Concoa 5803007 User manual

Certified ISO 9001
Dual O2/ CO2Monitor
5803007
ADI5807-C
For continuous monitoring of gas levels
INSTALLATION AND OPERATION INSTRUCTIONS
Before Installing or Operating, Read and Comply with These Instructions
Controls Corporation of America
1501 Harpers Road • Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com September 2021

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Please Read Before Installation
The following will damage the Air Check Oxygen monitor.
1. The Dual O2/CO2 monitor requires 24 VDC regulated power.
Please do not connect the monitor to any voltage that exceeds 24
Volts DC, or Any AC voltage.
2. Do not power the Dual with the Oxygen sensor or Carbon Dioxide
sensor unplugged from the main PC board. Do not connect the O2 or
CO2sensor to the PC board while the monitor is powered. This Will
Damage the sensors.
3. The Oxygen sensor cell is matched to the electronics. Never exchange
the electronics with an Oxygen sensor from a different monitor.
4. When calibrating or challenging the Dual O2/CO2 monitors,
a. Do not expose the monitor to flow rates that exceed ½ literper
minute (500 cc per minute) flow.
b. Expose the monitor to span gas blends that consist of oxygen,
nitrogen or carbon dioxide only. Do not expose the monitor
to any combustible gas, i.e., methane, hydrogen, etc.
Exposure to combustible span gases can damage the oxygen
zirconium sensor cell.
5. Do not expose the Dual O2/CO2 monitor to silicone compounds. They
can cause a loss of sensitivity.
6. Do not expose the monitor to high flow air or install it directly in front of
fans. The high air flow can cool the oxygen sensor and cause an inaccurate
reading.
7. When using the Dual O2/CO2 monitor, do not expose the Oxygen sensor
directly to a water stream. In areas requiring wash downs cover and protect the
monitor and power supply. Contact CONCOA for details on a waterproof
enclosure.
8. Please refer to section 6.3 of this manual regarding the CO2 sensor.
YOU MUST choose a calibration method before use.

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Table of Contents
1: Introduction..................................................................................................................................................4
1.1 Key Features..........................................................................................4
1.2 Component identification........................................................................6
2: Specifications.............................................................................................................................................11
2.1 Performance Specifications Oxygen.....................................................11
2.2 Performance Specifications Carbon Dioxide Sensor............................11
2.3 Gas Detection System..........................................................................11
2.4 Signal Outputs......................................................................................12
2.5 Electrical Requirements........................................................................12
2.6 Physical Characteristics .......................................................................12
2.7 Dual O2/CO2 System Default Factory Settings....................................13
3: Installation .................................................................................................................................................14
3.1 Site Requirements................................................................................14
3.2 Mounting...............................................................................................14
3.3 Wiring...................................................................................................15
3.4 Initial Startup ........................................................................................16
4: Normal Operation ......................................................................................................................................17
4.1 Signal Outputs......................................................................................17
4.2 Instrument Faults..................................................................................17
4.3 Routine Maintenance Schedule............................................................18
4.4 Loss of Power Indicator........................................................................19
4.5 Alarm Reset..........................................................................................19
5: Dual O2/CO2 Monitor Programming..........................................................................................................20
5.1 Joystick Operation.................................................................................20
5.2 Program Flowchart................................................................................21
5.3 Entering the Password...........................................................................25
5.4 Changing the User Password................................................................26
5.5 Entering the Menus ...............................................................................29
5.5.1 Set 4-20mA Loop.......................................................................29
5.5.2 Set Formats...............................................................................31
5.5.3 Set Alarm Threshold Polarity.....................................................34
5.5.4 Set Latching...............................................................................35
5.5.5 Resetting a Latching Alarm........................................................37
5.5.6 Set Alarm Delay.........................................................................37
5.5.7 Set Zero Suppression................................................................38
5.5.8 Set Alarm Thresholds ................................................................38
5.5.9 Set Alarm Hysteresis.................................................................40
5.5.10 Set Sensor Adjust .....................................................................41
5.5.11 Auto Calibrate Feature for CO2 NDIR Sensor ..........................42
5.5.12 Main Operation Mode ...............................................................43
6: Maintenance & Cell Verification.................................................................................................................44
6.1 Sensor Verification, O2............................................................................44
6.2 Sensor Verification Procedure, O2..........................................................45
6.3 Sensor Calibration, CO2 .........................................................................48
7: Appendix....................................................................................................................................................49

