Concoa 601 Series User manual

INSTALLATION AND OPERATION INSTRUCTIONS
Certified ISO 9001
ADI 3218A
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
Before Installing or Operating, Read and Comply with These Instructions
601 Series
Regulators
February,2004
®

2
Warning: An appropriately sized pressure relief device downstream
of the regulator should be installed in your system to prevent damage
to equipment and/or injury to personnel should an internal failure
of the regulator occur.
Warning: Maximumallowableworkingpressureindicatedonproduct
labeling is for the regulator only. Ratings for peripherals/accessories
may be less than the pressure indicated on the product label. Do not
exceed the pressure ratings of the attached peripherals/accessories
and the regulator’s maximum allowable working pressure. Please
contact your gas supplier for more information.
Warning: for regulators with tube fittings, select the appropriate
tubing. Use seamless tubing with the proper consideration given to
wall thickness and material. Please contact your gas supplier for more
information.

3
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. This equipment must be checked periodically. Improperly
working equipment should not be used. Parts that are broken, missing,
worn, distorted or contaminated, should be replaced immediately.
CONCOA recommends that a telephone or written request for service
advice be made to CONCOA Customer Service in Virginia Beach, Vir-
ginia, PHONE: [phone], FAX: [phone], or E-MAIL:
[email protected].
Thisequipmentoranyof its partsshouldnotbealtered withoutpriorwritten
approval by CONCOA. The user of this equipment shall have the sole re-
sponsibility for any malfunction that results from improper use, faulty main-
tenance, damage, improper repair, or alteration by anyone other than
CONCOA or a service facility designated by CONCOA.
In the event of equipment failure, call CONCOA Customer Service. Please
be prepared to provide the model number and serial number of the equip-
ment involved, in addition to some details regarding its application.
Things to consider before removing the
regulator from the box….
1. Know the properties and special handling requirements of the gas
being used. Many gases are quite dangerous (flammable, toxic, cor-
rosive,simpleasphyxiant,oroxidizers). Equipmentfailureor misuse
may lead to problems such as a release of gas through the relief valve
orregulatordiaphragm. Propersafetymeasuresshouldbeestablished
to handle these and other component failures.
2. Besurethat the assembly purchased is suitable for the gas and typeof
service intended. The system label provides the following informa-
tion:
a. Model number
b. Serial number
c. Maximum inlet pressure
CUSTOMER SERVICE

4
Be sure that the equipment received conforms to the order specifi-
cations. The user is responsible for selecting equipment compat-
ible with the gas in use, and conditions of pressure, temperature,
flow, etc. Selection information can be found in CONCOA tech-
nical data sheets. In addition, CONCOA representatives are trained
to aid in the selection process.
3. Inspect the assembly upon receipt to be sure that there is no dam-
age or contamination. Pay particular attention to connecting
threads. While CONCOA assembles system components to ex-
acting leak-tight standards, the customer should also inspect for
any loosening of parts that may occur in shipping or installation.
Loose parts may be dangerously propelled from an assembly. If
there are adverse signs (leakage or other malfunction), return the
assembly to the supplier. While it is advised that soiled regulators
be returned for cleaning, simple external dust or grease may be
removed by a clean cloth and if required with aqueous detergent
suitable for the application. If there are signs of internal contami-
nation, return to the supplier.
4. Before system start-up, it is recommended that all systems be pres-
sure tested, leak tested, and purged with an inert gas such as nitro-
gen. 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, for start-up and system checks only.
Adapters should never be used on a permanent basis.
If the regulator includes gas specific inlet connections, their pur-
pose is to prevent usage on the wrong gases. Adaptation or alter-
ation for use on other gases can be dangerous, and is not recom-
mended.
Comply with precautions listed in C.G.A. Pamphlet P-1, Safe Handling of
Compressed Gases in Containers.
Consult the cylinder distributor for the proper use of cylinders and for any
restrictions on their use (such as flow rate and temperature requirements).
Never use an open flame when leak testing.
Always open valves slowly when high-pressure gases are being used.
Always be sure that a cylinder contains the correct gas before connecting it
to any regulator.
GENERAL SAFETY PRACTICES

