Concoa CryoWiz User manual

1
ADI 5770-J
CryoW iz™
Liquid Nitrogen
Cryogenic Switchover
INSTALLATION AND OPERATING INSTRUCTIONS
Carefully Read These Instructions Before Operating
Controls Corporation of America
1501 Harpers Road • Virginia Beach, VA 23454
Telephone [phone] or 757-422-8330 • Fax [phone]
www.concoa.com

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Table of Contents
Safety .................................................................................................................. 4
User Responsibility ..................................................................................................................... 6
Description of Product ........................................................................................ 6
Features – Operation from Cyrogenic Liquid Nitrogen Sources ........................................... 6
Features – High Flow Cryogenic Valves ................................................................................... 6
Features – Compact Enclosure with Condensate Drain ......................................................... 6
Features – Insulated Switching Mechanism............................................................................. 6
Features – Switchover ................................................................................................................ 6
Features – Oxygen Deficiency Monitor Input........................................................................... 7
Features – Manual Bank Switching ........................................................................................... 7
Features – Purging ...................................................................................................................... 7
Features – Units of Measure....................................................................................................... 7
Features – Security Lockout ...................................................................................................... 7
Features – Alarm Notification .................................................................................................... 7
Features – Ethernet Port / Web Server...................................................................................... 7
Features – USB Port .................................................................................................................... 7
Features – Relief Valve Overpressure Protection ................................................................... 7
Modes of Operation – On Demand Mode & Display When in On Demand Mode...............8
Modes of Operation – Keep Full Mode & Display When in Keep Full Mode.....................10
Installing the CryoWiz™ .......................................................................................................11
General Arrangement ...........................................................................................................11
Left Side Detail ......................................................................................................................12
Right Side Detail ...................................................................................................................13
Back Detail Showing Mounting Tabs ..................................................................................14
Connecting Inlets and Outlets .............................................................................................15
Installing Pipe Thread Connections ....................................................................................15
Connecting the Condensation Drain Line...........................................................................15
Connecting the Dry Nitrogen Line.......................................................................................15
Connecting the Relief Valve Vent Line................................................................................16
Connecting the Hot Gas Purge Vent Line...........................................................................16
Connecting an Oxygen Deficiency Monitor ........................................................................17
Connecting a Remote Alarm ................................................................................................18
DIP Switches .........................................................................................................................19
SW2-1 - Keypad Lockout......................................................................................................20
SW3-1 - Alarm Configuration ...............................................................................................20
SW3-2 – Audible Alarm On/Off.............................................................................................20
Setting Remote Alarm Outputs............................................................................................21
Installing Real Time Clock Backup Batteries .....................................................................22
Connecting Power ................................................................................................................23
CryoWiz ™ Startup ................................................................................................................23
Operating the CryoWiz™ .......................................................................................................... 24
Alarm Conditions ....................................................................................................................... 25
Communication Mode ............................................................................................................... 26
Connecting the Web Server ..................................................................................................... 26
Power Requirements ........................................................................................... 26
Service............................................................................................................... 26
Factory Default Settings....................................................................................... 26
CE Declaration of Conformity................................................................................ 28
Warranty...................................................................................................................................... 29

SAFETY
Handling Liquid Nitrogen
Nitrogen is a colorless, odorless, and tasteless gas. Liquid nitrogen (LN2) is a potential asphyxiate and may
cause severe frostbite. Please observe all proper safety precautions to ensure proper handling of LN2.
Consult your local LN2 dealer for detailed handling instructions.
Cryogenic liquid containers (dewars) must be operated in accordance with the manufacturer’s instructions.
Dewars must be kept in a well-ventilated space where they are protected from the weather and are away from
any sources of heat.
Nitrogen is a potential asphyxiate and can cause rapid suffocation without warning. Store and use it in area
with adequate ventilation. DO NOT vent the container or system in confined spaces. DO NOT enter confined
spaces where gas may be present unless the area has been well ventilated. If inhaled, remove to fresh air. If
not breathing, give artificial respiration. If breathing is difficult, supplemental oxygen may be required. SEEK
MEDICAL ATTENTION IMMEDIATELY.
LN2 can cause severe frostbite to the eyes or skin. DO NOT touch frosted pipes, hose assemblies or valves. In
case of frostbite, consult a physician at once. If a physician is not readily available, warm the affected areas
with water that is near body temperature.
Never place LN2 in a sealed container without a pressure relief device. The expansion of LN2 to N2 gas is
approximately 1 to 700. When handling LN2, the most important safety aspects to consider are adequate
ventilation and eye and skin protection. Although nitrogen gas is non-toxic, it is dangerous in that the gas will
displace the oxygen in ambient air. Therefore, it is imperative that cryogenic supply and storage dewars be
stored and operated in open and well-ventilated areas. Oxygen Deficiency Monitoring Equipment should be
used in areas where use of LN2 poses the risk of creating an oxygen deficient atmosphere. Never enter a space
where oxygen deficiency is detected.
Persons transferring LN2 should make every effort to protect the eyes and skin from accidental contact with liquid
or cold gas. Protect the eyes with a full-face shield. Safety glasses are not adequate. Always wear cryogenic
gloves or equivalent when handling anything that is or may have been in contact with the liquid, cold gas, cold
pipes, or cold equipment. Long sleeve shirts and trousers without cuffs that are of sufficient length to prevent
liquid from entering the shoes are recommended.
Notice
The CryoWiz™ is intended for low pressure 22 to 35 PSIG Cryogenic Liquid Nitrogen Applications

