Carbon Dioxide (CO2)

HVAC Basics

Copyright © 1998 Honeywell Inc. • All Rights Reserved 63-7049

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BACKGROUND
Building managers and owners have become aware that control of temperature and humidity alone is insufficient to meet
occupant comfort needs. Air quality affects performance and, in some cases, occupant health. To help maintain proper
ventilation rates, Honeywell offers the C7242 line of CO2 sensors.

CO2—What it is
CO2 is exhaled from us all. Although not normally a health concern, CO2 levels increase as building occupancy levels
increase. Number of occupants, activity level, building tightness, ventilation rate, space volume, plants, and building
construction all affect building CO2 levels. CO2 levels typically correlate with other bio-effluents such as gases, odors,
particulates, bacteria, viruses, and perfumes. Monitoring CO2 levels helps facilitate ventilation decisions that allow
balancing occupant comfort and energy-savings.

CO2 Levels
Rural outdoor CO2 levels are about 350 parts per million (ppm) while urban CO2 levels are considerably higher. OSHA
guidelines allow a CO2 air contaminant limit of 5,000 ppm for more than 8 hoursa. In comparison, submarines can reach
as high as 7,000 ppm (and on rare occasions even reach a level of 30,000 ppm). Offices typically are 800-1200 ppm.
Tightly packed conference rooms with minimal ventilation can be 2,000 ppm. To learn how stuffy the air feels at higher
CO2 levels, carry a portable C7242 and monitor CO2 levels throughout your day. This is an excellent way to sell CO2
sensors.

Claims that 1,000 ppm and greater CO2 levels cause drowsiness, fatigue or headaches are highly subjective and often
unfounded. Elevated CO2 levels do not necessarily cause these symptoms, but can indicate a buildup of other contami-
nants that do cause such symptoms. Managing ventilation using CO2 levels can improve occupant comfort because other
pollutants are also exhausted with the CO2.

IMPORTANT
Do not confuse carbon dioxide (CO2) with carbon monoxide (CO), a highly toxic gas that is also a byproduct of
combustion in furnaces, fireplaces and automobiles. Carbon monoxide (CO) can be harmful, even at very low
levels (25 to 50 ppm).

CO2 as an IAQ Indicator

Claims that CO2 sensors are indoor air quality (IAQ) sensors are inaccurate. CO2 levels are one piece of the undefined
indoor air quality equation. Low CO 2 levels do not indicate good air quality while high CO2 levels do not mean that air is
harmful. So CO2 sensors should be presented and sold as sensors of CO2 levels that provide information useful in
determining ventilation rates to control CO 2 levels. C7242 CO 2 sensors should not be used as a primary life safety device
or as an IAQ sensor and they are no substitute for an indoor air quality analysis, especially when building air quality is
questionable.

NOTE: Refer to ASHRAE 62-1989 Standard for details relating CO2 level to ventilation rate.

There are devices marketed as IAQ sensors that output one composite signal. Regardless of what some vendors may say,
there are no reliable HVAC market priced indoor air quality sensors because IAQ is a complex problem that includes
many variables. To further confuse the issue, some substances are deadly when present in low ppm while others are
harmless when present in high thousands of ppm. The list of substances is quite long and not totally defined; see the
OSHA web sitea. Sensors currently sold on the market cannot solve these issues. However, when one becomes available,
Honeywell plans to offer it.

It is anticipated that CO2 sensor use in codes and legislation will improve in the future. The codes will define relation-
ships among ventilation, occupancy and IAQ parameters (including CO2). The new family of C7242 products is designed
to meet all CO2 sensor needs and is also compatible with most controllers. Watch for geographic area code changes that
can affect your CO2 sensor sales.

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CARBON DIOXIDE, DEMAND-CONTROLLED
VENTILATION (DCV) QUESTIONS AND ANSWERS
IMPORTANT
Always refer to state and local codes for details on required and recommended CO2 levels.