5
Always leak-test any manifold or distribution pipeline before using.
Always be sure that the gas in the system is the correct gas for the intended
use.
For the United States, some applicable safety rules and precautions are
listed below:
1. American National Standards Institute standard Z49.1, Safety in
WeldingandCutting,AmericanWeldingSociety,2501NWSeventh
Street, Miami, Florida 33125
2. N.F.P.A. Standard 51, Oxygen-Fuel Gas systems for Welding and
Cutting,N.F.P.A.,470AtlanticAvenue,Boston,Massachusetts02210
3. N.F.P.A. Standard 51B, Cutting and Welding Processes (same ad-
dress as #2).
4. CONCOApublicationADE872,SafetyPrecautionsinWeldingand
Cutting.
5. Local Ordinances
6. O.S.H.A. Standard 29 CFR
7. C.G.A.PamphletC-4,AmericanNationalStandardMethodofMark-
ing 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 hydro-
gen.
12. C.G.A. Pamphlet G-6, Carbon Dioxide – Information on the prop-
erties,manufacture,transportation,storage,handling,anduseofcar-
bon 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 Con-
tainers.
15. C.G.A. Safety Bulletin SB-2, Oxygen Deficient Atmospheres.
*C.G.A. pamphlets can be obtained from the Compressed Gas Associa-
tion, 1235 Jefferson Davis Highway, Arlington, VA 22202-3239, (703)
979-0900. Publications: [phone]. Fax: [phone].

6
Please observe the previously mentioned safety precautions before actual
installation.
1.1 Before removing the cylinder cap, move the cylinder of gas to the work
site:a. Secure cylinder to floor, wall or bench with appropriate chain 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.
1.2 Following procedures below, secure the regulator inlet connector to the
outletconnectoronthecylinder. Useanopen-endwrench,notapipewrench.
a. The connection should be easily threaded. Do not force. If it is
not easy, you may have the wrong regulator for the gas you are
using.
b. LEFTHANDTHREADSareusedon someinletconnectorsand are
indicated by a notch in the middle of the hex nut.
c. GASKETS are used on some inlet connectors. If so, it will be pro-
vided with the regulator. Be sure the gasket is in good shape. Do not
overtighten to avoid squashing the gasket into the gas line. You may
want to order an extra supply of these gaskets from your gas supplier.
d. Never use oil or grease on regulator or cylinder fittings, as you may
contaminate pure gases, or create a fire hazard.
1.3 Close the regulator by turning the pressure control knob, or handle,
counterclockwise. As the control knob is closed, turning should become
easier.
1.4 Shut the regulator outlet valve (if supplied) by turning the knob on the
valve clockwise.
1.5 Observing the following procedures; make connections from the regula-
tor outlet to your downstream equipment.
a. BE SURE TO CONSIDER ALL FACTORS WHEN SELECT-
ING MATERIALS. For example, if you have both high pressure
and corrosive service, select material that is suitable for both.
INSTALLATION

7
b. Do not use oil or grease on fittings, especially not on oxidizing gas
service equipment.
c. Be sure that all fittings are secure and leak tight. Teflon tape should
be used on pipe fittings, but avoid impinging on the gas stream.
Before applying Teflon tape, inspect the NPT threads and if neces-
sary, clean the fitting to remove any dirt or thread sealant that
remains on the threads. Start the Teflon tape on the second thread
as shown above; make sure the tape does not overlap the end of the
fitting. As the tape is wrapped in the direction of the thread spi-
ral, pull tightly on the end of tape so that the tape conforms to the
threads. Apply two overlapping layers of Teflon tape. Cut off the
excess tape and press the end firmly into the threads.
d. RELIEF VALVE. Some regulators are equipped with a relief valve.
The purpose of a relief valve is to protect the regulator and it com-
ponents. If there is pressure sensitive equipment downstream of
the regulator it is recommended that a relief valve be installed in
the line to protect this equipment. If you are using toxic, corro-
sive, or flammable gases, it is recommended that the exhaust from
the valve be piped to a safe discharge area.
e. PURGE DEVICES (Optional). If your regulator includes a purge,
review the safety operation in the specific instruction manual for
your regulator. Purge devices are highly recommended when us-
ing toxic or corrosive gases.
Read the “Safety” and “Installation” sections before operating your equip-
ment.
2.1 It is advised that high purity systems be thoroughly purged before
use.
Figure 1. Tape
Installation
procedures.
OPERATION

8
2.2 The regulator adjusting knob should be turned fully counterclockwise
(see 1.3) and the outlet valve should be closed (see 1.4).
2.3 Put on safety glasses and gloves.
2.4 Position yourself with the cylinder between you and the regulator.
Keep hands off the regulator while opening the cylinder valve.
2.5 To avoid damage to regulator parts, slowly open the cylinder valve.
Observe the high pressure gauge for a rise in pressure up to full cylinder
pressure.
2.6 Observe all connections for leaks.
a. An approved leak detection solution may be applied to the con-
nections, if compatible to your usage. Leaks are indicated by bub-
bling.
b. To further check for leaks, or if you cannot use the leak detection
solution, reclose the cylinder valve for five minutes, and observe
the high pressure gauge for a drop in pressure. If so indicated,
recheck the CGA connection and all other high pressure port con-
nections.
2.7 (Open the cylinder valve fully in order to form a good seal at the
cylinder valve packing.) Keep the valve hand wheel or wrench on the open
cylinder valve at all times to allow prompt emergency shutoff.
2.8 Adjust to the desired working pressure by turning the pressure con-
trol knob or handle clockwise, while observing the delivery pressure gauge
for the approximate desired setting.
a. Do not exceed the maximum delivery pressure indicated on the
regulator label.
b. Again check for leaks on the low pressure ports.
c. Check the delivery pressure gauge for any drop in pressure. If a
drop is indicated, check all low pressure ports for leakage.
2.9 Again set the delivery pressure, open the outlet valve if any, and check
your system for leaks and otherwise proper functioning.
a. With gas flowing through your system, some adjustment to deliv-
ery pressure may be required.
b. TWO-STAGE REGULATORS. After the above final setting of
delivery pressure, no further adjustment should be required as the
cylinder depletes.

