Concoa INTELLISWITCH Installation And Operating Instructions Manual Download Page 16

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CONNECTING TO A SERIAL PORT

The IntelliSwitch is equipped with a serial port.  This port is typically configured as an RS-232 Port but can 
be factory configured as an RS-485 Port.

The Serial Port is used to communicate with external serial devices, primarily a PC.  There are a number of 
commands as well as data that can be communicated between the IntelliSwitch and the peripheral device.  
Contact your CONCOA representative for more information.

TROUBLESHOOTING

Symptom

Possible Cause

Possible Solution

No display or status lights ON.

·  No power to the system.
·  Check that the power source is live.
·  Check the system fuse.

·  Restore power.
·  Replace fuse.
·  Replace electronic control board.

System will not switch from one side 
to the other automatically.

·  Check that the pressure on the 

destination side is greater than the 
switchover pressure setting.

·  Restore pressure to proper 

operating level.

·  Check that the switchover pressure 

setting is correct for the cylinder 
size and inlet pressures required.

There are pressure readings on both 
inlet displays but no delivery pressure.

·  Air supply is off or its pressure is 

too low.

·  Internal regulator for the valve 

system is plugged or faulty

·  Restore pressure
·  Clean or replace internal regulator

There is a pressure reading on the left 
inlet display and no pressure on the 
right inlet display or outlet display.

·  In a system using delivery process 

gas activation, the right side must 
be pressurized for gas delivery.

·  Restore a minimum of 80 PSI 

pressure to the right side.

Remote alarm does not work with the 
system.

·  Remote alarm is not powered.
·  Wiring between the IntelliSwitch 

and the alarm is incorrect.

·  Check the remote alarm LED on 

IntelliSwitch front panel.

·  Check alarm is powered and on.
·  Check wiring between alarm and 

IntelliSwitch

Outlet pressure from the system drops 
below the adjusted value.

·  Flow demands on the system are 

greater than the cylinders can 
supply.

·  Cylinder pressures are too low.
·  Switchover pressure set too low for 

the application.

·  Replace or resize cylinders.
·  Change switchover pressure on 

IntelliSwitch.

Gas from one side appears to be 
flowing to the other.

·  Dirty or bad check valve.

·  Replace check valve.

Gas escaping from side of regulator 
block.

·  Failed burst disk.

·  Replace burst disk.

Inlet display shows "Err2"

·  Inlet pressure greater than 

maximum inlet operating pressure.

·  Reduce pressure to the inlet to 

maximum allowable.

Outlet display shows "Err2"

·  Outlet regulator failure.

·  Replace outlet regulator.

Any display shows "Err3"

·  Switchover pressure value is greater 

than the cylinder size selected.

·  Change cylinder size by pressing 

the "Source Select" button

·  Change switchover pressure value.

Summary of Contents for INTELLISWITCH

Page 1: ...ion of America 1501 Harpers Road Virginia Beach VA 23454 To Order Call 1 800 225 0473 or 757 422 8330 Fax 757 422 3125 www concoa com INSTALLATION AND OPERATING INSTRUCTIONS Carefully Read These Instr...

Page 2: ...o drop below the switching point even if there is plenty of gas left in the cylinder When a typical switchover enters such a state two undesirable situations may occur First the system may switch to t...

Page 3: ...PSI This value is factory set but can be changed in the field To change this value refer to the section on changing the switchover pressure Manual Bank Switching It is possible to manually change the...

Page 4: ...nment If product appears damaged in any way do not use and request service from CONCOA Do not attempt to operate the IntelliSwitch with the front panel off Consult the cylinder distributor for the pro...

Page 5: ...and Welding Processes same address as 2 4 CONCOA publication ADE 872 Safety Precautions in Welding and Cutting 5 Local Ordinances 6 O S H A Standard 29 CFR 7 C G A Pamphlet C 4 American National Stan...

Page 6: ...n external air driven IntelliSwitch turn the air source on at this time Finally connect AC power to the IntelliSwitch The system is factory set to operate at either 115VAC 60hz or 230 VAC 60hz Connect...

Page 7: ...s being used by each side All switching is automatic If the primary side drops below the set switchover point the system will transfer to the reserve side and the status lights will indicate the trans...

Page 8: ...tch will redirect itself to draw the pressure down through the delivery stream Once the pressure reaches a normal value it will return to drawing from the previous side Bank Selection The Bank Select...

Page 9: ...9 Figure 2...

Page 10: ...d removing the nut Using a Phillips screwdriver remove the 4 screws and washers holding the front panel Unscrew the nut on the outlet pressure adjustment regulator being careful not to allow the front...

Page 11: ...6 Switchover pressure set 6 32 7 Switchover pressure set 7 64 8 Switchover pressure set 8 128 9 Switchover pressure set 9 256 10 Reserved 11 PSI units set if SW1 11 and SW2 11 both not set units MPA O...

Page 12: ...itches REMOVE AC power from the system Remove the knob on the outlet pressure adjustment regulator by carefully lifting the center label on the knob and removing the nut Using a Phillips screwdriver r...

Page 13: ...nger tight Re install the 4 screws and washers holding the front panel Attach the knob to the regulator using the nut and reapply the label The nut holding the knob should be tightened securely Re app...

Page 14: ...is also possible to purchase a ready made cable assembly Contact your local CONCOA Distributor or call 1 800 225 0473 for information Cut the 4 conductor cable to length Remove the outer jacket of the...

Page 15: ...low Using the pin assignments shown in Table 7 and the connector views in Figure 6 and Figure 7 solder the wires to the appropriate pins After soldering is complete attach the connector cover to the 2...

Page 16: ...regulator There is a pressure reading on the left inlet display and no pressure on the right inlet display or outlet display In a system using delivery process gas activation the right side must be p...

Page 17: ...e valve that controls flow from the left inlet to ON This helps determine if there is gas flow from the left side If gas is not flowing during this test check that the cylinder s is turned on and full...

Page 18: ...s a liquid cylinder to recover its pressure to a predetermined value Hysteresis Pressure above the set switchover pressure point as viewed in Test 9 This number is factory set between 0 and 60 minutes...

Page 19: ...ON OFF OFF ON 89 ON OFF ON ON OFF OFF ON 26 OFF OFF ON ON OFF ON OFF 90 ON OFF ON ON OFF ON OFF 27 OFF OFF ON ON OFF ON ON 91 ON OFF ON ON OFF ON ON 28 OFF OFF ON ON ON OFF OFF 92 ON OFF ON ON ON OFF...

Page 20: ...to the 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 assist...

Page 21: ...qqqq qqqq 3 Software Revision qqq qqqq qqqq 4 Transducer Test qqq qqqq qqqq 9 DIP Switch Value qqq qqqq qqqq 10 Button Test qqq Left Source Select qqqq qqqq Right Source Select qqqq qqqq Bank Select q...

Page 22: ...22 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 23: ...e other than CONTROLS CORPORATION OF AMERICA or if the equipment has been subject to abuse misuse negligence or accident CONTROLS CORPORATION OF AMERICA s sole and exclusive obligation and Buyer s sol...

Page 24: ...ADI 9502 A Certified ISO 9001 2000 Controls Corporation of America 1501 Harpers Road Virginia Beach VA 23454 To Order Call 1 800 225 0473 or 757 422 8330 Fax 757 422 3125 www concoa com...

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