Concoa 542 User manual

ADI 9519-A
Certified ISO 9001:2000
542 Generator
Backup System
INSTALLATION AND OPERATING 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
October 2009

i
Index
Safety ............................................................................................................................................1
User Responsibility.......................................................................................................................3
Description of Product..................................................................................................................3
Features.........................................................................................................................................3
Installing the Generator Backup System.......................................................................................6
Operating the Generator Backup System......................................................................................7
How it Works .........................................................................................................................7
Setting Delivery Regulator Pressure ......................................................................................8
Setting Alarm Trip Pointt Pressure.........................................................................................9
Setting Setpoint Pressure......................................................................................................11
Setting Units of Measure......................................................................................................13
Enabling Remote Setup........................................................................................................14
Setting Communication Mode..............................................................................................15
Connecting Alarm Outputs...................................................................................................16
Configuring Alarm Relay Jumpers.......................................................................................17
Connecting the Web Server..................................................................................................19
Trouble Shooting ........................................................................................................................20
Performing Self Test...................................................................................................................21
Mounting Detail..........................................................................................................................23
Power Requirements...................................................................................................................24
Service ........................................................................................................................................25
Warranty .....................................................................................................................................26

1
SAFETY
THIS PRODUCT IS NOT INTENDED FOR USE WITH TOXIC GASES, FLAMMABLE
GASES OR CORROSIVE GASES.
NOTICE
The 542 Generator Backup System is not intended for use in medical installations.
Basic safety precautions must be followed to reduce the risk of fire, electrical shock or injury.
•Connect the 542 Generator Backup System to the correct line voltage. A label on the
product identifies what voltage it is wired for. CONNECTION TO AN INCORRECT
VOLTAGE CAN CAUSE SERIOUS DAMAGE TO THE PRODUCT AND WILL
VOID ANY WARRANTY.
•Install the 542 Generator Backup System
•where the ambient temperature range is between 0° F and 140° F.
•Do not install this product in a hazardous environment.
•If product appears damaged in any way, do not use and request service from CONCOA.
•Consult the cylinder distributor for the proper use of cylinders and for any restrictions on
their use (such as flow rate and temperature requirements).
•Store cylinders with valve caps screwed on, and chain cylinders to a supporting wall or
column.
•Handle cylinders carefully and only with valve caps screwed on. The cap will reduce the
chance that the cylinder valve will break off if the cylinder is accidentally dropped or
falls over. The cap also protects the cylinder valve from damage to screw threads, which
could cause leaky connections.
•No smoking should be permitted near oxygen, nitrous oxide, any other oxidizer,
flammable gases, or flammable mixtures, or in areas where cylinders are stored.
•Where an oxidizer (such as nitrous oxide or oxygen) is used, the manifold and cylinders
must be kept clean. No oil, grease, or combustible substances should come in contact
with oxygen or nitrous oxide storage or handling equipment. Such materials in contact
with oxygen or nitrous oxide are readily ignitable and, when ignited, will burn intensely.
•Never lift gas cylinders with a magnetic lifting device.
•Never use an open 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
manifold.

