Chemglass Life Sciences CHEMcell User manual

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Chemglass Life Sciences Gas Mixing Module - User Manual

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Table of Contents
List of Figures................................................................................................................ 3
Overview ........................................................................................................................ 4
Common Terms ......................................................................................................................4
Power Button ..........................................................................................................................5
Connections............................................................................................................................5
Tubing.....................................................................................................................................6
Touchscreen Display .................................................................................................... 7
Main Page...............................................................................................................................7
Modes of Operation.............................................................................................................8
About...................................................................................................................................8
Summary Page .......................................................................................................................9
Ratio Control Pages ..............................................................................................................11
How to Change Parameters ..............................................................................................11
Totalizer Pages .....................................................................................................................13
Control Functionality .................................................................................................. 14
Ratio Control .........................................................................................................................14
Target Total Gas Flow Limitations.........................................................................................14
Pressure Control ...................................................................................................................15
Maximum Pressure Shutdown...........................................................................................15
Pressure Limit Control.......................................................................................................15
Appendix I - Admin Page ............................................................................................ 17
Control Modes (CtrlMode) .....................................................................................................18
Pressure Settings..................................................................................................................19
Pressure Control Settings (PressCtrlSettings) ...................................................................19
High Pressure Alarm (High Press Alrm) ............................................................................20
Raw Pressure Data (Raw Press Data) ..............................................................................21
Default Values:......................................................................................................................21
Low Flow Alarm Settings.......................................................................................................22
Calibrations...........................................................................................................................23
Tare Pressure ...................................................................................................................24
Tare Alicat Flow Controllers ..............................................................................................25
Calibrate CO2....................................................................................................................26
FactoryMaintenance..............................................................................................................28
Appendix II – Quick Setup Guide............................................................................... 29

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List of Figures
FIGURE 1–POWER BUTTON ON GAS MIXING MODULE (FRONT)........................................................................... 5
FIGURE 2: CONNECTIONS TO THE GAS MIXING MODULE (BACK) ............................................................................5
FIGURE 3–TUBING CONNECTION (FRONT) ........................................................................................................ 6
FIGURE 4–TUBING CUTTER .......................................................................................................................... 6
FIGURE 5–MAIN PAGE –RUNNING/STOPPED ..................................................................................................7
FIGURE 6–OPERATION MODE,RUNNING OR STOPPED ....................................................................................... 8
FIGURE 7–MAIN PAGE -ABOUT.................................................................................................................... 8
FIGURE 8–SUMMARY PAGE –“D” OR “I” CONDITIONS ......................................................................................9
FIGURE 9–SUMMARY PAGE –OVERPRESSURE CONDITION .................................................................................. 9
FIGURE 10–SUMMARY PAGE –LOW FLOW ALARM.......................................................................................... 10
FIGURE 11 –SUMMARY PAGE –2PT CALIBRATION ACTIVE................................................................................. 10
FIGURE 12 –RATIO CONTROL PAGE 1............................................................................................................ 11
FIGURE 13 –RATIO CONTROL PAGE 2, WITH AND WITHOUT 2PT CALIBRATION....................................................... 11
FIGURE 14 –NUMERICAL ENTRY KEYPAD........................................................................................................ 12
FIGURE 15 –TOTALIZERS –AVAILABLE UNITS .................................................................................................. 13
FIGURE 16 –TOTALIZERS –STANDARD CUBIC CENTIMETERS (SCC) AND LITERS (SL)................................................ 13
FIGURE 17 –ADMIN MAIN PAGE.................................................................................................................. 17
FIGURE 18 –ADMIN CONTROL MODES .......................................................................................................... 18
FIGURE 19 –CONTROL MODE OFF................................................................................................................ 18
FIGURE 20 –PRESSURE SETTINGS MENU........................................................................................................ 19
FIGURE 21 –PRESSURE CONTROL SETTINGS .................................................................................................... 19
FIGURE 22 –INVALID PRESSURE SETTINGS ...................................................................................................... 20
FIGURE 23 –MAX PRESSURE ALARM............................................................................................................. 20
FIGURE 24 –RAW PRESSURE DATA ............................................................................................................... 21
FIGURE 25 –DEFAULT PRESSURE SETTINGS..................................................................................................... 21
FIGURE 26 –LOW FLOW ALARM SETTING ON/OFF –PAGE 1 ............................................................................. 22
FIGURE 27 –LOW FLOW ALARM SETTING –PAGE 2 ......................................................................................... 22
FIGURE 28 –CALIBRATION LOGIN ................................................................................................................. 23
FIGURE 29 –CALIBRATION MENU................................................................................................................. 23
FIGURE 30 –TARE PRESSURE PAGE ............................................................................................................... 24
FIGURE 31 –TARE ALICAT PAGE –INITIAL....................................................................................................... 25
FIGURE 32 –ALICAT TARING EXAMPLE BEFORE AND AFTER TARING ..................................................................... 25
FIGURE 33 –CALIBRATE CO2PAGE 1–2PT CALIBRATION NOT USED/USED .......................................................... 26
FIGURE 34 –CALIBRATE CO2PAGE 2............................................................................................................. 26
FIGURE 35 –CALIBRATE CO2PAGE 2–ALL VALUES ZERO .................................................................................. 27
FIGURE 36 –CALIBRATE CO2PAGE 2–REPEATED ENTRIES ................................................................................ 27

