Welker HR User manual

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
WELKER HEATED INSTRUMENT REGULATOR
MODEL
HR
DRAWING NUMBER
ADHRO02
PATENT
U.S. PATENT 7,471,882
MANUAL NUMBER
IOM-158
REVISION
Rev. 1, 03/08/2023

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
TABLE OF CONTENTS
SAFETY 3
1. PRODUCT INFORMATION 4
1.1 Introduction 4
1.2 Product Description 4
1.3 Important Certification Information 5
1.4 Specific Conditions of Use 5
1.5 Specifications 6
1.6 Equipment Diagram 7
2. INSTALLATION & OPERATION 8
2.1 Before You Begin 8
2.2 Installing the HR 8
3. MAINTENANCE 11
3.1 Before You Begin 11
3.2 Maintenance 12
3.3 Heater Failure 19
APPENDIX 20
A: Referenced or Attached Documents 20
Copyright © 1997–2023 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks of Welker, Inc.

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
SAFETY
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 Heated Instrument Regulator, HR. 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 Heated Instrument Regulator 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 Heated Instrument Regulator, please contact a Welker representative immediately.
Phone: [phone]
Address: 13839 West Bellfort Street
Sugar Land, TX 77498

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
SECTION 1: PRODUCT INFORMATION
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 HR Heated Instrument Regulator provides a conditioned gas sample stream at the required temperature and pressure
for the instrumentation.
The HR heats product prior to decreasing the pressure to help compensate for the natural temperature drop that occurs during
regulation. In order to set the desired output pressure, an adjusting screw on the device is turned clockwise. The design of the HR
allows for the sample stream to flow through at a consistent rate of pressure and temperature.
The enclosure for the electrical parts of the equipment consists of one (1) of two (2) certified flameproof enclosures with either
two (2) or three (3) ¾" FNPT entries and a threaded cover. The certified enclosure houses a terminal block and a heater controller
for regulation of the heater cartridge.
Welker may custom design the HR to suit the particular application and specifications of each customer.

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
1.3 Important Certification Information
1. Ensure that the field technician installing the HR is trained in the protection practices required to maintain the area
classification for electrical equipment in ATEX and IECEx hazardous locations.
2. Before connecting power to the HR, the technician shall ensure that cabling components supplied by the end-user are
certified for explosion protection flameproof enclosure "d".
3. The cable entry points may reach 179.24 °F (81.8 °C). Appropriate selection of cabling components shall be made by the
end-user to ensure that the installation of the HR maintains its certifications.
4. The phase conductors should have a minimum cross-sectional area no less than 0.8325 mm² (18 AWG). The protective
earth conductors should have the same or larger cross-sectional area as the phase conductors. All external equipotential
bonding connections shall provide an effective connection of a conductor with a minimum cross-sectional area of 4 mm².
5. Do not open the certified enclosure until the surface temperature and any stored electrical energy have decayed to the
point that the certified enclosure can no longer be a potential ignition source.
6. Ensure that the HR is isolated from all incoming and outgoing connections (including neutral conductors) prior to
opening the certified enclosure.
7. When removing the HR to perform maintenance, ensure that the exposed conductors are correctly terminated in an
appropriate enclosure, are insulated and isolated from all power sources, or are properly grounded and isolated from all
power sources.
8. When reassembling the certified enclosure, all joints should be thoroughly cleaned and may be lightly lubricated with
suitable grease, such as Crouse-Hinds STL or HTL Thread Lubricant, to prevent corrosion and assist in weatherproofing.
Use only non-metallic scrapers and non-corrosive cleaning fluids to clean flanges. Keep blind bolt holes clear of grease.
1.4 Specific Conditions of Use
1. Some external parts of the equipment are non-conducting and may generate an ignition-capable level of electrostatic
charge under certain extreme conditions. The end-user should ensure that the equipment is not installed in a location
where it may be subjected to external conditions (such as high pressure steam), which might cause a build-up of
electrostatic charges on non-conducting surfaces. Additionally, cleaning of the equipment should be done with a damp
cloth.
2. The equipment shall be operated within an inlet process temperature range of -76 °F to 140 °F (-60 °C to +60 °C).

