Welker® OdorEyes® Accu/Line™ Injection System Installation, Operation, Maintenance Manual
Industry Manual Repository
Join the AnalyzeDetectNetwork and Read This Manual and Hundreds of Others Like It! It's Free!
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
WELKER® ACCU/LINE™ INJECTION SYSTEM
DRAWING NUMBERS
OE160VS
OE161VS
OE162VS.124
OE163VS
OE164VS
OE165VS
OE166VS.124
OE170VS.224
OE172VS.124
MANUAL NUMBER
IOM-179
REVISION
Rev. A, 04/13/2016
TABLE OF CONTENTS
SAFETY
3
1.
PRODUCT INFORMATION
4
1.1
Introduction
4
1.2
Product Description
4
1.3
Safety Warning
4
1.4
Specifications
5
1.5
Equipment Diagrams
6
2.
INSTALLATION & OPERATION
18
2.1
Before You Begin
18
2.2
Installation
18
2.3
Start-Up Procedures
19
3.
TOUCH SCREEN CONTROLLER
24
3.1
Understanding the Display
24
3.2
Navigating the Monitor Menus
27
3.3
Navigating the Setup Menus
35
4.
MAINTENANCE
64
4.1
Before You Begin
64
4.2
Maintenance
64
APPENDICES
66
A: Referenced or Attached Documents
66
B: Maintenance Schedule
67
Welker®, Welker Jet®, WelkerScope®, and OdorEyes® are Registered Trademarks owned by Welker, Inc.
2
IOM-179
|
MODEL: Accu/Line™
|
REV: A
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® OdorEyes® Accu/Line™ Injection System. 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 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 Accu/Line™ Injection System 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 Accu/Line™ Injection System, please contact a Welker® representative immediately.
Phone: 281.491.2331
Address: 13839 West Bellfort Street
Sugar Land, TX 77498
3
IOM-179
|
MODEL: Accu/Line™
|
REV: A
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® OdorEyes® 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® OdorEyes® Accu/Line™ Injection System is designed to inject liquid odorant proportional to flow into a natural gas
pipeline. This skid-mounted automatic injection system has three (3) primary components: the touch screen controller, the pump
cabinet, and the odorant supply tank. Each primary component plays an integral role in the operation of the Accu/Line™ and can
be customized to better suit each application.
The touch screen controller serves as the system’s brain. It continuously receives feedback from the customer’s gas flow meter
and the odorant flow meter in the pump cabinet, allowing the system to respond to changing flow conditions. As pipeline
conditions change, the controller increases or decreases the injection rate so that the Accu/Line™ continues injecting proportional
to flow. On-site and remote troubleshooting and monitoring are made easier by time- and date-stamped audit data detailing
system performance, alarm history, and odorant tank level.
The pump cabinet contains one (1) or two (2) Welker® BIP Bellows Injection Pumps, which inject the liquid odorant into the
pipeline. Having two (2) pumps allows the Accu/Line™ to better respond to and accommodate varying flow rates and limits
interruption to operation for pump maintenance. To prolong the operational life of the injection pumps, the Welker® F-9 Filter
removes particles from the liquid odorant and the Welker® F-5 Filter/Dryer conditions the pneumatic supply. The odorant flow
meter communicates the injection volume to the controller, which in turn actuates the solenoid(s) for proportional to flow
odorization.
Each odorant supply tank is equipped with a tank fill inlet, vent port, blanket pressure inlet, and level gauge. For added
automation, an electronic level transmitter can be installed to communicate tank level to the controller. Regardless of volume and
orientation, every odorant supply tank comes with 110% containment that is sloped to the drain port for easy draining.
Welker may custom design the Accu/Line™ Injection System to suit the particular application and specifications of each customer.
1.3 Safety Warning
Wherever hazardous gases or vapor-producing liquids are used, transported, or stored, the potential for an accidental leak exists.
Continuous monitoring of these hazards is essential to ensure personnel safety.
