FANs 216, 1628.3 Technical Bulletin CDS4000 Issue Date 0797 CDS4000 CO 2 Sensor Calibration and Troubleshooting Table of Contents Introduction 1 Handling Information 1 Calibration 2 Preparation 2 Cautions and Warnings 2 Equipment Needed 2 Standard Procedure 2 Default Procedure 5 Troubleshooting 6 Maintenance and Repair 7 Recommended Maintenance 7 Servicing the Sensor 7 Replacement and Accessories 7 CAUTION: This document does not include the mandatory training information required to receive, handle, or ship this product. Consult your local Johnson Controls representative. Refer to the Handling Information section for other important information. I ntroduction When properly installed, the CDS4000 Series Carbon Dioxide Sensor is accurate to ±100 ppm (parts per million). Recalibrate the sensor annually or whenever an accuracy problem is detected. Handling Information Please observe the following regulatory reference relating to the transportation of the zero and span calibration gas cylinders used with a CDS4000 sensor: IMPORTANT: Code of Federal Regulations, Transportation, 49 CFR 107.329 and 49 CFR 107.333: Maximum penalties. ( 107.329) A person who knowingly violates a requirement of the Federal hazardous material transportation law, an order issued thereunder, this subchapter, subchapter C of this chapter, or an exemption issued under this subchapter applicable to the transporting of hazardous materials or the causing of them to be transported or shipped is liable for a civil penalty of not more than $25,000 and not less than $250 for each violation. When the violation is a continuing one, each day of the violation constitutes a separate offense. Criminal penalties generally. ( 107.333) A person who knowingly violates 171.2(g) or willfully violates a provision of the Federal hazardous material transportation law or an order or regulation issued thereunder shall be fined under Title 18, United States Code, or imprisoned for not more than 5 years, or both. Note: The above penalties also apply to reshipping out of Johnson Controls branches or distributor warehouses. It is recommended that these gas cylinders be stored and shipped in the original packaging. 1997 Johnson Controls, Inc. 1 Part No. 24-8669-36, Rev. Code No. LIT-216220
Calibration Preparation Before calibrating the CDS4000, review the following steps: 1. Locate all necessary calibration kit components. 2. Prepare the gas bottles for calibration. 3. Connect the keypad. 4. Flow calibration gases and save calibration values. 5. Disconnect keypad and gas. 6. Confirm that the sensor is in normal operating mode and return it to service. Cautions and Warnings WARNING: Shock Hazard. Use caution when working with live electrical wiring to prevent electrical shock or possible damage to the equipment. Check the wiring to assure that there are no exposed live surfaces, and wires are correctly installed with no conductors exposed outside of the case. CAUTION: Equipment Damage Hazard. Do not hang a calibration gas bottle from the sensor. Place the gas bottle on the floor, a table, a portable cart, or another fixed surface. Attempting to use the sensor as a support for the bottle may cause damage to the sensor. WARNING: Personal Injury Hazard. Do not use or store a calibration gas bottle near heat or open flame. Exposure to temperatures above 125 F (52 C) may cause contents to vent or cause bursting which could result in bodily injury. Never throw the container into a fire or incinerate it. CAUTION: Equipment Damage Hazard. Do not attempt to use any other keypad device to calibrate the sensor. Damage to the sensor may result if non-approved keypads are used. Equipment Needed The following tools and supplies (provided in the CAL-A-KIT-5 Calibration Kit) are required for calibration: zero gas span gas a regulator to control the flow of calibration gas at 0.5 liters/minute 1/8 in. I.D. thin wall tubing to connect the regulator and the calibration inlet of the sensor the calibration keypad The gas supplied with the calibration kit has the capacity to calibrate approximately five sensors. Standard Procedure Follow this procedure to calibrate the CDS4000 sensor. If the sensor is not operating correctly after completing this procedure, and assuring that all installation steps have been properly completed, replacement of the sensor will be required. Refer to the Replacement and Accessories section. IMPORTANT: Incorrect calibration will cause unreliable sensor operation and may cause permanent damage to the unit. 2 CDS4000 CO 2 Sensor Calibration and Troubleshooting Technical Bulletin
