Welker OdorEyes ECOsystem Pulse Bypass System User manual

INSTALLATION, OPERATION, 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

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort 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 Sa ety Warning 4
1.4 Speci ications 5
1.5 Equipment Diagrams 6
2. INSTALLATION & OPERATION 16
2.1 Be ore 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 Be ore You Begin 46
4.2 Maintenance 46
APPENDICES 47
A: Re erenced or Attached Documents 47
B: Maintenance Schedule 48
Copyright © 2019 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks o Welker, Inc.

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
SAFETY
IMPORTANT SAFETY INFORMATION
READ ALL INSTRUCTIONS
Notes emphasize in ormation and/or provide additional in ormation to assist the user.
Caution messages appear be ore procedures that could result in damage to equipment i not observed.
Warning messages appear be ore procedures that could result in personal injury i not observed.
This manual is intended to be used as a basic installation and operation guide for the Welker OdorEyes ECOsystem™ Pulse Bypass System With X t Controller. 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 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 completely and care ully.
IMPORTANT – Save these instructions or local inspector’s use.
IMPORTANT – Observe all governing codes and ordinances.
No e o Ins aller – Leave these instructions with the end user.
No e o End User – Keep these instructions or uture re erence.
Installation o this ECOsystem™ Pulse Bypass System is o a mechanical and electrical nature.
Proper installation is the responsibility o the installer. Product ailure due to improper installation is not covered under the warranty.
I you received a damaged ECOsystem™ Pulse Bypass System, please contact a Welker representative immediately.
Phone: [phone]
Address: 13839 West Bell ort Street
Sugar Land, TX 77498

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
SECTION 1: PRODUCT INFORMATION
1.1 In roduc ion
We appreciate your business and your choice o Welker products. The installation, operation, and maintenance liability or this
equipment becomes that o the purchaser at the time o receipt. Reading the applicable Installation, Operation, and Maintenance
(IOM) Manuals prior to installation and operation o this equipment is required or a ull understanding o its application and
per ormance prior to use.*
I 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.
1.2 Produc Descrip ion
The Welker OdorEyes ECOsystem™ Pulse Bypass System With X t Controller is designed to in use the customer pipeline proportional
to low with natural gas that has been supersaturated with vaporized odorant. This skid-mounted automatic bypass system has
three (3) primary components: the touch screen controller, the valve section, and the odorant supply tank. Each primary
component plays an integral role in the operation o the ECOsystem™ and can be customized to better suit each application.
The touch screen controller serves as the system’s brain. It continuously receives eedback rom the customer’s gas low meter
and the low switch in the valve section, allowing the system to respond to changing low conditions. As pipeline conditions
change, the controller increases or decreases the injection rate so that the ECOsystem™ continues in using proportional to low.
On-site and remote troubleshooting and monitoring are made easier by time- and date-stamped audit data detailing system
per ormance, 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 the low o gas through the odorant supply tank
and into the pipeline. Having two (2) or three (3) solenoids allows the ECOsystem™ to better respond to and accommodate
varying low rates and limits interruption to operation in the event o solenoid maintenance. To prolong the operational li e o the
regulator and solenoid(s), the Welker F-5 Filter Dryer conditions the natural gas supply. The low switch communicates the
solenoid operation to the controller to ensure proper odorization. For pulse bypass systems used in cold climates, a heater with
thermostat can be added to replenish heat lost during regulation.
Each odorant supply tank is equipped with a tank ill inlet, vent port, blanket pressure inlet, level gauge, and outlet to the pipeline.
The temperature transmitter communicates odorant temperature to the controller so the system can compensate or
temperature changes within the odorant tank. For added automation, an electronic level transmitter can be installed to
communicate tank level to the controller. Regardless o volume or orientation, the odorant supply tank comes with 110%
containment that is sloped to the drain or easy draining.
Welker may custom design the ECOsystem™ Pulse Bypass System With X t Controller to suit the particular application and specifications
of each customer.
1.3 Safe y Warning
Wherever hazardous gases or vapor-producing liquids are used, transported, or stored, the potential or an accidental leak exists.
Continuous monitoring o these hazards is essential to ensure personnel sa ety.

