BioSpherix ProCO2 120 User guide

System 1
SystemManual
version0.2
Manual
version 0.2February2007
PO Box 87
19 Demott St.
Lacona, New York 13083
PHONE [phone]
FAX [phone]
TOLL FREE US/CAN 800-441-3414
www.biospherix.com
1.First,adaptthegenericchamber. Inthe“AdaptingaGenericChamber”manual,refertothe:
“InstallationOverview” section, for anoverviewofhowtoinstallthegenericchamber. Alsouse
the“Adapting a Chamber for a ProCO2” section for informationanddirectionson how to
adaptthe chamber for aProCO2.
2. Now, installing the ProCO2. In the “ProCO2 Model 120” manual refer to the: “BioSpherix
Supplied Parts” and “User Supplied Parts” sections for a parts list. Also refer to the:
“Setup of Gas Supply”, “ProCO2 Front Panel Installation” and “ProCO2 Back Panel Instal-
lation” for how to make all the connections.
3. Next, familiarize yourself with the push button interface. In the “ProCO2 Model 120”
manual refer to the: “Operation”, “Program Functions Menu” and “Configuration” sections
for information regarding the push button interface.
4. Now, calibration. In the “ProCO2 Model 120” manual refer to the: “Calibration” section
for information on how to calibrate the sensor.
5. Next, tuning. In the “ProCO2 Model 120” manual refer to the: “Tuning” section for spe-
cific information on fine tuning. You shouldn’t have to use this section much, because most
tuning is done at the factory.
6. Now, operating. In the “ProCO2 Model 120” manual refer to the: “Single Setpoint Con-
trol” section for information on how to operate with the ProCO2. Also refer to the: “Setting
the Alarm Setpoint” section for directions for how to set a specific alarm setpoint.
7. Finally, maintenance issues. In all of the manuals refer to; “Maintenance” sections on
how to maintain the respective equipment.
“ProCO2” Manual v1.0 d0207
“Adapting a Generic Chamber” Manual
v0.2 d0506
This section will provide you with a list of the order in which the equip-
ment should be: installed, setup, calibrated etc. After you have com-
pleted a step refer back to this page to see what the next step is.
There will be times when the manuals with need to be used in con-
junction with one another. This list is here to help you use the equip-
ment more efficiently, you should still read all of the manuals thor-
oughly before using this list. By reading all of the manuals and then
referring to this list you will have a better understanding of how the
equipment works.
This system consists of many parts. Each
part has it’s own manual. The name of the
each individual manual and it’s version
number are as follows:

ProCO2 Model 120
Manual
version1.0Feb2007
This manual is intended to help our customers efficiently
setup and operate the equipment. We encourage not only all
installers, but also all users, to read this manual thoroughly.
Keep it handy and refer to it often. Save it for future
reference. If you have any problems or questions, please do
not hesitate to call. We are here to help.
Introduction
The ProCO2is a versatile and compact gas carbon dioxide controller for people who do
carbondioxidesensitivework. ThoughdesignedtoworkwithBioSpherixchambersthe
ProCO2worksinincubators,glove
boxes,animalcages,refrigerators,
plantgrowthchambers, andmanyother
semi-sealablechambers. Practically
anysmall-mediumenclosure can be
fitted. Evencardboardboxesand
plasticbags. Theunitworksfrom
outsideofthehostchamberbyre-
motelysensinganddisplacingthe air inside the chamber with CO2.
Thenominalrangeofcarbon dioxide concetration is 0.1-20.0%. Advanced feedback algo-
rithmshandlepracticallyanycarbondioxide gas dynamic.
Infusionratesareadjustableupto35SCFH, sufficient for
mostlabchambers. Installationis easy. Operationissimple.
Theunitmoveseasily from onehostchambertoanother.
Pleasereadandfollowthesafetyandoperations instructions
onthefollowingpages. Becareful. Anypressurizedgascan
bedangerous. Knowwhatyouaredoinganddo it safely.
1
ProCO2 model 120
version 1.0
!!
Anyone who has not thoroughly read and under-
stood this manual, must never attempt to operate
the equipment.
PO Box 87
19 Demott St.
Lacona, New York 13083
PHONE [phone]
FAX [phone]
TOLL FREE US/CAN 800-441-3414
www.biospherix.com

Table of Contents
Safety Instructions........................................................................3
BioSpherix Supplied Parts............................................................4
User Supplied Parts.......................................................................5
Setup of Gas Supply......................................................................6
ProCO2Front Panel Installation.....................................................7
ProCO2Back Panel Installation....................................................8
Operation........................................................................................9
Program Functions Menu............................................................10
Configuration...............................................................................11
Calibration...............................................................................12-13
Tuning......................................................................................14-17
Single Setpoint Control...............................................................18
Setting the Alarm Setpoint..........................................................19
Maintenance.................................................................................20
Warranty........................................................................................21
2
ProCO2 model 120
version 1.0

