Concoa 522 Series User manual

522 Series
Autoswitch
System
(Brass)
For use with
Non-Toxic and
Non-Corrosive Gases
in High Purity Applications
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
January 2018
Supersedes August 2003
ADI 3196F
Certied ISO 9001
523 Series
Autoswitch
System
(Stainless Steel)
For use with
Non-Toxic and
Non-Corrosive Gases
in High Purity Applications

DESCRIPTION OF PRODUCT
The brass 522 Series and the stainless steel 523 Series AutoSwitches are automatic switchover systems
designed to provide a continuous supply of high purity gas. This unit may be used with one cylinder per
side, or used with a manifold that has increased storage capacity. The inlet of the switchover system
may be congured with open ports, diaphragm valves, manifold connectors, or exible hoses. The
system, when congured with manifold connectors, is for use with the 52B (brass) or 52S (stainless
steel) Series manifold systems. The standard autoswitch system will maintain a regulated line pressure
within the values shown in the table below:
The inlet pressure must be maintained above the value listed in the table below for the system to
operate properly.
Models of these AutoSwitches are available with neither pressure switches nor transducers (these are
not compatible with remote alarms), with inlet pressure switches, or with inlet pressure transducers.
None of these AutoSwitches can be connected directly to AC line voltage. Models with inlet pressure
switches or transducers can be congured for use with CONCOA’s optional Altos 2 Remote Alarm.
Models with pressure switches include a front Power Indicator light and LED status lights to indicate
the condition of the gas cylinders. A green indicator light signies a “Normal” condition while a red light
indicates an “Alarm” (Gas cylinder empty) condition. The pressure switch AutoSwitch systems also
include a separate connector that mates to the connector on the bottom of the unit. This can be used
to construct an interface cable between the Altos 2 Remote Alarm and the AutoSwitch. Optionally,
CONCOA can provide a prefabricated remote alarm connection cable*.
For models with pressure transducers, the status of the gas cylinder pressures can be viewed on the
optional Altos 2 Remote Alarm.
* Please refer to instruction manual ADI0025 (#9906 0025) that is included with the CONCOA Altos 2
Remote Alarm for wiring and operating instructions.
MODEL RANGE
522 or 523 2XXX 0-50 PSI (0-3.5 BAR)
522 or 523 3XXX 0-100 PSI (0-7 BAR)
522 or 523 4XXX 0-200 Psi (0-14 BAR)
522 or 523 5XXX 0-350 PSI (0-24 BAR)
522 or 523 7XXX 0-150 PSI (0-10 BAR)
MODEL RANGE
522 or 523 2XXX 265 PSI (18 BAR)
522 or 523 3XXX 265 PSI (18 BAR)
522 or 523 4XXX 345 PSI (24 BAR)
522 or 523 5XXX 540 PSI (37 BAR)
522 or 523 7XXX 265 PSI (18 BAR)

Figure 1
Pressure
Switch
Inlet Gauge,
Both Sides
Bank
Status
Lights,
Both Sides
Power Light
Set Point
Adjustment
Lever,
Both Sides
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Relief Valve Pipe-
Away Port, 1/2” NPT
Female
Inlet Port,
1/2” NPT
Female
Inlet Port,
1/2” NPT
Female
Line
Regulator
Adjustment
Knob
Priority Valve Drain
Circular Connector for Remote Alarm
25ft Long
Left & Right
Transducer
Cables
Inlet
Gauge
Inlet
Gauge
Delivery Gauge
Outlet Port,
1/4” Tube
Connection
ALL MODELS
PRESSURE SWITCH MODELS TRANSDUCER MODELS
Pressure
Switch
Inlet Gauge,
Both Sides
Bank
Status
Lights,
Both Sides
Power Light
Set Point
Adjustment
Lever,
Both Sides
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Relief Valve Pipe-
Away Port, 1/2” NPT
Female
Inlet Port,
1/2” NPT
Female
Inlet Port,
1/2” NPT
Female
Line
Regulator
Adjustment
Knob
Priority Valve Drain
Circular Connector for Remote Alarm
25ft Long
Left & Right
Transducer
Cables
Inlet
Gauge
Inlet
Gauge
Delivery Gauge
Outlet Port,
1/4” Tube
Connection
ALL MODELS
PRESSURE SWITCH MODELS
TRANSDUCER MODELS
Pressure
Switch
Inlet Gauge,
Both Sides
Bank
Status
Lights,
Both Sides
Power Light
Set Point
Adjustment
Lever,
Both Sides
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Relief Valve Pipe-
Away Port, 1/2” NPT
Female
Inlet Port,
1/2” NPT
Female
Inlet Port,
1/2” NPT
Female
Line
Regulator
Adjustment
Knob
Priority Valve Drain
Circular Connector for Remote Alarm
25ft Long
Left & Right
Transducer
Cables
Inlet
Gauge
Inlet
Gauge
Delivery Gauge
Outlet Port,
1/4” Tube
Connection
ALL MODELS PRESSURE SWITCH MODELS TRANSDUCER MODELS

