Concoa 5803008 User manual

ADI5811-B
Certified ISO 9001
CONCOA CO2Monitor
5803008
For continuous detection and measurement of ambient carbon
dioxide concentration levels
INSTALLATION AND OPERATION INSTRUCTIONS
Before Installing or Operating, Read and Comply with TheseInstructions
Controls Corporation of America
1501HarpersRoad•VirginiaBeach,VA23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com
February 2022
Rev B

Please Read Before Installation
The following will damage the CO2Monitor.
1. The CO2monitor 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 carbon dioxide sensor unplugged from the main PC board.
Do Not Connect the CO2sensor to the PC board while the monitor is powered.
This Will Damage the sensor.
3. The CO2cell range is matched to the electronics. Never exchange the
electronics with a CO2sensor from a different monitor.
4. When calibrating or challenging the CO2monitor,
a. Do not expose the monitor to flow rates that exceed ½ liter per 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.
5. Do not expose the CO2monitor 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.
7. When using the CO2monitor, do not expose the 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 CO2sensor. YOU
MUST choose a calibration method before use.

Table of Contents
1: Introduction.....................................................................................................................2
1.1 Key Features........................................................................2
1.2 Component Identification....................................................3
2: Specifications..................................................................................................................7
2.1 Performance Specifications.................................................7
2.2 Gas Detection System .........................................................7
2.3 Signal Outputs.....................................................................7
2.4 Electrical Requirements ......................................................7
2.5 Physical Characteristics.......................................................7
2.6 System Default Factory Settings.........................................8
3: Installation.......................................................................................................................9
3.1 Site Requirements ...............................................................9
3.2 Mounting.............................................................................9
3.3 Wiring................................................................................10
3.4 Initial Startup.....................................................................11
4: Normal Operation..........................................................................................................12
4.1 Signal Outputs...................................................................12
4.2 Instrument Faults...............................................................12
4.3 Routine Maintenance Schedule.........................................12
4.4 Loss of Power Indicator ....................................................13
4.5 Alarm Reset.......................................................................13
5: CO2 Monitor Programming..........................................................................................14
5.1 Joystick Operation.............................................................14
5.2 Program Flowchart............................................................15
5.3 Entering the Password.......................................................19
5.4 Changing the User Password ............................................20
5.5 Entering the Menus ...........................................................23
5.5.1 Set 4-20 mA Loop....................................................23
5.5.2 Set Formats...............................................................24
5.5.3 Set Alarm Threshold Polarity...................................26
5.5.4 Set Latching..............................................................27
5.5.5 Resetting a Latching Alarm...................................... 29
5.5.6 Set Alarm Delay.......................................................29
5.5.7 Set Zero Suppression................................................30
5.5.8 Set Alarm Thresholds...............................................30
5.5.9 Set Alarm Hysteresis................................................31
5.5.10 Auto Calibrate........................................................ 33
5.5.11 Main Operation Mode............................................34
6: Maintenance & Cell Verification..................................................................................35
6.1 Sensor Calibration, CO2....................................................35
6.1.2 Adjusting the CO2Sensor Manually...................................36
7: Appendix.......................................................................................................................37
How to Connect a Horn and Strobe to the CO2 Monitor.........39
Remote Display Alarm Indicator 5803009 .............................40

2
1: Introduction
The CONCOA CO2Monitor is a compact gas monitoring system that is ideal for the continuous
monitoring of inert gas storage areas, confined spaces, and other locations where carbon dioxide levels
may pose a hazard to personnel. The patented NDIR CO2cell provides stable readings even in areas where
temperature and humidity levels are changing. The CONCOA CO2Monitor 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 an NDIR self-calibrating carbon dioxide sensor. The CO2cell
responds to high carbon dioxide conditions within seconds and provides accurate measurements over a
wide temperature and humidity range. The NDIR CO2sensor cell will operate continuously for many
years and requires an absolute minimum of maintenance. There are no zero or span calibration pots to
adjust and its built-in auto calibration can save time and money in annual maintenance.
Ideal for continuously monitoring carbon dioxide levels in confined spaces or areas where inert gases are
used, the CONCOA CO2Monitor 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 NDIR sensor cell and three-wire transmitter. The CO2Monitor 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 CO2Monitor.
1.1 Key Features
The CONCOA CO2Monitor incorporates several user-friendly features designed to simplify installation,
operation, and maintenance.
1.1.1 NDIR CO2IR Sensor
The system’s CO2sensor cell is a patented Non Dispersive Infrared, (NDIR) cell designed to detect
continuous levels of CO2. It is fast responding and has a built-in auto calibration feature that adjusts the
sensor to ambient every 180 hours.
1.1.2 Smart Electronics
The CO2Monitor 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.

