Concoa 452 Series User manual

452 Series
Vaporizing
Regulator
INSTALLATION AND OPERATION INSTRUCTIONS
Before Installing or Operating, Read and Comply with These Instructions
Controls Corporation of America
1501 Harpers Road Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com
Certified ISO 9001
99060452E
Supersedes April 2012
September 2015

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DESCRIPTION OF PRODUCT
This single-stage pressure regulator is equipped with a heating element intended to vaporize a liquid
sample and maintain it in the gaseous state for chromatographic analysis. Further it provides a
positive heat source to prevent freeze up of the regulator. This product is designed for use in explosive
atmospheres. It is intended for above ground use and is moisture resistant. For more information
refer to the Section “Certifications and Compliances” in this manual.
USER RESPONSIBILITY
This equipment will perform in conformity with the description contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained, and repaired in accordance
with the instructions provided. It is the responsibility of the user to determine the suitability of this
product for the gas service and application. It is also the responsibility of the user to install this product
in accordance with National Electrical Codes and any local ordinances.
This equipment must be checked periodically. Improperly working equipment should not be used.
Parts that are broken, missing, worn, or distorted should be replaced immediately. This equipment,
or any of its parts, should not be altered without prior written approval by CONCOA. The user of this
equipment shall have the sole responsibility for any malfunction that results from improper use, faulty
maintenance, damage, improper repair, or alteration by anyone other than CONCOA or a serviced
facility designated by CONCOA.
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 [email protected].
CONCOA accepts no responsibility for damage or injury if this product is modified in any way.
CONCOA assumes/accepts no liability or responsibility for damage to individuals or equipment that
may occur when using this product.
CUSTOMER ASSISTANCE
In the event of equipment failure, call the CONCOA Customer Assistance Line: 1-800-225-0473; FAX:
757-422-3125; E-mail: [e-mail]. Please be prepared to provide the model number and serial
number of the equipment involved, in addition to some details regarding its application. This would
include inlet and outlet pressures, flow rate, environmental conditions, and gas service.
GENERAL SAFETY PRACTICES
Basic safety precautions must be followed to reduce the risk of fire, electrical shock, and injury.
CONNECTION TO AN INCORRECT VOLTAGE CAN CAUSE
SERIOUS DAMAGE TO THE PRODUCT AND WILL VOID ANY WARRANTY.
PRODUCT OPERATES AT HIGH TEMPERATURES. DO NOT TOUCH WHEN ON. ALLOW
SUFFICIENT TIME TO COOL BEFORE HANDLING.
Do not use in areas where large amounts of dust are present.
If product appears damaged in any way, do not use and request service from CONCOA.
Do not attempt to operate the Vaporizing Regulator with the electrical box cover off.
Comply with precautions listed in C.G.A. Pamphlet P-1, Safe Handling of Compressed Gases
in Containers.
Connect the Vaporizing Regulator to the correct line voltage. The product nameplate identifies
what voltage it is wired for.

