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Concoa IntelliSwitch 57 Series, Maintenance Instructions Manual, Page: 33 / 52

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Concoa IntelliSwitch 57 Series Maintenance Instructions Manual Download Page 33

 

33 

REPLACING DELIVERY REGULATOR (REPAIR) 

If it is necessary to change the delivery pressure regulator due to a regulator fault, as indicated on the front of the Medical 
IntelliSwich, perform the following steps: 

 

 

CAUTION:  Resetting the delivery regulators should be performed after replacing and while the Medical IntelliSwitch is flowing gas.  
Adjustment in a static condition (not flowing) will effect the available pressure during max flow conditions. 

WARNING:  Replacement of faulted regulator should be done as soon as possible to insure uninterrupted gas supply.  If the second 
regulator should fail while the first is out for repair, loss of line pressure and/or line over-pressurization will occur. 

 

1.

 

Open door by loosening the four screws holding it to the cabinet.   

2.

 

Locate delivery regulator toward the top of the system, see figure 25.  Isolate the faulted regulator by closing the inlet 
and outlet quarter turn valves for that side.   

 

Figure 25 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for IntelliSwitch 57 Series

Page 1: ...UCTIONS Carefully Read These Instructions Before Performing Any Maintenance Carefully Read These Controls Corporation of America 1501 Harpers Road Virginia Beach VA 23454 Telephone 1 800 225 0473 or 757 422 8330 Fax 757 422 3125 www concoa com January 2008 Preliminary TM ...

Page 2: ... installation testing operation and maintenance of their piped gas system This includes the incorporation of CONCOA s Medical IntelliSwitch Adhering to the CONCOA s ADI does not constitute full compliance to NFPA 99 requirements Refer to NFPA 99 for complete requirements This manual is not intended to replace or provide complete details of NFPA 99 ...

Page 3: ...Do not install this product in a hazardous environment If product appears damaged in any way do not use and request service from CONCOA Consult the cylinder distributor for the proper use of cylinders and for any restrictions on their use such as flow rate and temperature requirements Store cylinders with valve caps screwed on and chain cylinders to a supporting wall or column Handle cylinders car...

Page 4: ...gulators inside the cabinet A series of indicator lights show the status of the system at any given time The status of the Medical IntelliSwitch may be monitored remotely via a serial port or optional Ethernet port In addition the Medical IntelliSwitch can interface with a CONCOA Remote Alarm OPERATING THE MEDICAL INTELLISWITCH For a detailed explanation on the proper operation of the Medical Inte...

Page 5: ...5 Figure 1 ...

Page 6: ... connector for Alarm plug in bottom of the Medical IntelliSwitch Page 12 5295316 3 Alarm Connector Cable Assembly 6pin x 6pin 3ft long 5295316 10 Alarm Connector Cable Assembly 6pin x 6pin 10ft long 5295316 25 Alarm Connector Cable Assembly 6pin x 6pin 25ft long 5295316 50 Alarm Connector Cable Assembly 6pin x 6pin 50ft long 5295316 100 Alarm Connector Cable Assembly 6pin x 6pin 100ft long SERIAL ...

Page 7: ...44 8355024 Left Inlet Pressure Transducer 570 series Medical IntelliSwitch Page 45 8355025 Right Inlet Pressure Transducer 570 series Medical IntelliSwitch Page 45 8355026 Delivery Pressure Transducer 570 series Medical IntelliSwitch Page 45 8355034 Left Inlet Pressure Transducer 571 series Medical IntelliSwitch Page 45 8355035 Right Inlet Pressure Transducer 571 series Medical IntelliSwitch Page ...

Page 8: ...ery pressure 8350095 Relief Valve for 100 and 180 psi delivery pressure models 8305369 Check Valve for N2O and CO2 1 4 Pilot Regulator Note Each unit requires 2 8305383 Check Valve for O2 He and N2 1 4 Pilot Regulator Note Each unit requires 2 5500205 Gauge Inlet Regulator Dial 90800022 Tubing Red 8350282 Grips Yellow Plastic for 1 4 turn valves 8306619 Tube Fitting 1 2 NPT male x 1 2 Tube 90 Elbo...

Page 9: ...tly in use place the Allen wrench into the set screw and adjust the pressure to the desired value The delivery pressure of the inlet regulator can be seen on the internal pressure gauges Turning the set screw clockwise increases pressure Counterclockwise decreases pressure The system will not decrease in pressure if there is no flow See Figure 2 for the location of the regulators Default Factory S...

Page 10: ... a green light to the left or right of the delivery display that indicates which delivery regulator is in use If the left light is ON the pressure being displayed in the delivery display is the output pressure of the left regulator Similarly if the right green light is ON the pressure being displayed is from the right regulator 5 Locate the Allen wrench attached to the inside panel Starting with t...