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1: Introduction
The Dual O2/CO2 Monitor is a compact gas monitoring system that’s ideal for the
continuous monitoring of inert gas storage areas, confined spaces, and other locations
where low oxygen levels may pose a hazard to personnel. Unlike electrochemical
sensor cells the Dual O2/CO2 Zirconium oxygen cell and patented NDIR CO2 cell
provide stable readings even in areas where temperature and humidity levels are
changing. The CONCOA Dual O2/CO2 Monitor is suitable for either indoor or outdoor
use. Factory calibrated against a NIST traceable reference standard and CE approved.
The heart of the monitoring system is a long-lasting zirconium sensor for oxygen and
NDIR self-calibrating carbon dioxide sensor. The oxygen cell responds to low oxygen
conditions within seconds and provides accurate measurements over a wide
temperature and humidity range. The Zirconium O2 sensor cell will operate
continuously for 10 or more years and requires an absolute minimum of maintenance.
There are no zero or span calibration pots to adjust and, when compared to disposable
type sensors, our long life Zirconium O2 sensor can save up to hundreds of dollars in
annual maintenance.
Ideal for continuously monitoring oxygen levels in confined spaces or areas where inert
gases are used, the Dual O2/CO2 Monitor does not drift or lose sensitivity when the
weather or temperature changes. The electronics are housed in a Nema 3 housing.
Each system consists of a long life zirconium oxide sensor cell and three-wire
transmitter. The Dual O2/CO2 monitor may be used as a stand-alone gas detector,
linked to optional CONCOA single and multipoint controllers, or connected to your own
centralized control and surveillance system. This manual covers the installation,
operation, and maintenance of the Dual O2/CO2 monitor.
1.1 Key Features
The Dual O2/CO2 monitor incorporates a number of user-friendly features designed
to simplify installation, operation, and maintenance.
1.1.1 Long Life Zirconium Oxide O2 Sensor
The system’s O2 sensor cell has a life of well over 10 years of continuous operation.
Unlike concentration O2 cells, CONCOA’s exclusive zirconium oxide sensor cell does
not need an oxygen reference gas for proper operation. The Dual O2/CO2 monitor
can detect low oxygen levels in confined spaces and process tools without the need of
a reference gas.

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1.1.2 NDIR CO2 IR sensor
The system’s CO2 sensor cell is a patented Non-Dispersive Infrared (NDIR) cell
designed to detect continuous levels of CO2. It’s fast responding and has a built-in auto
calibration feature that adjusts the sensor to ambient every 180 hours.
1.1.3
Smart Electronics
The Dual O2/CO2 monitor incorporates a special electronic circuit that continuously
monitors sensor operation. With the addition of the alarm relay option, any cell degradation
or complete failure will immediately be detected. This smart circuitry alerts the user to
sensor faults and other electrical problems that may interrupt surveillance through the
standard mA output signal or through the optional fault relay option.
1.1.4 Calibration O2
The Dual O2/CO2 monitor incorporates a stable zirconium oxide sensor that rarely
requires calibration. Changing barometric pressures or changes in temperature and
humidity do not affect the zirconium oxide oxygen cell. The earth is a wonderful source
of calibrated oxygen at 20.9% therefore under ambient conditions verification of the
Dual O2/CO2 monitor to 20.9% oxygen is constantly being performed. There are no
zero or span pots to adjust. The O2 monitor only requires periodic testing with nitrogen
to verify the cells response to low oxygen levels. See Section 6.2 for the testing
procedure to nitrogen.
1.1.5 Calibration CO2
The Dual O2/CO2 monitor incorporates an NDIR CO2 sensor that provides an accurate
reading that is the difference between a reference baseline setting and the measured
gas concentration. The sensor is factory calibrated and requires no user calibration but,
as typical with most NDIR sensors, long term drift can affect the baseline setting. Under
normal conditions, the sensor provides automatic baseline adjustments and no further
action is required by the user. However, under certain conditions, manual adjustments
may be required. See Section 6.3 for further explanation and procedures for adjusting
the baseline setting.

