Manual

K-30 3% & 10% CO2

Sensor Module and OEM Platform

General
®
The K30 sensor platform CO2 Engine K30 3% can be customised for a variety of sensing and
control applications. This platform is designed to be an OEM module for built-in applications in a
host apparatus, and hence should be optimised for its tasks during a dialog between SenseAir
and the OEM customer. This document is to be considered as the starting point for such a
dialog.
 Item CO2 Engine ® K30 3% Art. No. 030-7-0001

Target gas Carbon dioxide (CO2)

Operating Principle Non-dispersive infrared (NDIR)

Measurement range 0 to 3%vol (extended range up to 10%vol)

1
Accuracy ±300ppm ±3% of reading

Response time (T1/e) 20sec diffusion time

Rate of Measurement 0.5Hz

Operating temperature 0 to 50°C

Operating humidity 0 to 95%RH non condensing

Storage temperature -30 to 70°C

Dimensions 51 x 57 x 14 mm (Length x Width x approximate Height)

Power supply 4.5 to 14.0VDC maximum rating (without reverse polarity

protection) stabilised to ±5% over load and line changes. Ripple
2
voltage less than 100mV.

Current Consumption 40mA average

<150mA peak current (averaged during IR lamp ON, 120msec)
<300mA peak power (during IR lamp start-up, the first 50msec)

Warm Up time to spec 1 min

precision
Life expectancy >15 years

Serial communication UART, Modbus protocol. Direction control pin for direct
connection to RS485 receiver integrated circuit.

OUT 1 D/A Resolution: 10mV (10 bit)

Linear Conversion Range: 1 to 4V = 0 to 2%
Electrical Characteristics: ROUT <100  RLOAD >5k

OUT 2 D/A Resolution: 5mV (10 bit)

Linear Conversion Range: 1 to 4V = 0 to 2%
Electrical Characteristics: ROUT <100 RLOAD >5k

OUT 3 -

OUT 4 -

Maintenance Maintenance-free with using SenseAir ABC logic Self calibration

using for normal indoor applications
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Table 1. Key technical specification for the CO2 Engine K30 3%

1
Accuracy is specified over operating temperature range at normal pressure 101.3kPa. Specification is referenced to certified calibration
mixtures. Uncertainty of calibration gas mixtures (±1% currently) is to be added to the specified accuracy for absolute measurements.
2
Notice that absolute maximum rating is 14V, so that sensor can be used with a 12V±10% supply.
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Terminal descriptions
The table below specifies what terminals and I/O options are available in the general K30
®
platform. Please note, however, that in the CO2 Engine K30 3% default configuration, only
OUT1, OUT2, Din1, Din2 and Status have any pre-programmed functions. These are described
in the chapter “Default Configuration”.

Functional group Descriptions and ratings

Power supply
G+ referred to G0: Absolute maximum ratings 4.5 to 14V, stabilised to within 5%
5.0 to 9V preferred operating range.
Unprotected against reverse connection!
Outputs
OUT1 Buffered linear output 0..5 or 1..5VDC or 0..10V or 2..10V, depending on
specified power supply and sensor configuration. Load to ground only!
Resolution: 10mV (8.5 bits in the range 1..5V).
Can be used as an overview alternative to OUT2, or in an independent
linear control loop, such as housing temperature stabilisation.
OUT2 Buffered linear output 0..5 or 1..5VDC, depending on specified power
supply and sensor configuration. Load to ground only!
Resolution: 5mV (10 bits)
OUT3 CMOS unprotected. Digital (High/Low) output.
High Output level in the range 2.3V min to DVDD = 3.3V. (1mA source)
Low output level 0.75V max (4mA sink)
Can be used for gas alarm indication, or for status indication etc.
OUT4 CMOS unprotected. Digital (High/Low) output.
High Output level in the range 2.3V min to DVDD = 3.3V. (1mA source)
Low output level 0.75V max (4mA sink)
Can be used for gas alarm indication, or for status indication etc.
Status CMOS unprotected.
High Output level in the range 2.3V min to DVDD = 3.3V. (1mA source)
Low output level 0.75V max (4mA sink)
Serial Communication
UART (TxD, RxD) CMOS, ModBus communication protocol.
Logical levels corresponds 3.3V powered logics. Refer “ModBus on CO2
Engine K30“ for electrical specification.
2
I C extension.

Contact SenseAir Pull-up of SDA and SCL lines to 3.3V.

Inputs & Optional jumper field

Din0, Din1, Din2, Digital switch inputs have pull-up 120kΩ to DVCC 3.3V most of the time.
Din3, Din4 Pull-up resistance is decreased to 4..10kΩ only during read of input / jumper
to provide cleaning of the contacts by larger currents. They are the same as
inputs on IDC connector.
Can be used to initiate calibration or to switch output range or to force
output to predefined state. All depends on customer needs.
Table 2. I/O notations used in this document for the K30 platform with some descriptions and
ratings. Please, beware of the red coloured texts that pinpoint important features for the
system integration!