Basic safety precautions must be followed to reduce the risk of fire, electrical shock, or injury.
• Connect the CryoWiz™ wall transformer to a 120 VAC or 220 VAC electrical outlet (see “Power
Requirements” section). CONNECTION TO AN INCORRECT VOLTAGE CAN CAUSE SERIOUS DAMAGE
TO THE PRODUCT AND WILL VOID ANY WARRANTY.
• Install the CryoWiz™ where the ambient temperature range is between 0° F and 140° F.
• Do not connect to cryogenic liquid sources lower than 22 PSIG or higher than 35 PSIG.
• Do not install this product in a hazardous environment.
• If product appears damaged in any way, do not use and request service from CONCOA.
• Connect system purge and relief valve outlets to appropriately sized piping to an exterior unobstructed
vent.
• Consult your local LN2 Dealer for detailed handling instructions. Always open valves slowly when being
used.
• Use appropriate protective equipment.
• 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 close all cylinder valves before disconnecting cylinders from a manifold.
• Always remove all empty cylinders from a manifold before connecting full cylinders.
• Always check 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 Society of Mechanical Engineers ASME B31.3 Process Piping; ASME Three Park Avenue
2. New York, NY 10016-5990
3. Local Ordinances
4. O.S.H.A. Standard 29 CFR
5. C.G.A. Pamphlet C-4, American National Standard Method of Marking Portable Compressed Gas
Containers to Identify the Material Contained.
6. C.G.A. Pamphlet G-4.1, Equipment Cleaned for oxygen service.
7. C.G.A. Pamphlet P-12, Safe Handling of Cryogenic Liquids.
8. 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, and [phone]. Publications: [phone]. Fax: [phone]

USER RESPONSIBILITY
Service and Installation of this product should only be performed by CONCOA or an authorized CONCOA
Service Center technician having extensive knowledge of cryogenic LN2 installations and systems. Requests
for service may be made using the following methods of contact:
CUSTOMER SERVICE: 1-800-225-0473
CONCOA’s FAX: [phone]
CONCOA’s E-MAIL: [email protected]
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.
DESCRIPTION OF PRODUCT
The CryoWiz™ is a cryogenic switchover used to monitor, control, and switch the flow of cryogenic liquid
nitrogen (LN2) from two independent banks while maintaining an uninterrupted supply.
It consists of four electronically controlled pneumatic valves, two of which are the inlet valves that control the
flow of cryogenic LN2 to the outlet on the bottom of the device. The other two are purge valves that will divert
hot gas upward through fittings on the top of the device, away from the outlet.
The CryoWiz™ monitors LN2 supply and demand using a proprietary computer algorithm to deliver an
uninterrupted supply of LN2 to the outlet of the device.
The status of the CryoWiz™ may be monitored remotely via the Ethernet port. A series of indicator lights
shows the status of the system at any given time. In addition, the CryoWiz™ can interface with a CONCOA
or other remote alarm.
The failsafe position of all valves is Normally Closed (N.C.). A power outage, a cessation of the dry nitrogen gas
supplytothe pneumatic valves, or an oxygen deficiency alert relayed to the CryoWiz™ will result in shutoff of the
LN2 supply and the purge outlets.
FEATURES
Operation from Cryogenic Liquid Nitrogen Sources
LN2 dewars provide the Cryowiz™ with an inlet pressure of 22 to 35 PSI. LN2 sources above 35 PSI are not
recommended. Pressures above 35 PSI will result in increased liquid wastage caused by increased flashing.
Each LN2 source bank may be composed of an individual dewar or multiple dewars connected via an
appropriate pipeline or manifold.
High Flow Cryogenic Valves
The CryoWiz™ uses high flow cryogenic valves. The cryogenic valves deliver an optimal supply of LN2 to the
outlet with minimal disturbance in flow and virtually no heat transfer.
Compact Enclosure with Condensate Drain
The entire system is encased in a compact enclosure with limited wall space and with a condensate drain
to eliminate moisture build-up.
Insulated Switching Mechanism
The Insulated Pneumatic Valve Block minimizes heat transfer, reduces condensation, and ensures optimal
delivery of LN2