4
IOM-179
|
MODEL: Accu/Line™
|
REV: A
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 1: Accu/Line™ Specifications
Liquid Odorant Injection
Pneumatic Supply to Operate Injection Pump(s)
Controller: AC 120 V
Flow Meter and Solenoid: DC 12 V or DC 24 V
20 US Gallons
100 US Gallons
250 US Gallons
500 US Gallons
Others Available
Odorant Tank Level Gauge
Pump Cabinet (See Table 2)
Skid With 110% Containment
Touch Screen Controller
Application
Utility Requirements
Electrical Connections
Odorant Tank Volume
Features
Table 2: Pump Cabinet Specifications
BIP-1, -2, and -3: 303 Stainless Steel, 316/316L Stainless Steel, Anodized
Materials of Construction
Aluminum, Buna, Kalrez®, Polyurethane, PTFE, and Teflon®
BIP-1 and -3: 2160 psig @ -20 °F to 100 °F (148 barg @ -28 °C to 37 °C)
Maximum Allowable Operating Pressure
BIP-2: 2000 psig @ -20 °F to 100 °F (137 barg @ -28 °C to 37 °C)
BIP-1: 0.5–3.00 cc
Injection Volume
BIP-2: 0.1–0.75 cc
BIP-3: 1.0–9.0 cc
Operation
BIP-1, -2, and -3: Bellows-Operated
Regulator for Pneumatic Supply
Features
Welker® F-5 Filter/Dryer for Pneumatic Supply
Welker® F-9 Filter for Odorant Supply
Flow Meter
Heater and Insulation
NEMA 4 or NEMA 4X Enclosure
Options
Pneumatic Timer
Purge System
Regulator for Blanket Pressure
Welker® AEF-1 Atmospheric Exhaust Filter
5
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
1.5 Equipment Diagrams
Figure 1: General Arrangement – Horizontal Odorant Tank
6
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 2: General Arrangement – Vertical Odorant Tank
7
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 3: Pump Cabinet – Single Injection Pump
8
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 4: Pump Cabinet – Single Injection Pump With Blanket Pressure Regulator
9
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 5: Pump Cabinet – Dual Injection Pumps
10
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 6: Pump Cabinet – Dual Injection Pumps With Blanket Pressure Regulator
11
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 7: Pump Cabinet – Dual Injection Pumps With Heater
12
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 8: Pump Cabinet – Dual Injection Pumps With Pneumatic Timer
13
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 9: Pump Cabinet – Dual Injection Pumps With Pneumatic Timer and Blanket Pressure Regulator
14
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 10: Pump Cabinet – Dual Injection Pumps With Pneumatic Timer, Blanket Pressure Regulator, and Heater
15
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 11: Pump Cabinet – Dual Injection Pumps With Pneumatic Timer (No Flow Meter)
16
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 12: Odorant Filter Subassembly
Figure 13: Pneumatic Filter
Figure 14: Optional Exhaust Filter
17
IOM-179
|
MODEL: Accu/Line™
|
REV: A
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.
The Accu/Line™ will ship skid-mounted and “hard-tube” connected with manufacturer-supplied fittings and hardware. However, the
customer will need to supply some tubing and fittings in order to complete the installation of the system.
2.2 Installation
Pipeline Injection Point
1.
2.
If the Accu/Line™ will be connected to a Welker® SFA Sight Flow Assembly at the pipeline, install the SFA to the desired
injection point. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the SFA for installation instructions.
If the Accu/Line™ will be connected to a Welker® SP-DP Diffusing Probe at the pipeline, install the SP-DP to the desired
injection point. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the SP-DP for installation
instructions.
System Skid
3.
4.
5.
Mount the skid to a flat, level surface, such as a concrete slab.
Connect a grounding wire to the grounding lug on the skid to safely ground the system.
Connect the skid drain port(s) to an appropriate draining location.
System Connections
6.
Using appropriately sized customer-supplied tubing, connect from the odorant outlet on the pump cabinet to the inlet of
the SFA or SP-DP (Figures 3-11).
Welker recommends using stainless steel tubing for all natural gas process lines, as plastic tubing can absorb odorant from the gas.
Welker recommends installing a valve between the system odorant outlet and the injection point.
7.
8.
9.
18
As necessary, connect a customer-supplied unodorized natural gas or inert gas supply to the inlet of the Welker® F-5
Filter/Dryer (Figure 13).
Ensure that all valves on the system are closed.
Ensure that all fittings, connections, and bolts are tightened.
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Electrical Connections
Turn OFF the electrical supply prior to making electrical connections.
10.
Connect an AC 120 V electrical supply to the controller. Refer to the industry standards for appropriate electrical
connections to interface with the PLC.
For systems used in hazardous locations, sealing compound is required to seal all fittings to restrict the passage of gases, vapors, or
flames.
11.
Connect the customer gas flow signal device to the termination block.
The controller can accept analog, pulse, or Modbus input.
2.3 Start-Up Procedures
Odorant Supply Tank
1.
Fill the odorant supply tank in accordance with company policy and procedure, taking care not to exceed 80% of the
total volume of the supply tank.
Never fill the odorant supply tank above 80% of its capacity. Allow at least 20% for product expansion, should the tank be exposed
to increased temperatures.
2.
Check the odorant supply tank for leaks and repair as necessary.
Pneumatic Supply Regulator
3.
4.
5.
6.
Open F-5 inlet valve O and F-5 outlet valve P (Figure 13).
Apply pneumatic supply pressure to the pump cabinet.
Open pneumatic supply inlet valve F to pressurize the pneumatic supply regulator (Figures 3-11).
