072-0150 NDIR IRC-A Transmitter Manual Draft 4

072-0150-04 ALPHASENSE USER MANUAL
4-20mA and Digital Transmitter for IRC-A1/AF NDIR CO2 Sensors
1 INTRODUCTION
The transmitter PCB includes circuitry for measuring the signals from the NDIR gas sensor,
converting and linearising into CO2 concentration and supplying an output as either 4-20mA or via
USB to an Excel spreadsheet.
Alphasense 4-20mA digital NDIR transmitters offer convenience and easy maintenance:
• Transmitters are shipped pre-calibrated for immediate use
• Small circuit board size allows smaller sensor housing
• Temperature is measured and reported via the digital output if you wish to temperature
compensate using Excel calculations.
• Range is selected when ordering. Range can be altered by Alphasense or distributor:
0-5000 ppm (indoor air, urban air, cabin air quality)
0-5 % (safety)
0-20% (combustion)
0-100% (industrial process monitoring)
Besides periodic sensor re-calibration by Alphasense or distributor, the transmitter electronics require
no maintenance throughout the lifetime of the sensor. Please read these instructions to ensure
correct installation and use of your CO2 gas sensor with transmitter.
Gas detected Carbon dioxide (CO2)

Alphasense dual channel pryroelectric non-dispersive infrared (NDIR)
Sensor type
CO2 gas cell, model IRC-A1 (or IRC-AF if fitted with extra light filter)
One of four ranges set at Alphasense:
Measuring range
0-5000 ppm, 0-5 %, 0-20 % or 0-100 % CO2
Measuring accuracy See IRC-A1 /IRC-AF data sheet
Warm-up time 25 minutes to full specification; 30 seconds to reading
Thermistor in IRC-A1/AF is monitored and temperature is transmitted via
Temperature monitor
USB for optional temperature correction in Excel
User selectable: either 10-30 VDC for 4-20mA and digital output or via
Power
USB port (digital output only)
4-pin Molex plug (requires 22-01-2045 + 4off 08-50-00) or 2.1 mm DC
DC connector
socket (positive tip)
Either via 2.1mm DC IN socket (positive tip) or pins 3,4 on Molex plug
4-20mA supply (pin 3 is ground). Both inputs are connected in parallel.
Maximum 0.5V ripple/ noise. Reverse polarity protected.
Loop resistance 700R @ 24VDC
Sensor out of range Output is clamped at 20mA
USB connector Mini B USB cable required. Not supplied.
Factory adjusted. User can rescale reading using USB port and
Calibration
software.
10-turn potentiometer to set IR bulb voltage from 2.7 to 4.4 VDC (lower
User adjustment
voltage improves long term drift, higher voltage improves resolution)
Usage and storage range -30 to +50°C (-22 to +122°F)
Usage humidity 0% to 95% (non-condensing)
CE approval BS EN 61326 (Industrial)
Table 1. NDIR Transmitter Specification
© Alphasense Ltd NDIR 4-20mA Digital Transmitter 1 of 9

Sensor Technology House, 300 Avenue West, Skyline 120, Great Notley. Essex.CM77 7AA. UK
Tel: +44 (0) 1376 556700 - Fax: +44 (0) 1376 335899
Email: sensors@alphasense.com - Web: www.alphasense.com
Figure 1. Component layout for NDIR Transmitter
Component Description
J1 Mini B USB socket for connection to PC or similar
J2 2.1mm DC In socket (positive tip)
J3 4-pin Molex plug for power (pins 3,4) and 4-20mA signal (pins 1,2)
J4 Six-pin debugging plug: DO NOT USE
P1 10-turn potentiometer to adjust IR bulb voltage (bulb is inside IRC-A1/ AF)
Table 2. PCB connectors and potentiometers for NDIR transmitter

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2 SETUP
2.1 Mechanical Mounting