2
•Always leak-test any manifold or distribution pipeline before using.
•Always be sure that the gas in a pipeline is the correct gas for the intended use.
•Always close all cylinder valves before disconnecting cylinders from a manifold.
•Always remove all empty cylinders from a manifold before connecting full cylinders.
•Always test cylinders to be sure the cylinders are full before connecting to a manifold.
All gas distribution piping systems must meet the appropriate industrial standards for the intended service
and must be thoroughly cleaned before using. For the United States, some applicable safety rules and
precautions are listed below:
1. American National Standards Institute standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 2501 NW Seventh Street, Miami, Florida 33125
2. N.F.P.A. Standard 51, Oxygen-Fuel Gas systems for Welding and Cutting, N.F.P.A., 470 Atlantic
Avenue, Boston, Massachusetts 02210
3. N.F.P.A. Standard 51B, Cutting and Welding Processes (same address as #2).
4. CONCOA publication ADE 872, Safety Precautions in Welding and Cutting.
5. Local Ordinances
6. O.S.H.A. Standard 29 CFR
7. C.G.A. Pamphlet C-4, American National Standard Method of Marking Portable Compressed
Gas Containers to Identify the Material Contained.
8. C.G.A. Pamphlet G-4, Oxygen – Information on the properties, manufacture, transportation,
storage, handling, and use of oxygen.
9. C.G.A. Pamphlet G-4.1, Equipment Cleaned for oxygen service.
10. C.G.A. Pamphlet G-4.4, Industrial Practices for Gaseous Oxygen Transmission and Distribution
Piping Systems.
11. C.G.A. Pamphlet G-5, Hydrogen – Information on the properties, manufacture, transportation,
storage, handling, and use of hydrogen.
12. C.G.A. Pamphlet G-6, Carbon Dioxide – Information on the properties, manufacture,
transportation, storage, handling, and use of carbon dioxide.
13. C.G.A. Pamphlet G-6.1, Standard for Low Pressure Carbon Dioxide Systems at Consumer Sites.
14. C.G.A. Pamphlet P-1, Safe Handling of Compressed Gases in Containers.
15. C.G.A. Safety Bulletin SB-2, Oxygen Deficient Atmospheres.
C.G.A. Pamphlets can be obtained from the Compressed Gas Association, 1235 Jefferson
Davis Highway, Arlington, VA 22202-3239, [phone]. Publications: (703) 979-
4341. Fax: [phone].

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, Virginia, PHONE: [phone], FAX: [phone]-
3125, or E-MAIL: [email protected].
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.
DESCRIPTION OF PRODUCT
The 542 Series Generator Backup System is designed to provide a reserve supply of gas to a Gas
Generator unit should that unit fail or become unable to provide an adequate gas supply. If the gas
generator becomes unable to provide an adequate gas supply to the application, the 542 Generator Backup
System will automatically activate and supply gas to the system without interruption. When the generator
system becomes capable again of supplying gas to the application the 542 Generator Backup System will
automatically turn off.
The 542 Generator Backup System can be configured in the field for different inlet pressure alarm points
as well as output set points. It provides a digital display of the inlet and outlet pressures. These pressures
are displayed alternately on the 4 digit LED display. Pressure can be displayed in PSI, BAR, or MPA.
The 542 Generator Backup System can communicate to remote devices through an optional Web Server.
In addition, the 542 Generator Backup System offers a connection to interface with CONCOA alarms or
an optional built in audible alarm.
Figure 1 provides an explanation of the display panel and the inputs and outputs.
FEATURES
Settable Inlet Alarm Pressure
The 542 Generator Backup System can be configured to activate an alarm notification at pressures
ranging from 500 to 2300 PSI in 120 PSI increments. This value is factory set but can be changed in the
field. To change this value, refer to the section on changing the inlet Alarm Trip Point Pressure.
Settable Setpoint Pressure
The Setpoint or point at which the 542 Generator Backup System turns ON to provide gas can be set at
pressures ranging from 25 PSI to 255 PSI in 1 PSI increments. This value is factory set but can be
changed in the field. To change this value, refer to the section on changing the Setpoint Pressure.
Selectable Units of Measure
The default units of measure for the 542 Generator Backup System are PSI. Alternate units of BAR or
MPA can be selected by changing internal DIP switch settings. To change units of measure refer to the
section on changing units of measure.

