Sensors

AMB II
9270-054

Hardware Interface
Version 1.04

Doc # 9315-031 Rev E

24-May-2000
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sensors, inc.

1 COPYRIGHT MICROBENCH
The information furnished in this manual is believed to be accurate and reliable.

Information in this document is subjected to change without notice.

Please contact our office in the US or Germany for application assistance.

1994-1999 Sensors, Inc., all rights reserved.

Sensors, Inc. Sensors Europe GmbH

6812 South State Road Papiermühlenweg 74
Saline, Michigan 48176 D-40882 Ratingen
U.S.A Germany

Phone: +1 (734) 429-2100 Phone: +49-(0) 2102-85680-0

Fax: +1 (734) 429-4080 Fax: +49-(0) 2102-85680-56
e-mail: TSimon@[Link]
Internet: [Link]

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2 CONTENT
1 COPYRIGHT MICROBENCH ......................................................................................................... 2

2 CONTENT ........................................................................................................................................ 3

3 IN GENERAL.................................................................................................................................... 4
3.1 INTRODUCTION ............................................................................................................................ 4
3.2 AREA OF USE .............................................................................................................................. 4
3.3 PRINCIPLE OF NDIR MEASUREMENT ............................................................................................ 4
4 MICROBENCH MODULE DESCRIPTION ...................................................................................... 5
4.1 MICROBENCH SYSTEM THEORY OF OPERATION ........................................................................ 5
4.2 SPECIFICATION ............................................................................................................................ 6
4.2.1 Storage Temperature ......................................................................................................... 6
4.2.2 Operational Temperature ................................................................................................... 6
4.2.3 Measured Gases................................................................................................................ 6
4.2.4 Ranges............................................................................................................................... 7
4.2.5 Accuracy/Performance....................................................................................................... 7
4.2.6 Resolution .......................................................................................................................... 7
4.2.7 Warm Up Time ................................................................................................................... 7
4.2.8 Response Time .................................................................................................................. 7
4.2.9 Flow Rate ........................................................................................................................... 7
4.2.10 Operating Pressure ............................................................................................................ 7
4.2.11 Proposed Calibration Gases for OIML Specification.......................................................... 8
4.2.12 Calibration Gases for BAR 90 Specification....................................................................... 8
4.2.13 O2 Specification.................................................................................................................. 8
4.2.14 NOx Specification ............................................................................................................... 8
5 MICROBENCH MODULE APPLICATION....................................................................................... 8
5.1 APPLICATION SPECIFICATION ....................................................................................................... 8
5.1.1 Power Requirements.......................................................................................................... 8
5.1.2 Mounting Requirements ..................................................................................................... 9
5.2 OPERATIONAL REQUIREMENTS .................................................................................................. 11
5.2.1 Sample System ................................................................................................................ 11
5.2.2 Summary.......................................................................................................................... 12
5.3 USER INTERFACE REQUIREMENTS SUMMARY ............................................................................. 12
5.3.1 Software & Communications............................................................................................ 12
5.3.2 Electrical & Electronic ...................................................................................................... 12
5.3.3 Mechanical & Pneumatic.................................................................................................. 12
5.4 MICROBENCH OPERATING INSTRUCTIONS .............................................................................. 13
5.5 RS-232 CONFIGURATION........................................................................................................... 13
5.6 CONNECTOR PIN-OUT ............................................................................................................... 14
5.6.1 Connector Location pc Board Assy 9211-032 ................................................................. 14
[Link] Connector – NOX Transducer (J1) ............................................................................................ 14
[Link] Connector – NOX (J3) ............................................................................................................... 15
[Link] Connector – O2 (J4) .................................................................................................................. 15
[Link] Connector – Analog RPM (JA4)................................................................................................. 16
[Link] Connector – Oil Temperature (J5) ............................................................................................. 16
[Link] Connector – Relative Humidity (JA5)......................................................................................... 17
[Link] Connector – RS232 Host (J7).................................................................................................... 17
[Link] Connector – Power (J8) ............................................................................................................. 18
[Link] Connector – I/O sample (J9, J10).............................................................................................. 18

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[Link] Connector – Digital RPM Input (J11) ..................................................................................... 19

[Link] Connector – External Temperature (J12) .............................................................................. 20
6 REVISION HISTORY ..................................................................................................................... 22

3 IN GENERAL
3.1 INTRODUCTION
The Sensors 5 gas MICROBENCH is a small gas detection module designed for easy incorporation
into automotive applications. Its innovative design meets OIML R 99 class 1, ISO 3930 and OIML R 99
class 1 specifications.

