slide the analog/digital switch to the left to the "A" position (Figure 6).
18 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

8. Slide switches 2 and 3 in the MODESELECT switch bank up to the ONposition, and then slide switches 1 and 4 in the
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

19 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

9. 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 15).

Figure 15: Divisor Switches Configured for Proportional to Flow Sampling With Analog (mA) Signal

10. Proceed to Section 2.5, Setting the Sampling Frequency.
20 IOM-001 MODEL: 4P REV: F 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331