INTENDED USE OF PRODUCT
USER RESPONSIBILITY
CUSTOMER ASSISTANCE
The brass 522 series and the stainless steel 523 Series autoswitch system is intended for use in high
purity, non-corrosive applications. Please note the safety information shown in the later sections.
The User of this equipment should follow all labeling, installation and operation instructions when
using this equipment. It is recommended that the user review all safety precautions listed in the safety
section of this manual .
Know the properties and special handling requirements of the gas being used. Many gases are
dangerous (ammable, toxic, corrosive , etc.) Consult with the cylinder distributor for the proper
use of the cylinders and any restrictions in their use. This equipment must be checked periodically.
Improperly working equipment should not be used. Broken, worn, distorted, contaminated, or missing
components should be replaced by a trained technician immediately.
In the event of equipment failure, call the CONCOA Customer Assistance Line: 1-800-225-0473.
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, ow
rate, environmental conditions, and gas service.
Carefully read and comply with these instructions before installing or operating any high pressure gas
manifold. These manifolds are designed, manufactured, and tested to conform to industry standards
for safety for high pressure gas manifolds for maximum inlet pressure of 3000 pounds per square inch
(200 bar), working pressure.
Always observe the following safety practices:
√ Store cylinders with valve caps screwed on, and cylinders chained to a supporting wall or
column.
√ Handle cylinders carefully and only with valve caps screwed on. The cap will prevent the
cylinder valve from breaking off at the top of the cylinder 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.
√ Due to the highly combustible nature of hydrogen, methane, ethylene and fuel gases, all
manifolds used with this gas are provided with ashback arrestors to stop any burning gas in
the pipeline from getting back to the manifold or cylinders. Flashback arrestors are either water
lled or dry check valve type. Gas owing from the regulators on the manifold ows through the
ashback arrestor to the pipeline. Also, arrestors on hoses are required for acetylene service.
√ Keep all cylinders away from any source of high temperature (not over 120° F, 50° C) or
possible re hazards. High-pressure gas contained in a closed cylinder becomes increasingly
dangerous when exposed to high temperature because pressure increases and the strength
of the cylinder decreases.
√ No smoking should be permitted near oxygen, nitrous oxide, ammable gases and ammable
mixtures and in area where cylinders are stored.
2
SAFETY

√ Where oxygen or nitrous oxide 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. Open valves all the way.
√ 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 install a blind gland and nut or piping plug on any manifold inlet tting if no cylinder is
connected to the tting before opening any cylinder valve which is already connected to the
manifold.
√ 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 they are full before connecting to a manifold.
√ NOTE: Use of Teon® lined hoses for oxygen installations is not recommended unless they
are equipped with a Distance Volume Piece (DVP). Components in the manifold system can
create a dead end passage. The combination of a dead end passage coupled with a rapid
pressurization may lead to adiabatic compression of the contained oxygen and subsequent
failure of the hose by ignition.
√ All gas distribution piping systems must meet appropriate industrial standards for the intended
service, and must be thoroughly cleaned before using.
Comply with all safety rules and precautions of the following:
1. American National Standards Institute standard Z49.1 or Safety in Welding and Cutting,
American Welding Society, 2501 NW Seventh Street, Miami, FL 33125.
2. N.F.P.A. Standard 51, Oxygen-Fuel Gas Systems for Welding and Cutting, N.F.P.A., 470 Atlantic
Avenue, Boston, MA 02210.
3. N.F.P.A. Standard 51B, Cutting and Welding Processes, (see Address in #2)
4. CONCOA Publication ADE 872, Safety Precautions in Welding and Cutting.
5. Local ordinances.
6. O.S.H.A.
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 C-4.4, Industrial Practices for Gaseous Oxygen Transmission and Distribution
Piping Systems.
3