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1.2 Component Identification
1.2.1
Front View Exterior
8
1
2 7
6
8
3 4 & 5
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1. Digital Display —3-digit backlit LCD digital display for showing the oxygen levels
in percent.
2. Joystick —Used for selecting and adjusting the built-inmenus.
3. Cable Port —This is the opening in the transmitter housing forconnecting the
4-20 mA output and 24 VDC power cable.
4.
Sensor Protector—The O2 sensor is heated and the sensor protectorshields the
cell and provides airflow to the cell.
NOTE: The sensor protector will feel HOT to the touch. This is normal.
5. Oxygen Sensor —A Zirconium Oxide sensor, which detects and measures the
level of Oxygen.
6.
CO2 Sensor—An NDIR sensor housed inside the cell protector.
7. Transmitter Cover —A removable cover that protects the interior of the
transmitter.
8. Transmitter Cover Fasteners —4 captive screws secure the transmitter cover in place.
9. Electronics Fasteners —Captive screws secure the electronics tothe enclosure.
10. Mounting Feet —4 feet to mount the Oxygen monitor to a wall or other flatsurface.

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1.2.2
Front View Exterior with Relay Option
10
9
2
6
9 11
10
3 4 & 5
1.2.3
Side View Exterior with Audio Alarm
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11. Audio Horn —This built-in horn is a 90dB high pitched audio sound which will
activate when either oxygen levels go below the selected alarm thresholds or CO2
levels go above the selected alarm threshold. The audio alarm is non-latching and will
automatically turn off when the alarm condition clears.
NOTE: The audio alarm is an immediate alarm. Alarm levels must recover to safe
levels before the horn turns off. There is no audible alarm delay function
available.

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1.2.4 Side view of the CO2 Sensor
**
*
* CO2 Sensor—An NDIR sensor housed inside the cell protector.
** NOTE: The CO2 sensor is an NDIR type that is continuously monitoring ambient
levels. You will see a blinking orange LED flash approximately every 2 seconds.
This is normal.

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1.2.5
Transmitter Interior
1. Power Analog output
Terminal Block
2. Sensor cell
Connector
3. PTC
Resettable Fuse
Common
Common
mA output
+ 24 VDC
+ 24 VDC
1. Power Analog Terminal Block —This terminal block is wherethe 24VDC
power and 4-20 mA analog output connection is made.
2. Sensor Cell Connector —This connector is where the Oxygen sensor cell is
connected. NOTE: Never connect the Oxygen sensor to this connector while
the monitor is powered. This will damage the Oxygen sensor
3. PTC Resettable Fuse - The PCB is protected with a PTC Fuse that is
resettable and never needs to be replaced. If it trips, you will need to turn
power off to the monitor. When power resumes, the fuse will reset.

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1.2.7 Alarm RelayBoard
Relay 2
Relay 1
Fault Relay
Remote
NC C NO
NC C NO
NC C NO
Reset
Horn Connector
Oxygen
Sensor
Connector
1.2.8 Enclosure Mounting Feet
Mounting Feet
can be oriented
in any direction.
Feet can also
be removed for
mounting the
Dual O2/CO2
monitor flush
with a wall or
other surface.