4
Hysteresis
The 542 Generator Backup System has a built in feature called Hysteresis that prevents the system from
“dithering” around a inlet alarm trip point or setpoint. For the Inlet pressure this value is factory set at 10
PSI. For the Setpoint this value is factory set at 5 PSI. What this means, as an example, is if the inlet
alarm trip point is set to 500 PSI the system will alarm at 500 PSI but the alarm will not clear until the
inlet pressure builds back to 500 PSI plus Hysteresis (10 PSI) or 510 PSI.
Alarm Notification
The 542 Generator Backup System is designed to interface with CONCOA Remote Alarms and comes
with the necessary mating connector for their use. Refer to the section on Connecting a Remote Alarm for
more information. There are effectively two alarm notifications. The first alarm occurs when the inlet
pressure to the 542 Generator Backup System drops below the inlet alarm trip point. When this condition
occurs the red “Replace” light on the control panel will light and a relay will activate. This relay has a set
of Normally Closed (N.C.) contacts and are accessible on the 4 pin circular connector labeled “Alarm
Outputs” on the bottom of the unit. The second alarm occurs when the 542 Generator Backup System
activates or is “In-Use”. When this condition occurs the Green “In-Use” light will light on the control
panel and a relay will activate. This relay has a set of Normally Closed (N.C.) contacts. These contacts
are also accessible on the 4 pin circular connector labeled “Alarm Outputs” on the bottom of the unit.
Ethernet Port – Web Server
The 542 Generator Backup System may be equipped with an optional Web Server allowing for remote
monitoring of functions, e-mailing, and remote configuration. For more information on the Web Server
Option contact CONCOA Customer Service at 1 800 225-0473.
Serial Port
The 542 Generator Backup System is capable of communicating to peripheral equipment via a
configurable serial port. For more information on the serial port refer to the section on Setting
Communication Mode in this manual.

5
Figure 1

6
INSTALLING THE GENERATOR BACK UP SYSTEM
Understanding the application and sizing the components properly is the key to any
successful system installation. Figure 2 shows a typical installation.
Figure 2
The inlet and outlet on the 542 Generator Backup System are 1/2” Female NPT fittings. It is strongly
recommended that two wrenches be used when tightening external devices to these fittings.
The 542 Generator Backup System uses four mounting tabs for mounting to a wall or panel. Refer to
Figure 12 at the back of this manual for the dimensions of the system. Anchor the 542 Generator Backup
System securely to a wall or panel at a height adequate to conveniently connect a manifold or pigtail.
THE HEIGHT SELECTED MUST MEET ALL REGULATORY REQUIREMENTS.
Once all mechanical connections are made pressurize the system and check for leaks.
Connect a Remote Alarm (if used) to the 542 Generator Backup System.
Finally connect AC power to the 542 Generator Backup System. The system is factory set to operate at
either 115VAC 60hz or 230 VAC 60hz. Check the product label for the product voltage. Connection of
the 542 Generator Backup System to the incorrect input voltage will damage the product and void any
warranty.
THERE IS NO ON/OFF POWER SWITCH FOR THE 542 GENERATOR BACKUP SYSTEM. The
installer must provide any required power switching external to the product.

