APPLICATION NOTES FOR TGS5042

Application Notes for CO Detectors using TGS5042

The TGS5042 is a battery-operable

an ISO9001 company
electrochemical CO sensor which is
provided with individual sensitivity
data printed on the sensor’s housing,
allowing users to eliminate the
process of calibration using CO
gas. This document offers example
circuits and important technical
advice for design and manufacture
of detectors.
Page
Sensor Marking.................................................................................2
Circuit Design
Basic Circuit.................................................................................2
Op-Amp Selection..........................................................3
Baseline Design of Sensor Output......................................................4
Microprocessor.......................................................................4
Anti-polarization Circuit........................................................4
Amplification Circuit..............................................................6
Amplification Factor (gain)................................................................6
Leak Prevention Circuit...................................................................7
Electric Noise Prevention....................................................................7
Temperature Compensation Circuit..........................................7
Self Diagnosis Circuit.....................................................7
Proposed Circuit Using Vcc=3V......................................................9
Proposed Circuit for 5000ppm CO Exposure Test........................10
PCB and Housing Design
Position Dependency of the Sensor..............................................12
Thermistor Location.....................................................................12
Housing Design for Quick Response..............................................12
Sensor Lead Configuration.............................................................12
Calibration
Calibration Using CO Gas..................................................13
Calibration Using Individual Sensor Data.....................................13
Temperature Compensation.........................................13
Calculation of CO Concentration...........................................14
Manufacturing Process
Handling and Storage of Sensors..........................................14
PCB Assembly.....................................................14
Sensor Assembly..........................................................15
F i n a l A s s e m b l y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5
Gas Test.......................................................................15
Storage of Finished Products..............................................15
Packaging.................................................................16
Quality Control......................................................................................17
Expected Performance......................................................................................17
Frequently Asked Questions..............................................................................17
IMPORTANT NOTE: OPERATING CONDITIONS IN WHICH FIGARO SENSORS ARE USED WILL VARY
WITH EACH CUSTOMER’S SPECIFIC APPLICATIONS. FIGARO STRONGLY RECOMMENDS CONSULT-
ING OUR TECHNICAL STAFF BEFORE DEPLOYING FIGARO SENSORS IN YOUR APPLICATION AND,
IN PARTICULAR, WHEN CUSTOMER’S TARGET GASES ARE NOT LISTED HEREIN. FIGARO CANNOT
ASSUME ANY RESPONSIBILITY FOR ANY USE OF ITS SENSORS IN A PRODUCT OR APPLICATION FOR
WHICH SENSOR HAS NOT BEEN SPECIFICALLY TESTED BY FIGARO.

TGS5042 is a UL recognized component in accordance with the

requirements of UL2034. Please note that component recognition testing
has confirmed long term stability in 15ppm of CO; other characteristics
shown in this brochure have not been confirmed by UL as part of component
recognition.

Revised 07/15 1
 APPLICATION NOTES FOR TGS5042

1. Sensor Marking One dimensional bar code

The TGS5042 comes with a sticker attached to FIGARO

TGS5042
the sensor housing (see Fig. 1) which contains
individual sensor data:
041124 1827

One dimensional bar code

Lot No. Sensitivity to CO (nA/ppm)
xxxx
(Ex.1827 = 1.827nA/ ppm)
where: xxx = x.xxx nA/ppm
This bar code indicates the sensor’s sensitivity Fig. 1 - Sensor markings
(slope) in numeric value as determined in
Figaro’s factory by measuring the sensor ’s
output in 300ppm of CO. This value is also
printed below the bar code--please note that
three decimal places should be added to the
sensitivity reading (e.g. 1827 should be read as
1.827 nA/ppm).
Sensor lot number is printed to the left of the C1
sensitivity data in YYMMDD format. 1µF
R1 I
2. Circuit Design
1MΩ
2-1 Basic circuit
TGS5042 is a fuel cell type electrochemical sensor -
Working IC
+
with two electrodes, with sensor output current
changing linearly with CO concentration. To use TGS5042 I Vout
the sensor for CO detection, it is necessary to Counter
convert sensor current to output voltage. There
Vout = I x R1
are two conversion methods:
2-1a Sensor current type (see Fig. 2a) Fig. 2a - Basic circuit for
amplifying sensor current
This method directly converts sensor current into
voltage according to the following equation:
Vout = Is x R1
where: Is = Sensor output current Working