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Installation
The modules are factory calibrated and ready for use directly after power up. There are several
®
alternative ways to connect the CO2 Engine K30 3% to a host system:

Do not use edge connector for connection to the host system without discussion with
SenseAir!

1. Using “UART connector”, including terminals for power supply (G+ and G0), UART (TxD,
RxD).

2. Using the 3 pins main terminal. Available signals are power supply (G+ and G0) and the
buffered analogue output (OUT1). A variety of user selections exists for this option
regarding standard 5.08 mm pitch components and mounting alternatives (top/bottom).

3. Using 20 pin connector strips, or IDC connector, most of the system information is
reached.

Host integration considerations and EMI shielding

If an IDC connector is being used to connect the K30 module to a host PCB, this connector can
in some situations be used as the only fixture. If instead fixing the K30 PCB using mechanical
poles and screws, no more than two (2) positions should be considered. This is because the
PCB should not be exposed to any mechanical stress, and it is small and lightweight enough for
just 2 attachment points.

To provide means for attachments, there are four (4) possible screw holes available, all of them
having a collar that is electrically connected to ground (G0). These connections are, however,
not totally equivalent:

 The two screw points in the upper left corner (having the IDC and edge connectors faced
downwards, are connected to the analogue ground. They are the preferred choice for
connection to some EMI shield, if so is required. This is normally necessary only if the
application is such that large EMFs are foreseen. If this option is being used, precaution
must be taken so as to exclude any power supply currents! Sensor reading instability is an
indication of the need for shielding, or of improper enclosure system groundings.

 The two screw points in the right bottom corner are connected to the digital ground.
Connection to some EMI housing shield is less effective when this option is used, but on
the other hand the sensor may be powered via these connections.

Note 1: To avoid ground loops, one should avoid connecting the analogue and digital
grounds externally! They are connected internally on the K30 PCB.

Note 2: The terminals are not protected against reverse voltages and current spikes!
Proper ESD protection is required during handling, as well as by the host interface
design.

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Default functions /configurations
Outputs
®
The basic CO2 Engine K30 3% configuration is a simple analogue output sensor transmitter
signal directed to OUT1 and OUT2. Output OUT1 is configured to give a measurement
overview, whereas OUT2 by default is to provide more exact measurements. Via the edge
connector serial communication terminal, the CO2 readings are available to an even higher
precision (Modbus protocol), together with additional system information such as sensor status,
analogue outputs, and other variables.

The user can modify the output ranges at any time using a dedicated development kit, including
PC software and a special serial communication cable.

Terminals Output Correspondence

OUT1 1.0…4.0VDC 0…2%CO2

OUT2 1.0…4.0VDC 0…2%CO2

®
Table 3. Default analogue output configuration for CO2 Engine K30 3%

Background- / Zero Calibration procedure

The sensor has two calibration functions: zCal that will adjust the sensor to show 0ppm, and
bCal that will adjust the sensor to 400ppm. The reference gas used should contain a CO 2
concentration of 0 or 400ppm. If the reference gas has a concentration that differs from 0 or
400ppm, we recommend to calibrate using UIP5 instead of the method described below.

1. Connect sensor with tube and nipple (two alternative positions for nipple attachment).
 Soft Tube: 2x4mm
 Nipple: nylon hose, 30x0.8x2.2mm

2. Let gas mixture flow into the sensor through applied tube.
 bCal: 400ppm CO2 zCal: 0ppm, e.g. Nitrogen
 Flow time: ≥3 minutes
 Flow range: 0.3─1.0 litre/minute

3. Short circuit Din1 (bCal)/Din2 (zCal)

 Shortcut Time: ≥8 seconds

Top view
4. Calibration executed?
Yes No
(Sensor shows (sensor detected unstable
400ppm (bCal)/0ppm (zCal) CO2) gas concentration)
1. wait 10 seconds
2. repeat step 3 and 4
5. Remove shortcut (do not breathe on sensor)!
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Input Switch Terminal Default function
(normally open) (when closed for minimum 8 seconds)

Din1 bCAL (background calibration) assuming 400ppm CO2 sensor exposure

Din2 zCAL (zero calibration) assuming 0ppm CO2 sensor exposure

Table 4. Switch input default configurations for K30 3% ext. range 10%

ABC algorithm
The default sensor OEM unit is maintenance free in normal environments thanks to the built-in
self-correcting ABC algorithm (Automatic Baseline Correction). This algorithm constantly keeps
track of the lowest reading of sensor over a 7.5 days interval and slowly corrects for any long-
term drift detected as compared to the expected fresh air value of 400ppm CO2.

When checking the sensor accuracy, PLEASE NOTE that the sensor accuracy is defined at
continuous operation (at least three (3) ABC periods after installation with ABC turned ON)!

Rough handling and transportation might result in a reduction of sensor reading accuracy. With
time, however, if actuated the ABC function will tune the readings back to the correct numbers.
The default “tuning speed” is limited to about 200ppm/week.