3
1.2 Component Identification
1.2.1 Front View Exterior
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-in menus.
3. Cable Port —This is the opening in the transmitter housing for connecting the 4-20 mA output
and 24 VDC power cable.
4. CO2Sensor—A NDIR sensor housed inside the cell protector.
5. Transmitter Cover —A removable cover that protects the interior of the transmitter.
6. Transmitter Cover Fasteners —There are 4 captive screws secure the transmitter cover in
place.
7. Electronics Fasteners —These captive screws secure the electronics to the enclosure
8. Mounting Feet —There are 4 feet used to mount the oxygen monitor to a wall or other flat
surface.
9. Alarm Indicators —3 multicolored LED indicators for showing:
Alarm level 1, CO2 Orange LED
Alarm level 2, CO2Red LED
Fault Alarm Yellow LED
5
4
9 AL 2
AL 1
Fault
8
1
2
7
6
8
3

4
1.2.2 Side View Exterior with Audio Alarm
10. Audio Horn —This built-in horn is a 90dB high pitched audio sound will activate when 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.
10

5
1.2.3 Side View of the CO2Sensor
1.2.4 Transmitter Interior
1. Power Analog Terminal Block —This terminal block is where the 24VDC power and 4-20 mA
analog output connection is made.
2. 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.
NOTE: The CO2sensor 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.
The CO2sensor and sensor
cable are hard wired
directly to the main board.
1. Power
Analog output
Terminal Block
Common
Common
mA output
+ 24 VDC
+ 24 VDC
2. PTC
Resettable
Fuse

6
1.2.5 Alarm Relay Board
1.2.6 Enclosure Mounting Feet
Relay AL2 Relay AL1 Fault Relay Remote
NC C NO NC C NO NC C NO Reset
Horn Connector
Mounting Feet
can be oriented
in any direction
Feet can also be
removed for
mounting the
CO2 Monitor
flush with a wall
or other surface

7
2: Specifications
NOTE: For our continual product improvement, all specifications are subject to change without notice.
2.1 Performance Specifications Carbon Dioxide Sensor
Sensor Type: Long Life NDIR Sensor 0-50,000 ppm
Response Time: Within 1 second of any change in CO2.
Accuracy: Accuracy: ±300 ppm, ±3% 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: Altitude 2000 m, PSU only UL spec. Pollution Degree 3, Intended for Indoor Use.
CE EN 61000-3-2:2006 EMC, EN 61000-3-3:2008 EMC, EN61010-1-3-2013 LVD
2.2 Gas Detection System
Transmitter: Microprocessor electronics with built-in 3-digit backlit LCD display
Joystick operated menus
2.3 Signal Outputs
Local Display: Digital display calibrated for Carbon Dioxide. The range is stated on the model
label and can also 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
Relay Output: Dual level user selectable alarm relays and one fault relay
Rated, 2amps @ 24VAC or 24VDC
2.4 Electrical Requirements
Power: 24 VDC external power. A regulated 24VDC power supply is required.
Consumption: Approximately 50mA
2.5 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.

8
2.6 CONCOA CO2System Default Factory Settings
The CONCOA CO2Monitor 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 = Normal
Audio = Not Available
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
Displayed as 05
How long do you want to wait
until the alarms activate?
Zero Suppression
0.0%
This function is Not Enabled
on the CO2monitor.
Set Alarm
Thresholds
Alarm 1 = 5,000 ppm
Alarm 2 = 10,000 ppm
At what level do you want to
alarm?
Set Alarm Hysteresis
Alarm 1 = 00 ppm
Alarm 2 = 00 ppm
For use when using the CO2
monitor for control of valves and
process.
Sensor Adjustment
Set CO2 Sensor span
CO2set to autocal on
CO2set to autocal off
Calibrate CO2to 400 ppm
For use when manually gas
calibrating the CO2monitor.
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.

9
3: Installation
3.1 Site Requirements
The CO2Monitor 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 CO2Monitor 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 CONCOA CO2Monitor 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.
3.2.2 CO2Monitor
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.
4.0”
6.25”

10
3.3 Wiring
The CO2Monitor 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 analog out and VDC power in connections are made on the terminal
block inside the transmitter housing.
These connections are made as follows:
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
NOTE: CONCOA has added additional contacts for +24VDC power and Common to accommodate
additional wiring for remote horns and strobes.
-
Common
-
Common
mA 4-20mA signal
output to PLC
+
24VDC Power
+
24VDC Power
Identification Legend

11
CO2
405 ppm
3.4 Initial 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 CO2Monitor LCD displays the
CONCOA logo and then displays CO2on the top line and the actual ppm reading on the bottom line. The
monitor will also output the proper mA signal to remote devices.
NOTE: Ambient outdoor carbon dioxide levels are approximately 400 ppm.