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Never use an open flame when leak testing.
Always open valves slowly when high-pressure gases are being used.
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.
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. Local Ordinances
2. O.S.H.A. Standard 29 CFR
3. C.G.A. Pamphlet C-4, American national Standard Method of Marking Portable Compressed
Gas Containers to Identify the material Contained.
4. C.G.A. Pamphlet C-4.1, Equipment Cleaned for oxygen service.
5. C.G.A. Pamphlet G-4.4, Industrial Practices for Gaseous Oxygen Transmission and Distribution
Piping Systems.
6. C.G.A. Pamphlet G-5, Hydrogen - Information on the properties, manufacture, transportation,
storage, handling, and use of hydrogen.
7. C.G.A. Pamphlet P-1, Safe handling of Compressed Gases in Containers.
8. C.G.A. Safety Bulletin SB-2, Oxygen Deficient Atmospheres.
*C.G.A. Pamphlets can be obtained from the Compressed Gas Association, 1235 Jefferson Davis
Highway,Arlington, VA 22202-3239, [phone]. Publications: [phone]. Fax: [phone].
Figure 1 - Vaporizing Regulator Assembly
MAY BE EXTREMELY HOT!
AVERTISSEMENT: LES SURFACES
ATTENTION: LISEZ LES INSTRUCTIONS
ÊTRE EXTRÊMEMENT
EXTERNES PEUVENT
AVANT L'EMPLOI
CHAUDES!
WARNING: EXTERNAL SURFACES
CAUTION: READ INSTRUCTIONS
MAXIMUM INLET: 3300 PSI (230 BAR)
CONTROLS CORP OF AMERICA
VIRGINIA BEACH, VA MADE IN USA
BEFORE USE
HOLE PLUG
PRESSURE
ADJUSTMENT
(UNDER
ACORN NUT)
1/4" NPT
LOW
PRESSURE
OUTLET
SOURCE
POWER
INLET
COVER SET SCREW
1/8" NPT
INLET
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Tamb -20° to 60°C
Ex d IIC T#, CL I, DIV 1, Grp A-D
SN:YOC:
Certified to CAN/CSA E60079-0
Conforms to UL-1203
& E60079-1
TR:
CONT. DUTY
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3068692
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Intertek
FIND
VOLTAGE
HERE
T1, T3, & T4 Models Available
D1
U3
Q1
T1
D2
J1
R8
R11
C3
J3
J13
U2
U1
R5
R13 R16
R3
J2
R1
J14
R4
R9
10
C1 C2
+
R7
R6
R12 R17
R15
C4
C5
+
J15
J16
J17
830 9442-#
###°
###V
###°
L1
L2
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INSTALLATION OF ELECTRICAL CONNECTIONS
THE SELECTION, AND USE OF CONDUIT, FLEXIBLE TUBING OR ARMORED CABLE IS THE
RESPONSIBILITY OF THE INSTALLER. PROPER CARE MUST BE TAKEN WHEN CONNECTING
THE DEVICE TO ELECTRICAL POWER WHERE THE DEVICE WILL BE USED IN AN EXPLOSIVE
ATMOSPHERE OR WITH COMBUSTIBLE GASES.
THE INSTALLER MUST FOLLOWALLAPPROPRIATE NATIONALAND LOCAL ELECTRICAL CODES
WHEN CONNECTING THIS DEVICE TO ELECTRICAL POWER. SPECIAL ATTENTION MUST BE
PAID TO THE INSTALLATION OF THIS DEVICE WHEN USED IN EXPLOSIVE ATMOSPHERES.
Cable
Routing
Ground: Green or
Green/Yellow Wire
L1: Black or
L2: White or
Blue Wire
Brown Wire
Figure 2 - Source Power Connections
1. Remove the set screw from the cover on the electrical box and unscrew the cover.
2. Route the Electrical power into the enclosure through the threaded opening. Use the appropriate
fitting to secure the conduit, etc... to the electrical enclosure. IN EXPLOSIVE ATMOSPHERES
THE OPENING INTO THE ENCLOSURE MUST BE SEALED TO PREVENT A PATH FOR
GAS TO TRAVEL. THE O-RING ATTACHED TO THE COVER IS NEEDED TO PREVENT
MOISTURE FROM ENTERING THE ENCLOSURE. DO NOT REMOVE.
Note: Electrical connections to this product should be made with insulated, 18
AWG stranded copper wire with a minimum operating temperature of 75°C
3. Remove ¼” of the insulation from each of the wires.
4. Attach the power wires to the terminal block according to the picture abvove.
5. Check that the temperature setting on the circuit board is correctly set. If not, refer to the
"Temperature Adjustment" section of this manual.
6. Reattach the cover to the electrical enclosure securing it tightly.
7. Re-install the setscrew into the cover. This setscrew is intended to make the removal of the
cover difficult without the use of tools. It is important that this screw be replaced.
8. Provision is made at the rear of the Regulator for an external ground connection for locations
where an external ground connection is required. The Ground connection is clearly marked
(GR) and a screw and washer is provided.
D1
U3
Q1
T1
D2
J1
R8
R11
C3
J3
J13
U2
U1
R5
R13 R16
R3
J2
R1
J14
R4
R9
10
C1 C2
+
R7
R6
R12 R17
R15
C4
C5
+
J15
J16
J17
830 9442-#
###°
###V
###°
L1
L2
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Figure 3 - PTFE Taping Procedure
INSTALLATION OF GAS CONNECTIONS
Note: BE SURE TO CONSIDER ALL FACTORS WHEN SELECTING
MATERIALS FOR GAS CONNECTIONS. For example, if you
have both high pressure and corrosive service, select material
that is suitable for both.
1. Do not use oil or grease on fittings, especially not on oxidizing gas service equipment.
2. Be sure that all fittings are secure and leak tight. PTFE tape should be used on pipe fittings, but
avoid impinging on the gas stream. Before applying PTFE tape, inspect the NPT threads and
if necessary, clean the fitting to remove any dirt or thread sealant that remains on the threads.
Start the PTFE tape on the second thread as shown in Figure 3. 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 the threads. Apply two overlapping
layers of PTFE tape. Cut off the excess tape and press the end firmly into the threads.
Pressure Adjustment
The Vaporizing Regulator’s delivery pressure is set at the factory. If the delivery pressure needs to be
adjusted follow the directions below.
1. The pressure adjustment is made from the top of the regulator bonnet.
2. Locate and remove the acorn nut at the top of the bonnet.
3. Using a 3/16” allen wrench inserted into the set screw beneath the acorn nut, turn the set screw
to vary the outlet pressure of the regulator. Turning the set screw clockwise will increase the
pressure setting and counter clockwise will reduce the pressure setting.
4. When the pressure is adjusted to the desired level, replace the acorn nut and secure in place.
CAUTION! NEVER EXCEED THE OUTLET PRESSURE RATING
OF THE REGULATOR.