System Cost Reduction

Sensors MICROBENCH is designed to reduce the overall system costs of a gas analyzer. The low
power consumption of 10 watts with a single 5 volts power supply allows the choice of a less expen-
sive power supply. Due to the small size of the MICROBENCH the flow rate can be reduced to 0.3
l/min. Because of the small size of the MICROBENCH, the reduced size of the pump module and the
simplification of the power supply, the complete analyzer could be built as a real handheld unit.

Life Time Cost Reduction

To offer overall lifetime cost reduction, Sensors removed all moving parts from the MICROBENCH and
is now chopping the infrared sources power directly (patent pending). This new technology and the use
of standard parts will increase the reliability of the MICROBENCH.
3.2 AREA OF USE
The MICROBENCH Module will be used to determine different concentrations in the automobile
exhaust gas. It measures carbon monoxide (CO), carbon dioxide (CO2) and hydrocarbons, i. e. as
propane (C3H8) or hexane (C6H14). Using an electrochemical cell, oxygen (O2: Sensors' part number
7014-006) and Nitric Oxide (NOx: Sensor’s part number 7014-011) can also be determined.

The measure of the above mentioned gases allows emission control for any mandatory inspection and
maintenance program, as well as vehicle diagnosis based on exhaust gas measurement under static
and dynamic conditions by sampling at the tailpipe or, on cars with a catalytic converter, before and
after the catalytic converter.

The MICROBENCH Module was especially developed to meet the OIML R 99 class I, OIML R 99 class
0 and ISO 3930 specification.

3.3 PRINCIPLE OF NDIR MEASUREMENT

The MICROBENCH Module is based on a Non-Dispersive Infrared technology. Instead of using a
refractive prism to achieve high spectral resolution of the infrared light stream (such as used in high-
end performance laboratory equipment), Sensors is applying NDIR in its MICROBENCH. NDIR devices
are generally dedicated to the measurement of concentrations of a limited, specific set of gases in
mixtures with a limited, known set of background gases.

An example of such a limited framework might be the measurement of CO2 concentration within an
automotive exhaust gas background. Gases that might have an absorption spectrum overlapping that
of CO2 are known - a priori - to be absent.

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A specific set of gases (i. e. CO, C6H14, CO2 for the MICROBENCH) is measured as follows: a single
waveband within the infrared spectrum is selected for each gas to measure (see Picture 3-1:
Absorption Spectrum) where its absorption is known to be substantial and where no other background
gas absorbs significantly.

Optical band pass filters which transmit electromagnetic energies only within the waveband are placed
before the thermocouple detector. When the sample cell is filled with sample gas, the IR detector
measures the resultant reduction of transmitted IR energy within the waveband of each gas.

Absorption Spectrum

100%

90%

80%

70%
Transmission [%]

60%

CO
50% CO2
Hexane
40%

30%

20%

10%

0%
3 3.5 4 4.5 5 5.5
Wave length [:m]

Picture 3-1: Absorption Spectrum

4 MICROBENCH MODULE DESCRIPTION

4.1 MICROBENCH SYSTEM THEORY OF OPERATION

The MICROBENCH Non-Dispersive Infrared gas analyzer is capable of measuring CO (carbon
monoxide), CO2 (carbon dioxide), and HC (hydrocarbons). It also performs both zeroing and calibration
routines that are completely microprocessor controlled. The gas readings and diagnostic data are then
transmitted out to a host computer, over a standard 3- wire RS-232 line, by the on-board
microprocessor.