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Overview
The Chemglass Life Sciences Gas Mixing Module is used to deliver a mixture of Air and
CO2at a controlled ratio. The Mixing Module houses built-in precision gas flow
controllers that are operated through a touchscreen display.In addition to the flows, the
pressure of the gas mixture is controlled within a safe limit. Gas temperatures are
available for monitoring.
The following parameters can be set by the user:
1. Target total gas flow rate (SCCM = Standard Cubic Centimeters per Minute).
2. Percent CO2– The required percent Air is automatically calculated as (100% -
%CO2).
The following values are measured or calculated by the Gas Mixing Module:
1. Setpoint and actual CO2flow rate (SCCM)
2. Setpoint and actual Air flow rate (SCCM)
3. Actual total gas flow rate
4. Totalized CO2flow (SCC = Standard Cubic Centimeters or SL = Standard Liters)
5. Totalized Air flow (SCC or SL)
6. Temperatures of Air and CO2(deg C)
7. Outlet Pressure of mixed gas (PSIG)
Common Terms
The following terms are used in this document and displayed on the touchscreen
displays:
Term
Description
CO2
Carbon Dioxide gas
Ctrl
Control
Deg C
Degrees Celsius temperature
OD
Outside diameter of tubing
Press
Pressure
PSIG
Pounds per square inch of gauge pressure
SCCM
Standard Cubic Centimeters per Minute
SCC
Standard Cubic Centimeters
SL
Standard Liters

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Power Button
The power button on the front of the module glows blue when on.
Figure 1 – Power Button on Gas Mixing Module (front)
Connections
The following are the connections to the Gas Mixing Module:
•CO2 gas inlet push-on connection accepts ¼” OD flexible tubing. Gas should be
filtered through a 0.2 micron filter.
oWarning: Do not exceed 20 PSIG on the CO2gas inlet. High pressure
may damage the internal pressure sensor.
•Air gas inlet push-on connection accepts ¼” OD flexible tubing. Gas should be
filtered through a 0.2 micron filter.
oWarning: Do not exceed 20 PSIG on the air gas inlet. High pressure may
damage the internal pressure sensor.
•Gas outlet push-on connection accepts ¼” OD flexible tubing
•Power connection from a 100 - 240 VAC to 24 VDC power adapter which is
supplied with the Mixing Module.
oWarning: Connecting a different power supply to the Mixing Module may
permanently damage the internal electronic components.
•Data communication cable – Ethernet, RJ-485
Figure 2: Connections to the Gas Mixing Module (back)

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Tubing
The gas mixer is configured for 1/4" tubing with quick-connects. Gas feed tubing is
connected to the rear of the device and the output tubing to the front of the mixer by
simply pushing the tubing into the quick connect fittings.
SMC 1/4" O.D. tubing such as TIUB Polyurethane Tubing or equivalent is
recommended.
To remove the tubing, push and hold the outer metal ring of the quick connect IN
towards the mixing box, while gently pulling out on the tubing. DO NOT force the tubing
out by pulling.
Figure 3 –Tubing Connection (front)
Always make a fresh 90 degree cut before re-connecting tubing. Use a tubing cutter as
displayed in the following figure.
Figure 4 – Tubing Cutter