The pneumatic supply regulator is factory-set to the setting required to stroke the pump(s) located inside the pump
cabinet according to the recommended settings in Table 3.
Table 3: Injection Pump Pressure Regulator Settings
Injection Pressure (psig)
Approximate Regulator Set Point (psig)
0-400
30
401-800
50
801-1200
80
1201-2160
100
19
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Blanket Pressure Regulator
7.
8.
9.
Open blanket pressure inlet valve X (Figure 1 or Figure 2).
Open blanket pressure outlet valve L or open the regulated external blanket pressure supply source (Figure 4, Figure 6,
Figure 9, or Figure 10).
Check the blanket pressure connections for leaks and repair as necessary.
Valve Configuration
10.
Slowly open the valves indicated in Table 4.
Table 4: Start-Up Valve Orientation
Valve Description
Odorant Inlet
Odorant Outlet
Injection Pump Inlet
Injection Pump Outlet
Odorant Flow Meter Bypass
Valve Letter
R
S
A (A1 and A2)
B (B1 and B2)
E
11.
12.
20
Reference Figure(s)
12
12
3-11
3-11
3-10
If the Accu/Line™ is connected to an SFA or SP-DP at the pipeline, slowly open any valves between the odorant outlet on
the pump cabinet and the SFA or SP-DP.
Check for leaks and repair as necessary.
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Purging the Injection Pump
13.
14.
15.
Open injection pump purge outlet valve M to purge the injection chamber of any trapped air (Figure 3).
Once all air has been purged from the injection chamber, close injection pump purge outlet valve M (Figure 3).
As necessary, adjust the injection volume of the injection pump.
Loosen the jam nut on the adjustment screw.
To increase the injection volume, turn the adjustment knob counterclockwise.
To decrease the injection volume, turn the adjustment knob clockwise.
Tighten the jam nut on the adjusting screw to secure the adjusting screw at the desired volume.
Figure 15: BIP Diagram
16.
17.
18.
21
As necessary, repeat steps 13-15 for the backup injection pump (Figure 11).
Slowly open flow meter outlet valve D and flow meter inlet valve C, and then close flow meter bypass valve E (Figures 310).
Open the valve on the inlet of the SFA or SP-DP, if applicable, or any valve(s) restricting the flow of odorant from the
Accu/Line™ to the pipeline.
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Verifying Pump Operation
Pump operation can be verified using the optional pneumatic timer or using the controller.
To verify pump operation using the optional pneumatic timer, continue to step 19.
To verify pump operation using the controller, proceed to step 31.
Using the Optional Pneumatic Timer
19.
20.
21.
22.
Close primary injection pump actuation valve G (Figures 8-11).
Open pneumatic timer isolation valve K (Figures 8-11).
Open primary injection pump actuation valve H (Figures 8-11).
Turn the dial on the front of the pneumatic timer to set the stroke frequency of the primary injection pump.
To get a full stroke of the injection pump, do not set the stroke frequency faster than every six (6) seconds.
23.
As the injection pump strokes, verify liquid odorant is being injected into the pipeline.
Welker recommends a minimum of ten (10) actuations to verify injection.
The injection of liquid odorant into the pipeline can be verified a number of ways.
If an SFA is used, product flow can be observed by visually examining the incorporated Welker® SG-4 Sight Glass.
•
If an SP-DP is used, product flow can be indicated by a sight glass or pressure gauge. If the SP-DP is equipped with a
•
Welker® SG-4 Sight Glass, the Visual Flow Indicator (a.k.a. Spinner Wheel) should spin. If a pressure gauge is installed
upstream of the inlet check valve, the pressure gauge will spike as pressure builds to overcome the check valve.
24.
25.
26.
27.
28.
29.
Once the collection and injection of the primary injection pump has been verified, prepare to verify the collection and
injection of the backup injection pump.
Open primary injection pump actuation valve G (Figures 8-11).
Close primary injection pump actuation valve H (Figures 8-11).
Close backup injection pump actuation valve I (Figures 8-11).
Open backup injection pump actuation valve J (Figures 8-11).
As necessary, turn the dial on the front of the pneumatic timer to set the stroke frequency of the backup injection pump.
To get a full stroke of the injection pump, do not set the stroke frequency faster than every six (6) seconds.
30.
As the injection pump strokes, verify liquid odorant is being injected into the pipeline.
Welker recommends a minimum of ten (10) actuations to verify injection.
The injection of liquid odorant into the pipeline can be verified a number of ways.
If an SFA is used, product flow can be observed by visually examining the incorporated Welker® SG-4 Sight Glass.
•
If an SP-DP is used, product flow can be indicated by a sight glass or pressure gauge. If the SP-DP is equipped with a
•
Welker® SG-4 Sight Glass, the Visual Flow Indicator (a.k.a. Spinner Wheel) should spin. If a pressure gauge is installed
upstream of the inlet check valve, the pressure gauge will spike as pressure builds to overcome the check valve.
