Concoa IntelliSwitch 57 Series Technical specifications

ADI 9506
Medical
IntelliSwitch
Electronic
Switchover
MAINTENANCE INSTRUCTIONS
Carefully Read These Instructions Before Performing Any Maintenance
Carefully Read These
Controls Corporation of America
1501 Harpers Road • Virginia Beach, VA 23454
Telephone [phone] or 757-422-8330 • Fax [phone]
www.concoa.com January 2008
Preliminary
TM

2
CAUTION!
Persons performing installation,
maintenance and repairs to a medical gas
pipeline system must adhere to NFPA-99
requirements in the design, installation,
testing, operation and maintenance
of their piped gas system.
This includes the incorporation of
CONCOA's Medical IntelliSwitch.
Adhering to the CONCOA’s ADI does not
constitute full compliance to NFPA-99
requirements - Refer to NFPA-99 for
complete requirements.
This manual is not intended to replace or
provide complete details of NFPA-99.

3
USER RESPONSIBILITY
Service to this product should only be performed by CONCOA or an authorized CONCOA agent. Requests for service may be made
through CONCOA CUSTOMER SERVICE at 1-800-225-0473. Written requests may be made using CONCOA’s FAX number at 1-
757-422-3125 or CONCOA’s E-MAIL at [e-mail]
CONCOA accepts no responsibility for damage or injury if this product is modified in any way. CONCOA assumes/accepts no
liability or responsibility for damage to individuals or equipment that may occur when using this product.
SAFETY
THIS PRODUCT IS NOT INTENDED FOR USE WITH TOXIC GASES, FLAMMABLE GASES OR CORROSIVE GASES.
NOTICE
The Medical IntelliSwitch™ is intended for use in medical installations. This product meets NFPA-99
requirements for switchover systems. Compliance with NFPA-99 for a complete installation (ie Cylinders, piping,
alarms, etc.) are the responsibility of the installer. Refer to NFPA-99 for complete system requirements.
Basic safety precautions must be followed to reduce the risk of fire, electrical shock or injury.
•Connect the Medical IntelliSwitch™ 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.
•While the Medical IntelliSwitch™ Switchover is dust and moisture resistant, it is NOT water-proof or completely sealed. It
should be installed where it will not be subjected to rain or high concentrations of dust. Never pour or spray liquids directly
onto the product.
•Install the Medical IntelliSwitch™ 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.
•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.

4
DESCRIPTION OF PRODUCT
The Medical IntelliSwitch™ is a device used to monitor, control and switch the flow of gas from cryogenic or high pressure cylinders
from either of two independent sources to either of two independently controlled and isolated delivery regulators. In turn these
regulators are connected to a single point of use output.
It consists of two electronically controlled inlet valves controlling the flow of gas into two electronically controlled valves that in turn
direct the flow of gas into one of two delivery regulators.
Pressure coming into the Medical IntelliSwitch™ is monitored and displayed on two independent 4-digit displays. The outlet pressure
of the system is monitored and displayed on a 3-digit display. Outlet pressure adjustment is available using an adjusting screw on the
delivery regulators inside the cabinet.
A series of indicator lights show the status of the system at any given time.
The status of the Medical IntelliSwitch™ may be monitored remotely via a serial port or optional Ethernet port. In addition, the
Medical IntelliSwitch™ can interface with a CONCOA Remote Alarm.
OPERATING THE MEDICAL INTELLISWITCH™
For a detailed explanation on the proper operation of the Medical IntelliSwitch™, refer to the CONCOA instruction manual ADI
9504.
IN-SERVICE REPAIR VS REPAIR CLASSIFICATION
Some repairs and adjustments can be made to the Medical IntelliSwitch™ while it is delivering gas to downstream users – these are
refered to as in-service repairs. Others require that the Medical IntelliSwitch™ be turned off in order to perform the necessary repairs.
Throughout this manual, each section will indicate either ‘IN-SERVICE REPAIR’ or ‘REPAIR’
CAUTION: When a REPAIR is needed and the unit must be turned off to complete the necessary repairs, actions must be taken to be
able to provide gas to the downstream users.