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2: Specifications
NOTE: For our continual product improvement, all specifications are subject to
change without notice.
2.1 Performance Specifications Oxygen Sensor Type: Long Life Zirconium
Oxide Sensor Cell 0-25% Response Time: Within 1 second of any change in O2.
Accuracy: ±1% of full scale
Fault Indicators: Loss of VDC power (analog signal drops to 0 mA).
Sensor cell failure: Fault relay activated. (Must have alarm relay option for cell
failure to operate)
Operating Temp: -40° to 134°F (-40° to +55°C); consult CONCOA for lower or
higher operating temperatures.
Humidity: 0 to 95% RH; consult CONCOA for sensors which can operate in
100% condensing RH environments.
Environment: Max. Altitude 2000 m, Pollution Degree 3, Intended for Indoor Use.
CE EN 61000-3-2:2006 EMC, EN 61000-3-3:2008 EMC, EN61010-1-3-2013LVD
2.2 Performance Specifications Carbon Dioxide sensor
Sensor Type: Long Life NDIR Sensor 0 10,000ppm
Response Time: Within 1 second of any change in CO2.
Accuracy: ±5% of measured value.
Fault Indicators: Loss of VDC power (analog signal drops to 0 mA).
Sensor cell failure: Fault relay activated. (Must have alarm relay option for cell failure to
operate)
Operating Temp: 32° to 122°F (0° to +50°C); consult CONCOA for lower or higher
operating temperatures.
Humidity: 0 to 95% RH.
Environment: Max. Altitude 2000 m, Pollution Degree 3, Intended for Indoor Use.
CE EN 61000-3-2:2006 EMC, EN 61000-3-3:2008 EMC, EN61010-1-3-2013LVD
2.3 Gas Detection System
Transmitter: Microprocessor electronics with built-in 3-digit backlit LCD display Joystick
operated menus

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2.4 Signal Outputs
Local Display: Digital display calibrated for oxygen and carbon dioxide.
The range is stated on the serial number and can be accessed via the joystick on the
front panel. In the measurement mode pushing the joystick down will scroll the gas
and range on the display. Push the joystick down again to stop the scrolling and
display the gas again.
Standard Analog Output: DC 4-20 mA
Optional Relay Output: Dual level user selectable alarm relays and one fault relay.
Rated, 2amps @ 24VAC or 24VDC
2.5 Electrical Requirements
Power: 24 VDC external power. A regulated 24VDC power supply is required.
Consumption: Approximately 250mA
2.6 Physical Characteristics
Dimensions: 6.5 (W) x 3.15 (H) x 3.00 (D) inches; 165 x 80 x 76 mm (Max with feet)
Weight: 1.1 pounds (0.5 kg)
Enclosure Type: General purpose; not intended for explosive atmospheres.

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2.7 Dual O2/CO2 System Default Factory Settings
The Dual O2/CO2 monitor is shipped with factory defaults for the alarm relay settings.
The following are the factory defaults:
Menu Function
Factory Default
Menu Defined
Set 4-20mA loop
The mA output is set at
the factory using a
calibrated Fluke meter.
Use this function to adjust the
monitor’s 4mA, (Zero) and 20mA,
(Span) to your PLC or distributive
control system.
Set Formats
LED and alarm
relay State **
Alarm 1 = Normal
Alarm 2 = Normal
Fault = Normal
Do you want the relays to energize
(normal) or de-energize (fail safe) when
the alarm activates?
Set Alarm
Threshold Polarity
Alarm 1 = Normal
Alarm 2 = Inverted
Audio = Inverted
Do you want to alarm at a level higher
(normal) or lower (inverted) than the
alarm threshold?
Set Latching
Alarm 1 = Non-latching
Alarm 2 = Non-latching
Audio = Non-latching
Do you want the alarm to
automatically reset (non-latching) or
do you want to manually reset the
alarm (latching)?
Alarm Delay
Alarm = 5 seconds
How long do you want to wait until the
alarms activate?
Zero Suppression
000 = 0.00%
Refer to section 4.5.6
This function is Not Enabled on the
Dual monitor.
Set Alarm
Thresholds
Alarm 1 = 5,000ppm
Alarm 2 = 19.5%
At what level do you want to alarm?
Set Alarm Hysteresis
Alarm 1 = 00 PPM
Alarm 2 = 0.0 %
For use when using the O2 monitor for
control of valves and process.
See Section 5.4.8
Sensor Adjustment
Set O2 sensor span
Turn CO2 autocal on
Turn CO2 autocal off
Calibrate CO2 sensor
For use when dynamically gas
calibrating the oxygen and CO2
monitor.
See Section 6.2
Manage Passwords
Factory default is 557
For use when changing the password
from factory default to a new password
of your choice.
NOTE: The built in relay settings may be changed by the user in the field. Refer to Section 5.5.2
** NOTE: The LED indicators on the front panel are connected directly to the alarm relays.

