Concoa 529 Series User manual

ADI 5135-D
Protocol Station
Remote Alarm
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
INSTALLATION AND OPERATING INSTRUCTIONS
Carefully Read These Instructions Before Operating
June 2005
Supercedes March 2004
®
Certied ISO 9001:2000
529 5135-01-120
529 5135-01-220

THIS PAGE INTENTIONALLY LEFT BLANK

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PART NUMBERS
529 5135-01-120 Protocol Station Remote Alarm 120 VAC version
529 5135-01-220 Protocol Station Remote Alarm 220 VAC version
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 [email protected].
CONCOA accepts no responsibility for damage or injury if this product is modied in any way.
CONCOA assumes/accepts no liability or responsibility for damage to individuals or equipment that may occur
when using this product.
INTENDED USE OF PRODUCT
The Protocol Station Remote Alarm is used to monitor and report the status of inlet pressure on Protocol Stations.
The Alarm can be congured to operate with either normally open or normally closed pressure switch contacts.
The Alarm contains a set of relay contacts that can be used to control any device that can be activated using a
normally open or normally closed switch. One example of such a device would be the CONCOA telephone
dialer (PN 5295306).
Connections to the Alarm are made through input and output connectors. Customer supplied cables are easily
soldered to the connectors prior to plugging the connectors into the Alarm. For connector pin assignments
please refer to the “CONNECTING THE ALARM” section of this manual.
GENERAL SAFETY PRACTICES
Basic safety precautions must be followed to reduce the risk of re, electrical shock or injury.
a. Connect the Alarm to the correct line voltage. The product is supplied with either a 120 VAC or
220VAC wall mount power supply.
b. While the Alarm is dust and moisture resistant, it should be installed in a location where it will not
be subjected to rain or high concentrations of dust. Never pour or spray liquids directly onto the
product.
c. Install the Alarm where the ambient temperature range while operating is between 0°F and 140°F.
d. Do not install the product in hazardous locations.
e. If product appears damaged in any way, do not use and request service from CONCOA.
f. Do not attempt to operate the Alarm with the cover off.
DESCRIPTION OF PRODUCT
The Protocol Station Remote Alarm is capable of operating at either 120VAC or 220VAC depending on which
wall mount power supply it was ordered with. It is capable of providing operating status for a bank tanks for
one CONCOA protocol system. The Protocol Station Remote Alarm provides power to operate the pressure
switches.
A protocol product that is congured with the alarm option is equipped with one pressure switch gauge. A
pressure switch gauge is used to monitor and report the state of the pressure for the Protocol System.

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Audible Alarm Silence
Protocol Station Output
Relay Contact Output
Audible Alarm
Power Jack
Red “Alarm” Indicators
Green “Normal” Indicators
Figure 1
The front panel of the Alarm consists of two (2) status indicator lights, an “Alarm Silence” button, and an
audible Alarm. See Figure 1. In addition to the front panel, the left side of the Remote Alarm has a power jack
connector where the power supply cable is connected. At the bottom of the Alarm are two (2) connectors where
the Protocol Station and Output Devices are connected.
The Protocol Station Remote Alarm controls one (1) set of relay contacts that are brought to the Output Connector
so they may be used to control an external device.
When a system is operating normally the status indicator light will be green. If the pressure should drop below
the preset value of the Protocol Station, the audible alarm will sound and the light will turn from green to red.
When this happens, the output relay will activate. It is sometimes desirable to silence the audible alarm prior to
the alarm condition being xed. Pressing the “Silence” button will accomplish this. The status indicator lights
and the relays will remain activated until the alarm condition is corrected.
Correcting the low pressure condition will return the status lights back to green and de-activate the relay.