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CAUTION! SURFACES OF REGULATOR EXTREMELY HOT WHEN OPERATING.
ALLOW SUFFICIENT COOLING TIME AFTER REMOVING POWER
BEFORE HANDLING
1. TURN ELECTRICAL POWER OFF BEFORE OPENING THE COVER TO THE ELECTRICAL
ENCLOSURE.
2. Remove the setscrew from the cover of the electrical box and unscrew the cover.
3. Using the thermostat adjusting tool provided with the regulator, adjust the thermostat.
Figure 4 - Thermostat Location
Note that fully Counterclockwise (CCW) is the lowest setting in the range. Fully Clockwise
(CW) is the highest temperature in the range.
4. The temperature range for the Vaporizing Regulator is listed on the label affixed to the top
of the circuit board inside the electrical enclosure. The temperature range listed on the label
is body temperature. Actual gas temperatures will be dependant on the flow rate of the gas
passing through the regulator, ambient temperature and the temperature of the gas entering
the Vaporizing Regulator.
5. Once thermostat is set, securely tighten the cover on to the electrical enclosure.
6. Re-install the setscrew into the cover. This setscrew is intended to make the removal of the
cover difficult without the use of tools. It is important that this screw be replaced.
7. Restore Electrical Power.
Min.
Max.
Uncovered
Thermostat:
ACTIVE
(2) Covered
Thermostats:
INACTIVE
D1
U3
Q1
T1
D2
J1
R8
R11
C3
J3
J13
U2
U1
R5
R13 R16
R3
J2
R1
J14
R4
R9
10
C1 C2
+
R7
R6
R12 R17
R15
C4
C5
+
J15
J16
J17
830 9442-#
###°
###V
###°
L1
L2
G
R5
R13 R16
+
J15
J16
J17
R5
R13 R16
+
J15
J16
J17
R5
R13 R16
+
J15
J16
J17
77°-180° F 160°-280° F 250°-380° F
Jumper Jumper Jumper
Thermostat Thermostat
This tool must be used to prevent damage to the thermostat. Refer to Figure 4 for
thermostat location.
Special Thermostat Adjusting Tool
Provided with the Regulator
Temperature Adjustment
The Vaporizing Regulator operates over a specific temperature range. This range is determined by
the part number. To gain access to the adjustment thermostat, the cover on the electrical enclosure
must be removed.

