Concoa AutoBlend 650 Series User manual

The 650 Series
AutoBlend™
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 February 2003
New Release
ADI 3214-A
Certied ISO 9001
®

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INTENDED USE OF PRODUCT
The CONCOA gas mixer has been designed to mix two non-ammable and noncorrosive gases. The gas mixer can
be wall mounted in an indoor location.
EXPLANATION OF MODEL NUMBER
Series 650 AutoBlend™
SPECIFICATION SHEET
The specication sheet is a summary of the important technical information about the gas mixer. This includes the
inlet/outlet pressure conditions, pressure settings, voltage requirements and pressure alarm options. This data sheet
also lists the major parts and recommended spare parts.
MECHANICAL DESCRIPTION
Located on the front panel of the mixer are gauges for the major gas inlet pressure, minor gas inlet pressure.
The gas inlets are located on each side of the gas mixer, designed for inlet pressure of 100 - 125 PSI. Each of these
gas inlets is a 1/2 inch female NPT tting and is labeled for a specic gas. On the top of the enclosure is a 1/2 inch
NPT female outlet header.
Following the check valves is the pressure equalization subsystem. This system reduces and equalizes the major and
minor gas pressures to within ±1 psig. The pressure equalizing subsystem contains 40-micron lters. The equalized
pressure gases then ow through the dual metering valve subsystem into the mixing chamber where they are precisely
mixed.

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OPERATING PRINCIPLE
Constant mixture percent is accomplished by maintaining equal owrate at equal pressures across the major and
minor gas ow control devices, regardless of the delivery owrate. One of up to seven (7) selector settings can be
chosen by dialing to the proper point and hearing an audible click.
WARNING: Do not allow any liquid gases to enter the gas mixer. Liquid gases will damage the internal parts and
may cause personal injury.
CARBON DIOXIDE REGULATOR FREEZE UP
Regulators owing carbon dioxide may “freeze” due to the pressure drop of the carbon dioxide in the regulator.
If this “freeze” should occur, a manifold heater assembly or heated regulator should be used. Contact CONCOA
customer service.
GAS STORAGE SYSTEMS
Bulk liquid tanks are excellent supply sources for gas mixers provided that the diameter of the piping to the gas mixer
is adequate. High-pressure cylinders manifolded together are also an acceptable supply system. The high pressure
must be reduced by using the high pressure kit to the lower pressures (100 - 125 PSIG maximum) required by the
gas mixer.
MANIFOLDS
CONCOA manifold systems are adequate in capacity for the gas mixer. CONCOA automatic change over systems
are recommended to ensure that a continuous supply of gas is available to the gas mixer.
WARNING Most gases, such as carbon dioxide, argon, and nitrogen are colorless and odorless. These gases can
displace the oxygen in a conned area and cause death or injury by asphyxiation. Therefore, the gas mixer should
not be place in a conned area without ventilation. Leaks from the mixing system or associated piping could cause
oxygen deciency in such an area.
USE OF PRODUCT
The mixer is intended for use in non-corrosive gas applications. Please note the safety information shown in later
sections. This product is not intended for use in toxic or corrosive applications.
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, Virginia, PHONE:
1-800-225-0473, FAX: [phone], or E-MAIL: [email protected].
USER RESPONSIBILITY
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 service facility designated
by CONCOA.