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
1.5 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: HR Specifications
Products Natural Gas and Natural Gas Liquids Compatible With the Materials of
Construction
Materials of Construction
Regulator Base & Body: 6 Moly Stainless Steel, 17-4 PH Stainless Steel,
304/304L Stainless Steel, 316/316L Stainless Steel, 317/317L Stainless
Steel, 321/321H Stainless Steel, 347/347H Stainless Steel, Duplex
Stainless Steel, HASTELLOY® C276 Alloy, Inconel Alloy 625, Monel®
Alloy 400, and Super Duplex Stainless Steel
Seals: Varies Based on Customer Specifications and the MAOP and
MAOT of the Unit
Maximum Allowable Operating Pressure Bolted: 6000 psig @ -76 °F to 140 °F (413 barg @ -60 °C to +60 °C)
Threaded: 3600 psig @ -76 °F to 140 °F (248 barg @ -60 °C to +60 °C)
Process Temperature Range -76 °F to 140 °F (-60 °C to +60 °C)
Connections Product Inlet: ¹⁄" FNPT (Standard) or ¼" FNPT
Product Outlet: ¼" FNPT
Electrical Connections ¾" MNPT
Output Range
0–25 psig (0–1.7 barg)
0–50 psig (0–3.4 barg)
20–100 psig (1.3–6.8 barg)
75–200 psig (5.1–13.7 barg)
Operation Diaphragm- or Piston-Operated Regulator
Features
Explosion-Proof Certified Enclosure
Heating Element With Adjustable Temperature Range
(See Table 2 for Options)
Product Certifications
Patent U.S. Patent 7,471,882
Options
Bracket for Mounting
Regulator Subassembly
Relief Valve With Pressure Gauge
Table 2: Heating Element Options
Electrical Connection Power Temperature Range Current Resistance
AC 110/220 V 150 W 68 °F to 210 °F (20 °C to 98 °C) 1.25 A 196 
200 W 180 °F to 380 °F (82 °C to 193 °C) 1.67 A 75 
AC 220/240 V 100 W 68 °F to 210 °F (20 °C to 98 °C) 0.417 A 576 
200 W 180 °F to 380 °F (82 °C to 193 °C) 0.833 A 288 

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
1.4 Equipment Diagram
Figure 1: Welker Heated Instrument Regulator Diagram

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
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.
2.2 Installing the HR
Ensure that the field technician installing the HR is trained in performing installations as well as the protection practices required to
maintain the area classification of the electrical equipment in ATEX and IECEx hazardous locations.
1. As necessary, install a pressure gauge to the pressure gauge port (Figure 2).
Figure 2: Port Diagram
Welker can install a relief valve and pressure gauge if requested at the time of order.
2. As necessary, use a safe auxiliary gas supply to set the relief valve to the proper pressure. Refer to the Installation,
Operation, and Maintenance (IOM) Manual for the relief valve for instructions on setting the relief.
If a Welker relief valve is used, Welker can set the relief valve prior to shipment if requested at the time of order.
3. As necessary, install the set relief valve to the relief valve port (Figure 2).

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
4. With the customer-supplied electrical power turned OFF, connect the appropriate leads to terminals 2 and 4 in the
provided certified enclosure (Figure 3).
See Section 1.3, Important Certification Information, for information on selecting appropriate cabling components for the HR to
ensure it maintains its certifications.
Figure 3: Wiring Diagram
5. Conductors used to supply power to the certified enclosure are required to use adequate barrier glands or conduit seals
and an appropriate sealing compound to maintain flameproof "d" rating.
For systems used in hazardous locations, sealing compound is required to seal all fittings to restrict the passage of gases, vapors, or
flames.
When sealing fittings with sealing compound, refer to the proper sealing instructions for the brand used.
6. Set the heater controller dial to the desired temperature.
Note that the temperature scale on the heater controller is for reference only.
7. Secure the cover to the certified enclosure and fasten the set screw.
8. Using customer-supplied ¼" tubing, connect from the product supply outlet to the product inlet of the HR (Figure 1).
9. Install customer-supplied tubing or other fittings to the product outlet port of the HR (Figure 1 or Figure 2).

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IOM-158 | MODEL: HR | REV: 1 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Welker recommends that this tubing be insulated and heat-traced so that the sample maintains its temperature increase prior to
reaching the analyzer.
10. Loosen the jam nut on the adjusting screw (Figure 1).
11. Screw the adjusting screw clockwise to adjust the outlet pressure. Tighten the jam nut to secure the adjusting screw at
the desired outlet pressure (Figure 1).
12. Turn ON the electrical power to begin operation. Allow at least thirty (30) minutes for the HR to warm up.
Welker recommends that the unit be enclosed or insulated to maximize the heating effect of the HR.