5
Figure 1

6
IN-SERVICE ADJUSTMENTS
Resetting Inlet Regulator Pressure---------------------------------------------------------------------------------------------------------------Page 9
Resetting Delivery Regulator Pressure -------------------------------------------------------------------------------------------------------- Page 10
Performing Self Test----------------------------------------------------------------------------------------------------------------------------- Page 14
IN-SERVICE REPAIR PARTS
DELIVERY REGULATORS FOR N2O AND CO2 SERVICE:
8056763-41 ------Regulator, 55 psi delivery pressure (with Chloroprene Seat) --------------------------------------------------------- Page 33
8056767-41 ------Regulator, 100 psi delivery pressure (with Chloroprene Seat)-------------------------------------------------------- Page 33
8056769-41 ------Regulator, 180 psi delivery pressure (with Chloroprene Seat)-------------------------------------------------------- Page 33
DELIVERY REGULATORS FOR OXYGEN, HELIUM, AND NITROGEN SERVICE:
8056762-41 ------Regulator, 55 psi delivery pressure (with Viton® Seat) --------------------------------------------------------------- Page 33
8056766-41 ------Regulator, 100 psi delivery pressure (with Viton® Seat)-------------------------------------------------------------- Page 33
8056768-41 ------Regulator, 180 psi delivery pressure (with Viton® Seat)-------------------------------------------------------------- Page 33
ALARM WIRING CONNECTOR AND CABLE ASSEMBLIES:
8309170-17 ------Wiring connector for Alarm plug in bottom of the Medical IntelliSwitch® ---------------------------------------- Page 12
5295316-3--------Alarm Connector Cable Assembly, 6pin x 6pin, 3ft long
5295316-10 ------Alarm Connector Cable Assembly, 6pin x 6pin, 10ft long
5295316-25 ------Alarm Connector Cable Assembly, 6pin x 6pin, 25ft long
5295316-50 ------Alarm Connector Cable Assembly, 6pin x 6pin, 50ft long
5295316-100-----Alarm Connector Cable Assembly, 6pin x 6pin, 100ft long
SERIAL PORT WIRING CONNECTOR AND CABLE ASSEMBLY:
5295321 ----------Serial Connector Cable Assembly, 9pin x D9(female), 10ft long
GASKETS:
8350234 ----------Gasket, Inside Door - Note: Each unit requires 2 door gaskets, 570 Series
8350235 ----------Gasket, Inside Door - Note: Each unit requires 2 door gaskets, 571 Series
WIRE ROUTING COMPONENTS:
8309240-27 ------Clip, Self Adhesive Cable Routing, 1/2" Square
8309240-28 ------Clip, Self Adhesive Cable Routing, 3/4" Square
8309240-23 ------Clip, Self Adhesive Cable Routing, 1" Square
8309240-4--------Tie Wrap for 1/2" Square Clip
8309240-30 ------Tie Wrap for 3/4" Square Clip
8309240-29 ------Tie Wrap for 1" Square Clip