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CONNECTING THE ALARM
To connect the Protocol Station Remote Alarm to a Protocol Station, an interface cable must be made. The
Protocol Stations are shipped with a connector that is used for this cable. Two connectors are provided with the
alarm. One is used to connect to the Protocol Station and the other is to connect to the output relay contacts.
To perform the assembly task you will need a soldering station or pencil, rosin core solder, and a wire stripper.
It would also be helpful to have a vise to hold a connector while soldering the wires to it.
OPTION 1: For Protocol Stations that have a 6 pin circular connector.
It will be necessary to obtain a 6 conductor cable. The length of the cable is determined by the application,
but should be limited to no longer than 1500 feet. It is recommended that 22 AWG stranded wire be
used. (Alpha #5006C is an acceptable type.)
Cut the 6 conductor cable to length. Remove the outer jacket of the cable to expose approximately 1
inches of the internal conductors. Strip away  inch of the insulation on each of the 6 conductors. Tin
the leads of the conductors. Slide the protective cover, cable retainer, and locking nut for the circular
connector over one end of the cable as shown in Figure 2.
Table 1
SYSTEM
Protocol
Station
Pin#
Remote Alarm
Connector
Pin #
Function
RIGHT BANK 4 4 RBSW status
5 5 alarm
3 3 +12
6 6 Gnd
notch
Figure 3 - View A-A
Figure 2
A
A
Cable Retainer
Cable Retainer Tabs
Cable Cover Plug
Locking Nut
Connector pins (Figure 6 viewed
from this side

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OPTION 1 (continued)
Using the pin assignments shown in Table 1 and the connector view in Figure 3, solder the wires to the
appropriate pins. After soldering is complete attache the cable cover, cable retainer, and locking nut to
each of the circular connector plugs.
Plug the one side of the cable into the Remote Alarm and secure it by turning the locking nut until it
locks. Plug the other circular connector into the Protocol Station securing it by turning the locking
nut until it locks.
OPTION 2: For Protocol Stations that have a 4 pin circular connector.
It will be necessary to obtain a 4 conductor cable. The length of the cable is determined by the application
but should be limited to no longer than 1500 feet. It is recommended that 22 AWG stranded wire be
used. (Alpha #5004C is an acceptable type.)
Cut the 4 conductor cable to length. Remove the outer jacket of the cable to expose approximately 1
inches of the internal conductors. Strip away  inch of the insulation on each of the 4 conductors. Tin
the leads of the conductors. Slide the protective cover, cable retainer, and locking nut for the circular
connector over one end of the cable as shown in Figure 4.
SYSTEM Protocol Station
Pin #
Remote Alarm
Connector Pin # Function
RIGHT BANK 2 4 RBSW status
--- --- alarm
1 3 +12
4 6 Gnd
Table 2
notch
notch
Figure 5 - View A-A Figure 6 - View A-A
Figure 4
Cable Retainer Tabs
Cable Cover Cable Retainer Locking Nut Plug
Connector pins (Figures 3 and 4)
viewed from this side

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Figure 8 - View A-A
OPTION 2 (continued)
Using the pin assignments shown in Table 2 and the connector views in Figure 5 and Figure 6, solder
the wires to the appropriate pins. After soldering is complete attach the cable cover, cable retainer, and
locking nut to each of the circular connector plugs.
Plug the Input Connector side of the cable (6 pin connector) into the Remote Alarm and secure it
by turning the locking nut until it locks. Plug the 4 pin circular connector into the Protocol Station
securing it by turning the locking nut until it locks.
CONNECTING THE OUTPUT
The Protocol Station Remote Alarm activates a set of relay contacts in response to an alarm condition. This set
of relay contacts can be connected to any external device that is activated by the opening or closing of a switch.
Examples would be CONCOA’s telephone dialer, a Warning Light, an external buzzer, or another monitoring
or alarm system. Whatever the connecting device, care must be taken not exceed the rating of the relay contacts
(Table 3). Refer to Table 4 for the pin assignments for the Output Connector.
Relay Contact Rating
24 VDC 1 amp Resistive Load
115 VAC 0.5 amp Resistive Load
Table 3
Pin Number Function Contact
1
Relay Output
Common (C)
2 Normally Closed (N.C.)
3 Normally Open (N.O.)
4 Unused
Table 4
Figure 7
Cable Retainer Tabs
Cable Cover Cable Retainer Locking Nut Plug
Connector pins (Figure 8 viewed
from this side
notch