2-1b Load resistor type (see Fig.2b) R2

TGS5042 I 100kΩ Vout
This method measures generated voltage across
a fixed load resistor which is connected to the Counter
sensor electrodes. In this case, sensor output is Vout = I x R2
expressed by the following equation:
Fig. 2b - Basic circuit with
Vout = Is x R2
fixed load resistor
where: Is = Sensor output current
The load resistor type circuit does not include an the circuits of the sensor current type and load
op-amp. An op-amp is used to amplify voltage resistor type become very similar. However,
since sensor current is very small, in which case large differences in characteristics can be seen

Revised 07/15 2
 APPLICATION NOTES FOR TGS5042

between amplifying current and using a fixed 3.5 Op-Amp type

Resitor type (5.6k_)

load resistor. 3
CO400ppm Resitor type (1.0k_)

1) Response time to CO is slower when using 2.5

a fixed load resistor (see Fig. 3). When using a CO 150ppm

fixed load resistor, the larger the value of the 2

CO 70ppm
load resistor, the slower the response time. In Vout (V)
1.5 CO 30ppm
addition, the expected output voltage may not
be obtained if a larger than 5.6kΩ load resistor 1

value should be selected. 0.5

2) When amplifying current, an additional load
resistor or FET is required for anti-polarization 0
0 200 400 600 800 1000 1200 1400

of the sensor. Time (sec.)

Figure 3 - Sensor response curve in various

Note 1: Please pay attention to sensor polarity. basic circuits (amplified 3.13M times)
Although the sensor’s package is physically
similar to that of a dry battery, the sensor’s
polarity is opposite to that of a dry battery.
Note 2: When voltage is applied to the sensor
output terminal, the sensor may be damaged.
Voltage applied to the sensor should be strictly
limited to less than ±10mV.
 
Figure 4 - Internal equivalent circuit when using an op-amp
2-2 Op-amp selection
C1
When using a fixed load resistor, in most cases
an op-amp is required to amplify the sensor’s R2 VR2

small output voltage. 100kΩ

Rail-to-Rail Op-Amps such as the following

are recommended for both basic conversion Working
-
IC
+
circuits:
TGS5042
AD708, AD8698, OP07 (Analog Devices), Vout

TLC272(TI), OPA177(BB), MCP6042 (Microchip), Counter

VR1

MCP616 (Microchip), OPA2355 (TI)

For circuits employing an op-amp, Figure 4 VR1: Variable resistor for zero adjustment
shows the internal equivalent circuit which can VR2: Variable resistor for span adjustment

be expected according to Figaro’s test results.

Component values are estimated as follows, Figure 5 - Circuit example for zero adjustment
including variation in sensor characteristics and
internal DC resistance of the sensor (Rs+Rp).
temperature/humidity dependency:
The voltage shift drives an increase and decrease
Rs: 0~1kΩ from default base line level due to the value (±)
Rs+Rp: 10kΩ~∞ offset voltage for the op-amp. To prevent such
C: 0.8mF~10mF a voltage shift, the above listed op-amps are
recommended.
Off-set voltage of an op-amp (current to voltage
converter) affects the base line level of sensor Please note for circuits employing an op-amp,
output. This is because a small current reaches when a fixed load resistor is used for anti-
the sensor due to the offset voltage of the op- polarization, only an op-amp with small leak
amp, causing a voltage shift according to the current (such as AD708 , OPA2355) can be used.
Revised 07/15 3
 APPLICATION NOTES FOR TGS5042

When an op-amp with large leak current is used, C1

offset voltage may fall outside of the adjustable 1µF

range by leak current. (see 2-5 Anti-polarization R2

Circuit). 1.2MΩ

To obtain high accuracy in an analog circuit, an

op-amp with a zero adjustment function, such Working
-
IC
+
as LF356 (National), is recommended. In Figure AD708
R1
5, a typical zero-span adjustable circuit using TGS5042
1kΩ Vout

LF356 is shown. Counter

2-3 Baseline design of sensor output

Since sensor output may have a negative value
due to the offset voltage of the op-amp, the Figure 6 - Anti-polarization circuit using
a fixed resistor
baseline of sensor output should be set >1V. If
an anti-polarization circuit (using JFET), and a
self diagnosis circuit (see Items 2-6 and 2-12) are
C1
added, the base line of sensor output should be
set >2V. 1µF