After the required tools have been assembled, and the full procedure has been reviewed, proceed to calibrate the sensor. IMPORTANT: Calibration keypad operations are designed to be simple, sequential steps. Buttons labeled Begin Zero, Save Zero, Begin 800, and Save 800 should be pressed once each and in order during the calibration procedure. Pressing a given key more than once, or out of proper order, will result in incorrect calibration. This will not damage the sensor; however, the calibration procedure must be restarted from the beginning after resetting. To reset (return the sensor to normal operating mode), press the Reset button once while the keypad is connected to the sensor. (Refer to Figure 1.) P in #1 IMPORTANT: Use of excessive force while attaching tubing will damage the sensor. Regulator Knob Note: Sensor is shown unmounted for clarity. Gas Bottle 1/8 inch I.D. Tubing Sensor Gas Inlet Figure 2: Calibration Setup 3. Rotate the top of the sensor out from the wall to gain access to the calibration keypad connector, and view the LEDs that will confirm keystroke operations during the calibration procedure. (See Figure 3.) Figure 1: Calibration Keypad Complete the following steps: 1. Screw the regulator onto the zero gas bottle and attach the tubing to the hose barb on the side of the regulator. (See Figure 2.) 2. Locate the sensor to be calibrated. Connect the tubing from the regulator to the sensor gas inlet. (Refer to Figure 2 for proper calibration setup.) Figure 3: Rotating the Sensor CDS4000 CO 2 Sensor Calibration and Troubleshooting Bulletin 3
4. Attach the calibration keypad to the calibration port located in the back of the sensor. (See Figure 4.) The connector is keyed. Note the polarity of the connector. Pin 1 is indicated by a white arrow on the keypad corresponding to the red stripe on the cable. Note the marking on the case for the proper orientation of Pin 1. Align both markings for correct connection. (Incorrect connection can damage the sensor.) Pin 1 Marking: Red Stripe C arb on D ioxide Se nso r 2 4 V A C P in 1 Pin 1 Marking: Arrow C alib ratio n P o rt 0 C a l 80 0 C al Indicator LEDs Plugged Common V Output + P in #1 Calibration Keypad Figure 4: Calibration of the CDS4000 5. Begin the flow of zero gas to the sensor by turning the knob on the side of the regulator Counterclockwise (CCW). Open the valve fully, and continue the gas flow for 5 minutes. IMPORTANT: Press and hold the specified key in each step, while watching the appropriate Light Emitting Diode (LED) indicator. As soon as the LED goes on or goes off, release the key within 5 seconds. 6. After 5 minutes and while the gas is still flowing, press the button labeled Begin Zero only once. Hold this button until the LED labeled 0 Cal has turned on to confirm the operation. Release the button within 5 seconds after the LED lights. This will set the sensor to Zero Calibration mode. 7. Immediately after Step 6, press the button labeled Save Zero only once. Hold this button until the 0 Cal LED has turned off to confirm the operation. Release the button within 5 seconds after the LED goes out. The zero point of the sensor is now calibrated. 8. Stop the zero gas flow by turning the knob on the side of the regulator Clockwise (CW). Unscrew the regulator from the gas bottle. (Do not disconnect tubing from the sensor.) 9. Screw the regulator onto the span gas bottle. 10. Begin the flow of 800 ppm span gas by turning the knob on the side of the regulator CCW. Open the valve fully, and continue the gas flow for 5 minutes. 11. After 5 minutes and while the gas is still flowing, press the button labeled Begin 800 only once. Hold this button until the LED labeled 800 Cal turns on to confirm the operation. Release within 5 seconds after the LED lights. This will set the sensor to the 800 ppm Calibration mode. 12. Immediately after Step 11, press the button labeled Save 800 only once. Hold this button until the 800 Cal LED turns off to confirm the operation. Release the button within 5 seconds after the LED goes out. The span point of the sensor is now calibrated. 4 CDS4000 CO 2 Sensor Calibration and Troubleshooting Technical Bulletin
13. Confirm that no LEDs are lit. (This LED condition indicates that the calibration procedure has been completed and that the unit is in the normal operating mode.) Turn off the 800 ppm span gas flow by turning the knob on the side of the regulator CW. 14. Carefully disconnect the tubing from the sensor. (Avoid using excessive force, which could damage the sensor.) 15. Remove the regulator from the gas bottle. 16. Unplug the keypad connector from the rear of the unit, and rotate the sensor up and snap it into place. (Make sure that the wires are routed so the sensor can be snapped firmly into place.) Default Procedure If for any reason, the calibration process cannot be completed (ran out of calibration gas unexpectedly, etc.), this option is available to save preset, average calibration values. This will allow the unit to operate, but the unit may not meet factory accuracy specifications. Some inaccuracy may be a better option than a service outage. Use of the Default Calibration mode will not harm the sensor, but the unit should be correctly calibrated at the earliest opportunity to assure that performance is brought up to specifications. To do a default calibration, perform the following steps: 1. Connect the calibration keypad to the rear of the sensor. 2. Press the button labeled Begin Zero. Hold this button until the LED labeled 0 Cal lights to confirm operation. Release the button within 5 seconds after the LED lights. 