Temperature Control and CO2 Control

Temperature controls and CO2 controls have similarities; both controls have a desired setpoint. The CO2 setpoint is the
equilibrium level necessary to maintain the ventilation rate (cfm per person) for the space. The same factors influencing
temperature distribution in a space influence CO2 distribution. These factors include convection, diffusion, and mechani-
cal air movement. It is important to determine CO2 sensor placement based on the anticipated loads. For optimum
control, place a CO2 sensor in every zone. If an HVAC system is serving a series of zones with similar occupancy
patterns, it may be appropriate to place sensors in return air ducting. It is important to eliminate duct leakage as this can
introduce false CO2 readings.

There are also differences between CO2 and temperature sensing and control. Temperature is usually quite uniform
throughout a zone whereas CO 2 levels can vary widely. CO2 levels within a conference room can reach 2,500 ppm while
the level on the other side of the door remains at 800 ppm. Therefore, sensor placement strongly affects the result
because the control system attempts to control CO 2 levels at the sensor location.

There are a variety of CO2 control strategies and algorithms used in ventilation control. Proper selection depends on the
complexity of the building and its HVAC system. Three common strategies follow.

On/Off
On/Off control employs an open-closed damper strategy based on CO2 level. This strategy is the most common approach to
CO2 control. A damper opens at a setpoint and closes when levels drop 50 to 100 ppm below setpoint. This strategy works
best in applications with high occupancy densities (20 to 50 people per 1,000 sq ft) and with occupancy varying from zero to
full in a very short time. Theaters, conference rooms and some school classrooms are applications where this strategy is used.

When CO2 levels vary around the setpoint, the dampers drive fully open and fully closed, depending on the reading so
when other control options are not available, use setpoint control.

Proportional
The amount of heating or cooling energy provided to a space is the basis for staging many HVAC systems. Ventilation
systems with proportional control use a CO2 sensor signal proportional to CO2 level. Control begins when indoor levels
exceed outdoor levels by a defined difference (100 ppm). Air delivery to the space increases proportionally to provide
100% ventilation rate. Compared to setpoint control, this approach allows faster system reaction to varying occupancy
levels. It does not always wait for levels to build to the control point. Applications requiring a higher degree of control
use a proportional strategy. Proportional control uses sensor models that allow the installer to scale the output to corre-
spond with the control range desired. For example, a 2 to 10 Vdc signal can be adjusted to match a CO2 level differential
range of 400 to 1,000 ppm. Proportional ventilation control is ideal in spaces with highly variable and unpredictable
occupancies such as bars, restaurants, conference rooms, courtrooms, classrooms, and retail spaces.

Proportional-Integral-Derivative (PID)
Time required to reach equilibrium CO2 levels in low-density applications creates a potential disadvantage for CO2
control. Low densities such as six people per 1,000 sq ft can require hours to reach equilibrium CO2 and staggered or
varying occupancy can aggravate these problems. Temperature control of large complex buildings encounters similar
problems as a result of unpredictable changes in outdoor temperature, solar gain and internal heat generation. Simple
temperature control approaches, such as setpoint or proportional, can be disaster in this type of building.

A solution to these complex control problems is PID control. PID control directs system control sequences to examine
distance from setpoint, time spent at setpoint, and speed of change from setpoint. PID CO2 control views trends and CO2 level
change rates. For example, minutes after people enter a building in the morning, the HVAC system reacts to adjust fresh air
delivery. This adjustment is based on actual occupancy predicted by the CO2 level rate of rise. Much like the proportional
control system, the PID controller operates based on the linear output signal from a CO2 sensor. Most DDC and building
control systems use PID control algorithms. Stand-alone controllers are available that can translate a linear signal from a CO2
sensor into a PID signal. However, only experienced control designers and installers should apply PID control approaches.
When applied properly, PID control provides fast ventilation rate response to changing occupancy conditions. Remember that
PID control integrates best in high-rise, multi-zone buildings with low density, highly variable or unpredictable patterns of
occupancy.