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3: Installation
3.1 Site Requirements
The Dual O2/CO2 monitor enclosure should be mounted in an area free of vibration and
electrical noise or interference. If possible, avoid areas with high temperatures or
condensing humidity.
WARNING: The Dual O2/CO2 monitor is not designed for installation in hazardous
areas. Consult CONCOA for information on enclosures for use in hazardous
environments.
3.2 Mounting
3.2.1 Transmitter Enclosure
The Dual O2/CO2 monitor is designed primarily for wall mounting and should be
installed at a height convenient for operation, maintenance, and viewing of the
instrument display. The following is a drawing of the mounting dimensions.
3.2.2Dual O2 /CO2 monitor
The transmitter and sensor should be installed in a location where gas leaks are likely to
occur or where released gases may accumulate. It should be mounted no closer than
12 inches above floor level. Airflow within the monitored area, the characteristics of the
gas (lighter or heavier than air), and the position of workstations and personnel should
all be considered in determining the most suitable installation location.
6.5”

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3.3 Wiring
The Dual O2/CO2 monitor requires a single, 3-wire shielded cable for analog output
and 24 VDC power input. A three-wire shielded cable; 3- conductor, 18 AWG stranded
General Cable E2203S.30.860, or equivalent is recommended for the connection. The
maximum permissible cable length is 0.62 miles (1 km). The analog out and VDC
power in connections are made on the terminal block inside the transmitter housing.
- Common
- Common
mA 4-20mA signal output to
PLC
+ 24VDC Power
+ 24VDC Power
Identification Legend
NOTE: CONCOA has added additional contacts for +24VDC power and common to
accommodate additional wiring for remote horns and strobes
Pin #
Connection
Description
-
Common (Signal Ground)
0V
-
Common (Signal Ground)
0V
mA
Signal Out
DC 4-20mA Output
+
Power
DC + 24V Input
+
Power
DC + 24V Input

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O2/CO2
239 WARM
3.4Initial Startup
Once installation of the gas detector has been completed, it is ready for startup. The
following procedures should be performed before putting the instrument into operation:
1. Check the integrity of all wiring.
2. Apply 24 VDC power.
The instrument should now be powered up. Upon power up the Dual O2/CO2 monitor LCD
displays the CONCOA logo and then starts a 4-minute (240 second) count down as the
current to the zirconium oxide O2 sensor stabilizes. The monitor will output a 4 mA signal
during the entire warm-up period. After the countdown, the oxygen sensor will continue to
reach its operating temperature for approximately 30 minutes and the reading displayed
will slowly increase to ambient. Do not make any adjustments to the reading until after
the monitor has been powered for at least anhour.
NOTE: The Dual O2/CO2 monitor is supplied with an audio horn, it will activate
momentarily at the completion of the warm up.
NOTE: The Dual O2/CO2 monitor’s oxygen reading may be adjusted to the
ambient oxygen level. The CO2 sensor has an auto calibration feature. It also may
be manually calibrated to span gas. See section 6.1 for instructions on adjusting.