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REPAIR ADJUSTMENTS
Resetting Switchover Pressure ----------------------------------------------------------------------------------------------------------------- Page 19
Resetting Delivery Regulator Pressure Tolerance ------------------------------------------------------------------------------------------- Page 21
Resetting Units of Measure --------------------------------------------------------------------------------------------------------------------- Page 22
Resetting Keypad Security Lockout ----------------------------------------------------------------------------------------------------------- Page 23
Resetting Remote Alarm Outputs-------------------------------------------------------------------------------------------------------------- Page 24
Enabling Remote Setup-------------------------------------------------------------------------------------------------------------------------- Page 26
Changing AC Input Power---------------------------------------------------------------------------------------------------------------------- Page 27
Setting Communication Mode------------------------------------------------------------------------------------------------------------------ Page 29
REPAIR PARTS (REPAIR)
INLET REGULATORS FOR N2O AND CO2 SERVICE:
8056761-41 ------Regulator, for 55 psi delivery pressure units (with Chloroprene Seat)----------------------------------------------- Page 31
8056765-41 ------Regulator, for 100 psi and 180 psi delivery pressure units (with Chloroprene Seat)------------------------------- Page 31
INLET REGULATORS FOR OXYGEN, HELIUM, AND NITROGEN SERVICE:
8056760-41 ------Regulator, for 55 psi delivery pressure units (with Viton® Seat) ---------------------------------------------------- Page 31
8056764-41 ------Regulator, for 100 psi and 180 psi delivery pressure units (with Viton® Seat) ------------------------------------ Page 31
INTERNAL CABLE ASSEMBLIES:--------------------------------------------------------------------------------------------------------- Page 37
8355031 ----------Power Cord Assembly ----------------------------------------------------------------------------------------------------- Page 39
8355028 ----------Remote Alarm--------------------------------------------------------------------------------------------------------------- Page 41
8355027 ----------Serial Port-------------------------------------------------------------------------------------------------------------------- Page 42
8355030 ----------Power Cable (between fuse block and circuit board) ------------------------------------------------------------------ Page 43
8355032 ----------Ground Strap ---------------------------------------------------------------------------------------------------------------- Page 44
8355024 ----------Left Inlet Pressure Transducer, 570 series Medical IntelliSwitch®-------------------------------------------------- Page 45
8355025 ----------Right Inlet Pressure Transducer, 570 series Medical IntelliSwitch® ------------------------------------------------ Page 45
8355026 ----------Delivery Pressure Transducer, 570 series Medical IntelliSwitch®--------------------------------------------------- Page 45
8355034 ----------Left Inlet Pressure Transducer, 571 series Medical IntelliSwitch®-------------------------------------------------- Page 45
8355035 ----------Right Inlet Pressure Transducer, 571 series Medical IntelliSwitch® ------------------------------------------------ Page 45
8355036 ----------Delivery Pressure Transducer, 571 series Medical IntelliSwitch®--------------------------------------------------- Page 45
8309140-11 ------Solenoid Valves------------------------------------------------------------------------------------------------------------- Page 46
8355022 ----------Solenoid Valve Connector Cable, Delivery Regulator Valve (upper), 570 Series Only--------------------------- Page 47
8355023 ----------Solenoid Valve Connector Cable, Switch Valve (lower)-------------------------------------------------------------- Page 47
CIRCUIT BOARDS:
8355005 ----------Control Board, 570 series Medical IntelliSwitch®-------------------------------------------------------- Contact CONCOA
8355029 ----------Display Board, 570 series Medical IntelliSwitch® ------------------------------------------------------- Contact CONCOA
8355003 ----------Control Board, 571 series Medical IntelliSwitch® ------------------------------------------------------- Contact CONCOA
8355009 ----------Display Board, 571 series Medical IntelliSwitch® ------------------------------------------------------- Contact CONCOA
FUSE COMPONENTS:
8309200-2--------Fuse – Note: Each unit requires 2 fuses --------------------------------------------------------------------------------- Page 28
8309200-12 ------Fuse Holder
8309245-12 ------Screws for Fuse Holder - Note: Each unit requires 2
8309828 ----------Fuse Cover Plate
8309245-12 ------Screw for Cover Plate
8307270 ----------Label, Electrical Warning Symbol

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REPAIR PARTS (REPAIR) - Continued
ASSORTED COMPONENTS:
8309765-7--------Gasket, Solenoid Vent Bulkhead
8309765-2--------Gasket, Anti-Spin Plate - Note: Each unit requires 4
8350008 ----------Anti-Spin Plate - Note: Each unit requires 4
8309245-20 ------Screws, Anti-Spin Plate – Note: Each unit requires 8
8309170-47 ------Port Cap for Serial and Alarm Ports on bottom of unit – Note: Each unit requires 2
8350019 ----------Outlet and Relief Valve Bulkheads – Note: Each unit requires 2
835XXX----------Inlet Bulkhead / Inlet Filter Assemblies – Note: Each unit requires 2
8350094 ----------Relief Valve for 55 psi delivery pressure
8350095 ----------Relief Valve for 100 and 180 psi delivery pressure models
8305369 ----------Check Valve for N2O and CO2, 1/4", Pilot Regulator – Note: Each unit requires 2
8305383 ----------Check Valve for O2, He and N2, 1/4", Pilot Regulator – Note: Each unit requires 2
5500205 ----------Gauge, Inlet Regulator Dial
90800022---------Tubing, Red
8350282 ----------Grips, Yellow Plastic for 1/4-turn valves
8306619 ----------Tube Fitting, 1/2 NPT male x 1/2 Tube, 90° Elbow, for Delivery Regulators
5802041 ----------Relief Valve, Prior to Delivery Regulators
8350006 ----------Magnet
8350007 ----------Hex Key
8350280 ----------Label, Regulator Status
8350281 ----------Label, Valve Status
835XXXX--------Door Tether
8309246-27 ------Nut, KEPS for Door Tether – Note: Each unit requires 2
8355032 ----------Ground Strap
8309246-27 ------Nut, KEPS for Ground Strap – Note: Each unit requires 2