Transmitters should be mounted to your housing using the pillars provided. These pillars should first
be attached to the PCB using the supplied screws and washers.
Eight washers are supplied to allow adjustment of screw and pillar heights to fit your enclosure.
Mounting holes are provided so that the assembly can be fixed to either the top or the base of the
housing (figures 1 to 4).
Note: Long pillars may be required for the configuration show in Figure 3. Alphasense Part No: 034-
0005-00.
Figure 6 below shows mounting hole locations (dimensions are in mm).
Dimensions
The pillars are tapped to accept M3 screws. We recommend a screw length of at least 8mm to
ensure rigid fixing. It is good practice to hold the pillar when screwing into the pillars to stop the pillar
from rotating on the PCB. It may be easier to remove the sensor whilst screwing the circuit board
pillars to your housing. If you remove the pillars, ensure that, if mounting to the lid of your housing,
you include the washer between the pillar and PCB to ensure correct height of the assembly - see
figures 2 and 5.
Figure 2. Mounting pillar configuration for .Figure 3. Mounting pillar configuration for attaching to
attaching to the lid of an enclosure. the base of an enclosure.
(Long pillars may be required Pt: No 034-0005-00)
Figure 4. Side view of mounting to lid of Figure 5. Side view of mounting to the base of an
an enclosure. an enclosure.

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Allow 30 minutes after plugging the sensor back into the board for the output to stabilise.
Figure 6. Mounting holes.
Optional Gas hood (089-0446-00)

The inner four mounting holes are supplied to allow mounting of either the gas hood from Alphasense
or your own design gas hood. Use M3 x 8 screws to fix your gas hood to the transmitter PCB.

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2.2 Connection and Wiring

Your transmitter can be powered by one of three ways:
1 Supplying 10 to 30V to the 4-20mA and USB ports through the 2.1mm DC socket (positive tip).
2 Supplying 10 to 30 V to the 4-20mA and USB ports through two of the four Molex pins (4- way
connector is supplied).
3 Through the USB port, but with this option the 4-20mA signal is disabled.
The transmitter is supplied with one 4-pin Molex socket for power and 4-20mA signal, with 200mm of
cable. User sources the optional 2.1mm DC IN socket or USB cable.
2.2.1 4-20mA Power Supply

Your power supply must be between 10 and 30 V dc with less than 0.5Volt ripple. The USB port is
automatically activated when the 4-20mA power is supplied.
Note that since the NDIR cell and transmitter requires 100mA when the IR bulb is pulsed, a separate
power supply for the 4-20mA is required: this is NOT a 2-wire 4-20mA transmitter.
WARNING Do not supply mains AC power to this unit: this will destroy the transmitter and
void the warranty.
The transmitter is protected against incorrect polarity and over voltage, and will not function if you
have reversed the power supply.
Your 4-20mA supply must be able to provide 100mA with at least 10 volts to either the DC IN socket
(socket J2) or to pins 3 (ground) and 4 (power in) on the Molex socket.
Although there is an on-board regulator, it is good practice to minimise noise pickup in your power
cable. If the digital or 4-20mA signals are noisy, check your power cable and 4-20mA cable for noise
and ripple.
2.2.2 4-20mA signal cable

When connecting the measuring cable (pins 1 (current out) and 2 (ground) on the Molex plug) you
must not exceed the maximum total loop resistance, which includes your measuring resistor (which is
in series with pin 1) used to change the 4-20mA current into a measured voltage.
The transmitter requires a minimum of 10 volts to operate; therefore, the maximum potential drop
allowed across your (sensing resistor plus cable) is (power supply voltage) -(7 V).
Assuming full-scale deflection at 20mA, use Ohm's law to calculate the maximum (cable plus sensing
resistor) allowed loop resistance for your supplied voltage.
To maintain CE requirements it is recommended that either twisted pair or screened cable are used
for 4-20mA signal cable lengths greater than 30 metres. It is important to ensure the 4-20mA loop is
grounded at one point, ideally at the power source.
2.2.3 USB Port

The USB socket (J1) is connected to a PC, Mac or similar device with a standard mini B USB cable.
This cable also supplies power to the transmitter if you are not powering the transmitter via the DC IN
socket (J2) or pins 3 and 4 on the Molex plug. If you are using only the USB socket for power, the 4-
20mA output is disabled and you must have a USB port that can supply at least 70mA

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3 CORRECT USAGE AND MAINTENANCE
Ensure that there is a good gas seal between the sensor and the housing during both calibration
check and use.
If the gas sample is pumped, ensure that the flow rate is sufficient. A flow rate of at least 300sccm
(0.3L/m) is the minimum flow rate for pumped gas sampling lines, with 500sccm the recommended
flow rate. Alternatively, the sample gas can diffuse to the front face of the sensor.
If the top dust/ oil filter has become badly contaminated, contact Alphasense for replacement dust
filter.
4 IRC-A1/ IRC-AF REORDERING PART NUMBERS
Replacement dust/ oil filters and spare parts can be ordered by quoting the part numbers below.
Part Number Description