SAFETY INSTRUCTIONS
ELECTRICAL POWER SOURCE unit should be connected to a power supply only of the
type described in the operating instructions or as marked on unit.
POWER CORD PROTECTION power supply cords should be routed so that they are not
likely to be walked on or pinched by items placed upon or against them.
ELECTRIC SHOCK do not remove cover of ProCO2due to presence of uninsulated "dan-
gerous voltage" within product's enclosure.
ELECTRIC SHOCK unit should never be used where it can fall or be pushed into water.
ELECTRIC SHOCK if modifying host chamber, be careful not to drill or cut into electrical
wires hidden behind chamber wall. Never drill or cut blindly.
NONUSE PERIODS power cord of unit should be unplugged from electrical outlet when left
unused for long period of time.
FALLING OBJECTS AND LIQUID SPLASH care should be taken so that objects do not fall
on equipment and liquids do not spill, splash, or drip onto or into unit enclosure or
power cord.
PRESSURIZED GAS secure all connections with hose clamps. Never exceed pressure
limits. Bleed all lines before disconnecting. Wear safety glasses at all times.
LOW OXYGEN ATMOSPHERES never enter a chamber which has a low oxygen atmo-
sphere because of severe danger of suffocation. Host chamber should be in well venti-
lated room. Control gas (nitrogen or other low oxygen gas) continuously leaks out of
chamber and should never be allowed to build up in room outside of chamber.
HIGH OXYGEN ATMOSPHERES never enter a chamber which has a high oxygen atmo-
sphere due to danger of oxygen toxicity. Never smoke or allow any source of fire or
spark in or around a chamber with high oxygen atmosphere. Oxygen radically promotes
combustion and can be explosive. Host chamber should always be in well ventilated
room. Oxygen continuously leaks out of chamber and should never be allowed to build
up in room outside chamber.
VENTILATION unit should be situated so that its' location or position does not interfere
with proper ventilation. Neither ProCO2nor host chamber should be in poorly ventilated
areas.
HEAT unit should be situated away from heat sources such as radiators, heat registers,
stoves, or other appliances or processes that produce heat.
CLEANING do not immerse unit in water. Do not wipe unit with wet cloth or sponge or
paper. Clean only with a dry cloth.
3
ProCO2 model 120
version 1.0

BioSpherix Supplied Parts
This section will familiarize you with the components that come with
the ProCO2.
12VDC power supply
Gas Fittings Infusion tubing
Calibration chamber
with tubing
Carbon dioxide gas sensor
and sensor cable
ProCO2unit
4
ProCO2 model 120
version 1.0
Short piece of 1/8 in. ID
tubing

User Supplied Parts5
ProCO2 model 120
version 1.0
1. Qty. 2 regulators, either a one stage regulator or a two staged regulator. Either way you
will need two gauges, one for the amount of gas in the tank and one for the gas coming out
of the tank. (2500 PSIG input 0-60 PSIG output, recommended). PSIG stands for Pounds
per Square Inch Gauge as opposed to PSIA which stands for Pounds per Square Inch
Absolute.
2. Qty. 1 compressed gas source (tank) of carbon dioxide.
3. Qty. 1 compressed gas source (tank) of carbon dioxide/oxygen mix (ratio should be 10-
90).
4. Qty. 1 compressed gas source (tank) of nitrogen (optional, see “Calibration” section for
information).
This section will list the parts that the user will need to supply in order to
operate the equipment.

Control gas must be supplied through a 1/8 in. ID tube to the back panel of the
ProCO2. If the tubing coming from the compressed gas source (tank) isn’t 1/8 in. then use
one of the provided gas fittings to adapt the tubing to 1/8 in. The pressure must be regu-
lated to 0-25 PSIG. For best results use approximately 2 PSIG in aCulture Chamber and
use 15 PSIG in an Animal Chamber. (refer to “Tuning” section under the “Power” heading
for further information). Do not connect any tubing yet, wait until told to do so in the “Cali-
bration” section and “Single Setpoint Control” section.
The amount of gas used is determined by how the chamber is used, not the ProCO2.
The ProCO2uses the least amount of gas possible, which is only what the chamber needs.
The amount of gas used is dependent on: (1) The size and leakiness of the chamber, (2)
The amount of times and how long the chamber door(s) are opened, (3) The carbon diox-
ide level being controlled.
Use a one or a two stage, 2500 PSIG input, 0-60 PSIG output regulator at the source
of the compressed gas. It is best to have two gauges so that you can monitor the amount
of gas in the compressed source and also monitor the amount passing through the output.
Never allow the pressure coming out of the compressed source to exceed 25 PSIG or
damage will occur to the ProCO2. If the regulator is not near the ProCO2 then there
should be a shutoff valve placed upstream of the unit. When taking off gas supply tube
always make sure to shut off compressed gas at the source first, then bleed the pressure
out of the line and then take off the tube from back of ProCO2.
Step-by-Step Procedure for Connecting Gas to Machine
1. Before connecting the regulator to the tank, close the regulator and make sure the tank
is also closed off.
2. Connect the regulator to the compressed nitrogen (if applicable), compressed carbon
dioxide and to the compressed carbon dioxide/oxygen mix gas sources.
3. Connect the tubing from each compressed gas source to the ProCO2when told to do so
in the calibration procedures and the operation procedures.
4. At this point you don’t have to open the regulator or turn on the gas. You will be turning
the gas on at the beginning of the calibration/single setpoint control procedures, for now
just connect the regulator.
Setup of Gas Supply
This section will describe how to setup the gas supply, for information
on how to connect the gas supply to the machine, see the calibration
sections and the “Single Setpoint Control” section.
6
ProCO2 model 120
version 1.0

ProCO2Front Panel Installation
The following steps will explain how to set up the ProCO2 front panel
and prepare it for installation to a chamber.
1. Placing the Unit
Place the unit on a level secure surface either on the
chamber or within seven feet of the chamber. Make sure
you can easily access the front panel.
2. Gas Connected Properly
Each time you connect a gas supply, make sure that
the gas is connected properly open the bleed valve by
turning the knob on the front of the ProCO2counterclock-
wise. If gas is heard expelling out the “BLEED” barb on
the front panel then the gas is connected properly. Once
you have confirmed then close the valve. Do this after
you have followed the procedure in the “Setup of Gas
Supply” section and are beginning either operation or
calibration.
3. Connecting Calibration Chamber
Attach the calibration chamber by connecting the
1/16 in. ID tubing to the barb labeled “BLEED” on the
front of the ProCO2, when calibrating.
4. Gas and Alarm Switches
Flip the “GAS” switch up to allow the gas to flow to
the chamber. Flip the “ALARM” switch down to enable
the alarm to sound.
2
3
4
7
ProCO2 model 120
version 1.0