Page 11: ... be the same to within 1 2 PSI for best performance 8 When the desired delivery pressure for both regulators is set turn OFF SW4 4 on the control board See Figure 4 9 Locate SW5 on the control board Figure 3 and press it once The system should go back to normal operation showing inlet pressures on both inlet displays 10 Calibration is complete Close door and re attach screws Figure 5 ...

Page 12: ...onnect the two devices For convenience a mating 6 pin connector is provided to use in building this cable assembly The Advantium Rx Alarm comes with a mating connector that is used to attach to the remote alarm side of the cable assembly The recommended cable for this assembly is 22 AWG 6 conductor stranded wire Alpha 1176C or equivalent The length of this cable should be limited to 1500 feet Cut ...

Page 13: ...12v provided by the remote alarm 4 4 Right Inlet Alarm Status 5 5 Auxiliary Gas Supply Alarm 6 6 Ground provided by the remote alarm Wire terminations to the Alarm side of the cable are done in the same fashion as the Medical IntelliSwitch connector Slide the protective cover cable retainer and locking nut over the end of the cable as shown in Figure 6 Figure 8 Using the pin assignments shown in T...

Page 14: ...arm indication If serial communication is selected the system will output a code indicating that a self test is being performed Test 2 Date of Manufacturing This test shows the year month and day the product was manufactured Test 3 Software Revision This is the revision of the software running the product Test 4 Analog Channel Check This checks the circuitry that is used to read the pressure trans...

Page 15: ...ssure of the product It is used to determine the allowable range of operation before a delivery regulator fault condition is declared Test 8 Look Back Time This value is the number of minutes the system waits before looking back Test 9 Switch Back Time This is the value in minutes used by the system to determine when a cylinder is truly empty and incapable of supplying sufficient gas Test 10 Hyste...

Page 16: ...st Left Inlet Valve This test turns ON the left inlet valve allowing gas to flow from that side while turning OFF the right inlet valve Test 14 Test Right Inlet Valve This test turns ON the right inlet valve allowing gas to flow from that side while turning OFF the left inlet valve Test 15 Test Left Delivery Regulator This test turns ON the left delivery regulator while turning OFF the right deliv...

Page 17: ...eft Inlet Alarm This test activates the left inlet alarm relay contact Test 18 Test Right Inlet Alarm This test activates the right inlet alarm relay contact Test 19 Test Regulator Alarm This test activates the delivery regulator alarm relay contact Test 20 Test Reserve Gas Supply Alarm This test activates the reserve gas supply alarm relay contact ...

Page 18: ...ON OFF OFF OFF 152 ON OFF OFF ON OFF ON OFF OFF OFF 33 OFF OFF ON OFF OFF OFF OFF OFF ON 161 ON OFF ON OFF OFF OFF OFF OFF ON 34 OFF OFF ON OFF OFF OFF OFF ON OFF 162 ON OFF ON OFF OFF OFF OFF ON OFF 36 OFF OFF ON OFF OFF OFF ON OFF OFF 164 ON OFF ON OFF OFF OFF ON OFF OFF 40 OFF OFF ON OFF OFF ON OFF OFF OFF 168 ON OFF ON OFF OFF ON OFF OFF OFF 65 OFF ON OFF OFF ON OFF OFF OFF ON 193 ON ON OFF OF...

Page 19: ...PSIG 1 Turn power OFF to the system 2 Open door by loosening the four screws holding it to the cabinet 3 Using Figure 9 locate DIP switch SW1 at the bottom of the electronic circuit board on the door Figure 9 4 Using Table 3 or Table 4 set the desired switchover pressure 5 Close system door and tighten 4 screws holding door to cabinet 6 Turn power back ON The new switchover pressure will take effe...

Page 20: ... OFF OFF ON OFF OFF ON ON OFF OFF 125 ON OFF ON ON ON ON ON OFF OFF 135 ON ON ON OFF OFF OFF OFF ON OFF 150 OFF ON ON OFF ON OFF OFF ON OFF 175 ON ON ON ON OFF ON OFF ON OFF 200 OFF OFF OFF ON OFF OFF ON ON OFF 225 ON OFF OFF OFF OFF ON ON ON OFF 250 OFF ON OFF ON ON ON ON ON OFF 275 ON ON OFF OFF ON OFF OFF OFF ON 300 OFF OFF ON ON OFF ON OFF OFF ON 325 ON OFF ON OFF OFF OFF ON OFF ON 350 OFF ON ...

Page 21: ...ing Figure 10 locate DIP switch SW6 at the bottom of the electronic circuit board on the door Figure 10 4 Using Table 5 set the pressure range tolerance Note It is highly recommended that the tolerance setting be no less than 5 PSI for proper system operation 5 Close system door and tighten 4 screws holding door to cabinet 6 Turn AC power back ON The new tolerance will take effect on power ON Tabl...