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Vcc Gas Out

CO

x1
x2
x3
u1
x4
x5
xn

HC & REF

CO2
u1

x1 u5

un

Controler

Gas In

16 bit
L-micro controler

11.02.99
THS / Sensors Europe

Picture 4-1: Principle of the MICROBENCH

There are a number of technically significant improvements that the MICROBENCH offers over
conventional gas analyzers:
• Low Power Consumption
• No Moving Parts
• Single Power Operation
• 5 Gas System
• High Reliability
• No Fan Required

A comprehensive simple to use communication protocol allows the host PC to control the
MICROBENCH activity. Things such as zero, calibration, as well as sample system control are easily
accomplished with the powerful command set.

4.2 SPECIFICATION
4.2.1 STORAGE TEMPERATURE
-50 °C to 70 °C

4.2.2 OPERATIONAL TEMPERATURE

-12 °C to 48 °C

4.2.3 MEASURED GASES

HC Hydrocarbons as C6H14 Hexane
CO Carbon Monoxide
CO2 Carbon Dioxide

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HC Hydrocarbons as C3H8 Propane

O2 Oxygen (optional through Electrochemical sensor)
NOx Nitric Oxide (optional through Electrochemical sensor)

4.2.4 RANGES
HC = 0 to 2000 ppm Hexane (Standard resolution)
= 0 to 4000 ppm Propane (Standard resolution)
= 0 to 3276.7 ppm Hexane (High resolution)
= 0 to 3276.7 ppm Propane (High resolution)
CO = 0 to 15%
CO2 = 0 to 20%
HC = 0 to 20000 ppm Hexane (Standard resolution only)
= 0 to 40000 ppm Propane (Standard resolution only)
O2 = 0 to 25%
NOx = 0 to 5000 ppm (As Nitric Oxide)

4.2.5 ACCURACY/PERFORMANCE
The performance of the AMB is :
1. OIML R99 class 0
2. OIML R99 class 1
3. ISO 3930
4. BAR 90

4.2.6 RESOLUTION
HC: 1 ppm vol. (Standard resolution)
0.1 ppm vol. (high resolution)
CO: 0.01% vol. (Standard resolution)
0.001% vol. (high resolution)
CO2: 0.1% vol. (Standard resolution)
0.01% vol. (high resolution)
O 2: 0.01% vol.
NOx: 1 ppm

4.2.7 W ARM UP TIME

The warm-up time is software controlled and depends on several internal parameter. For more
details see Sensors Software manual.

4.2.8 RESPONSE TIME

T90 = 3.5s

4.2.9 FLOW RATE

0.3 ... 6.0 l/min

4.2.10 OPERATING PRESSURE

750 mbar - 1100 mbar
1000 mbar nominal

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4.2.11 PROPOSED CALIBRATION GASES FOR OIML SPECIFICATION

Cal Gas 1 Cal Gas 2

CO 0.50 % vol. 3.50 % vol.
CO2 6.0 % vol. 14.0 % vol.
C3H8 200 ppm vol. 2000 ppm vol.
N2 rest rest

Table 4-1:Calibration Gases for OIML R99

4.2.12 CALIBRATION GASES FOR BAR 90 SPECIFICATION

Cal Gas 1 Cal Gas 2

CO 1.00 % vol. 4.00 % vol.
CO2 6.0 % vol. 12.0 % vol.
C3H8 300 ppm vol. 1200 ppm vol.
N2 rest rest

Table 4-2: Calibration Gases for BAR 90

4.2.13 O2 SPECIFICATION
The MICROBENCH meets the German and English O2-requirements with its O2-Transducer
(Sensors´ P/N: 7014-006). The MICROBENCH software determines whether the transducer is
still accurate or inaccurate.

Sensors’ O2-Transducer:
New Transducer in ambient air: 7 - 13.5 mV
Used Transducer in ambient air: 5 - 13.5 mV

If the transducer is outside of the above specifications, a flag will indicate that there is a
problem with the transducer. Limits are host programmable.

