Concoa 452 Series Installation And Operation Instructions Manual

Certified ISO 9001

452 Series

99060452E

Vaporizing

Regulator

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

September 2015

Supersedes April 2012

THIS PAGE INTENTIONALLY LEFT BLANK

-2-

DESCRIPTION OF PRODUCT

This single-stage pressure regulator is equipped with a heating element intended to vaporize a liquid
sample and maintain it in the gaseous state for chromatographic analysis. Further it provides a
positive heat source to prevent freeze up of the regulator. This product is designed for use in explosive
atmospheres. It is intended for above ground use and is moisture resistant. For more information
refer to the Section “Certifications and Compliances” in this manual.

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. It is the responsibility of the user to determine the suitability of this
product for the gas service and application. It is also the responsibility of the user to install this product
in accordance with National Electrical Codes and any local ordinances.

This equipment must be checked periodically. Improperly working equipment should not be used.
Parts that are broken, missing, worn, or distorted should be replaced immediately. 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 serviced
facility designated by CONCOA.

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.

CUSTOMER ASSISTANCE

In the event of equipment failure, call the CONCOA Customer Assistance Line: 1-800-225-0473; FAX:
757-422-3125; E-mail: [e-mail]. Please be prepared to provide the model number and serial
number of the equipment involved, in addition to some details regarding its application. This would
include inlet and outlet pressures, flow rate, environmental conditions, and gas service.

GENERAL SAFETY PRACTICES

Basic safety precautions must be followed to reduce the risk of fire, electrical shock, and injury.

Connect the Vaporizing Regulator to the correct line voltage. The product nameplate identifies
what voltage it is wired for.

SERIOUS DAMAGE TO THE PRODUCT AND WILL VOID ANY WARRANTY.

PRODUCT OPERATES AT HIGH TEMPERATURES. DO NOT TOUCH WHEN ON. ALLOW
SUFFICIENT TIME TO COOL BEFORE HANDLING.
Do not use in areas where large amounts of dust are present.
If product appears damaged in any way, do not use and request service from CONCOA.
Do not attempt to operate the Vaporizing Regulator with the electrical box cover off.
Comply with precautions listed in C.G.A. Pamphlet P-1, Safe Handling of Compressed Gases
in Containers.

CONNECTION TO AN INCORRECT VOLTAGE CAN CAUSE

-3-

Never use an open flame when leak testing.
Always open valves slowly when high-pressure gases are being used.
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.

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. Local Ordinances

2. O.S.H.A. Standard 29 CFR

3. C.G.A. Pamphlet C-4, American national Standard Method of Marking Portable Compressed
Gas Containers to Identify the material Contained.

4. C.G.A. Pamphlet C-4.1, Equipment Cleaned for oxygen service.

5. C.G.A. Pamphlet G-4.4, Industrial Practices for Gaseous Oxygen Transmission and Distribution
Piping Systems.

6. C.G.A. Pamphlet G-5, Hydrogen - Information on the properties, manufacture, transportation,
storage, handling, and use of hydrogen.

7. C.G.A. Pamphlet P-1, Safe handling of Compressed Gases in Containers.

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, VA22202-3239, [phone]. Publications: [phone]. Fax: [phone].

PRESSURE
ADJUSTMENT

HOLE PLUG

(UNDER

ACORN NUT)

SOURCE
POWER
INLET

FIND
VOLTAGE
HERE

COVER

R12

R13

J15

R6

R16

R15

J17

R17

R7

U3

R8

R11

C4

R4

L1

L2

G

CONT. DUTY

0359

10

J16

R5

C2

C5

+

J1

C1

+

U1

###°

T1

Q1

###°

###V

J3

SN:YOC:

Tamb -20° to 60°C

x

E

J2

D1

830 9442-#

E

T

N

I

C US

L

I

S

Intertek

3068692

II 2 G Ex d IIC T# Gb
ITS05ATEX13688

R9

R3

R1

U2

D2

C3

J13

J14

TR:

1 Ø VAC (50-60 HZ) W

Ex d IIC T#, CL I, DIV 1, Grp A-D
Certified to CAN/CSA E60079-0
& E60079-1
Conforms to UL-1203

CONTROLS CORP OF AMERICA

VIRGINIA BEACH, VA MADE IN USA
MAXIMUM INLET: 3300 PSI (230 BAR)
CAUTION: READ INSTRUCTIONS

BEFORE USE

WARNING: EXTERNAL SURFACES

R

T

E

K

CM

D

E

T

MAY BE EXTREMELY HOT!

ATTENTION: LISEZ LES INSTRUCTIONS

AVANT L'EMPLOI

AVERTISSEMENT: LES SURFACES

EXTERNES PEUVENT
ÊTRE EXTRÊMEMENT
CHAUDES!