22
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Using the Controller
31.
32.
33.
34.
35.
As necessary, ensure that primary injection pump actuation valve G is open (Figures 8-11).
As necessary, ensure that primary injection pump actuation valve H and pneumatic timer isolation valve K are closed
(Figures 8-11).
Set the controller gas flow signal to fixed rate. Use the gas flow meter on the customer pipeline to obtain a current flow
rate, and then use this value to set the fixed rate gas flow (Figure 50). Set the fixed mode to “enabled” (Figure 50). See
Section 3.3, Navigating the Setup Menus, for instructions on changing numeric and text values in the Setup submenus.
From the controller, stroke the primary pump. From the Setup Menu, select System Setup (Figure 30). From the System
Setup Menu, select Odorant Pump Setup (Figure 32). From the Odorant Pump Menu, select Pump 1 Setup (Figure 33). The
Manual Stroke field will highlight just before the controller strokes the pump (Figure 33).
As the injection pump strokes, verify liquid odorant is being injected into the pipeline.
Welker recommends a minimum of ten (10) actuations to verify injection.
The injection of liquid odorant into the pipeline can be verified a number of ways.
If an SFA is used, product flow can be observed by visually examining the incorporated Welker® SG-4 Sight Glass.
•
If an SP-DP is used, product flow can be indicated by a sight glass or pressure gauge. If the SP-DP is equipped with a
•
Welker® SG-4 Sight Glass, the Visual Flow Indicator (a.k.a. Spinner Wheel) should spin. If a pressure gauge is installed
upstream of the inlet check valve, the pressure gauge will spike as pressure builds to overcome the check valve. Readout
from the flow meter.
36.
37.
38.
Once the collection and injection of the primary injection pump has been verified, prepare to verify the collection and
injection of the backup injection pump. If the Accu/Line™ is not equipped with a backup injection pump, proceed to step
39.
From the controller, stroke the backup injection pump. From the Setup Menu, select System Setup (Figure 30). From the
System Setup Menu, select Odorant Pump Setup (Figure 32). From the Odorant Pump Menu, select Pump 2 Setup (Figure
33). The Manual Stroke field will highlight just before the controller strokes the pump (Figure 33).
As the injection pump strokes, verify liquid odorant is being injected into the pipeline.
Welker recommends a minimum of ten (10) actuations to verify injection.
The injection of liquid odorant into the pipeline can be verified a number of ways.
If an SFA is used, product flow can be observed by visually examining the incorporated Welker® SG-4 Sight Glass.
•
If an SP-DP is used, product flow can be indicated by a sight glass or pressure gauge. If the SP-DP is equipped with a
•
Welker® SG-4 Sight Glass, the Visual Flow Indicator (a.k.a. Spinner Wheel) should spin. If a pressure gauge is installed
upstream of the inlet check valve, the pressure gauge will spike as pressure builds to overcome the check valve. Readout
from the flow meter.
Controller Configuration
39.
40.
23
Verify that the customer set points have been correctly set by the manufacturer.
Once the collection and injection of liquid odorant has been confirmed, the Accu/Line™ is operational.
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
SECTION 3: TOUCH SCREEN CONTROLLER
3.1 Understanding the Display
The touch screen controller is used to modify system parameters and view current system information 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 16).
Figure 16: Home Screen
From the Home screen, the user can access three (3) types of screens:
Menu-from this type of screen, the user can access submenus.
•
Informational-from this type of screen, the user can monitor the odorizer and view current operating conditions.
•
Setup-from this type of screen, numeric and/or text values that affect the setup of the odorizer can be changed.
•
24
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Navigating the Display
Figure 17: Toolbar and Function Keys
The toolbar appears on every screen except the Home screen.
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.
25
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Viewing the Current Alarms
From any screen, press the Alarms button to go to the Current Alarms screen (Figure 18).
Figure 18: Current Alarms Screen
Table 5: Current Alarms
Analog Flow
Pulse Flow
Constant Rate
Shutdown Mode
Can only be active if Pulse Input method is selected.
Can only be active if Constant Rate mode is specified as the desired fail mode.
The controller will go into gas flow fail mode when there is a gas flow signal loss.
Can only be active if Shutdown Mode is specified as the desired fail mode.
The controller will enter this gas flow fail mode when there is a gas flow signal loss.
Fixed Rate
Can only be active if Fixed mode is enabled.
Tank Level
Can only be active if an electronic level transmitter is used to track the odorant tank level and the
controller loses the 4-20 mA signal from the transmitter.
NOTE: If this alarm is active, the controller will automatically switch to the odorant flow method to track
the odorant tank level. The controller will use the value of odorant in the tank and subtract the appropriate
volume with each stroke.