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RESETTING INLET REGULATOR PRESSURE (IN-SERVICE)
The Inlet Regulator Pressure is factory set based on the model purchased. If it is necessary to change the pressure of the regulators
after installation perform the following steps:
CAUTION:
Adjustment of the inlet regulators could result in reduced flow performance and malfunction of the reserve inlet
(optional) for the Medical IntelliSwitch.
1. Open door by loosening the four screws holding it to the cabinet.
2. Locate the Allen wrench attached to the inside panel.
Figure 2
3. Starting with the inlet regulator that is currently in use, place the Allen wrench into the set screw and adjust the pressure to
the desired value. The delivery pressure of the inlet regulator can be seen on the internal pressure gauges. Turning the set
screw clockwise increases pressure. Counterclockwise decreases pressure. The system will not decrease in pressure if there
is no flow. See Figure 2 for the location of the regulators.
Default Factory Settings:
Model Number
I
n
l
e
t
R
egu
l
a
t
or
S
e
t
P
o
i
n
t
(while flowing gas)
57X2XXX 155-160 PSIG
57X3XXX 240-250 PSIG
57X7XXX 240-250 PSIG
4. After setting the first inlet regulator, press the bank select button on the front panel to switch to the other bank. Repeat step 3
to set the second inlet regulator. For best performance, both inlet regulators should be set to the same pressure.

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RESETTING DELIVERY REGULATOR PRESSURE (IN-SERVICE)
The Delivery Regulator Pressure is factory set based on the model purchased. If it is necessary to change the pressure of the
regulators after installation perform the following steps:
CAUTION: Adjustment of the delivery regulators should be performed while the Medical IntelliSwitch is flowing gas. Adjustment in
a static condition (not flowing) will effect the available pressure during max flow conditions.
1. Open door by loosening the four screws holding it to the cabinet.
2. Using Figure 3, locate DIP switch SW4 at the bottom of the electronic circuit board on the door. Move SW4-4 to the
ON position. The front panel display will show a screen similar to Figure 4 indicating the system is in CALIBRATE
mode. The front panel display will show the inlet pressure from the side that it is currently drawing from.
Figure 3
3. Locate the Allen wrench attached to the inside panel.
4. There is a green light to the left or right of the delivery display that indicates which delivery regulator is in use. If the
left light is ON, the pressure being displayed in the delivery display is the output pressure of the left regulator. Similarly,
if the right green light is ON the pressure being displayed is from the right regulator.
5. Locate the Allen wrench attached to the inside panel. Starting with the delivery regulator that is currently in use, place
the Allen wrench into the set screw and adjust the pressure to the desired value. Turning the set screw clockwise
increases pressure. Counterclockwise decreases pressure. The system will not decrease in pressure if there is no flow.
See Figure 5 for the location of the regulators.
Default Factory Settings:
Model Number
D
e
li
very
R
egu
l
a
t
or
S
e
t
P
o
i
n
t
(while flowing gas)
57X2XXX 54-57 PSIG
57X3XXX 98-102 PSIG
57X7XXX 178-182 PSIG
6. After the pressure is set to the desired value, press the Output Source Pushbutton on the front panel to switch to the other
delivery regulator.
7. Place the Allen wrench into the set screw of the second regulator and adjust the pressure to the desired value.