R2

2-4 Microprocessor Vcc 1.2MΩ

Incorporating a microprocessor into a circuit
offers several advantages. The complex -
IC
Working SW
calculation of alarm concentration based on +
AD708

COHb and temperature compensation can be TGS5042 Vout

carried out by the microprocessor, simplifying Counter

circuit design. By recording sensor sensitivity
data from the sensor’s bar code label in the
microprocessor and by using the microprocessor
to compensate for offset voltage, the calibration Figure 7 - Anti-polarization circuit using
an external switch
process for detector production can be greatly
simplified. In addition, useful values such as
a maximum CO concentration and a sensor
output timing chart can be recorded in the
C1
microprocessor as additional functions.
1µF
From the viewpoint of signal resolution, the R2

recommended specification of a microprocessor

1.2MΩ
is 10 bit or higher.
-
Working IC
2-5 Anti-polarization Circuit JFET
(N-Channel)
+

When the sensor is stored without connection TGS5042 Vout

between the working electrode (W) and counter Counter

electrode (C), polarization will occur between the

electrodes. When a polarized sensor is connected 1.5V or more of baseline is required
to an operating circuit, it takes about one hour for baseline to operate JFET

to stabilize sensor output (refer to 3-5 Influence of Figure 8 - Anti-polarization circuit using
an N-channel JFET
Storage in TGS5042 Technical Information).

Revised 07/15 4
 APPLICATION NOTES FOR TGS5042

To avoid polarization during storage, it is C1

necessary to keep a short-circuit (or <1kΩ 1µF

Vcc
resistance) between the electrodes. In this R2

manner, measures such as a timed warm-up

1.2MΩ
period for stabilizing the sensor are not required
in circuit design. -
Working IC
+
In a load resistor type circuit, it is not necessary
TGS5042
to add additional parts for anti-polarization JFET Vout
(P-Channel)
since the circuit already contains a load resistor Counter

between the sensor electrodes.

Figure 9 - Anti-polarization circuit using
A sensor current type circuit can use three a P-channel JFET
methods for anti-polarization: C1

1) JFET (Figs. 8 and 9) - Figaro’s recommendation 1µF

This method is normally used in CO alarms R2

3.0V
without an external switch. In this case a JFET 1.2MΩ
(Field Effect Transistor) is recommended. 3.0V of baseline is set
Junction type transistors are not recommended Counter -
to operate JFET.
IC
due to their large leak current. MOSFETs cannot JFET
(N-Channel)
+

be used. TGS5042 Vout

2) Fixed resistor (Fig. 6) Working

As a simple method, a fixed load resistor can be Vout decreases by a CO

used. In this case, it is necessary to use an op- concentration increases.

amp with very low leak current (such as AD708 Figure 10 - Circuit for extending effective
or OPA2355). Op-amps with large leak current voltage range using N-channel JFET
may cause offset voltage to fall outside of the
adjustable range. It is necessary to choose a P-channel or N-channel
FET, depending on the required effective output
To avoid polarization on the sensor during
range, gain, and the variation range of Vcc.
power-off, Figaro recommends that both of
Figures 8 and 9 show the basic circuit for each
electrodes of the sensor be shorted by using
type.
a JFET (see Item 2-5.1 above). Alternatively,
adding a fixed resistor (10~100kΩ) between The advantage of a P-channel FET is a wider
both electrodes will have a similar effect for effective voltage range. However P-channel
anti-polarization. However, since this effect FETs have higher cost, weakness against
will be smaller than in case of using a JFET, the applied voltage fluctuation, and they require
recovery time after powering on may be longer. higher operating voltage than 5V (making them
Furthermore, resistors between both sensor unsuitable for applications which need <5V).
electrodes may cause a large shift from the base Recommended P-channel FETs are J177, J270
amplified signal. (Fair Child), and 2SJ103 (Toshiba).
3) External switch (Fig. 7) N-channel JFETs are widely available in many
This method is normally used for CO analyzers models, have lower cost, and are more stable
where there is an external switch to control to voltage fluctuation of power supply. Their
power on/off. By using an external switch, the disadvantage is their narrower effective voltage
connection between the W and C electrodes can range. However, one option to extend their
be controlled, whether open or short (<1kΩ) effective voltage range is to shift baseline to Vcc
circuit. as shown in Fig.10. In the example circuit, output
Revised 07/15 5
 APPLICATION NOTES FOR TGS5042

voltage decreases with a CO concentration C1

increase. The recommended N-channel JFETs 22µF

are J201, PN4117 (Fair Child), and 2SK117 R2

(Toshiba). 100kΩ

V1= - (I xR1) R3
-
2-6 Amplification Circuit (see Figs. 11 and 12) Working 1kΩ +
IC
AD708