INSTALLATION
The site chosen for the installation of the system shall be level, well ventilated, and at a safe distance
from sources of ames, sparks, and excessive heat. The system should not be placed in an area
that may subject it to damage from passing trucks, cranes, or other heavy machines. Any oxygen
system must not be installed under shafting, belting, or other places where oil can drip on it. Refer to
the Manifold ADI for Manifold installation instructions.
a. Be sure to consider all factors when selecting materials.
b. Do not use oil or grease on ttings.
c. Be sure that all ttings are secure and leak tight. Teon tape should be used on pipe threads.
See Figure 6.
d. Relief valve: The purpose of the relief valve is to protect the autoswitch system and its
components only (Figure 2). If there is pressure sensitive equipment downstream of the
autoswitch system, it is recommended that an appropriately sized relief valve be installed in
the line to protect this equipment.
e. CAPTIVE VENTS: These AutoSwitches are available with internal captive vents installed on all
internal regulator bonnets. These captive vents are used to capture the most probable internal
system leaks, and they are tied into the pipe-away relief valve plumbing so that the leaking gas
can be pipe-away and discharged in a safe area.
WARNING: Equipment failure or misuse may lead to problems such as a release of gas
through the relief valve or regulator diaphragm. The autoswitch box is not sealed and will leak
gas from faulty components. Proper safety measures should be established to handle these
and other component failures.
4
HI
HI
Relief Valve
Pipe-Away
Port
Relief Valve
Relief Valve
Internal
Tubing
Remote Alarm
Connector for
Models with
Pressure
Switches
25ft Long Transducer
Cables to Remote
Alarm for Models with
Transducers
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.C.A. Pamphlet P-1, safe handling of compressed gases in containers.

Follow Compressed Gas Association, OSHA and all applicable local codes. Manifolds should not be
placed in locations where the temperature will exceed 102°F (49°C) or fall below 0°F (-18°C). Manifolds
installed in open locations should be protected from weather conditions. During winter, protect the
manifold from ice and snow. In summer, shade the manifold and cylinders from continuous exposure
to direct sunlight. Always leave access to the manifold for cylinder replacement.
1. Determine and mark the vertical center line for installation of the AutoSwitch Console.
(Figure 3).
2. Measure from the oor 73” in height* of this center line. This height will place the manifold
header approximately 66” from the oor. Using a level, mark a horizontal line at this point
extending approximately 10 inches to the left and right of center.
3. Remove the mounting bracket from the rear of the AutoSwitch Console by removing the
retaining nuts at the bottom of the mounting bracket (Figure 5). Place the upper edge of
the bracket cross-member on the horizontal line so that it is centered with the vertical line.
Holding the bracket with the slotted extensions away from the wall, mark the location of the
two mounting bolts (Figure 4)
4. Using appropriate hardware based on wall construction, anchor the mounting bracket to the
wall (Figure 4).
5. Place the autoswitch system so that the mounting bracket slots align with the shoulder nuts.
With the autoswitch box hanging on the shoulder nuts, align the retaining bolts so that they
protrude through the bracket. Replace the mounting nuts that were removed in step 3.
Figure 3 - Center-line Mark Figure 4 - Mounting Bracket
Figure 5 - Console and Mounting Bracket
Mounting Bracket
Retaining nuts
Console
5
Mounting Screws
Shoulder Nuts
WALL MOUNTING

Use an open-end wrench, not a pipe wrench, to install accessories to the autoswitch system. ALWAYS
hold the bulkhead tting with a wrench when installing the accessories to the autoswitch
system. Do not allow the bulkhead tting to turn; otherwise, connections inside the box may
be loosened. NPT connections require the use of Teon tape on the threads to make a gas tight seal.
(See Figure 6.) On stainless steel connections, the thread sealant helps prevent the connections from
galling together when tightening or loosening. CONCOA uses Teon tape on all of its NPT connections.
Follow these rules when using Teon tape.
Inspect the NPT threads and if necessary, clean the tting to remove any dirt or thread sealant that
remains on the threads. Start the Teon tape on the second thread as shown in Figure 6; make sure
the tape does not overlap the end of the tting. 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. Wrap the tape around
the threads twice. Cut off the excess tape and press the end rmly into the threads.
Figure 6 - Pictorial view of tape seal installation
Installing the inlet connection:
When Using a Manifold System:
The 1/2” male NPT end of the manifold connector will need to be installed in the inlet port of the
autoswitch. The other end of the manifold connector will be connected to the starter block of the 52B
(brass) or 52S (stainless steel) Series Manifold system. Please follow the instructions provided with
the manifold system when connecting and operating the manifold system.
Figure 7 - Manifold connector for the Manifold system
General:
6
1/4” NPT M 1/2” NPT M
INLET AND OUTLET CONNECTIONS