3. Press the button labeled Save Default to save factory set default setting. Hold this button until the 0 Cal LED turns off to confirm operation. Release the button within 5 seconds after the LED goes out. 4. Press the button labeled Begin 800. Hold this button until the LED labeled 800 Cal lights to confirm operation. Release the button within 5 seconds after the LED lights. 5. Press the Save Default button to save factory set default setting. Hold this button until the 800 Cal LED turns off to confirm operation. Release the button within 5 seconds after the LED goes out. 6. Check that no LEDs are lit to confirm completion of the default calibration procedure. This LED condition indicates that the calibration procedure has been completed and that the unit is in normal operating mode. Unplug the calibration keypad and close the sensor case. Note: If an LED is lit after completing Steps 1-6, reset the sensor by pressing the Reset button while the keypad is connected to the sensor. The reset is successful if all LEDs are off. When a reset has been performed, repeat the default calibration procedure. CDS4000 CO 2 Sensor Calibration and Troubleshooting Bulletin 5
Troubleshooting Use Table 1 to determine the cause of the problem if the sensor is not operating properly. Table 1: Troubleshooting Guide for the CDS4000 Condition Next Action How To Device does not operate. Inspect the fuse. If it is blown, check the wiring before replacing it. (The CDS4000 needs an electrically isolated transformer to work with most controllers.) Make sure that an isolated 24 VAC transformer is used to power the CDS4000. Replace the fuse with a Littelfuse P/N 22501-5 or an equivalent 1-1/2A 250V fuse (9/16 in. long x 3/16 in. diameter). Button is pressed out of sequence, is pressed more than once, or is not held or released for the correct amount of time. LEDs status not as described in procedure. Cannot reset via use of the Reset key. Cannot locate all required calibration equipment. Calibration gas is available, but it is not gas purchased through Johnson Controls. Have used all available calibration gas and was unable to save calibration values. Unit will not calibrate after several attempts. Reset sensor and redo the calibration from the beginning. Reset sensor and redo the calibration from the beginning. Full cold restart. Do not attempt to calibrate the unit. Do not attempt to calibrate the unit. Calibration gases for these sensors are custom mixed to high precision. (Use of gases other than specified gases may cause the unit to operate unreliably.) Perform default calibration. Replace the unit. Press the Reset button. Note that both LEDs are in the unlit condition to confirm that the sensor is fully reset. Press the Reset button. Note that both LEDs are in unlit condition to confirm that the sensor is fully reset. Unplug the sensor power connector. Leave the unit unpowered for 1 full minute. Plug in the sensor power connector, and allow the unit to warm up for 5 full minutes before beginning the calibration procedure. See Equipment Needed section. See Equipment Needed section. See Calibration, Default Procedure section. Contact your local Johnson Controls representative. 6 CDS4000 CO 2 Sensor Calibration and Troubleshooting Technical Bulletin
Maintenance and Repair Recommended Maintenance To ensure maximum performance from the CDS4000: Keep the air vents on the unit clean and unobstructed. Recalibrate the sensor annually to prevent inaccuracy due to drift. Replacement and Accessories If a replacement unit is required, contact your local Johnson Controls representative and specify the complete product code number from Table 2. A calibration kit for the CDS4000 can also be ordered using Table 2. Servicing the Sensor The CDS4000 cannot be repaired in the field. If the CDS4000 fails verification and subsequent field adjustment of the calibration settings does not correct the problem, contact your local Johnson Controls representative. Table 2: Products and Accessories Available Product Code Number Product Description CDS4100-0 CO 2 Sensor With base, 0-2030 ppm CO 2 range, 0-10 VDC output CDS4200-0 CO 2 Sensor With base, 0-2030 ppm CO 2 range, 0-10 VDC output and SPST/high limit relay CDS4300-0 CO 2 Sensor With base, 0-2030 ppm CO 2 range, 0-10 VDC output and SPST/high limit relay, and digital display CAL-A-KIT-5 Calibration Kit (Includes zero and For calibration of CDS4000 Series Carbon Dioxide Sensor span gas, regulator, 1/8 in. I.D. tubing, and calibration keypad) CAL-A-0-5 Zero Gas 17 liter gas bottle with nitrogen CAL-A-800-5 Span Gas 17 liter bottle with 800 ppm CO 2 A-4000-137 Air Filter Use with the CDS4000 in duct applications where the flow pickup tube is installed. FTG18A-600R Flow Pickup Device Remote Mounted Sensing Probe Kit A-303 (Dwyer Model) Flow Pickup Device (alternate) Order through the Dwyer Corporation. Code No. LIT-216215 CDS4000 CO 2 Sensor Installation Supplement to this technical bulletin Part No. 24-8669-28, Rev. Technical Bulletin CDS4000 CO 2 Sensor Calibration and Troubleshooting Bulletin 7
Notes Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI 53201 Printed in U.S.A. 8 CDS4000 CO 2 Sensor Calibration and Troubleshooting Technical Bulletin