Tank Low Level
Active if the odorant tank level has dropped below the specified value.
P1(2) Overflow
Active if the pump output for the last ten (10) strokes exceeds the allowable average deviation.
P1(2) Low Flow
Active if the pump output for the last ten (10) strokes is below the allowable average deviation.
P1(2) No Flow
Active if after ten (10) strokes there is no output from the pump.
Dual Pump Mode
SD Card Error
26
Can only be active if Analog Input method is selected.
IOM-179
|
Indicates the odorizer is currently actuating both pumps.
Active if SDcard Data Logging is enabled but no micro SD card is installed.
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
3.2 Navigating the Monitor Menus
Through the Monitor menu, the user can access the System Status, System I/O, Local Audit Trail, and Local Alarms Log to view
current information for the odorizer.
Monitor screens are information screens: no values can be changed from these screens.
Figure 19: Monitor Menu Submenus
27
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
SYSTEM STATUS
The System Status submenus provide the user with an overview of system performance.
Figure 20: System Status Submenus
Figure 21: System Status – Rates & Totals
28
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 22: System Status – Stroke Frequency
29
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 23: System Status – Pump Stats
Figure 24: System Status – Tank Level
30
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
SYSTEM I/O
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 25: System I/O, 1 of 2
31
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 26: System I/O, 2 of 2
32
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Local Audit Trail
From the Local Audit Trail submenu, the user can access the audit tail records stored on internal memory. Up to 600 audit trail
records can be stored and viewed.
If SDcard Data Logging is enabled, the audit trail records will also be stored on the installed micro SD card. The micro SD card is
equipped with 8 GB of storage.
Figure 27: Local Audit Trail
33
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Local Alarms Log
From the Local Alarms Log submenu, the user can access the alarms logs stored on internal memory. Up to 428 alarms logs can be
stored and viewed.
If SDcard Data Logging is enabled, the alarms logs will also be stored on the installed micro SD card. The micro SD card is equipped
with 8 GB of storage.
Figure 28: Local Alarms Log
34
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
3.3 Navigating the Setup Menus
Through the Setup menu, the user can access the System Setup, Controller Options, Local Data Logging, and SDcard Data Logging
submenus and change numeric and/or text values that alter the parameters and features of the odorizer.
Changing numeric and/or text values in the Setup submenus will alter how the system operates.
Figure 29: Setup Menu Submenus
35
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Changing Values on Setup Screens
Numeric Values
1.
2.
3.
To change a numeric value, press on the value to be changed. A keypad will appear on the screen.
Type the new value using the keypad.
Once the new numeric value has been entered, press ENTER to save the changes.
If the new value entered is outside the range of allowable values, the value will revert back to the previous value once ENTER is
pressed. The keypad will stay active, allowing another value to be entered.
Text Values
4.
5.
6.
To change a text value, press on the value to be changed. A dropdown menu will appear on the screen.
Scroll through the value’s options using the arrow keys in the dropdown menu.
Highlight the desired text value, and then press ENTER to save the changes.
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.
System Setup
Through the Setup menu, the user can configure all items related to the operation and performance of the odorizer.
Figure 30: System Setup Submenus
36
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
System Control
Through the System Control submenu, the user can set the general parameters for the odorizer.
Figure 31: System Setup – System Control
37
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Odorant Pump Setup
Through the Odorant Pump Setup submenus, the user can input information for the injection pump(s).
Figure 32: System Setup – Odorant Pump Setup Submenus
38
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 33: Odorant Pump Setup
39
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 34: Odorant Pump Setup – Pump Configuration
Figure 35: Odorant Pump Setup – Advanced Setup
40
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Odorant Tank Setup
Through the Odorant Tank Setup submenus, the user can input information for the odorant tank.
Figure 36: Odorant Tank Setup Submenus
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 Odorant Flow.
41
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Odorant Flow Setup
Figure 37: Odorant Tank Setup – Odorant Flow Setup
The Current Level numeric value cannot be directly changed. Instead, the user must enter a value in the Adjust Level field to increase
or decrease the Current Level by the specified amount.
To decrease the Current Level, enter the volume to be subtracted from the current level as a negative number in the
•
Adjust Level field, and then press ENTER to save the changes. The Current Level should have decreased by the amount
entered, and the Adjust Level should have reverted to 0.0 Gal.
To increase the Current Level, enter the volume to be added to the current level in the Adjust Level field, and then press
•
ENTER to save the changes. The Current Level should have increased by the amount entered, and the Adjust Level should
have reverted to 0.0 Gal.
42
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 38: Odorant Tank Setup – Transmitter Setup
43
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 39: Odorant Tank Setup – Additional Tank Setup
44
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 40: Odorant Tank Setup – Additional Tank Setup, Strapping Tables
If the odorant tank is horizontal, the strapping points will be calculated and entered at the factory.