12
4: Normal Operation
The CONCOA CO2Monitor is a single point monitor designed for the continuous detection and
measurement of ambient carbon dioxide concentration levels.
4.1 Signal Outputs
The CO2Monitor outputs a continuous 4-20 mA analog signal proportional to the measured concentration of
carbon dioxide. For CO2, 4 mA represents 0 ppm CO2and 20 mA represents 50,000 ppm CO2which 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 CO2Monitor incorporates a several self-checking features to ensure reliable operation. If a fault
condition is detected, the analog output signal is altered: A few common error codes are displayed in the
following table:
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.
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 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 approximately 4.6 mA signal when the carbon
dioxide is at ambient 400ppm. The LCD digital display should also indicate
approximately 405 ppm level when the carbon dioxide level is at ambient.
Condition
Analog Signal
**Supply Voltage Out of Range
Fault code 16
Analog output drops to 2mA
Fault Relay activates
Transmitter cable cut
Analog output drops to 0mA
CO2Cell complete failure
Fault code 128
Analog output drops to 2mA
EEPROM Fault 08
Analog output drops to 2mA Fault Relay activates
CO2 sensor not responding
Fault code F01
Analog output drops to 2mA Fault Relay activates

13
4.3.2 Recommended Routine Maintenance Schedule
Routine Visual Checks Every 6 - 12 months
Sensor Verification with nitrogen Every 6 - 12 months**
The ambient CO2level is 400 ppm and the sensor provides automatic baseline adjustments to ambient
levels on a regular time schedule. However, the CO2sensor can be manually calibrated by using span gas.
See section 6.3 for how to manually calibrate the CO2sensor.
4.4 Loss of Power Indicator
In the event the CO2Monitor 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
It the CO2 Monitor is supplied with individual alarm relays. 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, LEDs, and horn will automatically reset. If the relay settings are
latching, then a manual reset of the alarms are required. Resetting the alarms can be performed through use
of the joystick or using the remote reset function.
Joystick –You must enter the password 557, 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 carbon dioxide levels must recover above the alarm thresholds before the horn can
be reset from the remote reset switch or joystick.

14
5: CO2 Monitor Programming
The CONCOA CO2Monitor is supplied with user selectable settings to adjust the alarm settings, 4 and
20mA output and minor sensor adjustments. The settings are arranged in menus that are accessed by
moving the joystick. To access the menus a factory set password is used.
NOTE: The CO2Monitor will continuously monitor levels while accessing the menus. The alarm,
fault relays and mA output are all active and online while making any changes to the menus.
5.1 Joystick Operation
The CONCOA CO2Monitor uses a 4-position joystick with a center pushbutton for selecting menus and
changing values. The joystick is programmed to standard protocol as follows:
NOTE: The joystick has a built-in delay to prevent accidental tampering of the menus.
Deliberate entries are required.
CAUTION: Only qualified personnel should perform programming, maintenance, and sensor
verification.
+ Plus
-Minus
Previous
s
Next
Plus –Pushing the joystick in this direction increases the value.
Minus –Pushing the joystick in this direction decreases the value.
Next –Pushing the joystick in this direction moves you to the next level of the menu hierarchy.
Previous –
Pushing the joystick in this direction takes you out to the last level of menu hierarchy.
Enter –Pushing the joystick directly in the center enters the information into the microprocessor.

15
5.2 Program Flowchart
PassCode OK
CO2
400 ppm
Enter
Password
557
Invert
Invert
Format
Fault Relay
Normal
Invert
NOTE: All
numerical values
shown are only
examples and are
not Factory
Defaults
PassCode OK Set 4-
20mA
loop
Set 4mA
Zero
157
Set 20mA
Span
115
Set
Formats
Format
Relay 2,
CO2
Format
Relay 1,
CO2
Normal
Normal

16
Invert
Nonlatch
Set Latching
Relay 2 CO2
Nonlatch
Set
Latching
Audio
05
Not Available
*
NOTE: Zero
suppression
function is not
available for
Carbon dioxide
Set Alarm
Threshold
Polarity
Set Alarm 1,
CO2, Polarity
Normal
Set Alarm 2,
CO2, Polarity
Invert
Normal
Alarm
Delay
Set Audio
Alarm
Polarity
PassCode OK
Set
Latching
Set Latching
Relay 1,
CO2
Nonlatch
Latch
Latch
NOTE: All
numerical
values
shown are
only
examples
and are not
Factory
Defaults
Latch
NOTE: Factory
defaults are:
CO2 polarity is
Normal
The audio horn will
activate when the
polarity is changed
to Invert

17
Sensor
Adjustment
Calibrate
CO2sensor
to 400 ppm
Press ENTER to
continue
Set CO2
sensor span
1.00 **
Zero
Suppression
0.0% *
Set Relay 1,
CO2, Alarm
5000 ppm
Set Relay 2,
CO2, Alarm
10,000 ppm
Set Alarm
Thresholds
PassCode OK
Set Alarm 1,
CO2, Hysteresis
**NOTE: The
factory
setting is
1.00. Do not
change this
setting
unless you
have the
proper
calibration
equipment
00 ppm
Set Alarm 2,
CO2, Hysteresis
00 ppm
Set Alarm
Hysteresis
NOTE: All
numerical
values shown
are only
examples
and are
Not Factory
Defaults
Turn CO2
autocal on
Press ENTER to
continue
Turn CO2
autocal off
Press ENTER to
continue

18
PassCode OK
Manage
Passwords
Enter New
User Password
Enter
minimum of
2 characters
Enable User
Password
Enabled
Disabled
Reset User
Password
Reset to
Factory
Default