ProCO2Back Panel Installation 8
ProCO2 model 120
version 1.0
3. Connecting Sensor
Plug the sensor cable into the port labeled
“SENSOR” on back of ProCO2 by twisting the sensor
cable into the port until it pushes in, then push in until
“click is heard. When removing pull the ring back and
pull cable off. Plug the other end of the sensor cable into
the sensor itself by lining up the key on the terminal with
the key on the connector of the sensor cable. Push in
and twist the ring on. The display on the front of the
ProCO2should respond.
2. Connecting Gas
Attach 1/8 in. ID tubing to hose barb labeled “IN” on
the back of the ProCO2. Making sure that the gas com-
ing in Never exceeds 25 PSIG or damage will occur to
the ProCO2. Depending on if you are calibrating or
operating will determine what type of gas you will be
using. (see “Calibration” and “Single Setpoint Control”
sections).
1. Power Supply
Plug the jack end into the port labeled “12VDC” on
back of ProCO2. Plug the 12VDC power supply into a
wall outlet. The display on the front of ProCO2should
turn on.
4. Connecting Infusion Tube
Attach 1/8 in. infusion tube to “OUT” barb on back of
ProCO2.
1
4
2
3
This section will describe how to setup the back panel of the ProCO2.

This section will give an overview of some of the different modes and
functions within the ProCO2
RESET ALARM/ERROR
MESSAGES
When the alarm or
error condition has
been cleared,
momentarily press
both upkey and
downkey at the
same time.
CHANGESETPOINT
Press and hold star
key. Press up key to
increase setpoint.
Press downkey to
decrease setpoint. If
change requires
control output, SP1
indicator will flash.
VIEWSETPOINT In work mode,
press and hold
star key. Setpoint
is shown in
alternating display.
CHANGEOPTION
Index to required function. Press and
hold star key (current option
displayed). Press up and/or down keys
to display new setting.
Release star key.
IMPORTANT:Check
new selection
(alternating with
function) before
moving to another
function or exiting
program mode.
VIEWFUNCTION/OPTION
On release of up or
down key at
function, display
alternates with the
option selected.
ENTER/EXITPROGRAMMODE
Simultaneously hold both up and down
keys for 3 seconds. You enter
program mode from
normal operating
mode at the tune
function on level 1 in
the menu. You exit
program mode at
any point in the
menu, returning to normal operating
mode. With exit, any new instructions
get entered into memory.
ENTRY TO HIDDEN LEVEL 4
At "VEr" function on
level 3, press and hold
both upkey and
downkey
simultaneously for 10
seconds. To enter level
4
PROGRAM MODE
All configuration, calibration,
and tuning operations take place in
program mode. You access the
programmenu,navigatethroughit,
selectappropriate options, andexit
back to work mode.
Entry into menu is always at
same point, the "tunE"function on
level1.
During programming, control
withexistingsettingsismaintained.
Newsettingsarewrittentomemory
only upon exiting program mode.
Settingsareretainedinnon-volatile
memory for years even if unit is
unpowered.
Security locks can configure
certainoptionsunadjustable. How-
ever, all functions and locked op-
tions may be viewed even when
locked.
Exit program mode from any
place in menu. Exiting program
modereturnstoworkmodewithnew
settings.
WORK MODE
Workmodeisthenormalday-
to-day operating mode. Whether
controlling or not (parked), carbon
dioxide concentration at the sensor
is continuously displayed, unless
pre-emptedbyotheroperations.
Operations in work mode are
limited to: (1) view setpoint, (2)
change setpoint, (3) reset alarm/
error message, (4) enter program
mode.
CHANGE LEVELS
Multi-level menu of functions requires
navigating from level to level.
Index down key to
level function.
Release down key
to display current
level.
Press and hold star
key while using
down key or up key
to select new level.
Release star key to
display new level.
SINGLE LEVEL NAVIGATION
Press up
or down
key once
to move to
the next
function.
Hold up or down keys to automatically
index through the functions. Always
index down to get to level function.
OPERATION 9
ProCO2model120
version1.0

SelectAutotuneorPark ProportionalBand/Gain orDeadbandwidth
Integraltime/Reset (Automaticoffset) Derivativetime/Rate
Derivativeapproach control
Proportionalcycle-time orON/OFF
Offset/Manualreset
LockmainsetpointSP1
AdjustalarmSP2 setpoint
Select SP2 dead band width or Proportional band
SelectSP2ON/OFF orCycle-time
ReadcontrolSP1 outputpower%
SP1manualpower control%
SetSP1powerlimit%
SetSP2powerlimit%
SubsidiaryalarmSP2 mode:latch/sequence
MainalarmSP2 mode: strategy.
Selectdisplayresolution (decimalpoint)
Setscalemaximum
Setscaleminimum
Selectsensorinput
ReadSP1control outputdevice
ReadSP2alarm outputdevice
Burn-outprotection
Selectoutputmodes: Direct/Reverse
SelectSP1/SP2 L.E.D.modes
Sensorspanadjust Sensorzeroadjust
Selectcontrol accuracymonitor
Readmonitorresults
ReadAutotune tuningdata
Functionsreset
Derivativesensitivity
Displaysensitivity Disablealarm annunciator
Disableprogram auto-exit
Securitylock
Softwareversion
2
1
4
3
Ú
Ú
×
Ø
×
PROGRAMENTRYPOINT
PROGRAM FUNCTIONS MENU
Selectunitsof measurement
PROGRAM MODE FUNCTIONS MENU is arranged on 4 levels. Entry into menu is
bottom of level 1. Exit menu from any point. Level 4 is hidden for security;
there's one way in. Menu items are loosely grouped together according to
similar functions. Some functions are defaults
(hard or soft). Some are read only. Some are only
active depending on other function settings. Some
are used only in rare instances. Chances are
99.99% you'll have to become intimately familiar
with only a few of the important ones.
10
ProCO2model120
version1.0