45
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Gas Flow Signal
Through the Gas Flow Signal submenus, the user can set up the parameters of the odorant gas flow input signal.
Figure 41: System Setup – Gas Flow Signal Submenus
Figure 42: Gas Flow Signal – Input Signal Setup
46
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 43: Gas Flow Signal – Analog Input Setup
If the gas flow signal will be analog, the analog signal must be 4-20 mA powered by the user.
47
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 44: Gas Flow Signal – Pulse Input Setup
If the gas flow signal will be a pulse, the pulse will be a digital pulse powered by the controller.
48
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 45: Gas Flow Signal – Modbus Input Setup Submenus
If the gas flow signal will be Modbus, the Modbus input will be a value downloaded from the Modbus master device in Mscf/h. The
Modbus Register is 43275, and the input value should be downloaded as a 32-bit float.
49
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 46: Modbus Input – Modbus Setup
Modbus Setup can also be accessed through the Controller Options submenu (Figure 51).
Figure 47: Modbus Setup – Current Status
50
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 48: Modbus Input – Comm Port Setup
Comm Port Setup can also be accessed through the Controller Options submenu (Figure 56).
51
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 49: Gas Flow Signal – Fail Mode Setup
Setting the Fail Mode to Shutdown will halt odorization until the alarm is cleared.
Setting the Fail Mode to Constant Rate will allow odorization to continue at the specified rate.
If the gas flow value does not change during the Pulse/Modbus Cutoff Time, the system will alarm for loss of flow and will enter the
specified Fail Mode. The alarm will clear on the next pulse input or change in Modbus gas flow, and the system will resume normal
operation.
52
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 50: Gas Flow Signal – Fixed Rate Setup
53
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Controller Options
Through the Controller Options submenus, the user can customize the screen operation and set up communication for the
controller.
Figure 51: System Setup – Controller Options Submenu
54
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 52: Controller Options – Auto Scroll Setup
The Auto Scroll behavior can also be started and stopped by pressing the F4 function key (Figure 17).
55
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 53: Controller Options – Date/Time Setup
The date and time can also be edited by selecting the current date and time on any screen (Figure 17).
56
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 54: Controller Options – Modbus Setup
Figure 55: Modbus Setup – Current Status
Modbus Setup can also be accessed through Gas Flow Signal submenus (Figure 45).
57
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 56: Controller Options – Comm Port Setup
Comm Port Setup can also be accessed through Gas Flow Signal submenus (Figure 48).
58
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Local Data Logging
Through the Local Data Logging submenus, the user can set up and reset the data logs stored locally.
Figure 57: System Setup – Local Data Logging Submenus
59
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 58: Local Data Logging – Audit Trail and Audit Log
60
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
SDcard Data Logging
Through the SDcard Data Logging submenus, the user can set up and monitor the data logs stored on the installed micro SD card.
If a micro SD card is installed, data will automatically be logged to the installed card when Data Logging is enabled.
Figure 59: System Setup – SDcard Data Logging Submenus
If the micro SD card needs to be removed, first enter Data Log Setup to disable Data Logging. Failure to disable Data Logging prior
to removing the micro SD card will trigger the SD Card Error alarm.
To continue data logging, insert a new micro SD card, and then enable Data Logging through the Data Log Setup (Figure 60).
61
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 60: SDcard Data Logging – Data Log Setup
62
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Figure 61: SDcard Data Logging – Log File Status
63
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
SECTION 4: MAINTENANCE
4.1 Before You Begin
1.
2.
Refer to Appendix B, Maintenance Schedule, for the itemized Welker-recommended maintenance schedule for the
Accu/Line™.
Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit available for repairs of the system in
case of unexpected wear or faulty seals.
New seals supplied in spare parts kits should be lightly lubricated before being installed. This eases the installation of the seals and
reduces the risk of damage when positioning them on parts. Welker recommends non-hydrocarbon-based lubricants, such as
Krytox®, for use with all seals exposed to the sample product and silicone-based lubricants, such as Molykote® 111, for use with seals
not exposed to the sample product.
Wipe excess lubricant from the seals, as it may adversely affect analytical instrument results.
After the seals are installed, the outer diameter of shafts and inner diameter of cylinders may be lubricated to allow smooth
transition of parts.
3.
All maintenance and cleaning of the unit should be performed on a smooth, clean surface.
4.2 Maintenance
1.
2.
During injection, monitor the system for leaks. If leaks are present, halt operation and repair as necessary.
To perform maintenance on a single injection pump system, continue to step 3. To perform maintenance on a dual
injection pump system, proceed to step 4.
Single Injection Pump System
3.
64
Occasionally, a system component may need to be repaired or replaced for manufacturer recommended maintenance.