024-0018-00 Self-adhesive dust/oil filter
4 pin Molex cable assembly
010-0178-01
(200mm)
034-0005-00 20mm long Pillar (set of four)
Replacement sensor.
Although linearisation is not
required, gain recalibration will be
IRC-A1 or IRC-AF
required, so please return
transmitter to Alphasense if the
sensor has been damaged.
Table 3. Replacement/ extra parts for NDIR transmitter
5 CALIBRATION
The 4-20mA transmitter is shipped pre-calibrated to the range specified in your purchase order.
5.1 To correct errors after calibration check

The sensor uses dual channel detection (active + reference) to correct for any drift in the IR bulb or
detector. However, if you find long term drift and need to correct for this drift , depending on your data
collection (either 4-20mA or USB/ digital), follow this procedure:
If you are using digital data collection, add an additional column to the Excel spreadsheet,
multiplying the transmitter calculated concentration by a scaling factor that corrects for your
determined calibration error. You do not need to correct for zero error, if you have also
applied temperature correction.
If 4-20mA signal, adjust your alarm points to correct for the error.
If you need to recalibrate the [transmitter plus sensor], return the complete unit to Alphasense,
specifying your signal method (4-20 or digital), reported error and gas concentration that you
determined the error and full scale (range).

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5.2 IR bulb voltage adjustment

Long term drift is due mainly to the IR lamp output changing with time. Reducing the voltage to the IR
lamp can solve this universal problem. The voltage is factory set, but can be adjusted by the user.
P1, a 10-turn potentiometer adjusts the bulb voltage from 2.7 to 4.4 volts. 4.4 volts is the default
setting, but if you need better long term stability rather than resolution, reduce the bulb voltage. We
recommend 3.5 to 4 volts as the lamp voltage to increase long term stability. The USB port can read
lamp voltage. Alphasense recommends that you do not adjust the lamp voltage unless long term
stability is a problem.
5.3 Temperature compensation

If you wish to apply temperature compensation to the digital readings from the USB port, read
application note AAN 201 on the Alphasense website (www.alphasense.com). This is also an option
in the Alphasense software.
6 INSTALLING THE SOFTWARE
The USB interface on the NDIR transmitter uses a virtual COM port (VCP) on the PC. The USB
drivers are supplied with the software. These need to be unzipped into a directory. The first time the
board is attached, the PC will attempt to find the drivers. Use the "Search for a suitable driver for my
device" option, specify a location, and then browse to the directory where the ftdi drivers were
unzipped.
If you wish to write your own application to read the sensors:

The VCP should be set to 19200 baud rate, 8 bits , 1 stop bit, no parity.
The following commands are used to get data from the board -
N <cr> - returns NDIR reading (in ppm)
T <cr> - returns Temperature (in degC)
V <cr> - returns lamp Voltage (in units of 10mV)
If you wish to install the supplied software onto your PC:
WARNING Do not plug the transmitter PCB into your PC without first installing the correct
drivers (“NDIR Transmitter interface V1.10”). Failure to do so could compromise future
installations of USB devices.
Download the file NDIR Transmitter board from the Alphasense Web site. This file is compressed with
WinZip® and will need to be extracted into a temporary directory prior to installation.
This file is located at: http://www.alphasense.com/index.php/safety/application-notes/
Once the downloaded file has been extracted into a temporary directory, either double click the
“Setup.exe” icon or run the setup file using Start|Run from the Windows® Start menu. Once the setup
has started you will be prompted for a installation directory. The default location is C:\Program
Files\Alphasense_NDIR\ but you can change this. The installation program will then ask for a
particular program group, Again, you can change this. We recommend you follow the default settings
during the setup process. The installation software will confirm that the setup is complete.
If the installation fails to complete the setup for any reason, it is recommended that you use the
Windows® Add and Remove function (Start|Control Panel) to uninstall the software and start the
setup again.
Once the software has been installed correctly, you can navigate to C:\Program
Files\Alphasense_NDIR and double click the NDIR.exe icon to start the program. You can also create
a desktop short cut from here.

