Concoa INTELLISWITCH Manuale utente
ADI 9502-A
4,500 PSI
INTELLISWITCHTM
ELECTRONIC
SWITCHOVER
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
INSTALLATION AND OPERATING INSTRUCTIONS
Carefully Read These Instructions Before Operating
October 2005
®
Certied ISO 9001:2000
PATENT PENDING
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DESCRIPTION OF PRODUCT
The IntelliSwitch is a device used to monitor, control and switch the ow of gas from cryogenic or high
pressure cylinders from either of two independent sources to a single point of use.
It consists of two controllable valves that direct the ow of gas into a delivery regulator.
Pressure coming into the IntelliSwitch is monitored and displayed on two independent 4-digit displays. The
outlet pressure of the system is monitored and displayed on a 3-digit display. Outlet pressure adjustment is
available using a knob on the front panel.
A series of indicator lights show the status of the system at any given time.
The status of the IntelliSwitch may be monitored remotely via a serial port. In addition, the IntelliSwitch can
interface with any of the CONCOA Remote Alarms.
There are two basic models of the IntelliSwitch. One uses the delivery gas to activate the valves used for bank
switching. The other uses compressed air or an inert gas to activate the valves used for bank switching.
Each model features several different versions targeted at the pressures and ows of specic applications.
FEATURES
Operation from Multiple Gas Sources
The IntelliSwitch is capable of operating from 230, 350, and 500 PSI liquid cylinders, 4,500 PSI high
pressure cylinders, or any combination.
Look Back
The IntelliSwitch switches from one bank to the other based upon the pressure supplied to the selected bank.
When the volume of the liquid in the cylinder becomes low or the gas ow becomes particularly high, it is not
uncommon for the pressure to 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 the reserve temporarily until pressure builds on the primary enough to cause the system to switch
back. This situation often leads to depleting both sides at the same time as the system rapidly alternates
drawing from both sides or even draws both sides at the same time. Second, the system may permanently
switch to the reserve leaving unused product in the primary and triggering a false alarm.
To avoid either of these situations, the IntelliSwitch has a Look Back feature that allows the system to switch
banks and wait a predetermined time period before checking the former primary cylinder. If the pressure has
recovered enough, the system will switch back to the former primary cylinder. This look back time allows the
pressure building circuit to recover and build sufcient pressure to supply the system and fully draw down the
primary cylinder before an alarm is triggered indicating the cylinder is empty, allowing maximum utilization
of cylinder contents.
Switchback Delay
Using the Look Back feature alone can result in the switchover switching back several times well after the
cylinder can provide a useful gas supply. To prevent this, the Switchback Delay feature keeps track of how
often the IntelliSwitch switches back to a liquid cylinder that has been used and whose pressure has been
restored to be used again.
If the system switches away from the priority side before the Switchback Delay timer has timed out, the
system determines that all the useful gas has been extracted from the cylinder and switches to the auxiliary
side and draws from it.
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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 congured to switch at pressures ranging from 100 to 500 PSI. This value is factory
set but can be changed in the eld. 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 sufcient 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 Notication
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.
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USER RESPONSIBILITY
Service to this product should only be performed by CONCOA or an authorized CONCOA agent. Requests
for service may be made through CONCOA CUSTOMER SERVICE at 1-800-225-0473. Written
requests may be made using CONCOA’s FAX number at 1-757-422-3125 or CONCOA’s E-MAIL at
CONCOA accepts no responsibility for damage or injury if this product is modied in any way.
CONCOA assumes/accepts no liability or responsibility for damage to individuals or equipment that may
occur when using this product.
SAFETY
THIS PRODUCT IS NOT INTENDED FOR USE WITH TOXIC GASES, FLAMMABLE GASES OR
CORROSIVE GASES.
Basic safety precautions must be followed to reduce the risk of re, electrical shock or injury.
· Connect the IntelliSwitch to the correct line voltage. A label on the product identies what voltage it is
wired for. CONNECTION TO AN INCORRECT VOLTAGE CAN CAUSE SERIOUS DAMAGE
TO THE PRODUCT AND WILL VOID ANY WARRANTY.
· While the IntelliSwitch Switchover is dust and moisture resistant, it is NOT water-proof or completely
sealed. It should be installed where it will not be subjected to rain or high concentrations of dust. Never
pour or spray liquids directly onto the product.
· Install IntelliSwitch where the ambient temperature range is between 0° F and 140° F.
· Do not install this product in a hazardous environment.
· 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 proper use of cylinders and for any restrictions on their use (such
as ow rate and temperature requirements).
· Store cylinders with valve caps screwed on, and chain cylinders to a supporting wall or column.
· Handle cylinders carefully and only with valve caps screwed on. The cap will reduce the chance that the
cylinder valve will break off if the cylinder is accidentally dropped or falls over. The cap also protects
the cylinder valve from damage to screw threads, which could cause leaky connections.