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Touchscreen Display
All user interface with the Gas Mixing Module is accomplished through the touchscreen
display mounted on the front.
Screen will go blank after 60 minutes of inactivity. Touching anywhere on the screen
makes it come back on.
If an alarm is activated, the display will flash and a buzzer will sound. Touching the
display once will stop the flashing and sound but the alarm will remain active.
On initial power up, the Gas Mixing Module starts in the RUNNING mode with the
parameters set at the values entered prior to power down. The complete startup will
take approximately 5 seconds. The Main page will appear on the Gas Mixing Module
touchscreen display.
Main Page
The following figure shows the Main page in Running and Stopped modes of operation.
Figure 5 – Main Page – Running/Stopped
The Main page provides touch targets to the following:
-Mode of Operation: Allows toggling between modes of operation.
-Summary Page: Provides overview of the Gas Mixing Module operation.
-Ratio Ctrl Page: Allows entering of the control parameters for the Gas Mixing
Module.
-Totalizer Page: Provides viewing of the current flow totals and resetting of the
totalizers.
Alarm Status/Clear Alarm: Provides indication of high pressure alarm and target for
clearing this alarm.

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-Admin Page: For administration and maintenance use only. Not used during normal
operation (see appendix).
Each of the above is described in more detail in the following sections.
Modes of Operation
Two modes of operation are available:
1. RUNNING – Gas Mixing Module will operate automatically to maintain the set
operating parameters.
2. STOPPED – Gas Mixing Module shuts down and zero set points are delivered to
the flow controllers.
The following touch targets allow toggling between the two modes of operation. The
current mode is displayed:
Figure 6 – Operation Mode, Running or Stopped
About
The target ABOUT on the Main page brings up the software version information for the
Gas Mixing Module.
Figure 7 – Main Page - About

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Summary Page
The Summary page provides an overview of the current Gas Mixing Module Operation.
Set points (SP), flows, temperatures (T Deg C), and pressure are displayed. The
values are continuously updated while the Gas Mixing Module is running. Mode of
operation, Run/Stop, is also displayed on the upper left corner of the Summary page.
The control range for the operating pressure (high/low) is shown at the bottom of the
screen. If the actual Gas Mixing Module outlet pressure drifts outside this range, the
symbols “I” or “D” are displayed to indicate that the total flow is being increased or
decreased automatically to bring the pressure back to within the target control range.
More information is available on Pressure Control override later in this document.
Figure 8 – Summary Page – “D” or “I” Conditions
If the maximum control pressure is exceeded, the symbol “OP” or over-pressure in red
text appears on this page as well as on the Main page.
Figure 9 – Summary Page – Overpressure Condition

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If the low flow alarms are enabled and active, the white text LF in red background will
appear on the page.
Figure 10– Summary Page – Low Flow Alarm
If the 2-point calibration for CO2 flow is active, the text 2Pt in white with green
background is shown on the upper right corner of the Summary page.
Figure 11 – Summary Page – 2Pt Calibration Active

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Ratio Control Pages
Ratio Control Page 1 provides access to the user adjustable parameters for the
operation of the Gas Mixing Module. Ratio Control Page 2 contains calculated values
for reference.
Figure 12 – Ratio Control Page 1
Figure 13 – Ratio Control Page 2, with and without 2Pt Calibration
How to Change Parameters
1. On the Ratio Control page 1, touch the value to be changed to open the numerical
entry pad.

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NOTE: The CLR (clear) button will clear out the value shown at the top of the key
pad screen or clear out the value that has been just entered. The CAN (cancel)
button will close the key pad screen without making any changes.
Figure 14 – Numerical Entry Keypad
2. Type in the new value followed by ENT (enter). The numerical entry pad closes.
3. When all values have been changed, touch Enter on the RatioCtrl page 1 to
commit the new parameter settings to the Gas Mixing Module controller. NOTE:
Changes to values will NOT be sent to the controller unless Enter has been
touched.
The following table lists the allowable ranges for the adjustable parameters:
Parameter
Allowable
Range
Units
Limits
Percent CO2
0 – 100
%
100 SCCM CO2flow
Target Total Gas
Flow Rate
0 – 1100
SCCM
Flowmeter ranges and Pressure Override (see
sections below for details)
The operation mode button on the Ratio Control page 1 functions exactly the same as
the button on the Main page.The SUMMARY button provides a link to the Summary
page.
If the Target Total Gas Flow Rate is limited by the flow meter ranges, the text MAX
appears next to the value for the Total Flow in orange. The entered Target Total Gas
Flow Rate is automatically reduced to the limit of the flow meters. See the section later
in this document for more details.