11
ProCO2 model 120
version 1.0
CONFIGURATION
Extensive configuration options in alarming, security, and display
functions all can be set later, if necessary. Only one main
configuration setting is required to start carbon dioxide level
SECONDARY
CONFIGURATIONS
Alarmconfigurationoptionsin-
cludedeviation,band,andfullscale.
Outputcan bereverse ordirectact-
ing. Alarm intensity is configurable
bytimedpulseproportioning.
Securityoptionsagainstpeople
errors include set point lock, set
pointrangelimits,andlimitedmenu
access to prevent unauthorized
changes. Burnoutcontingenciesand
outputoverloadlimitsprotectagainst
machinemalfunctions.
Display resolution and sensi-
tivity,alarmannunciatorpriority,and
flashing indicator lights are adjust-
able too.
All these settings are second-
arytothemainjobofcarbondioxide
control. They are explained else-
where.
HIGH/LOW CARBON DIOX-
IDE Enterprogrammode. Navigate
to "rEV.d" functionon level 3.
Control output is either direct
or reverse. Direct means carbon
dioxide decreases as output de-
creases on approach to set point.
Reverse means carbon dioxide in-
creasesasoutputdecreasesonap-
proach to set point.
Tocontrolhighcarbondioxide
levels, set SP1 (setpoint 1) output
mode to reverse. To control low
carbondioxide,setSP1outputmode
to direct. Mnemonic: "1r" or "1d".
AlarmSP2outputalsosetsbut
isnotactiveuntilalarmisconfigured.
Set "2r" or
"2d"laterif
necessary.

SENSORS
Thesensordrivesthecontroller.
Ifthesensorisnotcalibrated,itwon't
be accurate. If the sensor is not
accurate,control won'tbeeither.
Everysensormustbecalibrated
both (1) initially when installed, new
orused,and(2)periodicallyoverthe
life of the sensor to compensate for
filmblockinginfraredpartofsensor.
Sensorsgenerateanelectrical
signal (output) which is linear and
directlyproportionalwithgascarbon
dioxideconcentration:
Although always linear and di-
rectlyproportional,rawoutputcanbe
quitedifferentforeachsensor:
Sensoroutputalsochangesover
time(drift),generallyinaslowdown-
warddirection. Sensorsremainlinear
butgraduallylosepower:
CALIBRATION
Calibration is the key to control accuracy. Check calibration once
every two weeks to have as much confidence as necessary in
accuracy.
CALIBRATION
Calibrationelectronicallycor-
rectsforthedifferenceamongsen-
sors. Makesrawoutputlinesuper-
imposeoncalibrated line. Then all
sensorsreadaccurately:
Calibrationalsocompensates
for drift. Monitor drift with periodic
calibration checks. Recalibrate
whennecessary:
12
ProCO2model120
version1.0
CALIBRATION
STANDARDS
Sensorsarecalibratedtostan-
dard gas mixtures with known car-
bon dioxide concentrations. Since
sensoroutputislinear,calibratingat
two known points makes all other
points accurate as well.
Onestandardforcalibrationis
a compressed gas source of 10%
carbon dioxide and 90% oxygen.
Immersethesensoringasbyusing
a calibration chamber. Set the
"SPAn"toread"10"inworkmode.
Compressed nitrogen can be
used as a standard. Immerse sen-
sor in control gas by using calibra-
tion chamber and bleed valve. Or,
you could use room air as the sec-
ondstandard. Inbothinstancesyou
would set the "ZEro" to read "0.0".
Ofcourse,otherstandardscan
beusedaswell. Orcalibratetothird
partycarbondioxideanalyzers. Just
beconfident inyour standard.
CALIBRATION MENU
FUNCTIONS
"SPAn"and"ZEro"functions
on level 3 of the menu calibrate the
sensor. Both adjust sensor output
line without disrupting linearity, but
eachworksdifferently.
The"ZEro"functionaffectsonly
the Y-intercept of the line, not the
slope. Itmovesthelineupanddown
withoutchangingtheslope. Always
dothe"ZEro"functionfirst:
Increasing makes the y-intercept more
positive (moves the line up) -
Decreasing makes the y-intercept
more negative (moves the line down)
The "SPAn" function adjusts
the slope of the line, but does not
affecttheY-intercept(setby"ZEro"
function). Always do "SPAn" after
"ZEro":
Raising increases slope:
Lowering decreases slope:
REMEMBER: never adjust
"ZEro" function without adjusting
"SPAn"functionafterwards. "ZEro"
affects"SPAn"setting,but"SPAn"
doesnotaffect "ZEro"setting.