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
1.4 Specifica ions
The speci ications listed in this section are generalized or this equipment. Welker can modi y the equipment according to your
company's needs. Please no e ha he specifica ions may vary depending on he cus omiza ion of your equipmen .
Table 1: ECOsys em™ Specifica ions
Applica ion Vaporized Odorant In usion
Elec rical Connec ion
AC 120 V
DC 12 V
DC 24 V
Odoran Tank Volume
5 US Gallons (18 )
20 US Gallons (75 )
50 US Gallons (189 )
60 US Gallons (227 )
100 US Gallons (378 )
120 US Gallons (454 )
250 US Gallons (946 )
500 US Gallons (1892 )
Others Available
Fea ures
Odorant Tank Level Gauge
Skid With 110% Containment
Temperature Transmitter
Touch Screen Controller
Valve Section (See Table 2)
Op ions
Flag Tracker Level Indicator
Heater or Controller Enclosure
NEMA 4 or NEMA 7 Enclosure or Controller
Solar Panel
Steel Building
Table 2: Valve Sec ion Specifica ions
Tubing Size
Low Flow: ¼" (0.6 cm)
High Flow: ³" (0.9 cm)
Variable Flow: ¼" and ³" (0.6 and 0.9 cm)
Fea ures
2-Way Solenoid Valve
Flow Switch
Regulator or Natural Gas Supply
Welker F-5 Filter Dryer or Natural Gas Supply
Op ions
Backup Solenoid
Enclosure
Heater With Thermostat
Low Flow Solenoid
Volume Bottle ( or Systems With ³" (0.9 cm) Tubing)

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
1.5 Equipmen Diagrams
Figure 1: General Arrangemen – Horizon al Odoran Tank

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 2: General Arrangemen – Ver ical Odoran Tank

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 3: Valve Sec ion – Single Solenoid, ³" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 4: Valve Sec ion – Dual Solenoid, ³" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 5: Valve Sec ion – Dual Solenoid Wi h Hea er, ³" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 6: Valve Sec ion – Single Solenoid, ¼" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 7: Valve Sec ion – Dual Solenoid, ¼" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 8: Valve Sec ion – Dual Solenoid Wi h Hea er, ¼" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 9: Valve Sec ion – Triple Solenoid Wi h Hea er, ¼" and ³" Tubing

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Figure 10: Pneuma ic Fil er
Figure 11: Volume Bo le Diagram (Applicable for Valve Sec ions Wi h ³" Tubing)

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
SECTION 2: INSTALLATION & OPERATION
2.1 Before You Begin
A ter unpacking the unit, check the equipment or compliance and any damage that may have occurred during shipment.
Immediately contact a Welker representative i you received damaged equipment.
When sealing ittings with PTFE tape, re er to the proper sealing instructions or the brand used.
The ECOsystem™ will ship skid-mounted and “hard-tube” connected with manu acturer-supplied ittings and hardware. However,
the customer will need to supply some tubing and ittings in order to complete the installation o the system.
The ECOsystem™ must be installed in a section o the natural gas pipeline with a regulated pressure drop, such as a regulator station
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 Ins alla ion
Sys em Skid
1. Mount the skid to a lat, level sur ace, such as a concrete slab.
2. Connect a grounding wire to each grounding lug on the skid to sa ely ground the system.
3. Connect the skid drain port(s) to an appropriate draining location.
Sys em Connec ions
4. Using appropriately sized customer-supplied tubing, connect rom the outlet o the pipeline upstream o the regulated
pressure drop to the inlet o the Welker F-5 Filter Dryer (Figure 10).
Tubing must have a minimum diameter o ³".
5. Connect rom odorized gas outlet valve K2 to an unused valve on the natural gas pipeline downstream o the regulated
pressure drop (Figure 1 or Figure 2).
Welker recommends using stainless steel tubing or all natural gas process lines, as plastic tubing can absorb odorant rom the gas.
6. Ensure that all valves on the system are closed.
7. Ensure that all ittings, connections, and bolts are tightened.