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CONFIGURING THE REMOTE ALARM
The Protocol Station Remote Alarm can be congured to allow connection to either Normally Open (N.O.) or
Normally Closed (N.C.) pressure switches.
Setting the Alarm for Normally Open or Normally Closed Pressure Switches
The Protocol Station Alarm is factory set to operate with Normally Open (N.O.) pressure switches. By denition,
a Normally Open (N.O.) pressure switch is one whose contacts are "open" when the pressure switch gauge
needle is below the trip point. To congure the alarm to operate with Normally Closed (N.C.) pressure switches
perform the following steps:
1. Unplug the power plug from the Remote Alarm power jack.
2. It is best to set the unit on a at surface face down. Remove the four (4) screws that hold the back
cover on and set the cover aside.
3. Locate the 4 position DIP switch array and then using a stylus or small screwdriver, open and close the
DIP switches according to Table 5A, 5B and Figure 9.
5. Place the back cover back onto the base and tighten the screws.
6. Reconnect the power plug into the power jack and plug the unit in.
DIP Switch Factory Default
Settings
1 Open
2 Close
3 Close
4 Close
Table 5A
Settings for Normally Closed (N.C.) Operation
*OFF = Open, ON = Closed
DIP Switch Factory Default
Settings
1 Close
2 Open
3 Open
4 Close
Table 5B
Settings for Normally Open (N.O.) Operation
(default)
*OFF = Open, ON = Closed
Figure 9

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TROUBLESHOOTING
Symptom Cause
Unit is plugged in but no lights are lighting on the
Alarm
1. Check to see that there is power at the source.
2. Check that cable to Protocol Station is plugged
in.
3. If the Alarm has been re-congured from the
factory settings, check that the DIP switches
were properly set. Refer to "Conguring the
Remote Alarm" section of the manual.
Unit is plugged in, red alarm light(s) are ON but
the gauge on the Protocol Station is above the alarm
pressure.
1. Check to see that the cable running between the
alarm and the Protocol Station is properly wired.
Audible Alarm begins to sound as soon as power is
turned ON.
1. Check that the Protocol Station Connector is
plugged in properly.
2. Check that the cable between the Protocol
Station and Alarm is not cut or pinched
somewhere.
3. Check to see that all the wires in the cable are
properly soldered to the connectors.
Output does not appear to be functioning. 1. Check the cable to the output device to be sure
it is properly connected.
2. Check the Output Connector to be sure it is
properly plugged into the Alarm.
3. Check the external output device to make sure it
is functioning properly.
SERVICE
Service by a factory authorized facility should be done if an Alarm becomes inoperative and troubleshooting has
not isolated the problem. Contact CONCOA Customer Service at 1-800-225-0473 for assistance.
If advised to return the unit for service you should:
1. Package the Alarm to prevent damage in shipping. If possible, use the original shipping materials.
2. Ship the unit back pre-paid.
3. Make sure the RMA number appears on the packaging and inside the package.
4. Include an explanation of the problem you encountered.

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Figure 10
Velcro
Mounting Strips
MOUNTING DETAIL
ELECTRICAL SPECIFICATIONS
Protocol Station Remote Alarm:
120 Volt Version 120 Volts A10%, 50-60 hz., 6VA
220 Volt Version 220 Volts A10%, 50-60 hz., 6VA
Fuses:
Internal - Resettable Polyfuse

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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 merchan-
dise 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 workman-
ship 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 in-
structions 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 COR-
PORATION 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 NEGLI-
GENCE, BREACH OF WARRANTY OR OTHERWISE.
THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE WAR-
RANTIES 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.

Product Serial Number:
PACKING LIST
ADI 5135-D
Certied ISO 9001:2000
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
Qty Part Number Description
1 . . . . 5295135-01-120 . . . ASSY, 120 VAC PROTOCOL STATION REMOTE ALARM
1 . . . . 5295135-01-220 . . . ASSY, 220 VAC PROTOCOL STATION REMOTE ALARM
INCLUDES:
1 . . . . 5295135 . . . . . . . . . PROTOCOL STATION REMOTE ALARM
1 . . . . 8309210-3 . . . . . . . . POWER SUPPLY, 120 VAC
1 . . . . 8309210-2 . . . . . . . . POWER SUPPLY, 220 VAC
1 . . . . 8309170-22 . . . . . . . CONN, 4 PIN SOC FEMALE (OUTPUT)
1 . . . . 8309170-17 . . . . . . . CONN, 6 PIN SOC FEMALE (INPUT)
1 . . . . 99065135 . . . . . . . . INSTRUCTION MANUAL, REMOTE ALARM