HOW TO USE
CALIBRATION CHAMBER
The calibration chamber is a
toolforimmersingthesensorincali-
brationgases. Itconnectstothegas
sourcevia1/16in.IDtubing. Itholds
the tip of the sensor in the gas
stream.
First, connect the calibration
chamber tubing to the "BLEED"
hose barb on the front panel of the
ProCO2.
Then insert the sensor tip into
thecalibrationchamber. Thesensor
holeissizedforasnugfitandallows
the sensor to be in the gas stream
withinthechamber:
Finally, open the bleed valve
knobonthefrontpaneloftheProCO2
until you hear gas expelling slightly
throughthecalibrationchamber:
CALIBRATION
PROCEDURE FOR
CARBON DIOXIDE
CONTROL
There are two ways to cali-
bratethe"ZEro"setting. Thefirst
way is to use room air as a stan-
dard and set the controller to
read "0.0", the second way is to
use compressed nitrogen as a
standard (BioSpherix recom-
mendstousenitrogen,asshown
in the following instructions).
1. Connectthe1/8in.IDtubing
coming from the compressed nitro-
gen gas source to the "IN" barb on
the back of the ProCO2. Make sure
the gas is regulated 0-25 PSIG.
Never exceed 25 PSIG. Use ap-
proximately2PSIGforCultureCham-
ber and use 15 PSIG for an Animal
Chamber.
2. Hook up calibration cham-
ber to "BLEED" hose barb on front
panelofProCO2. Slightlyopenbleed
valve knob on front panel until you
can hear gas expelling slightly
throughcalibrationchamberthiswill
establisha 0% carbon dioxide level
withinthecalibrationchamber.
3. Insertsensortipintocalibra-
tionchamberandletsensorstabilize
in0%carbondioxide(minuteortwo).
Watch sensor response to immer-
sioninnitrogenin workmodetotell
when it stabilizes. Note whether
carbon dioxide reading is above or
below"0.0" andbyhow much.
4.Enterprogrammodebyhold-
ingdowntheupanddownbuttonsfor
three seconds, navigate to"LEVL"
functionandwhileholdingdownthe
" * " button push the up button until
youreach"3". Thennavigatetothe
"ZEro"functionandraisethesetting
if reading was low, or decrease the
settingifreadingwashigh.Thenum-
berinthe"ZEro"functionstandsfor
thesameamountinworkmode. For
example:if you change the number
in"ZEro" functionby".2" the num-
berinworkmodewillchangeby".2".
Exitprogrammodetoseenewread-
ingby holdingtheup anddownbut-
tonsforthreeseconds. Repeatuntil
reading is what it should be "0.0".
5. Closethebleedvalve knob
thenremovethecalibrationchamber
tubingfromthe"BLEED"barb. Turn
off the nitrogen at the compressed
gas source, open the bleed valve
knob again and allow the gas to
escapeoutthe"BLEED"barb. When
the gas has all escaped close the
bleedvalveknob. Thendisconnect
the 1/8 tubing from the "IN" barb on
the back of the ProCO2.
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ProCO2model120
version1.0
6. Connectthecarbondioxide/
oxygen mix compressed gas with a
1/8 in. ID tubing to the "IN" barb on
the back of the ProCO2. The mix
should be a ratio of 10% (carbon
dioxide) - 90% (oxygen), check the
label on the compressed source for
exact percentage. Making sure the
gasisregulatedto0-25PSIG. Never
exceed 25 PSIG. Connectthecali-
bration chamber tubing to the
"BLEED" barb on the front of the
ProCO2. Slightly open bleed valve
knobonthefrontpaneluntilyoucan
heargasexpellingslightlyfromcali-
brationchamberthiswillestablisha
10%-90% ratio of carbon dioxide-
oxygen mix within the calibration
chamber.
7. Insertthesensortipintothe
calibrationchamberandletthesen-
sor stabilize in 10% carbon dioxide
(minute or two). Watch sensor re-
sponse in work mode to tell when it
hasstabilized. Notewhethercarbon
dioxide reading is above or below
"10.0" andbyhowmuch.
8. Enter program mode,
changethe"LEVL"to"3",navigate
to "SPAn" function, and raise the
setting if reading in work mode was
low, or decrease the setting if read-
ing in work mode was high. Exit
program mode to see new reading.
Repeatuntilreadingiswhatitshould
be "10.0". The number in "SPAn"
function isn't an exact corresponse
withthenumberinworkmode,itisa
coarseadjustment.
Sensor is calibrated when it
reads0%carbondioxideafterstabi-
lization in nitrogen and 10% carbon
dioxide after stabilization in carbon
dioxide/oxygenmixture.
When calibration is complete
close the bleed valve knob and dis-
connectthecalibrationchambertub-
ing. Then turn off the compressed
gassupplyandopenthebleedvalve
knob to expell the remaining gas.
Oncethegashasallescaped,close
thebleedvalveknob,anddisconnect
the 1/8 in. tubing from the "IN" barb
on the back of the ProCO2. Now
connect the 100% carbon dioxide
gastothe"IN"barb,makingsurethe
regulatorissetto0-25PSIG. Never
exceed 25 PSIG.

TUNING
Tuning matches control parameters of ProCO2to gas dynamics of
host chamber to achieve effective control.
TUNING
Differentcarbondioxidecontrol
jobs in different chambers require
specific control parameters. Tuning
means setting those control param-
eters that result in acceptable con-
trol. Which parameters to set, and
howtosetthem,dependsonthejob.
Is oscillation acceptable? If so how
much? Is overshoot permissable?
Undershoot? How much? For how
long? Is the load fixed or variable?
Doessetpoint change? Mustrecov-
ery be fast?
Capabilityexiststohandleprac-
ticallyanycarbondioxidecontroljob.
However,themorecomplexandde-
manding the job, the more involved
tuningbecomes.
Tune only what's necessary to
accomplish the job. Any additional
control parameters probably won't
help,andmighthurt. Excessivetun-
ing can reduce control stability.
Mostcarbondioxidecontroljobs
aresimple. Thustuningiseasy. Only
a few parameters need to be set.
Advancedcontrolcapabilitiesareavail-
able,butusethemonlyifyouneedto.
Just watch the control process
andseehoweachcontrolparameter
affects it. This is the only definitive
way. Usually it's the easiest too.
Tuningtakestime. Ittakesgas.
It means sitting and watching the
controlprocess,sometimesoverand
over. Thereisnoshortcut. Trialand
erroristheonlywaytotellifatuneset
works. AlongwiththeProCO2youare
providedwitha"ControlParameters
Chart",thischarthasallthepretuning
informationthatwasdoneatthefac-
tory. Don't lose this chart, but if you
dothencallthenumberatthefrontof
this manual to receive a new copy.
Alwayschangeonlyonecontrol
parameter at a time. See how that
setting works first, before changing
another. Recordeachtuneset. When
satisfied with control, copy and set
asideforsafekeeping.
A tune doesn't have to be per-
fect to work. But don't stop short
either. Oncetuningisdoneanddone
right, it may never need further at-
tention.
POWER
First adjust power. Power is
theonlycontrolparameternotsetin
programmode. Oncepowerisset,
other control parameters may be
tuned.
Powerisafunctionofinfusion
rate. Themoregasinfusedperunit
time,thehigherthepower. Infusion
rate is adjustable up to 35 SCFH
(StandardCubicFeetanHour).
Infusion rate is a function of
gas supply delivery pressure. The
higher the pressure, the faster the
infusion rate. Gas supply delivery
pressureissetatthepressureregu-
latorongassource. Infusionrateis
dependent on the pressure of the
gas coming from the compressed
gas source. Never exceed 25
PSIG.
ProCO2power must roughly
match dynamic gas load of cham-
ber. Too little power and it takes
forevertoreachsetpoint. Toomuch
powerandcontrolisunstable.
The bigger the chamber, the
more power (gas) it takes. For
example, a small baby incubator
might take 2-5 SCFH , but a tissue
culture incubator might take 10-30
SCFH.
The leakier the chamber, the
more power (gas) it takes. For
example, an incubator with a tight
seal might take 10 SCFH, but one
with a loose seal might take 20
SCFH.
There are methods to calcu-
latepower,butit'sfasterandeasier
toadjustpowerempirically. Watch
thecontrolprocessandadjustinfu-
sionratesoProCO2isabletodelib-
erately push carbon dioxide from
ambient to past set point under
normalloadconditions.
Mostjobscanbetunedovera
relativelywidepowerrange. Once
the other control parameters are
tuned,however, any change in the
power/loadbalancemayrequirere-
tuningthoseparameters.
STEPS:
1. Set gas supply delivery pressure.
Range 0-25 PSIG.
2. Watch the number in work mode
approach the set point. If too fast
and unstable, turn down pres-
sure to lower infusion rate. If too
slow, turn up pressure to
increase infusion rate. Never
exceed 25 PSIG.
ON/OFF CONTROL
Crude basic control. Suitable
when precise carbon dioxide levels
are not necessary.
Infusionstopswhencarbondi-
oxidereachessetpointandresumes
onlywhencarbondioxidedriftsback
pastsetpoint. Outputiseither100%
or 0%. Oscillations are natural.
The only tune adjustment is
the dead band width. Dead band
width is distance between on-to-off
point and off-to-on point above and
below setpoint. Defines where no
switchingoccurs,butoscillationdoes
occur.
Thelargerthedeadbandwidth,
thelargertheoscillation,buttheless
switching on and off. Maximize the
dead band width to minimize wear
andtearonequipment. Setforlarg-
est acceptable oscillation.
The smaller the dead band
width, the less oscillation, but the
morewearand tear.
On/offtuninghasnoprovision
forfluctuatingloads. Blindlyresponds
only to on-to-off point and off-to-on
point. Change in load may change
oscillationamplitudeand/orperiod.
14
ProCO2model120
version1.0