In a load resistor type circuit, voltage can be TGS5042 I R1

1kΩ Vout

amplified by using either an inverted or non- Counter

inverted amplifier. Depending on the method, Vout = I x R1 x (R2/R3)

the gain is slightly different. Please note that

direction of W and C electrodes are opposite Figure 11 - Inverting amplifier circuit
between non-inverting and inverting amplifier
C1
circuit.
22µF

Non-inverting amplification has lower leak R2

current from the sensor to the op-amp since the 100kΩ

working electrode is connected to the positive (+) V1= I x R1

+
terminal of the op-amp. To prevent leak current, Counter
-
IC

setting a voltage follower between sensor output TGS5042 I

R1
1kΩ
R3
1kΩ Vout
and the op-amp is recommended (refer to Sec. 2-8 Working
Leak Current Prevention Circuit).
Vout = I x R1 x (1+R2/R3)

2-7 Amplification Factor (gain)

Figure 12 - Non-inverting amplifier circuit
It is necessary to decide gain by selecting Vcc,
JFET and the op-amp in terms of sensor output C1

range, target gas concentration range, and 22µF

R2
required accuracy. V1= - (I xR1)
100kΩ
-
IC 1 R3
+
For example, a gain of at least 2.5 million is Working Current to Op-Amp 1kΩ
-
+
IC 2
will be shut out.
calculated to be necessary for the following TGS5042 I R1
Vout
1kΩ
example CO detector: Counter

- 5V Vcc Vout = I x R1 x (R2/R3)

- 10 bit microprocessor
- Accuracy: ±20% of reading
Figure 13 - Leak current measure
- Detection range: 0 ~ 750ppm using a voltage follower
To extend the detection range, it is necessary
to increase Vcc or to use a microprocessor with circuit design. For example, if a circuit voltage
higher resolution. For conformity to EN50291, (Vcc) would be 5V, the appropriate gain value
Figaro recommends at least a 10bit A/D converter is obtained as follows:
with 1.2M to 1.4M times as a gain value. - full scale of CO conc.: 1000ppm
- baseline of sensor output (in 0ppm CO): +1V
To meet EN50291 requirements, a CO alarm
- max CO sensitivity of TGS5042: 2.4nA/ppm
must be able to distinguish the output signal - temp dependency of TGS5042: I(60˚C)/I(20˚C)=1.2
(voltage) between 30ppm and 50ppm of CO.
For obtaining an appropriate gain value which Gain: 1.38*106 -times =
[5V-1V] / [2.4*1.2 * 10-9(V/ppm) * 1000(ppm)]
can meet with this requirement, the full scale of
CO concentration and baseline of output signal In the above conditions, since a 10bit A/D
in a CO alarm should be decided before starting converter can distinguish the difference in sensor

Revised 07/15 6
 APPLICATION NOTES FOR TGS5042

output between 30ppm and 50ppm CO, Figaro

recommends using at least a 10bit A/D converter
and 1.2M to 1.4M-times as a gain value in the
circuit.

2-8 Leak Current Prevention Circuit (Fig. 13)

In a fixed load resistor circuit, a non-inverting
amplifier circuit is recommended for simplicity.
For further countermeasures, adding a voltage
follower circuit between sensor output and the
op-amp is recommended.