To perform maintenance on components:
a. Turn OFF all electrical power to the system.
b. Depressurize the system and close all valves.
c. Disconnect the tubing and remove individual system components for maintenance.
d. For complete and proper maintenance on individual system components, refer to their respective Installation,
Operation, and Maintenance (IOM) Manual. A list of component Installation, Operation, and Maintenance (IOM)
Manuals is available in Appendix A, Referenced or Attached Documents, in this manual.
e. After performing necessary maintenance on system components, reconnect all instrument tubing.
f. Reinstall the system according to the instructions in Section 2.2, Installation, and Section 2.3, Start-Up Procedures.
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
Dual Injection Pump System
Primary Injection Pump
4.
5.
6.
7.
8.
Prior to performing maintenance on the primary injection pump, the pump operation must be changed in the controller.
From the Setup Menu, select System Setup (Figure 30). From the System Setup Menu, select Odorant Pump Setup (Figure
32). From the Odorant Pump Menu, select Change Pump Operation (Figure 34). Set Pump 1 to “None” and Pump 2 to
“Primary.”
Once the primary injection pump has been set to “None,” the primary injection pump can be removed from the pump
cabinet for maintenance. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the Welker® BIP Injection
Pump for maintenance instructions.
After maintenance has been performed on the primary injection pump, reinstall the pump to the pump cabinet.
To return to normal operation, the pump operation must be changed in the controller. From the Setup Menu, select
System Setup (Figure 30). From the System Setup Menu, select Odorant Pump Setup (Figure 32). From the Odorant Pump
Menu, select Change Pump Operation (Figure 34). Set Pump 1 to “Primary” and Pump 2 to “Backup,” or set Pump 1 to
“Backup” and Pump 2 to “Primary.”
To perform maintenance on the backup injection pump, continue to step 9. To perform maintenance on other system
components, proceed to step 14. If no other components require maintenance, maintenance is now complete.
Backup Injection Pump
9.
10.
11.
12.
13.
Prior to performing maintenance on the backup injection pump, the pump operation must be changed in the controller.
From the Setup Menu, select System Setup (Figure 30). From the System Setup Menu, select Odorant Pump Setup (Figure
32). From the Odorant Pump Menu, select Change Pump Operation (Figure 34). Set Pump 1 to “Primary” and Pump 2 to
“None.”
Once the backup injection pump has been set to “None,” the backup injection pump can be removed from the pump
cabinet for maintenance. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the Welker® BIP Injection
Pump for maintenance instructions.
After maintenance has been performed on the backup injection pump, reinstall the pump to the pump cabinet.
To return to normal operation, the pump operation must be changed in the controller. From the Setup Menu, select
System Setup (Figure 30). From the System Setup Menu, select Odorant Pump Setup (Figure 32). From the Odorant Pump
Menu, select Change Pump Operation (Figure 34). Set Pump 1 to “Primary” and Pump 2 to “Backup,” or set Pump 1 to
“Backup” and Pump 2 to “Primary.”
To perform maintenance on other system components, continue to step 14. If no other components require
maintenance, maintenance is now complete.
System Components
14.
65
Occasionally, a system component may need to be repaired or replaced for manufacturer recommended maintenance.
To perform maintenance on components:
a. Turn OFF all electrical power to the system.
b. Depressurize the system and close all valves.
c. Disconnect the tubing and remove individual system components for maintenance.
d. For complete and proper maintenance on individual system components, refer to their respective Installation,
Operation, and Maintenance (IOM) Manual. A list of component Installation, Operation, and Maintenance (IOM)
Manuals is available in Appendix A, Referenced or Attached Documents, in this manual.
e. After performing necessary maintenance on system components, reconnect all instrument tubing.
f. Reinstall the system according to the instructions in Section 2.2, Installation, and Section 2.3, Start-Up Procedures.