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Totalizer Pages
Total flows of CO2and Air are calculated and displayed in Standard Cubic Centimeters
(SCC) and Standard Liters (SL). The totalizers can be reset to zero by touching the
RESET buttons. Totalizers automatically reset to zero when the total reaches
999,999,999.
Figure 15 – Totalizers – Available Units
Figure 16 – Totalizers – Standard Cubic Centimeters (SCC) and Liters (SL)

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Control Functionality
Ratio Control
In normal operation, the target CO2percentage is used to calculate the setpoints for the
CO2flow controller and air flow controller based on the target total gas flow rate.
CO2flow setpoint (SCCM) = (% CO2/ 100) * Target total flow
Air flow setpoint (SCCM) = Target total Flow – CO2flow
Target Total Gas Flow Limitations
The target percentage of CO2is the most important parameter within the Gas Mixing
Module. If the combination of the requested CO2percentage and target gas flow rate
exceed the limits of the flowmeters, the gas flow set points are automatically reduced to
deliver the correct CO2 percentage. The symbol “MAX” appears next to the value on
the Ratio Control page1.
For higher accuracy, the CO2flowmeter has a maximum limit of 100 SCCM while the Air
flowmeter is limited to 1000 SCCM. The maximum total gas flow available is 1100
SCCM.
For example, if parameters of 20% CO2and 1000 SCCM target total flow are entered,
Requested CO2flow setpoint= 1000 * 0.20 = 200 SCCM (too high)
This value exceeds the 100 SCCM limit for CO2flow. The actual flow set points are
calculated by:
Actual (limited) CO2flow setpoint100 SCCM (max)
Actual (limited) total gas flow setpoint= 100 SCCM / 0.20 = 500 SCCM
Actual Air flow setpoint= 500 – 100 = 400 SCCM
Alternatively, if 4% CO2is required and a target total flow value of 1100 SCCM is
entered:
Requested CO2flow setpoint= 1100 * 0.4 = 44 SCCM
Requested Air flow setpoint= 1100 – 44 = 1056 SCCM (too high)
Actual (limited) Air flow setpoint1000 SCCM (max)
Actual CO2 (limited) flow setpoint= (1000/0.96) * 0.04 = 41.6 SCCM
Actual (limited) total gas flow setpoint= 1000 + 41.6 = 1041.6 SCCM

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Pressure Control
Maximum Pressure Shutdown
If the outlet pressure exceeds a maximum of 1.5 PSIG, the mixing module will shut
down both gas flows to protect the devices downstream of the mixing module. The text
“Maximum Pressure Alarm” will be displayed on the touchscreen display.
After resolving the high pressure problem, operation mode of the mixing module will
have to be changed manually from Stopped to Running before automatic control can
resume.
Pressure Limit Control
The Gas Mixing Module outlet pressure is normally controlled between low and high
pressure control limits displayed on the Summary page. These control limits are 0.05
and 0.50 PSIG, respectively, and are based on the requirements of the receiving vessel.
If pressure exceeds these limits, the gas flow rates for Air and CO2are automatically
adjusted to bring the pressure back to the target limits.
For example, if 5% is entered for %CO2and 1000 SCCM for the target total gas flow,
the following set points are set while the pressure is within the allowed limits:
Calculated CO2flow setpoint= 1000 * 0.05 = 50 SCCM
Calculated Air flow setpoint= 1000 - 50 = 950 SCCM
If pressure exceeds the high limit of 0.5 PSIG, both the Air and CO2 flow rates are
reduced by 10% every 10 seconds until the pressure is below 0.5 PSIG. The symbol
“D” appears on the Summary page to indicate decreasing flow rates.
After the first 10-sec period, pressure above 0.5:
Calculated CO2flow setpoint= 50 * 0.90 = 45 SCCM
Calculated Air flow setpoint= 950 * 0.90 = 855 SCCM
After the second 10-sec period, pressure has dropped below 0.5:
Calculated CO2flow setpoint= 45 SCCM
Calculated Air flow setpoint= 855 SCCM
No more adjustments are made while pressure is within the allowable gap. If pressure
continues to drop and falls below the low limit of 0.05 PSIG, both flow rates are
increased at the rate of 10% every 10 seconds until the pressure is above 0.05 and the
flow rates are back to the original target values. The symbol “I” appears on the
Summary page to indicate the increasing flow rates.
After the first 10-sec period, pressure below 0.05:
Calculated CO2flow setpoint= 40 * 1.10 = 44 SCCM
Calculated Air flow setpoint= 760 * 1.10 = 836 SCCM