9
c. SINGLE-STAGE REGULATORS. After the above final setting of
delivery pressure, you may have to periodically adjust delivery pres-
sure as the cylinder depletes.
d. As a general rule, a cylinder should be considered EMPTY when
the cylinder pressure drops to a value of two (2) times the delivery
pressure or less. This avoids the possibility of dangerous suck-
back conditions. However, particular system requirements may
indicate greater or less margin than the recommendation. Con-
tact your CONCOA representative if you have any questions.
As indicated in the “Operation” section, a cylinder should be regarded as
empty when the cylinder pressure has dropped to twice the delivery pres-
sure or less. This will avoid the possibility of dangerous suck-back condi-
tions, where other system gases are pulled back into the regulator and
cylinder.
3.1 BRIEF SHUTDOWN (less than 30 minutes). Simply close the regu-
lator outlet valve (if supplied). If the regulator does not have an outlet
valve use procedure 3.2.
3.2 EXTENDED SHUTDOWN (beyond 30 minutes).
a. NORMALLY OPEN SYSTEMS or COMPLETE SYSTEM DIS-
ASSEMBLY. This section applies when there is no concern about
entry of astmospheric gases into the system.
1. Close the gas cylinder valve.
2. Shut down any other gas supplies which may be connected to
your system.
3. Turn the adusting knob clockwise and open the outlet valve to
drain the line through your usage points. Both regulator
gauges should descend to zero.
4. With HAZARDOUS GASES run an inert purging gas through
the regulator and system before disassembly.
5. After venting (and purging when applicable), turn the adjust-
ing knob fully counterclockwise and close the outlet valve.
6. Disconnect downstream equipment.
7. In disassembling, slowly loosen the cylinder valve connection,
while listening for gas seepage. If leaking is evident, retighten
the connection, and check for effective closing of the cylinder
valve.
SHUTDOWN AND DISASSEMBLY

10
8. Cap the cylinder after disconnecting the regulator. Mark the
cylinder “EMPTY” if this is the case, and move it to the stor-
age area for return cylinders.
9. If HAZARDOUS GASES have been used, and there has not
been a purging procedure as recommended, some benefit can
be gained by directing a stream of dry nitrogen through the
fully opened regulator. When using HAZARDOUS GASES
or when in a CONFINED AREA, be sure to provide a safe
discharge area when clearing the regulator.
10. Install a new cylinder, if called for.
11. When a regulator is out of service, close the pressure control
knob by turning counterclockwise until the spring tension
relieves, and close the outlet valve. Also cap open ends of the
regulator, or if removed, store it in a plastic bag to prevent
contamination, especially by unobserved particulate buildup
inside the regulator.
b. ISOLATED GAS SYSTEMS. Some laser manufacturers, demand
that ambient air be excluded from the system. There are several
methods in use:
1. Seal the usage gas in the system via a check valve in the inlet
CGA gland.
2. Purge the regulator with the process gas using the innerstage
purge option.
3. Purge the regulator wth the process gas using the inlet block
and bleed option.
3.3 CYLINDER CHANGE - ISOLATED GAS SYSTEMS. For cylinder
change using the inner stage purge option, perform the following as shown
in Figure 2:
a. Tightly close the gas cylinder valve.
b. Turn pressure adjusting knob counter-clockwise until the positive
stop is reached.
c. Change cylinder.
d. Open cylinder valve.
e. Slowly open inner purge valve located at the seven (7) o’clock po-
sition until you hear a slight “hiss”.
f. Close inner purge valve after five (5) seconds.
g. Repeat steps e and f.
h. Turn pressure adjusting knob to the desired operating pressure.
i. Ready for use.