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CUSTOMER SERVICE
In the event of equipment failure, call CONCOA Customer Service. Please be prepared to provide the model number
and serial number of the equipment involved, in addition to details regarding its application. This would include
inlet and outlet pressures, ow rate, environmental conditions, and gas service.
INSTALLATION PLANNING
Things to consider before removing the system from the box....
1. Know the properties and special handling requirements of the gas being used. Many specialty gases are quite
dangerous (ammable, toxic, corrosive, simple asphyxiant, or oxidizers). This product is not intended for
use in toxic or corrosive applications. Equipment failure or misuse may lead to problems such as a release of
gas through the relief valve or regulator diaphragm. Please note the enclosure is not sealed and may leak gas
from faulty components. Proper safety measures should be established to handle these and other component
failures.
2. Be sure that the assembly purchased is suitable for the gas and type of service intended. The specication
label provides the following information:
a. Model number
b. Serial number
c. Selection inlet pressure range
d. mixture components
Be sure that the equipment received conforms to the order specications. The user is responsible for selecting
equipment compatible with the gas in use, and conditions of pressure, temperature, ow, etc. Selection
information can be found in CONCOA technical 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 damage or contamination. Pay particular
attention to connecting threads. While CONCOA assembles and tests system components to exacting 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 contamination, return to the supplier.
4. Before system start-up, it is recommended that all systems be pressure tested, leak tested, and purged with
an inert gas such as nitrogen.
Comply with precautions listed in C.G.A. Pamphlet P-I, 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 ow
rate and temperature requirements).
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 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.
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 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.

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GENERAL SAFETY PRACTICES
Never use an open ame 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 manifold.
Always leak-test any manifold or distribution pipeline before using.
WARNING GAS MIXER HAZARDS
Only use the gases shown on the labels in the gas mixer. These gas mixers are not designed to accept ammable or
corrosive gases. Use of these types of gases could damage the gas mixer and cause personal injury.
Do not replace any parts on oxygen models unless they have been cleaned for oxygen service. Use only the parts
specied by CONCOA.
The gas mixers are not designed to accept liquid gases. Exposure to liquid gases will damage the internal parts and
may cause personal injury.
Any damage caused by high-pressure gases or liquid gases is not covered by the warranty.
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 5lB, 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.
ll. 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 Decient 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].

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LOCATION
Keep all cylinders and manifolds away from any source of high temperature over 120oF (50oC) or possible re hazards.
High-pressure gas contained in a closed cylinder becomes increasingly dangerous when exposed to high temperature
because pressure increases. 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.
INSTALLATION
The site chosen for the installation 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 the system to damage from passing
trucks, cranes, or other heavy machines. The optional oxygen system must not be installed under shafting, belting,
or other places where oil can drip on them. For other location guidelines, see NFPA standard 51.
Installing the system:
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.
d. Relief valve: The purpose of the relief valve is to protect the system and its components only. If there is
pressure sensitive equipment downstream of the system, It is recommended that a relief valve (534 Series)
be installed to protect this equipment.
Mount the system to a at surface using the appropriate hardware at hole locations provided in the bracket. Dimensions
for these holes are shown in Figure 2.
Figure 2. Dimensions for the 650 Series AutoBlend™

OPERATION
INSTALLING INLET AND OUTLET CONNECTIONS:
Use an open-end wrench, not a pipe wrench, to install accessories to the system. ALWAYS hold the bulkhead tting
with a wrench when installing the accessories. Do not allow the bulkhead tting to turn; otherwise, connections
inside the enclosure may be loosened. The NPT connections require Teon tape on the threads to make a gas tight
seal. On stainless steel connections, the Teon tape helps prevent the connections from galling when tightening or
loosening. Follow these rules when using Teon tape.
Before applying 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 above; 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. Apply two overlapping layers of Teon tape. Cut off the
excess tape and press the end rmly into the threads.
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Figure 3. Teon Tape Placement
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. Threading the nut onto the cylinder connection should be easy. Do not force. If it does not t, 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 overtighten
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.