Page 22: ...ng Figure 11 locate DIP switch SW2 at the bottom of the electronic circuit board on the door 4 Using Table 6 set the appropriate units of measure 5 Close system door and tighten 4 screws holding door to cabinet 6 Turn AC power back ON The new units of measure will take effect on power ON Figure 11 7 The indicator light son the front panel show the units of measure selected If the PSI and BAR indic...

Page 23: ...ult for this feature is DISABLED To enable this feature perform the following steps 1 Turn AC power OFF to the system 2 Open door by loosening the four screws holding it to the cabinet 3 Using Figure 12 locate DIP switch SW4 1 at the bottom of the electronic circuit board on the door 4 Turn switch to the ON position 5 Close system door and tighten 4 screws holding door to cabinet 6 Turn AC power b...

Page 24: ...O Figure 14 shows the location of the jumpers on the Control Board To change a contact from N C to N O follow the steps below 1 Turn AC Power OFF to the system 2 Open front door by loosening the 4 screws holding it to the cabinet 3 Locate the jumpers on the Control Board 4 Using Table 7 and Figure 13 set the jumpers 5 Close door and re secure it to the cabinet 6 Make the necessary connections to t...

Page 25: ...25 Figure 14 ...

Page 26: ...DIP switch SW4 3 at the bottom of the electronic circuit board on the door 4 Turn SW4 3 to the ON position 5 Close system door and tighten 4 screws holding door to cabinet 6 Turn AC power back ON The Auxiliary Gas Supply Option will be enabled on power ON Note When this feature is enabled system setup parameters are saved to internal memory in the control electronics The DIP switches on the contro...

Page 27: ...product In the event that the AC Supply Voltage needs to be changed perform the following steps 1 Turn AC power OFF to the system 2 Open front door by loosening the 4 screws holding it to the cabinet 3 Locate the AC power switch on the Control Board Figure 16 4 Move the switch to the proper setting THIS SWITCH MUST BE SET TO THE AC INPUT VOLTAGE BEING SUPPLIED TO THE PRODUCT 5 Make sure the system...

Page 28: ...ng it to the cabinet 3 Locate the Fuse Cover on the lower left of the inside panel and remove the fuse cover screw see figure 17 Remove the fuse cover to expose the fuses Figure 17 4 Replace fuses see figure 18 with 1 amp type 3AG normal blow fuses Figure 18 5 Replace fuse cover and fuse cover screw 6 Close front door and re secure it to the cabinet 7 Re apply AC power to the system ...

Page 29: ...9 locate DIP switch SW3 at the bottom of the electronic circuit board on the door 4 Using Table 8 set the desired communication mode 5 If RS 485 is selected as the communication mode an additional step needs to be taken Refer to Figure 20 Move the jumpers as shown in the figure to the RS 485 positions 6 Close system door and tighten 4 screws holding door to cabinet 7 Turn AC power back ON The new ...

Page 30: ...30 Figure 20 ...

Page 31: ... valves and vent entire system of gas 3 Open door by loosening the four screws holding it to the cabinet 4 Locate the inlet regulator to be replaced see figure 21 5 Remove appropriate transducer connector from circuit board see figure 33 on inside of door 6 With zero pressure on entire system turn transducer to be replaced counter clockwise slowly Listen for any hissing indication of gas pressure ...

Page 32: ...ng 15 The replacement regulator was shipped preset to the approximate required inlet pressure The dial gauge provided on inlet regulator indicates the outlet pressure of the inlet regulator The dial gauges on each side should match the values listed in the table below Default Factory Settings Model Number Inlet Regulator Set Point while flowing gas 57X2XXX 155 160 PSIG 57X3XXX 240 250 PSIG 57X7XXX...

Page 33: ...ion not flowing will effect the available pressure during max flow conditions WARNING Replacement of faulted regulator should be done as soon as possible to insure uninterrupted gas supply If the second regulator should fail while the first is out for repair loss of line pressure and or line over pressurization will occur 1 Open door by loosening the four screws holding it to the cabinet 2 Locate ...

Page 34: ...ch down on the side to be replaced to indicate that the regulator is Out of Service 4 Close the inlet and outlet isolation valves for the delivery regulator to be replaced see figure 26 Figure 26 5 Loosen the inlet and outlet tube fittings and remove the faulty regulator see figure 27 Figure 27 ...

Page 35: ...very regulator is in use If the left light is ON the pressure being displayed in the delivery display is the output pressure of the left regulator Similarly if the right green light is ON the pressure being displayed is from the right regulator 17 Locate the Allen wrench attached to the inside panel Starting with the delivery regulator that is currently in use place the Allen wrench into the set s...