4.2.14 NOX SPECIFICATION

For detailed information consult with Sensors’ application engineers.

5 MICROBENCH MODULE APPLICATION

5.1 APPLICATION SPECIFICATION

5.1.1 POWER REQUIREMENTS

Nominal Supply Voltage: 5VDC ± 0.25V

Supply Accuracy (1): +/- 5 % (+/- 250mV) max.
Current: 2A typical
3A max.

Maximum Ripple(2): 150 mV Pk - Pk max. (10 Hz to 1MHz)

Note (1): Supply Accuracy is the maximum allowable deviation of the DC supply, including ripple,
from the nominal voltage.

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Note (2): Ripple > 1MHz may result in unpredictable Microbench performance. Non-periodic
step changes in supply voltage may cause momentary short term disturbances in gas readings.
Empirical testing is recommended.

5.1.2 MOUNTING REQUIREMENTS

1. Mount sample gas cell vertical to avoid water contamination.

2. Mounting near sources of RF1/EMI should be avoided.
3. Direct air flow to the Automotive Microbench has to be avoided. Convectional or indirect air flow
are recommended processes to cool the bench. The ambient temperature around the bench
should not exceed more than ambient temperature outside of the gas analyzer plus 5°C.
4. Consult with Sensors' Engineering Dept. for application assistance.

Pressure Transducer
Gas In

Sensors P/N: 2801-171

Non coductive mounting

Gas out

Picture 5-1: Mounting Orientation

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60.9 mm
( 2.40 in)

Drill and cp #6-32

(0.682 in)
17.3 mm
81.3 mm
(3.20 in)

J 12
3.81 mm
(0.15 in)

144.8 mm
(5.70 in)
4.44 mm
(0.175 in)

Picture 5-2: Mounting Holes

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5.2 OPERATIONAL REQUIREMENTS

5.2.1 SAMPLE SYSTEM

The design of the sample system has to assure that when the gas reaches the Automotive
Microbench, the temperature is at ambient temperature. Hot gas can cause inaccurate
readings or damage to the Automotive Microbench.

Condensation in the bench has to be avoided, therefore the relative humidity must be below
98% non- condensing. In case the bench reports a condensation condition, it is recommended
to shut the sample pump off until this condition is cleared.

The sample gas purity should not contain particulate greater than 5Lm.

The gas flow through the bench should be the same for all conditions (i.e. measuring mode,
zeroing and calibration).

CAL
1.5 psi

ZERO

0.5 psi Charcoal Filter

Sample IN

SV1

VAC SW

Sample Pump
Drain Pump

Sample
AMB O2
out

Drain Out

SV1 / J6 Drain Pump /J5 Sample Pump /

J5
Start-up 0 0 0
Zero 1 1 1
CAL 1 0 0
Sample 0 1 1

Picture 5-3 : Priciple of an AMB II sample system

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5.2.2 SUMMARY

• Relative humidity: non condensing

• Gas temperature: Tgas approx. Tambient
(Ambient temperature reported by the AMB)
• Particulate size: < 5Lm
• Ambient Temperature: Ambient temperature reported by the bench < 48°C

5.3 USER INTERFACE REQUIREMENTS SUMMARY

5.3.1 SOFTWARE & COMMUNICATIONS

• 9600 Baud rate.
• Communicates over RS-232.

5.3.2 ELECTRICAL & ELECTRONIC

• + 5 VDC input
• Typical 10 watts, max. 15 watts

5.3.3 MECHANICAL & PNEUMATIC

• 0.3 .. 6.0 l/min sample flow
• Weight: less than 450g
• Package size:156 mm x 97 mm x 52 mm

Note: Please consult with Sensors’ Engineering Department for application assistance.

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5.4 MICROBENCH OPERATING INSTRUCTIONS

1. Connect properly conditioned power as described in 5.1.1 on the Bench p. c. board,

reference Schematic 9211-032 for details of power requirements.