7
OPERATING THE GENERATOR BACKUP SYSTEM
Explanations in this section assume that an installer has properly mounted the 542 Generator Backup
System to the wall, connected the inlet gas source, connected the outlet to the point if use, checked for
leaks and connected power.
There are three minimum settings that must be made prior to using the 542 Generator Backup System.
1. Set Pressure Regulator
2. Set Inlet Alarm Trip Point Pressure
3. Set Outlet Setpoint Pressure
HOW IT WORKS
The 542 Generator Backup System control panel consists of a 4 digit display, 9 status lights and a
pushbutton. The display is used to display both the inlet pressure and the Generator pressure. This is
accomplished by alternating between the two pressures approximately every 3-4 seconds. There are two
indicator lights to the left of the display that identify which pressure is being displayed. They are labeled
INLET (pressure into the system) and OUTLET (pressure from the generator).
Above the 4 digit display are three indicator lights labeled “In-Use”, “Replace”, and “Ready”. The
“Replace”, and “Ready” lights provide the status of the Inlet gas source. When the “Ready” light is ON it
means that the inlet pressure is above the inlet trip point and ready for use. When the “Replace” light is
ON it means that the inlet pressure has dropped below the trip point and the inlet gas source should be
replaced. A relay is activated when the “Replace” light turns ON. The relay contacts for this relay are
brought out to the 4 pin circular connector at the bottom of the system. They are factory set as Normally
Closed (N.C.). This means that they are closed during a “normal” condition and open when the relay
activates. The “Replace” light and the Relay will turn OFF when the pressure at the inlet increases above
the inlet trip point plus the Hysteresis Value (typically 10 psi).
The “In-Use” light will light when the 542 Generator Backup System detects that the Generator pressure
has drooped below the “Setpoint”. At the same time a relay is activated when the “In-Use” light turns
ON. The relay contacts for this relay are brought out to the 4 pin circular connector at the bottom of the
system. They are factory set as Normally Closed (N.C.). This means that they are closed during a
“normal” condition and open when the relay activates. The “In-Use” light will begin to flash when the
Generator pressure builds back above the Setpoint plus the Hysteresis Value (typically 5 PSI) and the 542
Generator Backup System will shut off and allow the Generator to take over. The “In-Use” Relay will
remain active until the “Alarm Silence” pushbutton is pressed. Once pressed, the relay will shut OFF and
the “In-Use” light will stop flashing and turn OFF.
It is possible to check the Inlet Alarm Trip Point Pressure and Setpoint Pressure values at any time by
entering the “Self Test Mode”. Refer to the “Performing Test Mode” section in this manual

8
SETTING PRESURE REGULATOR
This pressure can be set without applying power. When there is no power to the system, the outlet valve
is ON allowing gas to flow.
The pressure out of the regulator must be set to match the requirements of the generator it is being
connected to and the application. To prevent drawing gas from the 542 Generator Backup System
prematurely the pressure out of the regulator must be set BELOW the primary pressure setting of the gas
generator.
Using an Allen wrench, turn the set screw on the 542 Generator Backup System regulator clockwise to
increase pressure or counterclockwise to decrease the pressure. This pressure should be set while there is
gas flowing from the unit.
Figure 3

9
SETTING ALARM TRIP POINT PRESSURE
The alarm trip pressure point for the Generator Backup System is changeable within a range from 500 PSI
to 2300 PSI. Each system has a specific alarm trip point pressure set at the factory based on the model
ordered. There are four (4) DIP switches used to set this pressure. Table 1 shows a number that each
switch represents. Each number adds 120 PSI to the trip point setting. This means that if the DIP
switches are set to a value of 8 this would equal a PSI value of 960 PSI (8 x 120). Add this value to the
minimum 500 PSI setting to yield a result of 1360 PSI.
To change the alarm trip pressure point from the factory set value, perform the following steps:
Note: In order for the DIP switches to be recognized, DIP switch SW4-1 must be OFF.
1. Turn power OFF to the system.
2. Open door by loosening the four screws holding it to the cabinet.
3. Using Figure 4, locate DIP switches SW2 at the bottom of the electronic circuit board on the
door.
Figure 4
4. Using Table 1 or Table 2, set the desired switchover pressure.
5. Close system door and tighten 4 screws holding door to cabinet.
6. Turn power back ON. The new alarm trip pressure will take effect on power ON.
Table 1 — DIP Switch Settings
SWITCH VALUE
SW2-1 120
SW2-2 240
SW2-3 480
SW2-4 960

10
Note: Tables 1 & 2 show values in PSI. If operating in BAR or MPA it will be necessary to convert
the PSI units to the units being used in order to use the tables. To convert values to BAR divide
the PSI value by 14.5. To convert the values to MPA divide the PSI value by 145.
Table 2
Typical Alarm Trip Pressure DIP Switch Settings
PSI SW2-1 SW2-2 SW2-3 SW2-4
500 OFF OFF OFF OFF
620 ON OFF OFF OFF
740 OFF ON OFF OFF
860 ON ON OFF OFF
980 OFF OFF ON OFF
1100 ON OFF ON OFF
1220 OFF ON ON OFF
1340 ON ON ON OFF
1460 OFF OFF OFF ON
1580 ON OFF OFF ON
1700 OFF ON OFF ON
1820 ON ON OFF ON
1940 OFF OFF ON ON
2060 ON OFF ON ON
2180 OFF ON ON ON
2300 ON ON ON ON