Installing the outlet connection:
The system has the outlet connection at the top of the box. The connection is a 1/2" NPT. Connect tubing to the
system that is compatible with the application and is capable of handling the pressure required. Follow the instructions
given at the end of this booklet when making up the tube connection.
START UP
Pressurizing the system for the rst time:
Before system start-up, it is recommended that all systems be pressure tested, leak tested and purged with an inert
gas such as nitrogen.
1. Wear safety glasses and gloves.
2. Be sure that both ends of all hoses or pigtails 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 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.
With aid of a regulator increase pressure into the system until 100 - 125 PSI is reached
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 - after pressurizing the system - 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 port connections. Never attempt to x a leak under pressure. If leaks are detected, depressurize
the system and retighten the connection. Begin again.
WARNING: While CONCOA assembles the 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.
NOTE: It is recommended that shutoff valves and pipe unions be installed on the inlet gas pipelines and a union
installed on the mixed gas pipeline to allow the gas mixer to be easily removed if necessary.
6. Dial to the desired mixture ratio.
7. Turn on and adjust the supply pressure for both gases to 100 - 125 PSI.
WARNING When opening valves in oxygen pipelines, open valves slowly. Rapid opening of oxygen valves can
produce large instantaneous increase in temperature, which can cause violent explosions and/or re.
8. If a shutoff valve has been placed on the outlet piping, it should be turned off. If there is no shutoff valve
present, you may shutoff the ow by turning the adjustment knob on the down stream pressure regulator.
9. Crack open the shutoff valve or begin to open the outlet pressure regulator to get a ow through the gas
mixer. The mixing system should begin to cycle. The entire piping system will need to be purged upon
start-up to displace any ambient air. During cycling the inlet pressure gauges should stay above 100 PSIG
at all times.
CHANGING THE GAS MIXTURE
To change the gas mixture the operator selects the mixture adjustment to the appropriate dial setting. The dial shows
the gas mixture selected. The AutoBlend will instantly start producing the new blend. However, depending on the
volume of the piping system, the residual mixes will need to be displaced by the new selection.
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MAINTENANCE
The system should be checked for leaks and proper function at regular intervals (see TROUBLESHOOTING).
Any leaks in the system should be corrected immediately.
The gas mixer requires minimum maintenance. All the moving parts in the gas mixer are expected to last several
years under normal conditions, To obtain a list of the recommended spare parts, contact CONCOA or refer to the
specication page.
TROUBLE SHOOTING
CHECKING THE GAS MIXTURE
If the gas mixture is in question, the mixer should be checked with an analyzer. Allow the gas mixer to ow for two
(2) minutes between each change in setting to get a correct reading. Be careful to follow the analyzer manufacturers
operating instructions. If there is any question about the operation or the suitability of a particular gas analyzer for
the gas mixture, please consult CONCOA.
If the gas mixer seems to be producing an incorrect mixture, follow these steps.
It is suggested that each of the following steps be taken in sequence. To avoid possible misadjustment, after each step
test the mixer to determine if the problem has been xed. If so, make no more adjustments.
The following information uses the standard pressure settings; some gas mixers may be built with non-standard
pressure settings. Refer to the specications to determine the actual pressure settings.
1. Check to be sure that the inlet pressures stay above 100 PSIG at all times. If either inlet pressure drops below
this gure, the gas mixer will be starved for the particular gas and an improper mixture will be created. If
it is found that the inlet pressures are dropping below 100 PSIG, the inlet pressure to the mixer must be
increased. This may require a higher regulator setting at the manifold or the liquid storage tank. Also, look
for blockages in the incoming pipeline such as lters and undersized regulators. Do not use smaller than ”
piping for the major gas.
If the previous step do not rectify the problem, you may call CONCOA for help. For troubleshooting help with a
gas mixer, the following information is required.
1. Model and serial number of the gas mixer.
2. Inlet major and minor gas pressure in owing condition which is shown on gauges on front of gas mixer.
3. Gases used.
The phone number is 1-800-225-0473. Ask for gas mixer service help.
Typical symptoms listed below indicate regulator malfunctions needing repair.
Replace with a clean, repaired and tested, or new regulator obtained from CONCOA.
1. With no ow through the system (downstream valves and regulator closed and adjusting screw in) line
pressure steadily increases.
2. Gas leakage from bonnet.
3. Gas leakage from any joint.
4. Gas leakage from relief valve.
5. Gas leakage from any gauge.
6. Gauge does not return to zero when not under gas pressure.
7. Gauge does not consistently repeat the same reading.
8. The system makes a noise or hums.