Concoa INTELLISWITCH Installation And Operating Instructions Manual Download Page 3

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Hysteresis

This feature is a pressure value added to the switchover pressure value to determine the pressure at which the 
IntelliSwitch will switch back to a cylinder after the “Look Back” time has expired.  This features provides 
added protection against inadvertently drawing from the reserve bank when the primary still has gas.

Economizer Function

When using liquid cylinders in switchover application, it is common for the reserve cylinder to build pressure 
due to the vaporization of liquid within the cylinder.  When this pressure reaches the set point of the relief 
valve on the liquid cylinder, the relief valve will open, venting gas to the atmosphere.  The IntelliSwitch 
constantly monitors the reserve cylinder and, at a predetermined pressure, will change the valving to allow gas 
from the headspace of the reserve cylinder to feed the system, thus drawing down the pressure in the reserve 
cylinder.  There are three pressure ratings for liquid cylinder relief valves, 230 PSIG, 350 PSIG and 500 PSIG;  
the IntelliSwitch has predetermined settings for all three types that may be selected on the front panel of the 
system.

Settable Switchover Pressure

The IntelliSwitch can be configured to switch at pressures ranging from 100 to 500 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 side that gas is being drawn from by pressing the “BANK SELECT” 
button provided that there is sufficient pressure on the side being switched to.

Selectable Units of Measure

The default units of measure for the IntelliSwitch are PSI.  Alternate units of BAR or MPA can be selected by 
changing internal DIP switch settings.  To change units of measure refer to the section on changing units of 
measure.

Security Lockout

The IntelliSwitch has the ability to electronically lockout the front panel buttons to discourage tampering.  
The factory default setting is OFF or disabled.  Refer to section on Keypad Security Lockout for details.

Alarm Notification

The IntelliSwitch is designed to interface with CONCOA Remote Alarms and comes with the necessary 
mating connector for their use.  Refer to the section on connecting a remote alarm for more information.

Serial Port

The IntelliSwitch is capable of communicating to peripheral equipment via a standard serial port.  For more 
information on the serial port refer to the section on connecting to a serial port.

Burst Disk Overpressure Protection

The IntelliSwitch is equipped with a replaceable burst disk for each bank to protect the system from extreme 
pressure increases and liquid withdrawal. 

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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