Connecting to a cylinder:
1. Before removing the cylinder cap, move the cylinder of gas to the work site:
a. Secure cylinder to the oor, wall, or bench with appropriate chain, strap, or stand to prevent
toppling.
b. Remove the cylinder cap.
c. Be sure the cylinder valve is tightly closed (clockwise)
d. Remove the cylinder valve plug, if any.
e. Inspect the cylinder valve and threads for damage or contamination.
2. Secure the cylinder connection to the cylinder in the following manner:
a. Do not force. Tightening the nut onto the cylinder connection should be easy. If it is
not, the connection may be wrong for the type of gas being used.
b. Left-hand threads are used on some cylinder connections. A notch in the middle of the
hex nut typically indicates a left-hand thread.
c. Gaskets are used on some inlet connections. Be sure the gasket is in good shape. Do not
over-tighten to avoid squashing the gasket into the gas line. Keep extra gaskets on hand.
d. Never use oil or grease on regulator or cylinder ttings, as it may contaminate pure
gases, or create a re hazard.
For non-manifold use:
If purchased with diaphragm valves, the male ½ NPT end of the diaphragm valve elbows is installed
into the inlet ports of the switchover system. Install the male ¼ NPT end of the hoses into the open
diaphragm valve ports.
The connection available at the other end of the hose will depend on how the system was purchased.
If the hose does not have a cylinder connection installed, there will be a female ¼ NPT on the end of
the hose. The female ¼ NPT hose end will connect to the user’s system. If congured with a CGA
connection or foreign inlet connection, the connection will be specic to the particular cylinder of gas
to be used. Some connections do require the use of a gasket. Please note that the material of the
gasket must also be compatible with the type of gas being used. Be familiar with the type of connection
being used, and its proper procedures for installation.
Figure 10 - HoseFigure 8 - Diaphragm Valve
with single pigtail arrangement
street elbow
Installing the Outlet Connection:
The autoswitchsystem has the outlet connection at the top of the box. The connection is a ¼” tube
connection. Connect tubing to the autoswitch that is compatible with the application and is capable
of handling the pressure required.
7
To Cylinder
1/4” NPT Male to
Diaphragm Valve or
Tee on Diaphragm
Valve
1/2” NPT Male to
AutoSwitch Inlet
Figure 9 - Dual pigtail
arrangement, diaphragm valve
with street elbow and tee

Pressurizing the system for the rst time (non-manifold use):
Before system startup, it is recommended that all systems be pressure tested, leak tested, and purged
with an inert gas such as nitrogen. To accomplish this with connections other than a CGA 580, it will
be necessary to use an adapter. The recommended use of an adapter is for temporary use only, for
system start up and checks. Adapters should never be used on a permanent basis.
1. Wear safety glasses and gloves.
2. Be sure that both ends of all hoses or hoses are secured before pressurizing. Turn the line
regulator knob counterclockwise until the knob stops turning.
3. When rst pressurizing, do not stand in front of or contact the switchover system. Slowly open
the cylinder valve. Observe the high pressure gauge for a rise in pressure up to full cylinder
pressure.
4. Keep the hand wheel or wrench on the open cylinder valve at all times, to allow prompt
emergency shut-off.
5. Inspect all connections for leaks and x any leaks. A leak detection solution may be applied
to the connections (if compatible with the application) which indicates leaks by bubbling. To
further check for leaks, or if the leak detection solution can not be used, close the cylinder
valve for a period of time (recommended 24 hours), and observe the high pressure gauge for a
drop in pressure. If so indicated, recheck the CGA connection and all other high-pressure port
connections. Never attempt to x a leak under pressure. If leaks are detected, depressurize
the system and retighten the connection. Begin again at step 3.
WARNING: While CONCOA assembles the autoswitch system components to exacting leak-tight
standards, the customer should also inspect for any loosening of internal parts that may occur in
shipping or installation by completing the pressure decay test detailed above. If all external leaks
have been found, corrected, and the system still indicates a leak, disassemble the front cover from
the autoswitch after removing the eight screws shown below. Check for leaks on the system’s
ttings as described above.
6. Slowly turn the line regulator knob clockwise. This will increase the pressure of the line. Adjust
to the desired working pressure and again check for leaks using the methods described above.
Figure 11
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Screw #7
Screw #8Screw #4
Screw #6
Screw #3
Screw #2
Screw #5Screw #1
REMOVAL OF FRONT COVER