T1, T3, & T4 Models Available

SET SCREW

1/4" NPT
LOW
PRESSURE
OUTLET

1/8" NPT
INLET

Figure 1 - Vaporizing Regulator Assembly

-4-

INSTALLATION OF ELECTRICAL CONNECTIONS

THE SELECTION, AND USE OF CONDUIT, FLEXIBLE TUBING OR ARMORED CABLE IS THE
RESPONSIBILITY OF THE INSTALLER. PROPER CARE MUST BE TAKEN WHEN CONNECTING
THE DEVICE TO ELECTRICAL POWER WHERE THE DEVICE WILL BE USED IN AN EXPLOSIVE
ATMOSPHERE OR WITH COMBUSTIBLE GASES.

THE INSTALLER MUST FOLLOW ALL APPROPRIATE NATIONALAND LOCAL ELECTRICALCODES
WHEN CONNECTING THIS DEVICE TO ELECTRICAL POWER. SPECIAL ATTENTION MUST BE
PAID TO THE INSTALLATION OF THIS DEVICE WHEN USED IN EXPLOSIVE ATMOSPHERES.

L1: Black or

Brown Wire

Figure 2 - Source Power Connections

L2: White or

Blue Wire

Ground: Green or

Green/Yellow Wire

R12

R13

J15

R16

R15

R9

R3

R1

R17

R7

U3

R8

R11

U2

D2

C3

J13

J14

R4

G

R6

10

J17

J16

R5

J2

C2

C5

C4

U1

T1

Q1

L1

J3

L2

D1

+

J1

C1

+

###°

830 9442-#

###°

###V

Cable
Routing

1. Remove the set screw from the cover on the electrical box and unscrew the cover.

2. Route the Electrical power into the enclosure through the threaded opening. Use the appropriate
fitting to secure the conduit, etc... to the electrical enclosure. IN EXPLOSIVE ATMOSPHERES
THE OPENING INTO THE ENCLOSURE MUST BE SEALED TO PREVENT A PATH FOR
GAS TO TRAVEL. THE O-RING ATTACHED TO THE COVER IS NEEDED TO PREVENT
MOISTURE FROM ENTERING THE ENCLOSURE. DO NOT REMOVE.

Note: Electrical connections to this product should be made with insulated, 18

AWG stranded copper wire with a minimum operating temperature of 75°C

3. Remove ¼” of the insulation from each of the wires.

4. Attach the power wires to the terminal block according to the picture abvove.

5. Check that the temperature setting on the circuit board is correctly set. If not, refer to the
"Temperature Adjustment" section of this manual.

6. Reattach the cover to the electrical enclosure securing it tightly.

7. Re-install the setscrew into the cover. This setscrew is intended to make the removal of the
cover difficult without the use of tools. It is important that this screw be replaced.

8. Provision is made at the rear of the Regulator for an external ground connection for locations
where an external ground connection is required. The Ground connection is clearly marked
(GR) and a screw and washer is provided.

-5-

INSTALLATION OF GAS CONNECTIONS

Note: BE SURE TO CONSIDER ALL FACTORS WHEN SELECTING

MATERIALS FOR GAS CONNECTIONS. For example, if you
have both high pressure and corrosive service, select material
that is suitable for both.

1. Do not use oil or grease on fittings, especially not on oxidizing gas service equipment.

2. Be sure that all fittings are secure and leak tight. PTFE tape should be used on pipe fittings, but
avoid impinging on the gas stream. Before applying PTFE tape, inspect the NPT threads and
if necessary, clean the fitting to remove any dirt or thread sealant that remains on the threads.
Start the PTFE tape on the second thread as shown in Figure 3. Make sure the tape does
not overlap the end of the fitting. 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 PTFE tape. Cut off the excess tape and press the end firmly into the threads.

Figure 3 - PTFE Taping Procedure

Pressure Adjustment

The Vaporizing Regulator’s delivery pressure is set at the factory. If the delivery pressure needs to be
adjusted follow the directions below.

1. The pressure adjustment is made from the top of the regulator bonnet.

2. Locate and remove the acorn nut at the top of the bonnet.

3. Using a 3/16” allen wrench inserted into the set screw beneath the acorn nut, turn the set screw
to vary the outlet pressure of the regulator. Turning the set screw clockwise will increase the
pressure setting and counter clockwise will reduce the pressure setting.

4. When the pressure is adjusted to the desired level, replace the acorn nut and secure in place.

CAUTION! NEVER EXCEED THE OUTLET PRESSURE RATING

OF THE REGULATOR.

-6-

Temperature Adjustment

The Vaporizing Regulator operates over a specific temperature range. This range is determined by
the part number. To gain access to the adjustment thermostat, the cover on the electrical enclosure
must be removed.

CAUTION! SURFACES OF REGULATOR EXTREMELY HOT WHEN OPERATING.

ALLOW SUFFICIENT COOLING TIME AFTER REMOVING POWER

BEFORE HANDLING

1. TURN ELECTRICAL POWER OFF BEFORE OPENING THE COVER TO THE ELECTRICAL
ENCLOSURE.

2. Remove the setscrew from the cover of the electrical box and unscrew the cover.

3. Using the thermostat adjusting tool provided with the regulator, adjust the thermostat.
This tool must be used to prev ent damage to the thermostat. Refer to Figure 4 for

thermostat location.