2-9 Electrical Noise Prevention

Since sensor impedance is 10Ω or less, the
sensor itself will not be a source of electric
  Figure 14 - Electrical noise prevention circuit
noise. However, the sensor is easily influenced
Temperature compensation
by external electric noise since sensor output is circuit

very small in both basic circuits. Therefore, it C2 C5

+

is necessary to incorporate measures into the

+
T2.2uF/16V T22uF/16V
R7
1 R2

circuit pattern and power supply to eliminate

110k
2 RT R9
310k VR3
BATT1 Tr 3
50k 10k at 20˚C 39k
UM3XI

electrical noise.
2SK117
VCC B: 3380
D1
1 680JT VCC

06P 10k
1

VR2
T33u/16V

2 0.1u
REG1

3 DINS4 +
C1

Three options to prevent electrical noise:

4 C3 A
5 12k
R5 67W 5k R1

1
2 2 NJU7031D

8
AD708JN

5
- 1 R4 - 6
CN1 5
1.5V 3 IC1A + R8 IC2
VR1

7 3

1) Use an electrical noise filter

MB5P-90S + 10k IC1B +
A R3 6 C4

7
- 10k

10.0k
4
AD708JN
9.1k

10k 0.1u

R6
2) Use a voltage follower (see Sec. 2-8 Leak Current
VCC

Prevention) RT: NTSA0XH103FE1B0 (Murata: Axial type)

3) Build up an RC network with a resistor and VR1, VR2: Zero adjust

VR3: Span Adjust

capacitor in place of the feedback resistor of the Figure 15 - Temperature compensation circuit
op-amp. The recommended time constant (T)
of RC circuit for power input is 2~2.5 seconds 1) Input the thermistor ’s signal into the
since the value in the basic recommended circuit microprocessor and compensate it with the
is 2.2 seconds. temperature compensation table which is also
To prevent external electrical noise, setting a stored inside microprocessor (refer to Item
noise filter inside the detector, making a noise 3-Calibration for details of the compensation process,
prevention circuit pattern, and averaging the and refer to Appendix 1 for temperature compensation
output signal are recommended. factors).
In addition to reduce electrical noise due to 2) Make an analog circuit with a negative
radio waves, adding fixed resistors (R3 and R4 temperature coefficient (NTC) thermistor and
as shown in Figure 14) on the input terminal resistors in place of the feedback resistor of IC2
of the op-amp is also effective. Please not that (see Fig.15)
the capacitor between the output and input
terminals (C2 on Figure 14) should not be added 2-11 Self Diagnosis Circuit (patented by Figaro)
when a CMOS type op-amp is used. Sensitivity to CO would be lost in case
several failure modes were to occur, such as
2-10 Temperature Compensation Circuit wire breakage, short circuit, or in case the
Temperature compensation can be done in one sensor’s water reservoir were to dry up. By
of two ways: using Figaro’s patented self diagnosis circuit,

Revised 07/15 7
 APPLICATION NOTES FOR TGS5042

malfunctions involving loss of CO sensitivity the sensor from the circuit so that self test may
can be detected. be conducted without activating an alarm.
Please note that this method cannot detect CO 2) Apply a minute current to the sensor
sensitivity loss caused by lack of gas diffusion Activate a transistor (TR1) and apply about
when dust or water droplets cover the pin 1µA (absolute maximum rating: 5µA), which
holes for gas diffusion. In addition, slight loss simulates exposure to about 1000ppm CO. This
of CO sensitivity cannot be detected by self- current should be applied for 2~5 seconds. If the
diagnosis. sensor is normal, sensor current will be output
and then quickly recover to its base level.
Depending on the user’s circuit design, factors
for self diagnosis such as current value, self 3) Reconnect the sensor to the circuit
diagnosis period, measurement timing, and 1~2 seconds after self diagnosis current is
voltage range for judgement may vary. Therefore, terminated (TR3 is reset), activate TR2 and
it is recommended that experimentation with the reconnect the sensor to the circuit. Then current
user’s circuit be conducted for fine tuning these applied to the sensor will be discharged.
factors in self diagnosis.
4) Self diagnosis determination is carried out
Figs. 16, 17, and 18 show examples of the circuit, Approx. 5 seconds after the sensor is reconnected
timing chart, and process chart. to the circuit, if the sensor output falls within the
range of 2.3 ~ 3.8V (normal output expected in
The basic steps of self-diagnosis are:
1000ppm of CO), which corresponds to 0.4 to
1) Temporarily cut the sensor off from the circuit 2µA of sensor current, the sensor can be judged
Activate a transistor (TR2) to temporarily isolate to have normal CO sensitivity. If the sensor