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
APPENDIX A: REFERENCED OR ATTACHED DOCUMENTS
Welker® Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:
•
•
•
•
•
•
•
•
•
IOM-010: Welker® OdorEyes® BIP-1, BIP-2, BIP-3, and BIP-4 Bellows Injection Pumps
IOM-033: Welker® RV-1, RV-2, RV-2CP, and RV-3 Relief Valves
IOM-046: Welker® F-4, F-5, F-19, F-23, and F-31 Filters/Dryers
IOM-105: Welker® NV-1 and NV-2 Instrument Valves
IOM-113: Welker® F-7, F-8, F-9, and F-10 Filters
IOM-180: Welker® AEF-1 Atmospheric Exhaust Filter
IOM-182: Welker® CV-K Check Valve
IOM-187: Welker® SFA Sight Flow Assembly
IOM-203: Welker® SP-DP Diffusing Probe
Other Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Cellex Manufacturing, Inc. ESE 150 and ESE 200 Constant Watt Heaters (Welker® IOM-V252)
Fisher® 67C Series Instrument Supply Regulators (Welker® IOM-V048)
Fisher® 1301 Series High-Pressure Regulators Types 1301F and 1301G (Welker® IOM-V107)
Horner APG XLe/XLt OCS (Welker® IOM-V224)
Inline Industries 201F Ball Valve (Welker® IOM-V222)
INTERTEC™ CP MULTITHERM C Electric Heater (Welker® IOM-V104)
Max Machinery, Inc. 286-300 Series Transmitters (Welker® IOM-V220)
Max Machinery, Inc. High Resolution, Linearized Frequency Transmitters Models 269, 294 and 295 (Welker® IOM-V221)
Max Machinery, Inc. Positive Displacement Flowmeters Models P001, P002, 213, 214, and 215 (Welker® IOM-V106)
Morgan Products Model TR2 Air Actuated Timer (Welker® IOM-V219)
MTS Sensors Corporation Level Plus® Liquid-Level Sensors With Temposonics® Technology M-Series Model MR Analog
Transmitter (Welker® IOM-V036)
Parker Ball and Plug Valves (Welker® IOM-V213)
™
Parker Skinner 71313, 71315, 71335, 71385, 71395, 7131V, and 7133V 3-Way Solenoid Valves (Welker® IOM-V016)
Power-Sonic Corporation PS-1270 12 Volt 7.0 AH Rechargeable Sealed Lead Acid Battery (Welker® IOM-V223)
Solutions With Innovation Visual Level Indicator L505 Dip-Tape Visual Level Indicator (Welker® IOM-V037)
Swagelok® Bleed Valves and Purge Valves (Welker® IOM-V208)
Swagelok® Check Valves C, CA, CH, CP, and CPA Series (Welker® IOM-V076)
Swagelok® One-Piece Instrumentation Ball Valves 40G Series and 40 Series (Welker® IOM-V085)
Swagelok® Plug Valves P4T and P6T Series (Welker® IOM-V102)
Versa® C Series Valves (Welker® IOM-V041)
WIKA Bourdon Tube Pressure Gauges Type 232.53 and Type 233.53 (Welker® IOM-V171)
Welker® drawings and schematics suggested for use with this unit:
•
•
•
•
•
•
•
•
•
66
System Drawing: OE160VS (Dual Pump Valve Section)
System Drawing: OE161VS (Dual Pump Valve Section With Pneumatic Timer)
System Drawing: OE162VS.124 (Dual Pump Valve Section With Blanket Pressure Regulator)
System Drawing: OE163VS (Dual Pump Valve Section With Heater)
System Drawing: OE164VS (Dual Pump Valve Section With Pneumatic Timer, Blanket Pressure Regulator, and Heater)
System Drawing: OE165VS (Dual Pump Valve Section With Pneumatic Timer and Blanket Pressure Regulator)
System Drawing: OE166VS.124 (Dual Pump Valve Section With Pneumatic Timer and Purge System But Without Flow
Meter)
System Drawing: OE170VS.224 (Single Pump Valve Section With Purge System)
System Drawing: OE172VS.124 (Single Pump Valve Section With Blanket Pressure Regulator)
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331
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: Accu/Line™ Maintenance Schedule
Action
Weekly
If applicable, confirm proper functioning of the heater.
Open F-5 drain valve Q to allow moisture to drain from the filter.
Verify the pneumatic supply pressure and blanket pressure, if
applicable.
Rebuild the BIP(s) using a Welker® repair kit.
• Replace the seals and bearing.
• Replace the check cartridges.
• Inspect the bellows, actuator piston, actuator spring, and
actuator housing for damage or wear.
Rebuild the F-5 using a Welker® repair kit.
• Replace the O-rings and filter cartridge.
View the controller’s current alarms.
Inspect the injection pump(s), tubing, valves, and fittings on the
system for leaks.
Open F-9 drain valve U to allow moisture to drain from the filter.
Rebuild the F-9 using a Welker® repair kit.
• Replace the O-rings and filter element.
Rebuild the RV-1(s) using a Welker® repair kit.
• Replace the O-rings.
• Inspect the spring and ball for damage or wear.
Replace the controller battery.
Maintain the flow meter.
Maintain the regulator(s).
Maintain the solenoid(s).
If applicable, maintain the atmospheric exhaust filter.
If applicable, maintain the pneumatic timer.
X
X
67
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
Every 12
Months
As Necessary
X
X
X
X
X
X
X
X
X
X
X
X
X
X
welker.com
Service Department: 281.491.2331
NOTES
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________________________
13839 West Bellfort Street
Sugar Land, TX 77498
Phone: 281.491.2331
welker.com
68
IOM-179
|
MODEL: Accu/Line™
|
REV: A
13839 West Bellfort Street, Sugar Land, TX 77498
welker.com
Service Department: 281.491.2331