Switchover
Depletion of the primary LN2 supply is detected when low dewar pressure is observed or when a purge to
reach the threshold temperature has timed out. The CryoWiz™ automatically switches to the reserve bank
and maintains an uninterrupted LN2 supply. The CryoWiz™ will alarm audibly, indicate “ALARM” with a red
light on the front graphic, indicate “REPLACE” with a red light for the depleted side on the front graphic,
send an electronic signal to a remote alarm if one is connected, and switch to the reserve supply side.
Oxygen Deficiency Monitor Input
It is recommended that an output from an oxygen deficiency monitor be permanently connected to the
CryoWiz™ for a safe and correct installation. The CryoWiz™ comes with a terminal strip under a cover on
the left side of the enclosure to which the output contact from an oxygen deficiency monitor can be
connected. When the oxygen deficiency monitor relay contact is broken, the red “O2” “ALERTS” light on the
front graphic will illuminate, and the system will shut down until the alarm condition has been cleared (see
section “Connecting an Oxygen Deficiency Monitor”).
Manual Bank Switching
It is possible to manually change the side from which LN2 is being drawn: press the “SOURCE” button on the
front graphic. Switching will occur only if there is a sufficient LN2 supply on the reserve side.
Purging
The CryoWiz™ will automatically purge hot gas as needed to reach the desired temperature threshold for liquid
delivery. Manual purging is possible by pushing and holding the “LEFT PURGE” or “RIGHT PURGE” button on
the front graphic. The system will purge as long as the button is held.
Units of Measure
The units of measure for the CryoWiz™ are Celsius and PSI. They are not changeable. The displays of the
units are available thru the Web Server.
Security Lockout
The CryoWiz™ has the ability to electronically lock-out the front panel buttons to discourage tampering.
The factory default setting is OFF or disabled for this feature (see “Keypad Lockout” section for details).
Alarm Notification
The CryoWiz™ has a local audible and visual alarm for 5 conditions: 1) left bank depleted; 2) right bank
depleted; 3) pneumatic supply pressure low; 4) cryogenic valve frozen; 5) oxygen deficiency relayed from a
separate oxygen deficiency monitor. The CryoWiz™ is designed to interface with CONCOA remote alarms
(e.g., CONCOA Altos 2 Alarm 5750025-01-000 or CONCOA Advantium 16 Alarm 5750164-01-000). The
normally closed dry contact output from the CryoWiz™ can be configured as five individual alarms or a single
alarm contact. Refer to the alarm instruction manual for wiring instructions (CONCOA instruction manual
99060025 [ADI0025] for the Altos 2 alarm, instruction manual 99069531 [ADI9531] for the Advantium 16
alarm). Note that because the Altos 2 alarm supports a maximum of 2 inputs, it would normally be configured
to detect the left and right bank alarms only or the master alarm. The Advantium 16 supports a maximum of
16 inputs, and can handle all 5 CryoWiz™ alarms independently.
Ethernet Port / Web Server
The CryoWiz™ is equipped with an integral Web Server enabling remote monitoring of functions,
E-mail alerts, and remote configuration. For more information on the Web Server feature, refer to the web
server instruction manual included with the CryoWiz™ (CONCOA manual 99065774 [ADI5774]).
USB Port
The USB port should only be used by factory trained and authorized CONCOA Service Center technicians
during factory warranty installations and system configuration.
Relief Valve Overpressure Protection
The CryoWiz™ is equipped with three 50 PSI cryogenic relief valves. The relief valves will protect the system
from pressure increases that may occur from the vaporization of trapped cryogenic liquid during operation.

MODES OF OPERATION
On Demand Mode
In ON DEMAND mode, the CryoWiz™ supplies LN2 based on the demand for LN2. In this mode, the
primary source inlet valve is maintained in the open position, flow being controlled by the connected
device downstream of the CryoWiz™. The reserve source valve is maintained in the closed position.
LN2 will flow when a valve on the connected device opens and allows LN2 to flow into the device. By
monitoring the outlet pressure, the primary inlet LN2 temperature, and the amount of time the device is
requesting LN2, the CryoWiz™ determines if the device is performing a quick chill, a defog, or is
actually requiring a fill cycle.
If the CryoWiz™ determines that a fill cycle is required, the primary side purge valve will open,
allowing purge gas to flow through the vent connection at the top of the enclosure. This results in a
quick drop to the user-settable threshold temperature, and maximization of liquid flow.
If the CryoWiz™ determines that a quick chill, defog, or other temporary demand is required, the
purge valve remains closed, and a purge is not performed, thus minimizing LN2 usage.
Display When in On Demand Mode
When configured for ON DEMAND mode, a green light indicating ON DEMAND will illuminate.
The side selected to be primary will be indicated by a green SELECTED light. Upon startup, the
CryoWiz™ will default to LEFT side primary.
Each side that is sensed to be connected to a liquid supply source will have an illuminated LIQUID
light. If the LIQUID light is yellow, that means the temperature at the source inlet valve is above the
temperature optimal for liquid delivery (the threshold temperature). A green LIQUID light indicates that
the threshold temperature has been reached, and conditions are optimal for liquid delivery.
When demand for a fill cycle is sensed, the green FILLING light will blink for a period of time and then
illuminate, and the user-settable defog timer will begin (this will not happen for a quick chill or defog).