Jumper

R13

R12

R13

J15

R6

R16

R15

10

R9

J17

R3

J16

R1

R17

R5

R7

U3

J2

C2

C5

R8

D1

+

J1

R11

C1

C4

U2

D2

+

C3

U1

###°

J13

T1

J14

8309442-#

Q1

###°

R4

L1

###V

J3

L2

G

R16

J17

J15

J16

Thermostat

R16

R5

Jumper

R13

J17

+

77°-180° F

160°-280° F 250°-380° F

Thermostat

J15

J16

R5

+

R16

R13

Jumper

J17

J15

Min.

J16

R5

Max.

+

Uncovered

Thermostat:

ACTIVE

(2) Covered

Special Thermostat Adjusting Tool
Provided with the Regulator

Figure 4 - Thermostat Location

Thermostats:

INACTIVE

Note that fully Counterclockwise (CCW) is the lowest setting in the range. Fully Clockwise
(CW) is the highest temperature in the range.

4. The temperature range for the Vaporizing Regulator is listed on the label affixed to the top
of the circuit board inside the electrical enclosure. The temperature range listed on the label
is body temperature. Actual gas temperatures will be dependant on the flow rate of the gas
passing through the regulator, ambient temperature and the temperature of the gas entering
the Vaporizing Regulator.

5. Once thermostat is set, securely tighten the cover on to the electrical enclosure.

6. Re-install the setscrew into the cover. This setscrew is intended to make the removal of the
cover difficult without the use of tools. It is important that this screw be replaced.

7. Restore Electrical Power.

-7-

TROUBLESHOOTING

Symptom Possible Cause Possible Solution

Regulator not heating

No flow or restricted flow
from regulator

Regulator Overheating Bad Control Circuit board Replace

Regulator not heating gas
sufficiently

No Power to the Regulator

Heater Element bad

Inlet plugged with debris Disconnect inlet gas sour

Thermostat needs to be adjusted
Ambient temperature & Gas inlet
temperature too low
Vaporizing Regulator chosen has
too low a tempera ture range or
wattage

Check power connection at
source.
Check that wires are properly
attached to the terminal block.
Replace

from regulator and clean inlet
to regulator if plugged.
Replacecapsule insideregulator

Adjust thermostat setting
Using higher wattage Vaporizing
Regulator
Change Regulato r to different
heat range or wattage.

SERVICE

ce

A Unit that is not functioning properly should not be used and should be returned to CONCOA for
service. A Return Material Authorization (RMA) number must be issued for any product returned to
CONCOA for service. Please contact a Customer Service Representative at 1-800-225-0473 to
receive this number. You will be asked to provide:

1. Model Number

2. Gas Service

3. Inlet pressure and type of gas supply

4. Outlet pressure

5. Approximate gas usage

When shipping product back to CONCOA for repair the following steps should be followed:

1. Package the product sufficiently to prevent damage. If possible return product in its original
packing.

2. Include RMA number on the outside of the carton.

3. Ship prepaid.

4. Include a written description of the problem you encountered with the product inside the package.

5. Include a statement of the gas service the product was used in.

6. Purge all equipment before shipping to protect the transporter and service personnel. Purging
is especially important if the equipment has been in hazardous or corrosive gas service.

-8-

CERTIFICATIONS AND COMPLIANCES

Tamb -20°C to 60°C

Ex d IIC T1, CL I, DIV 1, Grp A-D
Certified to CAN/CSA E60079-0

& E60079-1
Conforms to UL-1203

II 2 G Ex d IIC T1 Gb

x

E

0359

ITS05ATEX13688

Tamb -20°C to 60°C

Ex d IIC T3, CL I, DIV 1, Grp A-D
Certified to CAN/CSA E60079-0

& E60079-1
Conforms to UL-1203

II 2 G Ex d IIC T3 Gb

x

E

0359

ITS05ATEX13688

Tamb -20°C to 60°C

Ex d IIC T4, CL I, DIV 1, Grp A-D

Certified to CAN/CSA E60079-0

& E60079-1
Conforms to UL-1203

II 2 G Ex d IIC T4 Gb

x

E

0359

ITS05ATEX13688

R

T

E

E

T

K

N

I

CM

C US

L

I

D

S

E

T

Intertek

3068692

R

T

E

E

T

K

N

I

CM

C US

L

I

D

S

E

T

Intertek

3068692

R

T

E

E

T

K

N

I

CM

C US

L

I

D

S

E

T

Intertek

3068692

T1 Rated model.

T3 Rated model.

T4 Rated model.

-9-

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 merchandise and are extended to the first 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
workmanship 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 instructions 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 CORPORATION 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 deficiency, 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 L IMITED TO: INCIDENTAL DAMAGES, CONSEQ UENTIAL
DAMAGES, OR SPECIAL DAMAGES, WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE,
BREACH OF WARRANTY OR OTHERWISE.

THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE
WARRANTIES 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.

-11-

Certified ISO 9001

99060452E

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