· All manifolds used with ammable gases should be provided with approved ashback arrestors to stop
any burning gas in the pipeline from getting back to the manifold or cylinders.
· No smoking should be permitted near oxygen, nitrous oxide, any other oxidizer, ammable gases, or
ammable mixtures, or in areas where cylinders are stored.
· Where an oxidizer (such as nitrous oxide or oxygen) is used, the manifold and cylinders must be kept
clean. No oil, grease, or combustible substances should come in contact with oxygen or nitrous oxide
storage or handling equipment. Such materials in contact with oxygen or nitrous oxide are readily
ignitable and, when ignited, will burn intensely.
· Never lift gas cylinders with a magnetic lifting device.
· Never use an open ame when leak testing.
· Always open valves slowly when high-pressure gases are being used.
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· Always be sure that a cylinder contains the correct gas before connecting it to any manifold.
· Always leak-test any manifold or distribution pipeline before using.
· Always be sure that the gas in a pipeline is the correct gas for the intended use.
· Always close all cylinder valves before disconnecting cylinders from a manifold.
· Always remove all empty cylinders from a manifold before connecting full cylinders.
· Always test cylinders to be sure the cylinders are full before connecting to a manifold.
All gas distribution piping systems must meet the appropriate industrial standards for the intended service and
must be thoroughly cleaned before using. For the United States, some applicable safety rules and precautions
are listed below:
1. American National Standards Institute standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 2501 NW Seventh Street, Miami, Florida 33125
2. N.F.P.A. Standard 51, Oxygen-Fuel Gas systems for Welding and Cutting, N.F.P.A., 470 Atlantic Avenue,
Boston, Massachusetts 02210
3. N.F.P.A. Standard 51B, Cutting 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 Standard Method of Marking Portable Compressed Gas
Containers to Identify the Material Contained.
8. C.G.A. Pamphlet G-4, Oxygen – Information on the properties, manufacture, transportation, storage,
handling, and use of oxygen.
9. C.G.A. Pamphlet G-4.1, Equipment Cleaned for oxygen service.
10. C.G.A. Pamphlet G-4.4, Industrial Practices for Gaseous Oxygen Transmission and Distribution Piping
Systems.
11. C.G.A. Pamphlet G-5, Hydrogen – Information on the properties, manufacture, transportation, storage,
handling, and use of hydrogen.
12. C.G.A. Pamphlet G-6, Carbon Dioxide – Information on the properties, manufacture, transportation,
storage, handling, and use of carbon dioxide.
13. C.G.A. Pamphlet G-6.1, Standard for Low Pressure Carbon Dioxide Systems at Consumer Sites.
14. C.G.A. Pamphlet P-1, Safe Handling of Compressed Gases in Containers.
15. C.G.A. Safety Bulletin SB-2, Oxygen Decient Atmospheres.
C.G.A. Pamphlets can be obtained from the Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202-3239, (703) 979-0900. Publications: (703) 979-4341. Fax: (703) 979-0134.
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CONNECTING THE INTELLISWITCH
The key to any successful system installation is understanding the application and sizing the components
properly.
The inlets and outlet on the IntelliSwitch are 1/2” Female NPT ttings. These ttings have an anti-rotation
plate around them to keep them from twisting during installation. However, it is strongly recommended that
two wrenches be used when tightening external devices to these ttings.
The IntelliSwitch uses four mounting tabs for mounting to a wall or panel. Refer to Figure 8 for the
dimensions of the system. Anchor the IntelliSwitch securely to a wall or panel at a height adequate to
conveniently connect a manifold or pigtail.
If using an external air-driven IntelliSwitch, connect the air source to the air inlet on the bottom of the
system.
Note: Air used for this system must not contain moisture or oil. Air pressure should be in the range of 65-85
PSIG and must not exceed 100 PSIG.
Figure 1 shows a typical installation.
Once all mechanical connections are made, connect the Remote Alarm, and serial device to the IntelliSwitch.
If using an 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. Connection of the IntelliSwitch to the incorrect input voltage will damage the product and
void any warranty.
Pressurize both sides of the system; if using internal process gas-driven IntelliSwitch, pressurize the right side
rst. The inlet pressure readings will appear on the two 4-digit displays. If necessary use the Bank Select
pushbutton to choose the side considered to be the primary gas source. If gas pressures are on before the
system is powered up, the IntelliSwitch will default to the left side as the primary side.
Using the outlet pressure adjustment knob, set the desired delivery pressure. The value will appear on the 3-
digit display.
INUSE
REMOTE
READY REPLACE
RIGHT BANK
PWRBAR
PSI
LEFT BANK
REPLACE INUSE
DELIVERY
READY
34BAR
500PSI
MAX.