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TROUBLESHOOTING
Symptom Possible Cause Possible Solution
Regulator not heating No Power to the Regulator
Heater Element bad
Check power connection at
source.
Check that wires are properly
attached to the terminal block.
Replace
No flow or restricted flow
from regulator
Inlet plugged with debris Disconnect inlet gas source
from regulator and clean inlet
to regulator if plugged.
Replace capsule inside regulator
Regulator Overheating Bad Control Circuit board Replace
Regulator not heating gas
sufficiently
Thermostat needs to be adjusted
Ambient temperature & Gas inlet
temperature too low
Vaporizing Regulator chosen has
too low a temperature range or
wattage
Adjust thermostat setting
Using higher wattage Vaporizing
Regulator
Change Regulator to different
heat range or wattage.
SERVICE
A Unit that is not functioning properly should not be used and should be returned to CONCOA for
service. A Return Material Authorization (RMA) number must be issued for any product returned to
CONCOA for service. Please contact a Customer Service Representative at 1-800-225-0473 to
receive this number. You will be asked to provide:
1. Model Number
2. Gas Service
3. Inlet pressure and type of gas supply
4. Outlet pressure
5. Approximate gas usage
When shipping product back to CONCOA for repair the following steps should be followed:
1. Package the product sufficiently to prevent damage. If possible return product in its original
packing.
2. Include RMA number on the outside of the carton.
3. Ship prepaid.
4. Include a written description of the problem you encountered with the product inside the package.
5. Include a statement of the gas service the product was used in.
6. Purge all equipment before shipping to protect the transporter and service personnel. Purging
is especially important if the equipment has been in hazardous or corrosive gas service.

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CERTIFICATIONS AND COMPLIANCES
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Ex d IIC T1, CL I, DIV 1, Grp A-D
Certified to CAN/CSA E60079-0
Tamb -20°C to 60°C
Conforms to UL-1203
& E60079-1
T1 Rated model.
Intertek
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3068692
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II 2 G Ex d IIC T3 Gb
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Ex d IIC T3, CL I, DIV 1, Grp A-D
Certified to CAN/CSA E60079-0
Tamb -20°C to 60°C
Conforms to UL-1203
& E60079-1
T3 Rated model.
Intertek
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3068692
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II 2 G Ex d IIC T4 Gb
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Ex d IIC T4, CL I, DIV 1, Grp A-D
Certified to CAN/CSA E60079-0
Tamb -20°C to 60°C
Conforms to UL-1203
& E60079-1
T4 Rated model.
Intertek

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Warranty Information
This equipment is sold by CONTROLS CORPORATION OF AMERICA under the warranties set forth
in the following paragraphs. Such warranties are extended only with respect to the purchase of this
equipment directly from CONTROLS CORPORATION OF AMERICA or its Authorized Distributors as
new merchandise and are extended to the first Buyer thereof other than for the purpose of resale.
For a period of one (1) year from the date of original delivery (90 days in corrosive service) to Buyer
or to Buyer’s order, this equipment is warrantied to be free from functional defects in materials and
workmanship and to conform to the description of this equipment contained in this manual and any
accompanying labels and/or inserts, provided that the same is properly operated under conditions of
normal use and that regular periodic maintenance and service is performed or replacements made in
accordance with the instructions provided. The foregoing warranties shall not apply if the equipment has
been repaired: other than by CONTROLS CORPORATION OF AMERICA or a designated service facility
or in accordance with written instructions provided by CONTROLS CORPORATION OF AMERICA,
or altered by anyone 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 sole and
exclusive remedy under the above warranties is limited to repairing or replacing, free of charge, at
CONTROLS CORPORATION OF AMERICA’s option, the equipment or part, which is reported to its
Authorized Distributor from whom purchased, and which if so advised, is returned with a statement
of the observed deficiency, and proof of purchase of equipment or part not later than seven (7) days
after the expiration date of the applicable warranty, to the nearest designated service facility during
normal business hours, transportation charges prepaid, and which upon examination, is found not to
comply with the above warranties. Return trip transportation charges for the equipment or part shall
be paid by Buyer.
CONTROLS CORPORATION OF AMERICA SHALL NOT BE OTHERWISE LIABLE FOR ANY
DAMAGES INCLUDING BUT NOT LIMITED TO: INCIDENTAL DAMAGES, CONSEQUENTIAL
DAMAGES, OR SPECIAL DAMAGES, WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE,
BREACH OF WARRANTY OR OTHERWISE.
THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE
WARRANTIES HEREINABOVE SET FORTH. CONTROLS CORPORATION OF AMERICA MAKES
NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THE EQUIPMENT OR PARTS THEREOF.

Controls Corporation of America
1501 Harpers Road Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com
Certified ISO 9001
99060452E