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Why is CO2 Control Important?
Most building codes base new building ventilation recommendations on ASHRAE Standard 62-1989, “Ventilation for
Acceptable Air Quality.” This standard has a wide variety of recommended ventilation rates based on space use. Problems
related to poor IAQ increase when a serious energy crisis creates sufficient energy savings interest to prompt lowering
ventilation standards. A study of 500 IAQ investigations conducted by the National Institute for Occupational Safety and
Health (NIOSH) in the 1970s and 1980s indicated that 50% of problems identified resulted from inadequate ventilation.

People per Square Foot or cfm per Person

The terms cfm per square foot and people per square foot of floor space are often used when defining building ventilation
requirements. CO2 concentration is a function of building volume (not square footage), construction, tightness, ventilation rate
and occupant level of activity. One person every three square feet of a large gymnasium does not result in a significant CO2
level rise. Even if they are all physically exercising, the effects are similar. Apply the same occupant density to a typical room
in a multi-story office building, and a dramatic change in CO2 levels will result (with or without exercise).

Recognize that using cfm per person and cfm per square foot CO2 are attempts to simplify the discussion. Actual measure-
ments more accurately determine CO2 levels. Always refer to local code and requirements for implementation requirements.

High-ventilation Rate Tradeoff

While increased ventilation standards decrease the incidence of IAQ complaints, there is a tradeoff for building owners
and occupants. Generally, building owners must increase HVAC equipment capacity by 30% to 50% for proper outdoor
air preconditioning. So the cost of heating and cooling fresh air can become the most significant cost of HVAC system
operation. Extended and flexible work hours, and increased use of schools and public buildings beyond traditional
business hours add additional cost to HVAC system operation.

Balance Energy Savings and Air Quality

Traditionally, building engineers designed the fresh air ventilation system to meet space ventilation requirements based
on building design occupancy and application-recommended ventilation rate. This ventilation was maintained during all
occupied hours regardless of actual occupancy. However, extended and flexible work hours, work-at-home programs, and
other changes in work habits resulted in rarely-met design occupancies and occupancy periods extending beyond
traditional routine. So using the traditional approach of ventilation system sizing to design occupancy can result in costly
over-ventilation of large spaces. CO2 control strategy ensures sufficient outdoor air delivery for the occupancy level.
Avoiding over-ventilation during low occupancy periods provides attractive savings that a CO2 DCV system can realize.

Can CO2 Based Ventilation Control Increase Energy Costs?

CO2 used alone to control ventilation can result in increased energy costs. Proper application with ECONOMIZER™
Logic Modules ensures preventing these increased energy costs. When installed with ECONOMIZER Logic Modules,
significant energy savings are possible.

Outdoor CO2 Level Must be Considered

A guideline to follow regarding CO2 and ventilation is that an indoor space is under-ventilated if CO 2 levels exceed 1,000
ppm. This assumes outdoor level of 300 ppm. The indoor level of CO2 can provide useful guidelines; however, like many
guidelines, it is possible to over-simplify. For CO2, the important ventilation indicator is the difference between the
indoor and outdoor levels. Outdoor levels of 300 ppm exist only in areas far from urbanization and industrialization; for
example, outdoor levels in Los Angeles or Taipei often exceed 600 ppm. The corrected guideline is: “If indoor level
exceeds outdoor level by more than 700 ppm, a building space is considered under-ventilated for the number of occu-
pants in the space.”

Indoor/Outdoor Differential CO2 Levels

Consider outdoor CO2 levels when implementing CO2 ventilation control strategy. Calculate ventilation rates from
indoor/outdoor differential levels. Using an arbitrary CO2 control setpoint without considering outdoor levels can result
in over-ventilation. There are two approaches used in integrating outdoor CO2 conditions into a control strategy:
1. Fixed value, premeasured, average CO2 baseline for the geographic location.
2. Direct CO2 HVAC system monitoring.

NOTE: Use the second approach with extreme variations in outdoor levels (more than 200 to 300 ppm during a
day). Extreme variation occurs with building air intakes near sources of pollution (major highways, loading
docks, etc.)