OPERATION
The arrow on the priority valve always points to the primary side; the bank opposite the primary side
is considered the reserve side. Starting with the arrow pointing to the right side, gas will ow from
the right side cylinder. As the gas in the primary side is depleted, the gas pressure will drop on the
right gauge. When the inlet pressure drops to the pressure setting of the reserve side regulator, ow
will begin from the reserve cylinder; the inlet pressure on the primary side will also stabilize. This is
called a changeover. At this point, the gas pressure on the reserve side (preset regulator) will drop.
This indicates that its time to change the cylinders on the primary side. Before removing the nearly
depleted primary cylinder, the priority valve should be rotated 180°. This makes the reserve cylinder,
the primary source. Remove the depleted cylinder and replace with a full cylinder. Before removing
the cylinder be sure to close the cylinder valve and any other valves that connect the cylinder to the
system. The full, replacement cylinder is now the reserve cylinder. Note: while changing cylinders on
one side, there will be no interruption in ow. A depleted cylinder will have the following gas pressure
remaining:
Gas will continue to ow from the primary side until the outlet pressure of the preset regulator matches
the pressure of the priority valve regulator. (The pressure setting of the priority valve regulator changes
when the knob is turned 180°). When the gas pressure stops dropping on the preset regulator and
starts to drop on the priority valve regulator, it is time to change the left cylinder. The knob is rotated
180° to the right before the left cylinder is changed. It is helpful to maintain a log of cylinder pressure,
noting which direction the arrow is pointing on the priority valve. When the pressure gauge is very
low and the reserve side indicates that gas has begun to ow from the reserve cylinder, it is time to
rotate the knob and attach a full cylinder in reserve.
If the knob is not rotated before the empty cylinder is changed, two things can happen. First, gas
may ow from the changed cylinder to the existing cylinder. This is because the pressure setting
of the regulator on the primary side allows the regulator main valve to remain open. Second, when
the cylinder is changed, gas will begin to ow from the new cylinder, stopping ow from the existing
cylinder. This means the existing cylinder may be partially empty. After several cycles, it is possible
that the reserve cylinder may empty shortly after a switchover occurs. Always remember to rotate the
knob on the priority valve regulator before changing a depleted cylinder.
9
MODEL RANGE
522 or 523 2XXX 195-265 PSI (13.5-18.5 BAR)
522 or 523 3XXX 195-265 PSI (13.5-18.5 BAR)
522 or 523 4XXX 245-345 PSI (16.5-23.5 BAR)
522 or 523 5XXX 440-540 PSI (30.5-37 BAR)
522 or 523 7XXX 195-265 PSI (13.5-18.5 BAR)