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After second 10-sec period, pressure above 0.05, but flow rates are below original set
points:
Calculated CO2flow setpoint= 44 * 1.10 = 48.4 SCCM
Calculated Air flow setpoint= 836 * 1.10 = 919.6 SCCM
After third 10-sec period, pressure between 0.05 and 0.5:
Calculated (limited) CO2flow setpoint= 48.4 * 1.10 50 SCCM
Calculated (limited) Air flow setpoint= 919.6 * 1.10 950 SCCM
No more adjustments are made since the flow rates have returned to the original set
points.

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Appendix I - Admin Page
The Admin page is only used during the initial setup or periodic maintenance of the Gas
Mixing Module. Modifying the settings on this page can damage, disrupt the function, or
affect the accuracy of the Gas Mixing Module and should only be attempted by qualified
personnel.
Figure 17 – Admin Main Page
The following sections describe the function of each of the buttons on the Admin page.

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Control Modes (CtrlMode)
Figure 18 – Admin Control Modes
This displays allows activation/deactivation of the modes of control. When activated,
the corresponding box next to the mode appears in green. When deactivated, the
boxes appear in gray. In normal operation, all boxes should be in green. On the main
Admin Page, each of the control modes appear as a single letter.
-A, Autostart – The unit will normally start in RUNNING mode when the unit is
powered up. If this mode is deactivated, the unit will start in STOPPED.
-C, Ctrl – In normal operation, the unit operates in RUNNING mode. If this is
deactivated, the unit will be in STOPPED mode. (The same function as the
Operation Mode button).
-P, PressCtrl – In normal operation, pressure control overrides the total flow
requirements to maintain the pressure within desired limits. If deactivated, pressure
control will not function.
-M, PAlarmMgmt – In normal operation, when max pressure alarm is activated, gas
flows stop until the pressure is back to normal range, then gas flows re-start
automatically. If deactivated, automatic restart will not occur and a user must
manually clear a high pressure alarm to restart the gas flows.
-F, LowFlowAlarm – If activated, alarms will be generated if either Air or CO2
measured flows fall below a certain percentage. No control action is taken.
The following figure shows one of the elements turned off:
Figure 19 – Control Mode Off

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Pressure Settings
Pressure settings are available through the following page.
Figure 20 – Pressure Settings Menu
Pressure Control Settings (PressCtrlSettings)
The Gas Mixing Module pressure is controlled between low and high pressure limits
displayed on the Summary page. The limits can be adjusted from this display:
Figure 21 – Pressure Control Settings
The limits are based on the requirements of the receiving vessel on the outlet of the
Gas Mixing Module. If pressure exceeds these limits and if pressure control mode is
turned on, the gas flow rates for Air and CO2are automatically adjusted to bring the
pressure back to the target limits. At Max Pressure Alarm, the gas flow rates are
stopped and the high pressure alarm is turned on.
Note: If the high control pressure is exceeded and if pressure control mode is turned on,
the system will automatically reduce the two gas flows until the pressure is between the
high and low control pressures. The gas flows will not be increased unless the pressure
falls below the low control pressure. If it is desirable to increase flows after a high
pressure event, try increasing the low control pressure setting.

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The following table summarizes the allowable ranges for these parameters:
Parameter
Allowable Range
Units
Default Value
Max Pressure Alarm
0.01 – 5.0
PSIG
1.5
High Control Pressure
0.01 – 5.0, and lower
than Max Pressure
Alarm
PSIG
0.5
Low Control Pressure
0.01 – 5.0, and lower
than High Control
Pressure
PSIG
0.05
If invalid values are entered, the following error messages can appear on the display:
Figure 22 – invalid Pressure Settings
High Pressure Alarm (High Press Alrm)
This displays allows clearing of the alarm if the Max Pressure Alarm is activated. The
numerical values are for information only. When alarm is cleared, the red text becomes
gray. If “P Alarm Mgmt” is turned on (default setting is on), the system will automatically
try clearing the high pressure alarm if the pressure falls below the high control pressure.
To clear the high pressure alarm immediately, a user can touch the “Clear Alarm” button
and if the pressure is below the maximum pressure, the unit will restart gas flows.
Figure 23 – Max Pressure Alarm