STEPS:
1. For on/off control, enter program
mode, navigate to "CYC.t"
function on level 1. Set "on.of".
Have to go down to "0" by
holding "*" button and pressing
down to get to "on.oF".
2. Then set dead band width. Index
down to "bAnd" function and set
distance between on-to-off point
and off-to-on point.
PROPORTIONAL CON-
TROL
Proportionalcontroleliminates
oscillation. It controls steady-state
byweakeningpowerascarbondiox-
idelevelapproachessetpoint. When
power (gas infused per unit time)
exactly matches load (gas leaking
out per unit time), carbon dioxide
stabilizes.
UnlikeON/OFF control where
poweriseither100%or0%,propor-
tionalcontrolcanadjustpowerany-
wherebetween100%and0%. Power
is adjusted by timing gas pulses.
"Proportional"meansgaspulsesget
proportionately smaller as the dis-
tancebetweencarbon dioxidelevel
and setpoint (SP1) gets smaller.
Pulses are timed by setting a
cycletimeandvariedbypercentage
of the cycle time. Maximum pulses
are 100% of cycle time. Minimum
pulsesare0%ofcycletime. Propor-
tionedpulses are in between.
Timedpulseproportioningoc-
cursonlyoveranarrowbandofcar-
bon dioxide levels centered around
setpoint. Control gas isinfusedfull
blast (100% output) with no timing
until it reaches this band. Then it
cycles. The deeper it goes into the
proportional band, the shorter the
pulses. Band size determines how
quickpulsesshortenandpowerthus
weakens.
Somewhere between 100%
and 0% of the cycle time there's a
pulse time that holds steady state.
However,ifproportionalbandistoo
small, it may not be easy to find.
Smallchangesincarbondioxidewill
causehugechangesinoutput,simi-
lartoON/OFFcontrol. Carbondiox-
ide will oscillate and never reach
steady state.
On the other hand, if propor-
tionalbandistoowide,proportioning
inhibitsapproachtosetpoint. Power
starts decreasing way to soon.
Proportional band should be
bigenoughsothere'snogrossover-
shooteverytimeproportioningkicks
in, but not so big that there's need-
lesspulsinglongbeforecarbondiox-
idelevelgetsevenclosetosetpoint.
Cycle time should be as long
as possible to minimize wear and
tear on equipment, but not so long
thatitbecomesunresponsive.
If no other control parameters
are set, proportional band centers
around setpoint SP1. All additional
parametersaccentuateproportional
control. Withoutproportionalcontrol
(prop.bandandcycletime),noother
parametersareactive. Someaffect
the position of the band, but not the
size. Some affect the size, but not
the position. None affect the cycle
time.
STEPS:
1. To tune proportional control, enter
program mode, navigate to
"CYC.t" function on level 1. Set
cycle time, anywhere from 0.1 -
81 seconds.
2. Then index down to "bAnd"
function and set proportional
band. Gas power is reduced, by
time proportioning action, across
this band centered around SP1.
3. Exit program mode to work mode
and watch control process. Note
whether process overshoots and
oscillates, or undershoots from
cycling long before reaching
setpoint.
4. Enter program mode, and
navigate to "bAnd" function
again. If process overshot and
oscillated, increase band size. If
process undershot and took long
to reach setpoint, decrease band
size.
5. Repeat steps 3-4 till steady state
is achieved, whether steady state
is at setpoint or not.
MANUAL OFFSET
Proportional band is basically
a "blind" control parameter. When
setalone,itpositionsitselfarbitrarilly,
centered around the setpoint.
Chancesaresteady-statewillnotbe
at setpoint.
If proportional control steady-
state is not at setpoint, the offset
mustbeeliminatedtomovesteady-
state to setpoint.
ManualOffset movespropor-
tional band by a fixed distance so
that steady-state is at setpoint. If
steady-state is +0.3% carbon diox-
ideabovesetpoint,thenanoffsetof
-0.3willmoveproportionalbanddown
sopulseisperfectlyproportionedto
match load at setpoint.
Manualoffsetworksgoodwhen
controllingagainstafixedload. Once
set, it makes proportional control
nearlyperfect. Noovershooteither.
STEPS:
1. Watch control process in work
mode till steady state is reached.
Note the variance from setpoint.
2. Enter program mode, navigate to
"oFSt" function on level 1, and
set number that offsets variance.
NOTE: "int.t" function on level 1
must be set to "oFF" to manually
adjust offset, otherwise "oFSt"
function is not active but read-
only.
INTEGRAL CONTROL
AUTOMATIC OFFSET
RESET
Proportionalcontroljobs,with
fluctuating loads require automatic
offset to keep steady state at
setpoint.
Integralcontrolparameterau-
tomatically and continuously moni-
tors divergences between setpoint
andsteadystate,andactstocorrect
offset by repositioning proportional
band.Changestheareabetweenset
point line and carbon dioxide level
line, and shifts proportional band in
proper direction to minimize area.
As load changes, steady state fol-
lowssetpointifintegralistunedprop-
erly. Integralcontrolovershootson
initial start up and after significant
interruptions. Farawayfromsetpoint
it senses big offset, so it shoots
proportionalbandasfaraspossible
in corrective direction. Only after
passing setpoint does integral pick
up the need to bring proportional
band back to near setpoint.
Integral control parameter is
time. Resetsoffsetasfrequentlyas
you specify. If integral time is too
short,itrecalculatestoomanytimes
beforecarbondioxide moves much
andmovesproportionalbandtoofar
toofast. Resultisoscillation. Even-
tuallyoscillationwilldampentosteady
state, if load hasn't changed yet.
If integral time is too long, it's
slow to respond. Steady state and
setpoint take a long time to merge.
15
ProCO2model120
version1.0