2. Connect a PC 386 compatible on the Microprocessor p.c. Board through a standard RS-232
link to the serial port that you have configured on your PC compatible host computer. Reference
Schematic 9211-032 for details.

3. Start the operating software for the MICROBENCH Module on a PC. Refer to the
MICROBENCH Communication Specifications for detailed information.

4. Connect a sample handling system to the inlet tube (the 1/8“ ID tube). Connect the outlet tube
(the 1/8“ ID tube) to a proper exhaust vent.

5. Power up the MICROBENCH module and wait for it to come out of warm-up. The warm-up is
controlled by software and indicated by a status bit.

6. Zero the MICROBENCH. This is controlled by the computer and requires a supply of filtered
ambient air.

7. Calibrate the MICROBENCH if necessary. This is also controlled by the computer and
requires a supply of Tri-blend calibration gas. We recommend using the standard calibration gas
blends, as described in Table 4-1:Calibration Gases.

8. Sample exhaust gases. Supply the MICROBENCH with a stream of properly conditioned
exhaust gas sample at the pressure and flow rate as called out in 4.2.9 and 4.2.10.

5.5 RS-232 CONFIGURATION

Baud : 9600
Data Bits : 8
Stop Bits : 1
Parity : none

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5.6 CONNECTOR PIN-OUT

5.6.1 CONNECTOR LOCATION PC BOARD ASSY 9211-032

Connectors which are not described in this chapter are for Sensors internal use only and not
intend to be used by anyone else.

[Link] CONNECTOR – NOX TRANSDUCER (J1)

This input is designed to connect directly an electrochemical NO transducer (e.g.: CitTicel
Type NX1) to the bench.

J1
4-HDR +10V

1
+NO in
2
10K
3 0.001 LF
100K
4
10 1 LF

0.001 LF -NO in

10K
For Reference Only. See Schematic 9211-032
Drawing 5-1 : J1 - NOx Transducer

Housing: AMP# 102241-2

Pins: AMP# 1-87756-7

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Pin Meaning
1 +10V
2 1 LA sink (-NO in)
3 AGND
4 1 LA sink (+NO in)

[Link] CONNECTOR – NOX (J3)

This connector is used in conjunction with Sensors NO manifold (P/N:1408-114, -130) and NO
transducer (P/N: 7014-010, -011).

J3
4-HDR

1 +5V

2 -5V
A/D-NOX
3
10K
4 499K
0.1LF

Drawing 5-2 : J3 - NOX

Housing: AMP# 102241-2

Pins: AMP# 1-87756-7

Pin Meaning
1 Vcc (+5V), 1A source
2 -5V, TBD mA source
3 NO input (-2.5V .. +2.5V),
1 LA sink
4 AGND
Pin Description 5-1: NOX

[Link] CONNECTOR – O2 (J4)

This connector is used to connect an electrochemical O2 sensor to the bench.

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J4
3-HDR
-O2 in
1
10K
2 4.99K

3 0.01 LF

+O2 in

10K
4.99K

Drawing 5-3 : J4 - O2

Housing: AMP# 102241-2

Pins: AMP# 1-87756-7

Pin Meaning
1 1 LA sink (-O2 in)
2 AGND
3 1 LA sink (+O2 in)

[Link] CONNECTOR – ANALOG RPM (JA4)

Free A/D converter for customer specific applications.
JA4
3MTA100
0.01LF 100K RPM
1

2 +5V

Drawing 5-4 : JA4 - Analog RPM Input

Housing: AMP# 640441-3

Pins: 24AWG Wire

Pin Meaning
1 1LA sink (-2.5V ... +2.5V)
2 Vcc source
3 AGND

[Link] CONNECTOR – OIL TEMPERATURE (J5)

This A/D input is used in conjunction with Sensors RPM/OIL-Temperature boards(9219-140, -
147). If Sensors board is not used, this A/D input can be used for customer specific
applications.