After the set time has expired, if the liquid temperature at the primary inlet valve has not reached the
threshold temperature, a purge will begin. The selected bank’s PURGE light will illuminate, and the
CryoWiz™ will purge hot gas from the primary inlet.
When the CryoWiz™ detects that the threshold temperature has been reached, the LIQUID light will
turn green.
The purge valve will remain open and the PURGE light will remain on for a period of 15 seconds
after the LIQUID light has changed to green.
When the CryoWiz™ senses that demand for liquid has ceased, the FILLING light will extinguish, and
the temperature at the source valve will rise above the threshold temperature causing the LIQUID light
to change from green to yellow.
If during a purge cycle the threshold temperature for the primary side is not reached in a specific
period of time, the LIQUID light will be extinguished, the red REPLACE light will illuminate, and the
audible alarm will sound. The green SELECTED light will switch to the reserve side, indicating that
the CryoWiz™ has switched to supplying liquid from the reserve side. If the temperature at the
reserve side source valve is above the threshold temperature, the reserve side will be purged,
indicated by the purge light being illuminated until the threshold temperature is reached.
When the empty dewars are removed from the depleted side and full dewars are connected with
their valves opened, the RESET button on the front graphic must be pushed. The CryoWiz™ will
then detect the new source, turn on the LIQUID light for the replenished side, extinguish the
REPLACE light, and cut off the audible alarm.

Keep Full Mode
In KEEP FULL mode, the CryoWiz™ maintains the primary source valve in the open condition and
the reserve source valve in the closed position. In KEEP FULL mode, the system will purge the
primary and reserve inlets when necessary to maintain liquid at both source valves. This ensures that
liquid is instantaneously available from either side should there be a demand for it. When the
CryoWiz™ senses that liquid is no longer present at the primary inlet; it will automatically switch to the
reserve source and continue delivering LN2 to the outlet. In a high demand or continual use
application, the amount of LN2 consumed by purging will be minimal relative to that used to supply
the demand. It is recommended that in this mode, vacuum jacked (VJ) supply hoses and vacuum
jacketed downstream piping be used to minimize heat transfer and product loss. KEEP FULL mode is
not recommended for installations where demand is sporadic, as the automatic purging may lead to
excessive product loss.
Display When in Keep Full Mode
When configured for KEEP FULL mode, a green light indicating KEEP FULL and a green light for
FILLING will illuminate. The FILLING light will blink for a period of time before illuminating
continuously. The side selected to be primary will be indicated by a green SELECTED light. The
reserve side SELECTED light will remain off. If the CryoWiz™ senses liquid at the source valves
on both sides, the primary and reserve LIQUID lights will be illuminated green.
If liquid is not sensed at a source valve, the LIQUID light will illuminate yellow and the PURGE light
will illuminate green until the system has purged hot gas from that side. When the CryoWiz™ senses
that liquid has returned at the source valve, the LIQUID light will turn green and the PURGE light will
turn off. For short periods of time during normal operation, the purge light on either side may
illuminate indicating that the purge valve on that side has opened to expel hot gas and maintain
continuous liquid supply. The LIQUID lights will switch from green to yellow during purging.
During a purge, if liquid does not return to the source valve on the selected side within a specified
period of time (referred to as the PURGE TIMEOUT), the selected side LIQUID light will be
extinguished, the red REPLACE light will illuminate, and the audible alarm will sound. The
CryoWiz™ will switch to the reserve side, close the depleted side source valve, and open the
reserve side source valve. The reserve side SELECTED light will illuminate. If liquid is not detected
at the reserve side source valve, the reserve side purge light will remain on until liquid is detected. At
that point, the reserve side LIQUID light will turn from yellow to green, and the purge light will turn
off.
When the empty dewars are removed from the depleted side and full dewars are connected with
their valves opened, the RESET button on the front graphic must be pushed. The CryoWiz™ will
then detect the new source, turn on the LIQUID light for it, extinguish the REPLACE light, and cut
off the audible alarm.