11
SETTING SETPOINT PRESSURE
The set point is the pressure at which the Generator Backup System turns on to supply gas. The set point
for the Generator Backup System is changeable up to a value of 255 PSI. Each system is set to a specific
set point pressure at the factory based on the model ordered. To change the set point pressure from the
factory value, perform the following steps:
Note: In order for the DIP switches to be recognized, DIP switch SW4-1 must be OFF.
1. Turn power OFF to the system.
2. Open door by loosening the four screws holding it to the cabinet.
3. Using Figure 5, locate DIP switch SW1 at the bottom of the electronic circuit board on the
door.
Figure 5
4. Using Table 3 or Table 4, set the desired switchover pressure.
5. Close system door and tighten 4 screws holding door to cabinet.
6. Turn power back ON. The new set point pressure will take effect on power ON.
Table 3 — DIP Switch Settings
SWITCH VALUE
SW1-1 1
SW1-2 2
SW1-3 4
SW1-4 8
SW1-5 16
SW1-6 32
SW1-7 64
SW1-8 128

12
Note: Tables 3 & 4 show values in PSI. If operating in BAR or MPA it will be necessary to convert
the PSI units to the units being used in order to use the tables. To convert values to BAR divide
the PSI value by 14.5. To convert the values to MPA divide the PSI value by 145.
Table 4 — Typical Set Point Pressure DIP Switch Settings
1 2 4 8 16 32 64 128
PSI SW1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 SW1-7 SW1-8
25 ON OFF OFF ON ON OFF OFF OFF
50 OFF ON OFF OFF ON ON OFF OFF
75 ON ON OFF ON OFF OFF ON OFF
100 OFF OFF ON OFF OFF ON ON OFF
125 ON OFF ON ON ON ON ON OFF
150 OFF ON ON
OFF ON OFF OFF ON
175 ON ON ON ON OFF ON OFF ON
200 OFF OFF OFF ON OFF OFF ON ON
225 ON OFF OFF OFF OFF ON ON ON
250 OFF ON OFF ON ON ON ON ON

13
SETTING UNITS OF MEASURE
The Generator Backup System can display pressure in three different units of measure, PSI, BAR, and
MPA. The factory default is PSI. To change units of measure perform the following steps:
Note: In order for the DIP switches to be recognized, DIP switch SW4-1 must be OFF.
1. Turn AC power OFF to the system.
2. Open door by loosening the four screws holding it to the cabinet.
3. Using Figure 6, locate DIP switch SW2 at the bottom of the electronic circuit board on the door.
4. Using Table 5, set the appropriate units of measure.
5. Close system door and tighten 4 screws holding door to cabinet.
6. Turn AC power back ON. The new units of measure will take effect on power ON.
7. The indicator lights on the front panel show the units of measure selected. If the PSI and BAR
indicator lights are OFF, the system is displaying MPA units.
Table 5
Units SW3-1 SW3-2
PSI OFF OFF
default
BAR ON OFF
MPA OFF
ON
Figure 6