Tel: +44 (0) 1376 556700 - Fax: +44 (0) 1376 335899
COM Port Setup

The final part of the configuration is to inform the software which virtual COM port Windows® has
assigned to this device (NDIR Transmitter PCB), The virtual COM port assigned to the NDIR
transmitter PCB will depend on whether any other USB devices that are in use on the PC. The port
number assigned to the device (NDIR Transmitter PCB) can be viewed and edited in the Windows®
Device Manager.
First start the Alphasense NDIR software and plug in the NDIR transmitter PCB via the USB lead
provided. At the top left of the Alphasense NDIR software window you will see three menu items: Exit,
COM Port & About. Select COM Port and a drop down will show the available port numbers. If you
have an existing USB device in use you will have to select COM 3 as opposed to COM 1 (default).
If the message “Run-time Error 13“ is displayed, the wrong COM port is selected and the application
will shut down.
It is generally a good idea to allow Windows® to restart between installing the software and plugging
the USB device into the PC for the first time. If you should get a message prompting you about new
hardware being found allow Windows® to search the directory where the downloaded file was
unzipped for the USB drivers. This will correct any driver issues you may have on the first installation.
7 TROUBLESHOOTING
Problem Action
Ensure that you are supplying between 7 and 40VDC to either
the DC IN socket or pins 3 and 4 on the Molex socket.
No 4-20mA signal Ensure the polarity is correct.
Remember that if you are using only the USB cable, the 4-
20mA output is disabled.
Check for noise on your signal and power cables. Shielded
twisted pairs are recommended.
Add screening around PCB if it is located in an electrically
Noisy signal noisy environment.
If you have the IRC-A1 cell in an area where there is excessive
light, return transmitter and sensor to Alphasense to replace
with IRC-AF to reduce light interference.
Check digital or 4-20mA signal error with error specification in
Inaccurate readings
IRC-A1/AF data sheet on the Alphasense web site.
Return transmitter to Alphasense or distributor for calibration
Transmitter does not cover the
to your preferred range. Range will have been specified when
required concentration range.
you ordered.
Using the Excel spreadsheet, select the temperature
Temperature correction is required.
correction option. See CALIBRATION section above.
Software does not load on your PC
Contact Alphasense for assistance.
or Mac.
Table 4. Troubleshooting guide for NDIR transmitter
Test point
1 Reference channel signal
2 Active channel signal
3 Thermistor voltage signal
4 Reference voltage
5 DCI voltage (after internal regulator)
6 DAC (for 4-20mA signal)
Table 5. PCB test points

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8 WARRANTY
Transmitters are warranted for two years. IRC-A1 and IRC-AF are each warranted for two years.
If you have any difficulties or problems, contact:
Alphasense Limited
300 Avenue West
Skyline 120
Great Notley
Essex CM77 7AA
UK
Tel: +44 (0)1376 556700 Fax: + 44 (0)1376 335899

email: sensors@alphasense.com web: www.alphasense.com

Tel: +44 (0) 1376 556700 - Fax: +44 (0) 1376 335899

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072-0150-04 ALPHASENSE USER MANUAL

4-20mA and Digital Transmitter for IRC-A1/AF NDIR CO2 Sensors

Gas detected Carbon dioxide (CO2)

Table 1. NDIR Transmitter Specification

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 1 of 9

Figure 1. Component layout for NDIR Transmitter

Table 2. PCB connectors and potentiometers for NDIR transmitter

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 2 of 9

2.1 Mechanical Mounting

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 3 of 9

Figure 6. Mounting holes.

Optional Gas hood (089-0446-00)

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 4 of 9

2.2 Connection and Wiring

2.2.1 4-20mA Power Supply

2.2.2 4-20mA signal cable

2.2.3 USB Port

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 5 of 9

3 CORRECT USAGE AND MAINTENANCE

4 IRC-A1/ IRC-AF REORDERING PART NUMBERS

Part Number Description

Table 3. Replacement/ extra parts for NDIR transmitter

5.1 To correct errors after calibration check

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 6 of 9

5.2 IR bulb voltage adjustment

5.3 Temperature compensation

6 INSTALLING THE SOFTWARE

If you wish to write your own application to read the sensors:

If you wish to install the supplied software onto your PC:

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 7 of 9

COM Port Setup

Table 4. Troubleshooting guide for NDIR transmitter

Table 5. PCB test points

If you have any difficulties or problems, contact:

Tel: +44 (0)1376 556700 Fax: + 44 (0)1376 335899

© Alphasense Ltd NDIR 4-20mA Digital Transmitter 9 of 9

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