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When outdoor air CO2 levels exceed 800 ppm, investigate the source of CO2. Levels this high indicate polluted outdoor
air that likely contains high levels of other contaminants. When periodic high levels occur, devise a control strategy to
close air intakes during unacceptable levels (higher than 600 ppm).

Importance of CO2 Equilibrium

An important factor influencing ventilation assessment and control using CO2 levels is the principle of equilibrium.
Consider a number of people entering a space at the beginning of a workday. The CO2 level in the space would be very
low (close to the outdoor level). Then the CO2 level rises as people enter the room, and levels off eventually. The CO2
leveling point is the equilibrium. The amount of CO2 produced by the occupants is in balance with space ventilation. CO2
levels reach equilibrium as they stabilize to within a 100 ppm range.

IMPORTANT
The key factor in determining ventilation rate is the difference between indoor and outdoor CO2 levels.

The time required to reach equilibrium depends on number of people, activity level, space volume, and ventilation rate.
Poorly-ventilated rooms with low occupant densities can require several hours to reach equilibrium level. Once indoor level
exceeds a certain indoor/outdoor differential, the ventilation rate is below acceptable. If a space has high occupant density
(school classroom, bar or theater), or poor ventilation, the equilibrium level can be reached rapidly, in 20 minutes or less.

IAQ Diagnostic Measurement

During IAQ investigations, CO2 measurements are the first tests performed. When making diagnostic or spot measure-
ments of CO2 for ventilation assessment, consider the equilibrium effect. Performing a spot measurement before achiev-
ing equilibrium results in inaccurate CO 2 levels. For most office spaces, time to reach equilibrium can be two to three
hours. In a school classroom, the time can be a few minutes. When the occupancy of the space changes, the potential for
misinterpreted spot measurement increases. As a guideline, a high spot measurement—an indoor and outdoor ppm
difference greater than 700—indicates inadequate ventilation. Low levels with uncertain equilibrium conditions provide
inadequate information to evaluate ventilation rate.

The use of spot CO 2 measurements has several drawbacks. A more effective diagnostic measurement approach is
recording space CO2 levels for 24 hours. Use a data logger and a continuous CO2 monitor to record level changes. This
provides information about the HVAC system and fresh outdoor air delivery to building zones (in proportion to occu-
pancy levels). For diagnostic purposes, take CO2 measurements in at least every zone containing a single air handler.
Take measurements during typical occupancy patterns. If the HVAC system uses Variable Air Volume (VAV) systems,
perform measurements in every VAV zone during full occupancy. If diverse occupancies occur throughout the zone, take
separate measurements in each occupied area. It can also be worthwhile to measure CO2 levels in return air ducting. It is
important to take at least one measurement each season.

Guidelines for Diagnostic CO2 Measurement

1. Determine outdoor level.
2. Use trend analysis over at least a day rather than using more difficult spot measurements.
3. Make spot measurements under normal or peak occupancy conditions. An elevated level of CO2 (over 1,000
ppm or 700 ppm over outdoor levels) generally indicates insufficient ventilation.
4. When using CO2 to determine ventilation rate, base assessment on equilibrium conditions. (Levels below 1,000
ppm do not necessarily indicate good IAQ.)
5. Periodically check calibration of CO2 sensor.

Demand-Controlled Ventilation (DCV)

CO2 based DCV provides an effective approach for designers, contractors, building owners, and managers. It can apply
to new and existing buildings. DCV helps maintain ventilation for acceptable IAQ. Properly applied DCV strategies can
reduce energy costs by eliminating over-ventilation during partial or intermittent occupancy.

CO2 Ventilation Control Guidelines

1. Determine equilibrium level for each zone based on design density and ventilation rate. This is the upper
setpoint.
2. Actively measure or assume a representative value for outdoor CO2.
3. Continuously ventilate at a minimum level to control non-occupant related contaminants.
4. Select a control strategy based on occupancy density and variability; see Table 1.