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Elec rical Connec ions
Turn OFF the electrical supply prior to making electrical connections.
8. Connect an appropriate electrical supply to the controller. Re er to industry standards or appropriate electrical
connections to inter ace with the PLC.
For systems used in hazardous locations, sealing compound is required to seal all ittings to restrict the passage o gases, vapors, or
lames.
9. Connect the customer gas low signal device to the termination block.
The controller can accept analog or pulse input.
10. I the ECOsystem™ is not equipped with the optional lag tracker level indicator, installation is now complete; proceed to
Section 2.3, Start-Up Procedures. I the ECOsystem™ is equipped with the optional lag tracker level indicator, continue to
step 11.
Flag Tracker Level Indica or (Op ional)
The loat and gasket must be installed to the lag tracker level indicator prior to illing the odorant supply tank.
The loat and gasket are packaged separately or shipment.
11. Remove the bottom drain lange rom the base o the level indicator.
12. Install the loat to the spring on the bottom drain lange. The top o the loat should point up.
The top o the loat is marked to ensure proper orientation.
The spring attached to the bottom drain lange cushions the loat when the odorant supply tank is empty.
13. Replace the shipping gasket with the provided gasket.
14. Install the bottom drain lange with loat to the level indicator.

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
2.3 S ar -Up Procedures
Odoran Supply Tank
1. Open emergency bypass valves B1 and B2 (Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, or Figure 9).
2. Fill the odorant supply tank in accordance with company policy and procedure, taking care not to exceed 80% o the
total volume o the supply tank.
Never ill the odorant supply tank above 80% o its capacity. Allow at least 20% or product expansion, should the tank be exposed
to increased temperatures.
3. Check the odorant supply tank or leaks and repair as necessary.
4. Close emergency bypass valves B1and B2 (Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, or Figure 9).
Na ural Gas Supply Regula or
5. As necessary, open any valves between the outlet on the natural gas pipeline and the F-5 inlet.
6. Open F-5 inlet valve E and F-5 outlet valve F (Figure 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 actory-set to the setting required to operate the solenoid(s).
8. I applicable, open regulator outlet valve C (Figure 8 or Figure 9).
9. I applicable, open volume bottle valve D (Figure 11). The volume bottle will ill with the conditioned natural gas.
Only systems with ³" tubing are equipped with a volume bottle.
Valve Configura ion
10. Slowly open the valves indicated in Table 3.
Table 3: S ar -Up Valve Orien a ion
Valve Le er Valve Descrip ion Reference Figures
A Blanket Pressure Outlet 3–9
J1 & J2 Blanket Pressure Inlet 1 & 2
K1 & K2 Odorized Gas Outlet 1 & 2
Once odorized gas outlet valves K1 and K2 are open, gas may ree low rom the odorant supply tank to the pipeline until pressure in
the system equalizes. Note that ree low will last only or a short time and over-odorization will not occur.
11. I applicable, slowly open any valves between the odorized gas outlet on the odorant supply tank and the pipeline.
12. Check or leaks and repair as necessary.

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
Con roller Configura ion
13. Veri y that the customer set points have been correctly set by the manu acturer.
Verifying Solenoid and Flow Swi ch Opera ion
14. From the controller, veri y the correct operation o the solenoid and low 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, veri y that FlowSw and Sol 1 darken simultaneously.
16. As the controller closes the solenoid, veri y that FlowSw and Sol 1 clear simultaneously.
17. Once the correct operation o the solenoid and low switch has been con irmed, the ECOsystem™ is operational.

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IOM-181 | MODEL: ECOSYSTEM™ WITH XLT CONTROLLER | REV: C 13839 West Bell ort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331
SECTION 3: XLT TOUCH SCREEN CONTROLLER
3.1 Unders anding he Display
The touch screen controller is used to modi y system parameters and view current system in ormation 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: Con roller Menu Tree