STEPS:
1. Watch carbon dioxide control
process in work mode under
normal load change. Note offset
at one load. While load
changes, note time till new offset
stabilizes at steady state. To
change load open the chamber
door and ventilate.
2. Enter program mode, navigate to
"int.t" function on level 1, and
set integral time to 30-70% of
noted time. Range is 0.1 - 60
minutes.
3. Exit program mode to work mode.
Watch as normal load changes
occur, and note time till offsets
disappear.
4. Repeat steps 2 and 3 until control
is acceptable.
DERIVATIVE CONTROL
The most demanding control
jobistheonethathastobefastand
tight under fluctuating loads. With
power and proportional band tuned
aggressively (high power, narrow
band), conditions are ripe for over-
shoot. Addintegralactionandover-
shoot is virtually guaranteed, at
startupandafterlargedisturbances.
Derivativecontrolsuppresses
overshoot. Italsospeedsresponse
to disturbances, large or small.
Derivativealgorithmsmeasure
rate and direction of change of car-
bon dioxide in relation to setpoint.
Then temporarily but quickly shifts
proportionalbandinoppositedirec-
tion, by a distance proportional to
the rate of change. The faster the
change, the further it shifts. Shift is
justlongenoughto"extract"anout-
putdetermination.
Theeffectistoquicklyweaken
poweronapproachtosetpoint,and
quicklyboostpowerifcarbondioxide
suddenly pulls away from setpoint.
Properlytuned,derivativeshouldnot
disturbproportionalorintegralaction
at steady state.
On fast approach to setpoint
withoutderivative,whencarbondiox-
ide first hits proportional band the
initial pulse might be 97% of cycle
time. That'snotveryweak. Thenext
pulsemightbesignificantlyless,but
by that time it's too late. Carbon
dioxide changedtoofast. Overshoot
already occurred. When integral
action finally kicks in, it's way too
late. Withderivative,fastcarbondi-
oxide change immediately pulls up
proportional band. Then first pulse
might be 1% of cycle time. This
quickly slows approach to setpoint.
Slower rate of change calculation
might only "extract" a pulse of 12%
of cycle time. Slower still, maybe
19%.As rate of change of carbon
dioxidedecreases,derivativeaction
decreases. At steady state there's
no derivative action. Ideally at that
pointcarbondioxideisnearsetpoint
andintegralaction takesover.
Derivative also speeds re-
sponse to disturbances. Without it,
as carbon dioxide quickly diverges
away from setpoint, the first pulse
fromproportionalcontrolbandmight
be only 22% of cycle time, the sec-
ond pulse 53%, the third 87%, and
by the time output goes to 100%,
carbon dioxide is far away.
Withderivative,thefastchange
incarbondioxideawayfromsetpoint
wouldimmediatelypullproportional
bandbacktowardsetpointandresult
in 100% output before carbon diox-
ide gets too far.
Derivativecontrolishardestto
tune. Propersettingisverysensitive
to gas dynamics and other control
parameters. Ifitisnotrequired,keep
it off as it will tend to reduce control
stability.
Derivative parameter is time.
Setsrateofcorrectiveaction. Rule-
of-thumb: set 3-8 times faster than
integral. Iftooshortitinhibitsreach-
ing setpoint and slows response to
upsets. If too long, it oscillates and
overcorrects. Is only active in pro-
portionalband.
STEPS:
1. With power, proportional, and
integral parameters set, watch
control process in work mode.
Note overshoot. Next open
chamber briefly to induce large
upset in control. Note speed of
response.
2. Enter program mode, navigate to
"dEr.t" function on level 1,and
set derivative time. Range 0.1 -
0.4 of integral time.
3. Exit program mode, air out
chamber, watch control process
and note overshoot on approach
and response to disturbance.
4. Re-enter program mode, and
navigate to "dEr.t" function
again. If too much overshoot on
approach and too slow response
to upset, decrease derivative
time. If approach to setpoint is
inhibited and response under
corrects, increase derivative
time.
5. Repeat steps 3-4 until overshoot
on approach and response to
upset is acceptable.
16
ProCO2model120
version1.0