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2.5Vref

J5 10K
3MTA100
T-OIL
1

2 5V 0.01LF

Drawing 5-5 : J5 - OIL TEMP

Housing: AMP# 640441-3

Pins: 24AWG Wire

Pin Meaning
1 1LA sink (-2.5V ... +2.5V)
2 Vcc source
3 AGND

[Link] CONNECTOR – RELATIVE HUMIDITY (JA5)

Free A/D converter for customer specific applications.

JA5
3MTA100
0.01LF 1M HUMIDITY
1

2 +5V

Drawing 5-6 : Relative Humidity Input

Housing: AMP# 640441-3

Pins: 24AWG Wire

Pin Meaning
1 1LA sink (-2.5V ... +2.5V)
2 Vcc source
3 AGND

[Link] CONNECTOR – RS232 HOST (J7)

This connector is used to communicate between the host computer and the AMB. Serial
communication parameters are:
- 9600 baud
- 8 data bits
- 1 stop bit
- no parity

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J7
3MTA100
Rx
1
1K Tx
2
1K
3
0.001 Lf 0.001 LF

Drawing 5-7 : J7 - RS 232

Housing: AMB# 640441-3

Pins: 24AWG Wire

Pin Meaning
1 RxD (500 LA)
2 TxD (500 LA)
3 DGND

[Link] CONNECTOR – POWER (J8)

J8 Vccin (+5V)
3MTA156

1
1N5819

2 10LF
10V

Drawing 5-8 : J8 - Power Input

Housing: MOLEX# 09-50-8023

Pins: MOLEX# 08-65-0114

Pin Meaning
1 Vcc(+5V) 3A Source
2 DGND, AGND

[Link] CONNECTOR – I/O SAMPLE (J9, J10)

These connectors read digital inputs or write digital outputs and can be used to control the
pump system (P/N: 9213-014).

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+5V
J9
16HDR-2ROW
1

2
DOUT5
DRAIN 3
DOUT7
AIR 4
DOUT3
5
DOUT4
6
DOUT6
DRAIN 7
DOUT2
8
DIN0
VAC-SW 9
DIN1
10
DIN2
11
DIN3
12
DIN4
13
DIN5
14
DIN6
15
DIN7
16

+5V

J10
4MTA100
VAC-SW 1

AIR 2

DRAIN 3

PUMP 4

Drawing 5-9 : I/O Sample Sys

J9 Connector: ANY 16-Pin cable connector

J10 Connector Housing: AMP# 640441-4

Pins: 24 AWG Wire

[Link] CONNECTOR – DIGITAL RPM INPUT (J11)

This input is designed to read frequencies between 1Hz and 1 KHz. This input can be used to
read RPM.

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Vcc

J11 10K
3MTA100

1
10K
2 Vcc
0.01LF
3

Drawing 5-10: J11-TTL RPM Input

Housing: AMB#640441-3
Pins: 24AWG Wire

Pin Meaning
1 Digital Input
2 Vcc
3 DGND
Pin Description 5-2 : J11 - TTL RPM Input

[Link] CONNECTOR – EXTERNAL TEMPERATURE (J12)

A/D input can be used for customer specific applications.

+5V

0.1LF

J12
4MTA100
1
EXT-TEMP
2

3 0.01LF 499K

-5V

100R
0.1LF

Drawing 5-11 : J12 - External Temperature A/D Input

Housing: AMB#640441-3
Pins: 24AWG Wire

Pin Meaning
1 Vcc
2 Signal In (1LA sink)

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3 AGND
4 -5V (TBD mA source)

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6 REVISION HISTORY

Rev. Date Description

A 6-1-99 Release V1.00
B 7-14-99 Added board drawing to 5.6.1 , Updated revision to V1.01, 9315-031 B
C 8-30-99 Changed NO input circuit [Link] Connector – NOX Transducer (J1)
D 12-1-99 SCR AMB254
Add description for mounting holes on bc board (Picture 5-2: Mounting
Holes)
Correct Drawing 5-9 : I/O Sample Sys
Changed NO input circuit [Link] Connector – NOX Transducer (J1)
E 5-24-00 Changed power supply specification

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