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3.4 CYLINDER CHANGE - ISOLATED GAS SYSTEMS. For cylinder
change using a block and bleed inlet purge, perform the following as shown
in Figure 3:
a. Tightly close the gas cylinder valve.
b. Tightly close the block valve directly connected to the regulator
body.
c. Change cylinder.
d. Open cylinder valve.
e. Slowly open the bleed valve located at a right angle to the CGA
connection until you hear a slight “hiss”.
f. Close bleed valve after five (5) seconds.
g. Wait thirty (30) seconds.
h. Repeat steps e and f.
i. Open block valve.
j. Ready for use.
Innerstage
Purge
OUTLET
EE
NN
PP
OO
SS
EE
CC
LL
OO
AA
AA
NN
CC
EE
RR
II
EE
RR
CC
EE
DD
EE
SS
EE
SS
INLET
Figure 2. Innerstage
Purge Option.
Block / Bleed PurgeRelief Valve
Block Valve Bleed Valve
OUTLET
EE
SS
AA
EE
RR
CC
EE
DD
SS
CC
AA
EE
RR
EE
NN
II
PP
OO
NN
EE
CC
LL
SS
EE
OO
INLET
Figure 3. Block and
Bleed Inlet Purge
Option.

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General
A unit which is not functioning properly should not be used until all
required repairs have been completed and the unit has been tested to as-
certain that it is in proper operating order.
It is recommended that all servicing be done by a service facility autho-
rized by CONCOA. Contact the CONCOA Customer Service Depart-
ment in Virginia Beach or the nearest CONCOA District Sales Office for
assistance.
If so advised, the unit should be sent to a service facility authorized by
CONCOA, adequately packaged, in the original shipping container if pos-
sible, and shipped prepaid, with a statement of observed deficiency. The
gas service that the equipment has been subjected to must be clearly iden-
tified. All equipment must be purged before shipment to protect the
transporter and service personnel. The purging is especially important if
the equipment has been in hazardous or corrosive gas service. Return trip
transportation charges are to be paid by Buyer. In all cases other than
where warranty is applicable, repairs will be made at current list price for
the replacement part (s) plus a reasonable labor charge.
Test regulator for leaks on a routine schedule.
SERVICE

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Probable Cause
1. Seat leak or creep, have regulator
repaired.
2. Seat leak or creep, have regulator
repaired.
3. Diaphragmfailure,haveregulator
repaired.
4. Blockage in seat assembly or inlet
filter. Have regulator repaired.
5. Loose fitting, remove connection
clean, reapply Teflon tape and re-
tighten.
6. Possiblefaultyreliefvalve,replace.
Possible seat leak or creep, have re-
paired.
7. Seat sticking, have regulator re-
paired. Possible bad pressure gauge.
8. Gauge has suffered physical dam-
age, replace gauge.
Trouble Shooting
Symptoms
1. Gas leakage at the regulator out-
let when the adjusting screw is
turned fully counterclockwise.
2. With no flow through the sys-
tem (downstream valves closed),
outlet pressure increases steadily
above the set pressure.
3. Gas leakage from spring case or
bonnet.
4. Excess drop in outlet pressure
with regulator flow open.
5. Gas leakage from any pipe thread
joint.
6. Gas leakage from relief valve.
7. Inconsistent repeat reading
8. Inlet or outlet pressure gauge does
not return to zero with no pressure
applied to the regulator

14
THIS PAGE INTENTIONALLY LEFT BLANK

15
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
respecttothepurchaseofthisequipmentdirectlyfromCONTROLSCORPORATION
OF AMERICA or its Authorized Distributors as new merchandise and are extended to
the first Buyer thereof other than for the purpose of resale.
Foraperiodofone(1)yearfromthedateoforiginaldelivery(90daysincorrosiveservice)
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 equip-
ment 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 peri-
odicmaintenance andserviceis performedorreplacementsmade inaccordancewith the
instructionsprovided.Theforegoingwarrantiesshallnotapplyiftheequipmenthasbeen
repaired: other than by CONTROLS CORPORATION OF AMERICA or a desig-
natedservicefacilityorinaccordancewithwritteninstructionsprovidedbyCONTROLS
CORPORATIONOFAMERICA,oralteredbyanyoneotherthanCONTROLSCOR-
PORATION 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 pur-
chased, and which if so advised, is returned with a statement of the observed deficiency,
andproof of purchaseof equipmentorpartnot laterthan seven(7)days afterthe expira-
tion date of the applicable warranty, to the nearest designated service facility during nor-
mal business hours, transportation charges prepaid, and which upon examination, is
foundnottocomplywiththeabovewarranties.Returntriptransportationchargesforthe
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: INCI-
DENTALDAMAGES,CONSEQUENTIALDAMAGES,ORSPECIALDAMAGES,
WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE, BREACH OF
WARRANTY OR OTHERWISE.
THEREARENOEXPRESSORIMPLIEDWARRANTIESWHICHEXTENDBE-
YOND THE WARRANTIES HEREINABOVE SET FORTH. CONTROLS COR-
PORATION OF AMERICA MAKES NO WARRANTY OF MERCHANTABIL-
ITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE
EQUIPMENT OR PARTS THEREOF.

Certified ISO 9001
ADI 3218A
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
®