Page 36: ...gain The delivery pressure for both regulators should be the same to within 1 2 PSI for best performance 20 Locate SW5 on the control board Figure 29 and press it once The system should go back to normal operation showing inlet pressures on both inlet displays Figure 29 21 Repair is complete Close door and re attach screws Figure 30 ...

Page 37: ...37 INTERNAL CABLE ASSEMBLIES REPAIR Figure 31 ...

Page 38: ...38 Figure 32 Figure 33 ...

Page 39: ...tem 1 Figure 34 4 With unit UNPLUGGED remove fuse cover see figure 30 5 Remove spade connectors from power cord that connect to the fuse block see figure 34 Note the location of each colored wire 6 Remove the ground nut on internal panel assembly see figure 34 and remove ground wire ring terminal Note there are three ring terminals attached to this post When attaching new power cord ground wire ma...

Page 40: ...terminals are on stud and re attach the ground nut on the internal panel assembly see figure 34 10 Place spade connectors from new power cord on the fuse block Wire colors should match across fuse block If there is a black brown wire on the top of the left side of the fuse block attach the black brown wire to the top of the right side of the fuse block black and brown are interchangeable white and...

Page 41: ...e alarm connector nut see figure 36 from the outside and slide off the connector cap 5 Remove remote alarm cord connector from circuit board see figure 33 on inside of door Figure 36 6 Remove remote alarm cord nut from new cord see figure 32 item 2 7 Insert the new 6 pin remote alarm connector through the hole in the enclosure Slip on the connector cap then thread and wrench tighten remote alarm c...

Page 42: ...al port connector nut see figure 37 from the outside and slide off the connector cap 5 Remove serial port cord connector from circuit board see figure 33 on inside of door Figure 37 6 Remove serial port cord nut from new cord see figure 32 item 3 7 Insert the new 9 pin serial port connector through the hole in the enclosure Slip on the connector cap then thread and wrench tighten serial port conne...

Page 43: ...ring terminal Note there are three ring terminals attached to this post When attaching new power cable ground wire make sure all three rings are in place 7 Remove power cable from circuit board see figure 33 bottom right on inside of door 8 Place green wire ring terminal from new power cable on ground stud make sure all three ring terminals are on stud and re attach the ground nut on the internal ...

Page 44: ...und strap ring terminal Note there are three ring terminals attached to this post When attaching new ground strap make sure all three rings are in place 5 Remove the ground nut on front cover see figure 39 and remove ground strap ring terminal 6 Place ground strap ring terminal from new ground strap on ground stud on internal panel make sure all three ring terminals are on stud and re attach the g...

Page 45: ... out any excess Teflon tape still in port that transducer came out of Figure 40 9 Before applying Teflon tape inspect the NPT threads for cleanliness and damage Start the Teflon tape on the second thread as shown above make sure the tape does not overlap the end of the fitting As the tape is wrapped in the direction of the thread spiral pull tightly on the end of tape so that the tape conforms to ...

Page 46: ...ure STOP if you hear any pressure and vent system completely before continuing 9 Continue to turn thumb screws completely out and then gently pull upward to unseat the solenoid valve o rings 10 Unthread the red tubing tee and elbow connectors from the top of the solenoid valves 11 With a hex key remove the solenoid valve bases from the aluminum block by turning counter clockwise CAUTION Care shoul...

Page 47: ...s pressure STOP if you hear any pressure and vent system completely before continuing 9 Continue to turn thumb screws completely out and then gently pull upwart to unseat the solenoid valve o rings 10 Unthread the red tubing tee and elbow connectors from the top of the solenoid valves 11 With a hex key remove the solenoid valve bases from the aluminum block by turning counter clockwise CAUTION Car...

Page 48: ...osed Clean or replace internal regulator Open isolation valves Remote alarm does not work with the system Remote alarm is not powered Wiring between the Medical IntelliSwitch and the alarm is incorrect Check the remote alarm LED on Medical IntelliSwitch front panel Check alarm is powered and on Check wiring between alarm and Medical IntelliSwitch Outlet pressure from the system drops below the adj...

Page 49: ...or Service to the Medical IntelliSwitch contact your local Distributor or CONCOA Customer Service at 1 800 225 0473 Please fill in the Self Test Worksheet form included in this manual before contacting CONCOA for assistance This will ensure a more timely response to your needs An example of how to fill in the sheet is shown in Figure 21 Figure 43 ...

Page 50: ...50 SELF TEST WORKSHEET Page 1 ...

Page 51: ...51 SELF TEST WORKSHEET Page 2 ...

Page 52: ...ADI 9506 Certified ISO 9001 2000 Controls Corporation of America 1501 Harpers Road Virginia Beach VA 23454 Telephone 1 800 225 0473 or 757 422 8330 Fax 757 422 3125 www concoa com ...

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