NOTE: For proportional or rate of rise (PID) strategy, begin control 100 ppm above outdoor conditions.

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 Table 1. Recommended Control Strategy Based on Occupancy Density.
Occupancy Density (number of people per 1,000 sq ft) Recommended Control Strategy
Highly variable (unpredictable changes greater than 25% occupancy) PID or Proportional
Low (7 or fewer) PID or Proportional
Medium (7 to 20) Proportional
High (20 to 50) Setpoint or Proportional

PRODUCT DESCRIPTION SUMMARY

C7242 sensors operate on a well-known principle of infrared absorption of radiation called the Non-Dispersive Infrared
(NDIR) technique. Simply stated, NDIR relies on the fact that CO2 molecules have a unique molecular structure.
Consequently, they absorb light at a unique frequency. Measuring the amount of light absorbed at that frequency enables
CO2 level determination at the seyÉor.

When NDIR CO2 sensors were first introduced to HVAC markets, they used an aluminum tube to guide the light.
However, these aluminum tubes corroded due to normal air pollutants. The tube corrosion absorbed energy resulting in
false CO2 indications. The new Honeywell CO2 sensors are gold-plated to resist corrosion. Therefore, calibration lasts far
longer than other CO2 sensors. No other CO 2 sensor on the market offers gold-plating reliability, or the lasting calibration
these sensors offer. Using gold eliminates not only sensor chamber corrosion, but the need for a second sensor to
measure drift, and all the problems associated with a second sensor. (Products that incorporate a reference sensor must
deal with issues of reference sensor drift, correlation between the sensors, added cost and reliability issues.) Honeywell
has been closely tracking CO2 sensor product developments for years and discovered that many units evaluated did not
meet expectations. The new C7242 Sensors use technology unavailable in any other product and they provide the best
performance at the lowest service costs while remaining competitively priced.

Each unit has two analog outputs. Some models use the second output for other purposes such as a relay, heater control,
or low-battery indication. The available analog outputs can use factory defaults for plug and play simplicity, see Table 2.
The installer can reconfigure the devices to meet control requirements using the accessory 32002183-001 PC Configura-
tion Software. The analog outputs typically produce a linear output relative to the sensor reading (0-10 Vdc). By custom-
configuring the sensor, CO2, temperature and contact input can be combined to generate custom output curves. The
number of output options are too numerous to discuss.

Table 2. Factory Sensor Configuration.

AN1 AN2
Signal Slope Integral Time Signal Slope Integral Time
Model (Vdc) (ppm/Vdc) (sec) (Vdc) (ppm/Vdc) (sec)
Two 500 ppm = 0 150 64 0 ppm = 0 200 2
analog 800 ppm = 2 800 ppm = 4
outputs 2,000 ppm = 10 2,000 ppm = 10
One 500 ppm = 0 150 64 Switch Point: 800 ppm
relay 800 ppm = 2 (SPST contact closes when level rises above switch point)
output 2,000 ppm = 10 Differential: 100 ppm
Portable 500 ppm = 0 300 64 Not Available
800 ppm = 1
2,000 ppm = 5
Outdoor 500 ppm = 0 150 64 Not Available
800 ppm = 2
2,000 ppm = 10

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TARGET APPLICATIONS
The primary control strategy using CO2 is outdoor air intake regulation to provide fresh air when required, based on
occupancy. This avoids over-ventilation and associated energy costs. ECONOMIZER™ Logic Module applications, both
standalone and DDC based, represent the largest opportunity for CO2 sensor sales.

ECONOMIZER™ Logic Modules

ECONOMIZER Logic Modules provide energy saving decisions by using, when possible, outdoor air in place of
mechanically conditioned indoor air. The new line of W6215, W7215 and W7460 Logic Modules takes the control
process one step farther. It includes input and control for indoor air and (with B models) outdoor air sensors. The C7242
is the typical sensor that provides these inputs. See Table 3 for CO2 model details. When indoor CO2 levels are high, the
logic module opens the dampers, providing additional fresh air. On models with outdoor air sensors, the logic module
also monitors outdoor air, opening the outdoor air dampers only if outdoor air meets user-defined thresholds.