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4: Normal Operation
The Dual O2/CO2 monitor is a single point monitor designed for the continuous
detection and measurement of ambient oxygen concentration levels.
4.1 Signal Outputs
The Dual O2/CO2 monitor outputs a continuous 4-20 mA analog signal proportional to
the measured concentration of either oxygen or carbon dioxide. The 4-20 mA output
can only be used for gas. When oxygen is selected 4 mA represents 0% O2 and 20
mA represents 25% O2 which is the full range for oxygen. When carbon dioxide is
selected 4 mA represents 0ppm and 20 mA represents 10,000ppm which is the full
range for carbon dioxide. In the event of a system fault, a specific factory defined code
will be displayed on the local digital display. This code will indicate the exact nature of
the system fault.
4.2 Instrument Faults
The Dual O2/CO2 monitor incorporates a number of self-checking features to ensure
reliable operation. In the event that a fault condition is detected, the analog output signal
is altered as follows:
Condition
Analog Signal
**Supply Voltage Out of Range
Fault code 16
Analog output drops to 2 mA
Transmitter cable cut
Analog output drops to 0 mA
O2 Cell complete failure
Fault Code 128
Analog output drops to 2 mA (0 mA on request)
Fault Relay activates
(Available with Relay Option Only)
O2 / CO2 System Warm-Up
Analog output drops to 2 mA
Fault Relay activates and turns off when system is
in the Oxygen operation mode
(Available with Relay Option Only)
O2 Cell voltage fault
Fault Code 64
Analog output drops to 2 mA (0 mA on request)
Fault Relay activates
(Available with Relay Option Only)
EEPROM Fault 08
Analog output drops to 2mA (0 mA on request)
NOTE: All system faults are displayed on the front panel. Each fault has its own
specific code to identify the specific problem. Please contact CONCOA whenever
a fault is displayed.
** When using your own power supply please ensure that the voltage is
regulated to 24VDC +/- 0.5 volts. If the voltage is too low or high you will activate
a Supply Voltage Out of Range fault and disable the monitor.

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4.3 Routine Maintenance Schedule
Continuous gas detection systems depended upon to measure and detect hazardous
gas leaks in the workplace requires periodic maintenance to ensure proper operation.
The frequency with which this routine maintenance is required depends on the
environment. The following table is intended to serve as a general guideline for routine
maintenance. The conditions in your particular application, as well as your
organization’s maintenance policies, will ultimately determine the best routine
maintenance schedule for your equipment.
Routine Visual Checks
Items to check
Check for power and proper operation
Condition / status when
operating properly
Unit should be outputting a 17.4 mA signal when
the oxygen level is at 20.9% or approximately
4.6mA when the Carbon Dioxide is at ambient
400ppm. The LCD digital display should also
indicate 20.9% 02 and approximately 450ppm
level when the Oxygen and Carbon Dioxide
levels are at ambient.
4.3.2 Recommended Routine MaintenanceSchedule
Routine Visual Checks Every 6 - 12 months
Sensor Verification with nitrogen Every 6 - 12 months**
** The ambient oxygen level is 20.9%; therefore, under ambient conditions verification
of the Dual O2/CO2 monitor to 20.9% oxygen is constantly being performed. The
oxygen sensor only requires periodic testing with nitrogen to verify the cells response to
low oxygen levels. See Section 5.5.10 for how to make minor adjustments to theoxygen
sensor.
The ambient CO2 level is 400ppm and the sensor provides automatic baseline
adjustments to ambient levels on a regular time schedule. However, the CO2 sensor can
be manually calibrated by using span gas. See section 6.3 for how to manually calibrate
the CO2 sensor.

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4.4 Loss of Power Indicator
In the event the Dual O2/CO2 monitor loses 24VDC power, the 4-20 mA analog output
signal drops to 0mA. The LCD display will also display a blank screen.
4.5 Alarm Reset
The Dual O2/CO2 monitor is supplied with individual alarm relays for each gas.
Whenever the monitor’s alarms are activated, the built-in alarm relays, panel mounted
LED’s and audio horn will also activate. When the relay settings are non-latching, the
alarm relays, LED’s and horn will automatically reset. If the relay settings are latching,
then a manual reset of the alarms is required. Resetting the alarms can be performed
through use of the joystick or through the use of the remote reset function.
Joystick –You must enter the password to enter the reset function. After the password
is entered and accepted, push the joystick in (enter) to reset the alarms.
Remote Reset –See section1.2.7. The alarm relay board has a two-pin connector for
wiring to a remote switch. When connected to a switch, this remote reset will bypass the
joystick and a password will not be needed to reset the alarms.
NOTE: The oxygen levels must recover above the alarm thresholds before the
horn can be reset from the remote reset switch orjoystick.