14
ENABLING REMOTE SETUP
The Generator Backup System is equipped with a feature that allows setting of system parameters
remotely via the serial port or the optional Ethernet port. FACTORY DEFAULT IS ON. This feature
MUST be enabled in order for the remote setup feature to work. To disable this feature perform the
following steps:
1. Turn AC power OFF to the system.
2. Open door by loosening the four screws holding it to the cabinet.
3. Using Figure 7, locate DIP switch SW4-1 at the bottom of the electronic circuit board on the
door.
4. Using Table 6 turn SW4-1 to the OFF position.
5. Close system door and tighten 4 screws holding door to cabinet.
6. Turn AC power back ON.
Note:
When this feature is enabled, system setup parameters are saved to internal memory in the control
electronics. The DIP switches on the control board for these setup parameters will be ignored. To allow
use of the setup parameter DIP switches on the control board, SW4-1 must be in the OFF position.
Figure 7
Table 6
Function SW4-1 SW4-2
Allow
Remote ON N/A default

15
SETTING COMMUNICATION MODE
The Generator Backup System has the built in capability to communicate externally via the Ethernet
(Web Server) or an RS-232 serial port. The factory default value is Ethernet (Web Server). To change
the device from Ethernet to serial communication follow the steps below.
1. Turn AC power OFF to the system.
2. Open door by loosening the four screws holding it to the cabinet.
3. Using Figure 8, locate DIP switch SW5 at the bottom of the electronic circuit board on the door.
4. Using Table 7 set the desired communication mode.
5. Close system door and tighten 4 screws holding door to cabinet.
6. Turn AC power back ON. The new communication mode will take effect on power ON.
Figure 8
Table 7
Communication
Mode SW5-1 SW5-2
RS-232 OFF N/A
Ethernet ON N/A default

16
CONNECTING ALARM OUTPUTS
The 542 Generator Backup System provides an output signal corresponding to the low input
pressure alarm condition that it senses. This signal is brought out to a 4 pin circular connector on
the bottom of the unit. A mating 4 pin connector is provided to allow for connecting the
Generator Backup System to an external alarm. Pre-made cables are also available. Contact
your local CONCOA Distributor or call 1-800-225-0473 for information. The switch is
configured as Normally Closed (N.C.) which means that the switch opens on fault or alarm.
The recommended cable for making an output cable assembly is 22 AWG, 4-conductor stranded
wire (Alpha # 1174C or equivalent). The length of this cable should be limited to 1500 feet.
Cut the 4-conductor cable to length. Remove the outer jacket of the cable to expose
approximately 3/4 inch of the internal conductors on both sides of the cable. Strip away 1/4-inch
of the insulation on each of the conductors.
On the 4-pin connector, slide the protective cover, cable retainer, and locking nut over the end of
the cable as shown in Figure 9.
Using the pin assignments shown in Table 8 and the connector views in Figure 9 and Figure 10,
solder the wires to the appropriate pins. After soldering is complete, slide the locking nut over
the connector body. Snap the cable retainer into the body and then slide the protective cover over
the cable retainer.
Figure 9
Figure 10 Table 8— Alarm Output Pin Assignments
Alarm Output
Connector Pin Number Function
1 Inlet Alarm
2 +V (external)
3 +V (external)
4 In-Use

17
CONFIGURING ALARM RELAY JUMPER
The Generator Backup System is designed to interface to an external alarm system. A Relay contact is
brought out through a connector on the bottom of the cabinet. The pin connections on this connector are
set to connect directly to a CONCOA alarm. CONCOA alarms are designed such that the contacts are
Normally Closed (N.C.). In an alarm condition these contacts will open. This is the factory default. It is
possible to change these contacts to Normal Open (N.O.). Figure x shows the location of the jumpers on
the Control Board. To change a contact from N.C. to N.O. follow the steps below:
1. Turn AC Power OFF to the system
2. Open front door by loosening the 4 screws holding it to the cabinet.
3. Locate the jumpers on the Control Board.
4. Using Table 9 and Figure 11, set the jumpers.
5. Close door and re-secure it to the cabinet.
6. Make the necessary connections to the alarm and plug the alarm cable into the alarm connector on
the bottom of the cabinet.
7. Turn AC power ON.
8. Test Mode may be used to test the alarm installation.
Table 9
Jumper Function
J5 Alarm Output
J7 In-Use Output