Building DDC Configured

In all commercial buildings, code dictates minimum levels of fresh air brought into the building. Using CO2 sensors and
proper DDC controllers, fresh air ventilation rates can provide comfort, efficiency and temperature control. Both the
XL10 Constant Volume Air Handler Unit Controller (W7750) and the XL10 Unit Vent Controller (W7753A) accept
sensor inputs that indicate indoor air parameters. The C7242 CO2 Sensor output is one example. The XL10 Remote
Input/Output (RIO) module (W7761) provides a CO2 sensor interface and puts the ppm value on E-Bus. Controllers
properly programmed use readings directly from the E-Bus network. By networking multiple RIO modules and a Zone
Manager, a C-Bus application sensor bus can be created, potentially reducing installed cost. Refer to the XL10 product
literature for operation, connection and configuration information.

Residential Systems
Houses are subject to the same, if not worse, IAQ issues as buildings. Commercial building codes require a minimum
fresh air intake. Houses are now tighter and rarely have to follow codes that require fresh air intake. However, in a tight
house, CO2 levels increase during periods of higher occupancy or during use of unvented gas combustion appliances.
Houses equipped with fresh air ventilation devices, such as the Honeywell HR150 or HR200, can use the C7242 to
control the ventilation rate based on the indoor CO2 level. This can result in increased comfort and energy savings. The
C7242A1030 and 1048 models are compatible with the PC8900 Perfect Climate Comfort Center™, the Honeywell ERV
and HRV devices. CO2 sensor contact closure signals the controller or ventilation device that the CO2 threshold was
reached and the device takes appropriate action. See the device literature for wiring and control options.

General Sensor Application

This process defines the typical CO2 sensor application. Specific values are not suggested because it is the installer’s
responsibility to identify target CO 2 and ventilation levels based on the application and the local code.
1. Determine the sensor location. This is the location that the controller targets to maintain CO2 levels.

NOTE: CO2 levels can differ widely within the ventilation zone, resulting in over- or under-ventilation. Finer
control requires more sensors and greater area-independent ventilation ability.

2. Identify and set the level at which ventilation should increase; for example, an application requires increased
ventilation at 800 ppm. Configure the (effective) sensor zero point at 800 ppm.
3. Identify and set the level at which 100 percent ventilation should occur; for example, 100 percent ventilation is
required at 2,000 ppm. Configure the sensor to 10 Vdc at 2,000 ppm.

NOTE: The CO2 sensor cannot compensate for equipment that cannot handle the ventilation requirements.

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 Table 3. C7242 Models and Accessories.
Output
Product Description Display No display (quantity) Comments
Wall Mount with relay C7242A1030 C7242A1048 Analog (1), 7-1/16 in. x 3-15/16 in. x 2-3/16 in.
Relay (1)
Wall Mount C7242A1014 C7242A1022 Analog (2)
Portable C7242C1002 N/A Analog (1) 9 Vdc NiMH and 120 Vac Charger.
Duct Mount C7242B1012 C7242B1020 Analog (2) 9-5/8 in. x 3-11/16 in. x 2-3/16 in. with
1-3/16 in. D x 9-1/16 in. sampling tube.
Outside Air N/A C7242E1007 Analog (1) 9-5/8 in. x 3-11/16 in. x 2-3/16 in.
Zero Calibration Service Kit 32002181-001 N/A 7-1/2 in. x 7-1/2 in. x 4-1/2 in.
Duct Mount Housing only 32002182-001 9-5/8 in. x 3-11/16 in. x 2-3/16 in. with
1-3/16 in. D x 9-1/16 in. sampling tube.
PC Configuration Software 32002183-001 Includes RS232 Cable.

FOOTNOTES
a See http://www.osha-slc.gov/OshStd_data/1910_1000_TABLE_Z-1.html

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