3000PSI
GAS
CRYOGENIC
24BAR
350PSI230PSI
16BAR
BANKSELECT
GASSOURCE
34BAR
500PSI
CRYOGENIC
24BAR
350PSI
GASSOURCE
RESET
GAS
MAX.
3000PSI
ADJUSTMENT
DELIVERY PRESSURE
®
IntelliSwitch
16BAR
230PSI
SYSTEM 2
SYSTEM 4
SYSTEM 3
SYSTEM 1
SERIALPORT
INPUT
LEFTBANK
OUTPUT
RIGHTBANK
TEST
SILENCE
ALARM
Multi-Station
Alarm
Figure 1
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Normal operation of the IntelliSwitch can now begin. The “primary” or “active” side of the system, whether
left or right, will have the green Ready light ON and the In Use light ON. The “secondary” side or the “in-
active” side will have only the green Ready light ON.
Lighted green lights above the Source Select buttons should match the types of cylinders 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 transition. The Replace status light and alarm indicate
the need to replenish a bank. In the case of high pressure cylinders, the system will reset when pressure has
been restored to the depleted bank. In the case of liquid cylinders, the system will reset when both pressure
has been restored to the depleted bank and the Reset button has been depressed.
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OPERATING THE INTELLISWITCH
Figure 2 identies and locates the various front panel and external system features.
Selecting a Gas Source
The Source Select buttons on the front panel provide exibility in the choices of liquid or high pressure
cylinders used in an application. Further, they provide choices of liquid cylinders with different pressure
ratings. There are two Source Select buttons, allowing each side to be controlled independently. Green
indicator lights above the two buttons identify which cylinder choice is currently selected for the side. Each
time a Source Select Button is pressed, the indicator lights above the button will shift to the next choice as
long as the option is viable given the switchover pressure setting.
Cylinder Sizes
There are three liquid cylinder pressure ratings that can be selected. For each cylinder pressure, the
IntelliSwitch has a preset value it uses to determine when the cylinder has reached an overpressure condition.
Table 1 provides the cylinder pressure choices.
Table 1 — Cylinder Relief Valve Pressure
Cylinder Relief Valve Pressure
230
350
500
If a liquid cylinder’s pressure rises to the “activation” value, the IntelliSwitch 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 button on the front panel allows for manually switching the active bank. Status indicator
lights provide the feedback to indicate which side is selected.
Reset
The Reset button is primarily used to reset “alarm” or “replace” conditions. The Replace status light can
only be cleared if the side with the condition has its pressure restored to a value above the trip point plus the
hysteresis value AND the Reset button is pushed. If the button is pushed while the condition still occurs, the
system will attempt to clear the alarm but will reinstate the indicators automatically.
Testing
Holding the Reset button in for 5 seconds will place the system in test mode. This diagnostic and
troubleshooting tool performs 13 different tests. Each time the Reset button is pushed again, the system will
perform a different test. If after the test mode has been entered and there is no pushbutton activity for one
minute, the system will return to the normal display operation. Gas ow is maintained during the test mode.
Refer to the Troubleshooting Section for details on testing
Keypad Lockout
See Section “User Selectable Features” for explanation on enabling/disabling and using this feature.
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Figure 2
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USER SELECTABLE FEATURES
The IntelliSwitch allows various system parameters to be set in the eld. They are:
a. Switchover Pressure
b. Units of Measure
c. Keypad Security Lockout
d. Serial Port Enable
Switchover Pressure
The switchover pressure is factory set to optimize performance based on the outlet pressure range of the
system. These factory settings are shown in Table 3 in grey highlight. The switchover pressure can be changed
by setting DIP switches SW1-1 through SW1-9 on the Electronic Circuit Board inside the IntelliSwitch. The
switchover pressure can be eld set up to 500 PSIG. It is important that the switchover pressure be set higher
than the desired outlet pressure required by the application, but not higher than the pressure capability of the
gas source. Table 3 shows the DIP switch settings to establish the desired switchover value.
To access the DIP switches, 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, 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 panel to fall. There are two long studs attached to
the inside of the front panel that will allow hanging of the panel to the bottom of the enclosure.
Table 3 shows some typical switchover settings. To set values other than those in Table 3, use Table 2 or
contact CONCOA Customer Service for assistance. Using Table 3 and Figure 3, set the switchover pressure
DIP switches to the desired value. When completed, place the front panel back into place being careful not to
pinch any wires. Attach the large nut to the Outlet Pressure Adjustment Regulator rst. This only needs to
be 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-apply AC power. The new switchover setting may be viewed in test mode.
Note: Table 3 shows values in PSI. To set values in BAR or MPA, convert the numbers in the table. For PSI
to BAR, divide the PSI value by 14.5; for PSI to MPA divide the PSI value by 145.
Indice
Altri manuali Concoa Interruttore