Maintenance
®
The CO2 Engine K30 is basically maintenance free in normal environments thanks to the built-
in self-correcting ABC algorithm. Discuss your application with SenseAir in order to get advice
for a proper calibration strategy.

Self-diagnostics
The system contains complete self-diagnostic procedures. A full system test is executed
automatically every time the power is turned on. In addition, constantly during operation, the
sensor probes are checked against failure by checking the valid dynamic measurement ranges.
All EEPROM updates, initiated by the sensor itself, as well as by external connections, are
checked by subsequent memory read back and data comparisons. These different system
checks return error bytes to the system RAM. If this byte is not zero, the logic output terminal
Status would be put into Low level state. The full error codes are available from the UART port
2
or via I C communication. Offset regulation error and Out of Range are the only bits that are
reset automatically after return to normal state. All other error bits have to be reset after return
to normal by UART overwrite, or by power off/on.

Output Terminal Default function

Status High level = OK

Low level = Fault
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Table 5. Default Logic output configured for CO2 Engine K30 3%

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Error code and action plan
(error code can be read via one of communication channels)

Bit # Error Error description Suggested action

code

0 1 Fatal Error Try to restart sensor by power OFF/ON.

Contact local distributor.

1 2 Offset regulation error Try to restart sensor by power OFF/ON.

Contact local distributor.

2 4 Algorithm Error. Try to restart sensor by power OFF/ON.

Indicate wrong EEPROM Check detailed settings and configuration
configuration. with software tools.
Contact local distributor.

3 8 Output Error Check connections and loads of outputs.

Detected errors during output signals Check detailed status of outputs with
calculation and generation. software tools.

4 16 Self-Diagnostic Error. Check detailed self-diagnostic status with

May indicate the need of zero software tools. Contact local distributor.
calibration or sensor replacement.

5 32 Out of Range Error Check connections of temperature and

Accompanies most of other errors. relative humidity probe (if mounted).
Can also indicate overload or failures Try sensor in fresh air.
of sensors and inputs. Perform CO2 background calibration.
Check detailed status of measurements
Resets automatically after source of with software tools.
error disappearance. See Note 1!

6 64 Memory Error Check detailed settings and configuration

Error during memory operations. with software tools.

7 128 Reserved

Table 6. Error code and action plan

Note 1. Any probe is out of range. Occurs, for instance, during over-exposure of CO2 sensor, in which
case the error code will automatically reset when the measurement values return to normal. Could also
indicate the need of zero point calibration. If the CO 2 readings are normal, and still the error code remains,
any other sensor probe mounted (if any) can be defect, or the connection to this probe is broken.

Remark: If several errors are detected at the same time the different error code numbers will be
added together into one single error code!

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Support
The quickest way to obtain technical support is via email. Please send all support inquires to
[email protected].

Please include a clear, concise definition of the problem and any relevant troubleshooting
information or steps taken so far, so we can duplicate the problem and quickly respond to your
inquiry.

Warranty
This meter comes with a 1YEAR (warranty period) limited manufacturer’s warranty, starting from
the date the meter was shipped to the buyer.

During this period of time, CO2Meter.com warrants our products to be free from defects in
materials and workmanship when used for their intended purpose and agrees to fix or replace
(at our discretion) any part or product that fails under normal use. To take advantage of this
warranty, the product must be returned to CO2Meter.com at your expense. If, after examination,
we determine the product is defective, we will repair or replace it at no additional cost to you.
This warranty does not cover any products that have been subjected to misuse, neglect,
accident, modifications or repairs by you or by a third party. No employee or reseller of
CO2Meter.com’s products may alter this warranty verbally or in writing.

Use of this device in environments above 95% humidity may cause irreparable damage to
the components and is not warranted.

Liability
All liability under this agreement shall be limited to the actual cost of the product paid to
CO2Meter.com. In no event shall CO2Meter.com be liable for any incidental or consequential
damages, lost profits, loss of time, lost sales or loss or damage to data, injury to person or
personal property or any other indirect damages as the result of use of our products.

Returns
If the product fails under normal use during the warranty period, a RMA (Return Material
Authorization) number must be obtained from CO2Meter.com. After the item is received
CO2Meter.com will repair or replace the item at our discretion.

To obtain a RMA number, call us at or email us at (386) 256-4910 [email protected].

When requesting a RMA please provide reason for return and original order number.
If the product fails under normal use in the first 10 days of ownership, at our discretion we will
email you a postage-paid UPS label to return the product at our expense.

If we determine that the product failed because of improper use (water damage, dropping,
tampering, electrical damage etc.), or if it is beyond the warranty date, we will inform you of the
cost to fix or replace the product.

Contact Us
We are here to help!
For information or technical support, please contact us.
[email protected]
(386) 256-4910 ( Technical Support)
(386) 872-7665 (Sales)
www.CO2Meter.com

Address:
CO2Meter, Inc.
131 Business Center Drive
Ormond Beach, FL 32174
USA