DERIVATIVE APPROACH
CONTROL
Derivative action (1) sup-
presses overshoot and (2) speeds
responsetoupsets. However,itmay
not always be possible to do both
withonesetting. Depending on the
power/loadbalance,sometimesde-
rivativetunedforquickresponsewill
notsuppressovershootenough.
Derivative approach control
parameter "dAC" solves this prob-
lem. Ittunesovershootindependent
of normal operating parameters by
controlling when derivative action
startsonapproachtosetpoint. Nor-
mallyderivativeactionisonlyinpro-
portionalband. "dAC"isamultiplier
ofproportionalband.
Thesmallerthe"dAC"setting,
the closer to setpoint derivative ac-
tion begins. Too small and carbon
dioxide overshoots. Too large and
approachisslowedandstepped.
STEPS:
1. With power, proportional, and
integral parameters tuned, and
derivative time tuned for fast
response to upsets, watch
control process in work mode.
Note approach to setpoint.
2. Enter program mode and navi-
gate to "dAC" function on level 1.
If overshoot suppression is
needed, increase multiple of
proportional band. Range is
0.5 - 5.0. If approach is stepped
and slow, decrease multiple.
3. Repeat steps 1-2 until control is
acceptable.
DERIVATIVE SENSITIVITY
This parameter compensates
when power/load balance is such
thatderivativesuppressesovershoot
but does not sufficiently speed up
response to upsets.
Derivative sensitivity is frac-
tion multiplier of derivative time.
Range is 0.1 - 1.0. By fractioning
derivativetimeitspeedsactionupto
10 times faster.
STEPS:
1. With power, proportional, and
integral parameters tuned, and
derivative time tuned for over-
shoot suppression, watch
control process in work mode,
introduce upset by opening
chamber door(s), and note
speed of response to upset.
17
ProCO2model120
version1.0
2. Enter program mode and navigate
to "dEr.S" function on level 4. To
get to level 4 go to "VEr" on level
3 and press both up and down
buttons and hold for 10 sec-
onds. If response to upset is too
slow, decrease setting (limit is
0.1). If response is too fast
resulting in overcompensation,
increase setting (limit is 1.0).
3. Repeat steps 1-2 until control is
acceptable.
AUTOMATIC TUNING
If carbon dioxide setpoint is
sufficientlyfarawayfromoutsideair
level,ProCO2cancalculateit'sown
control parameters. It runs a few
testsonhostchamber. Takesafew
measurements. Calculatesoptimum
control parameters, and sets itself.
Ifsetpointisnotfarfromambi-
ent, autotuning will not work.
Autotuningsetsallcontrolpa-
rameters. Can't distinguish when
some are not needed. Thus some
jobsautotunedareovertuned.
Evenjobsthatareautotunable,
usuallyrequiresomemanualtuning
afterwardstofinetune.
Autotuning is most useful in
toughjobsthatrequirecomplextun-
ing. Getsyouclosefast(sometimes
veryclose). Thussavesontimeand
gas. Autotuninginstructionswillbe
in the next version of this manual.

Single Setpoint Control 18
ProCO2 model 120
version 1.0
This section will describe how to use single setpoint control with the
ProCO2. Single setpoint control is a way to control the level of gas in
the chamber. For more information, see the “Operation” section of this
manual. The ProCO2 can only use 0-20 for a set point. Other wise the
sensor will overload.To set a setpoint on the controller, follow these
steps:
1. Make sure the compressed carbon dioxide gas supply is connected to the back panel of
the ProCo2at the “IN” barb.
2. Open the regulator on the compressed carbon dioxide source to 0-25 PSIG, Never
exceed 25 PSIG or damage will occur to the unit. For the best results use approxi-
mately 2 PSIG in a Culture Chamber and 15 PSIG in an Animal Chamber when operating.
3. Check to make sure that the gas is connected properly by opening the bleed valve on
the front panel. If gas is heard expelling from the “BLEED” barb then it is connected cor-
rectly. Once you have confirmed that the gas is connected properly, close the bleed valve.
4. To set a setpoint, push and hold the “*” button. While holding the “*” button use the up
and down buttons to adjust the “set” to read what you want the setpoint to be. Once you
have adjusted the number to the desired reading, release the “*” button and the controller
will begin to go towards the new setpoint. Remember you can only use 0-20 for a setpoint
anything higher will overload the sensor.
5. Flip the switch on the front panel labeled “GAS” upward. This will allow the gas to enter
the chamber.

Setting the Alarm Setpoint 19
ProCO2 model 120
version 1.0
This section will explain how to set the alarm setpoint. Remember,
when you want the alarm function to be active you must make sure the
alarm switch on the front of the controller is on.
1.Pushtheupanddownbuttonsatthesametimefor3seconds.
2.Now, go to“LEVL2”. In ‘LEVL2” navigate to “SP2.A”. Change this number to either “DV.hi”
(DeviationHigh)or“DV.Lo”(DeviationLow). Thiswilldeterminewhetherthealarmactivates
beloworabovethe“SEt.2”(alarmsetpoint).
3.In“LEVL1” navigate to“SEt.2”. Adjustthisnumberbyholdingthe“*” button and using theup
ordownbuttons. Changethisnumbertothedesiredalarm setpoint.
4. In“LEVL1”navigateto“bnd.2”. Thisnumberwill determine the range of the alarm setpoint.
The “bnd.2” number is a coarse adjustment, the number that you change this to will
not be the exact size of the band width. To set the alarm to activate as quickly as possible,
setthebandto “0.1”. Increase the number to increase the range. Remember itisacoarse
adjustment.
5.Remember,ifyouwantthealarm to have the abilitytocomeonyoumustflip the “Alarm”
switchonthe frontpanel.