For models with pressure switches or transducers, a remote alarm can be used to provide an audible
and visual warning that the need for a changeover is imminent. To maximize usage from your depleted
bank of cylinders, wait until a changeover has actually occurred. The changeover may not coincide
exactly with the alarm condition. You can tell that a changeover has actually occurred when you see a
drop in the inlet pressure indicated on the inlet pressure gauge for the opposite side of the AutoSwitch.
The alarm set point can be adjusted on pressure switch models and transducer models. Adjusting the
set point does not affect the switchover point of the AutoSwitch.
IMPORTANT:
DO NOT SET THE ALARM PRESSURE BELOW THE SYSTEM CHANGEOVER PRESSURE.
Doing so will result in the alarm condition never being met, and the alarm will never be triggered.
For Pressure Switch Models:
Slide the red tab seen on the inlet gauge to adjust the alarm set point. The lowering of the alarm set
point pressure may cause the alarm not to work properly. When adjustments are made, check the
function of the system. With the knob arrow turned fully clockwise, pressurize the system and shut
off the inlet pressure to both sides. Allow the inlet pressure on the right side to decrease by allowing
a small ow (50 CFH). Observe both inlet gauges. When the right bank is low (below the set point on
the gauge), the red LED will illuminate. Make sure the red LED illuminates before the pressure on the
opposite side starts to decrease. Repressurize system and check the opposite side of the system in
the same manner (the knob arrow must be turned fully counterclockwise).
For Transducer Models:
The alarm set point can be adjusted through the Altos 2 Remote Alarm. Refer to CONCOA instruction
manual ADI0025 (#9906 0025).
MAINTENANCE
On regular intervals, the system should be checked for leaks and proper function (see trouble shooting).
Any leaks in the system should be corrected immediately. The hose check valve should also be checked
for leaks when a depleted cylinder is removed. Note: the system inlet and hose should be pressurized
when checking for leaks. At no time should the preset regulator’s or priority valve regulator’s pressure
settings be changed. 10
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Inlet Gauge:
Red Tab Indicates
Alarm Set Point
(Typical Both Sides).
Access the Alarm
Set Point in the
Channel Settings
Menu of the Altos 2
Remote Alarm.
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channel 1
2. alarm set point
1.
3.
MODELS WITH
PRESSURE SWITCHES
MODELS WITH TRANSDUCERS

TROUBLESHOOTING
11
Symptom Cause
1. Gas leakage at the line regulator outlet when the
adjusting knob of the line regulator is completely
backed out.
2. With no ow through the system (downstream valves
closed and adjusting screw in) line pressure steadily
increases above set pressure.
3. Gas leakage from spring case (adjusting screw/knob end
of regulator).
4. Gas leakage from any joint.
5. Excessive drop in working pressure with regulator
owing gas.
6. Gas leakage from relief valve.
7. Gas leakage from any gauge
8. Gauge does not return to zero when not undergas
pressure
9. Gauge does not consistently repeat the same reading.
Regulator(s) have malfunctioned. Replace or repair
1. Switchover system seems to be using gas fromthe
primary and reserve cylinders (pressure is decreasing on
both inlet gauges at the sametime)
1. Make sure the priority valve knob is turned
fully to the right or left.
2. Observe the inlet pressure. It may be
necessary to do this during times of the
heaviest use. If the inlet pressure is less than
the values listed below, replace the high-
pressure cylinders.
522 and 523 2XXX 265 PSI (18 BAR)
522 and 523 3XXX 265 PSI (18 BAR)
522 and 523 4XXX 345 PSI (24 BAR)
522 and 523 5XXX 540 PSI (37 BAR)
522 and 523 7XXX 265 PSI (18 BAR)
If liquid cylinders are used and the inlet pressure
increases signicantly when the system is not in use, then
the system is over- withdrawing the liquid cylinders.
Additional capacity may be added to the system to
1. Inlet Gauges not reading pressure 1. Check that the valves on the cylinders are
opened.
2. If using a manifold system, check that the valve on the
manifold is opened.
1. Power light is not on.
(Pressure Switch Models Only)
1. Check that connector to remote alarm is
properly plugged into the autoswitch and the
alarm.
2. Check that the remote alarm is powered on.
3. Check that cable between autoswitch and
remote alarm is wired correctly.

TROUBLESHOOTING (cont.)
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 sufciently 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. Purg-
ing is especially important if the equipment has been in hazardous or corrosive gas service.
12
Symptom Cause
1. Status lights are not lighted
(Pressure Switch Models Only)
1. Check that connector to remote alarm is properly
plugged into the autoswitch and the alarm.
2. Check that the remote alarm is powered on.
3. Check that cable between autoswitch and
remote alarm is wired correctly
1. Green status light(s) are lighted when the
pressure is below the set point on the gauges
(Pressure Switch Models Only)
2. Red status light(s) are lighted when the pressure
is above the set point on the gauges
(Pressure Switch Models Only)
1. Cable to remote alarm wired incorrectly. Follow
instructions in remote alarm ADI to correct
problem.
1. With full tank pressure, red alarm light(s) are on.
(Pressure Switch Models Only)
1. Cable to remote alarm wired incorrectly. Follow
instructions in remote alarm ADI to correct
problem.
For status indication problems on transducer models, refer to the CONCOA Altos 2 Remote Alarm
instruction manual ADI0025 (#9906 0025).

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 rst 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 deciency, 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.
14

ADI 3196F
Certied ISO 9001
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