Self test current control Self test drive control

Tr 1
2SK982 Microprocessor port2
H-Z on
0V off
R10 2M
Microprocessor port1
C2
Vcc on
0V off R11 1M 0.1µ
A
1 R2
2
Tr 2 1.2M
BATT1 2SK117
VCC UM3XI

D1
DINS4 Tr 3
1 VCC1
680JT

5V 2SK117 VCC1
2 C3
C3
33µ/50V

+
T1µ/16V

REG1

3
+
C1

4 0.1µ A MCP6042 0.1µ

C4

5
1.0k
R5 67W 10k R6

2
8

- 1
CN1 IC1 +
2.0V 7
VR1

MB5P-90S + 5
3 IC1
A
4

-
6
4
3.0k

MCP6042

Figure 16 - Self diagnosis circuit

Revised 07/15 8
 APPLICATION NOTES FOR TGS5042

output is ≥3.8V, the sensor is judged to be short Self test

Normal
circuited. If the sensor output is <2.3V, the sensor Normal for sensor

H-Z (on)
is judged to be open circuited. Please refer to
Drive
Fig. 19 (see following page) for the Vout pattern control
0V (off)
corresponding to each of these cases. approx. 1 min.
VCC (on)
Note: The above Vout range is valid only Self test

for the circuit shown in Fig.16. When gain current

control 0V (off)

of amplification and/or measuring timing is

approx. 5 sec.
different, the Vout range would be changed. 0.01 - 1sec.
0.01 - 1sec.

Sensor output recovers to its initial level about Measuring point

5 - 7 sec. after changing to 0V for drive port
1 minute after the sensor judgement in the
step 4 above. The total self diagnosis time for Figure 17 - Self diagnosis timing chart
Steps 1-4 is 1~2 minutes. Please note that the
larger or longer current is applied to the sensor,
the longer it takes to complete self diagnosis.
The self diagnosis process should be carried
out periodically to ensure that the sensor has
sufficient CO sensitivity to afford protection.
Note:
Please restart normal operation mode when
sensor output recovers to its initial level after Power on (Normal)
the self diagnosis operation. The interval Drive control: H-Z (on)
Current control: 0V (off)
between self diagnosis operations should be set
considering the recovery period for the sensor.
Normal mode
If current is applied to the sensor before it can Drive control: H-Z (on)
Current control: 0V (off)
recover to its initial level, the sensor may be
damaged due to overcharging.
NO
The recommended self diagnosis interval for Self test ?

the circuit in Fig.16 is 180 seconds or more. Yes

To shorten the interval, it is recommended to Drive control: H-Z (on) to 0V (off)

minimize the current applied to the sensor (less 0.1 - 1 sec.

current/shorter duration). However, the smaller Current control: 0V (off) to VCC (on)

the current, the more difficult to distinguish 5 sec.

Current control: VCC (on) to 0V (off)

between normal sensors and abnormal sensors.
0.1 - 1 sec.
Users should conduct a verification test using
Drive control: 0V (off) to H-Z (on)
their actual circuit. 5 - 7 sec.

Measure the output voltage (Vout)

2-12 Proposed circuit using Vcc=3V
In case that the Vcc is +3V, the maximum gain
Yes
value can obtain 0.7M-times under conditions Vout = 2.3 - 3.8V?
which is described in previous section.
NO

Gain: 0.69*106 -times = Trouble signal

[3V-1V] / [2.4*1.2 * 10-9(V/ppm) * 1000(ppm)]

This small gain value may not meet EN50291 Figure 18 - Self diagnosis flow chart

requirements due to the small signal resolution

Revised 07/15 9
 APPLICATION NOTES FOR TGS5042

Drive : H-Z
0V
5 - 7 sec.
Current: VCC
0V 5 sec.
5

4
Normal range
3

Vout/V
2.3 - 3.8 V
2

0
0 10 20 30 40 50 60
Time/sec.
Normal sensor
Drive : H-Z Drive : H-Z
0V 0V
Current: VCC Current: VCC
0V 0V
5 5

4 4
Normal range

Vout/V
Vout/V

3 Normal range 3
2.3 ~ 3.8V 2.3 ~ 3.8V
2 2

1 1

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60

Time/sec. Time/sec.
Open circuit No sensitivity
Drive : H-Z Drive : H-Z
0V 0V
Current: VCC Current: VCC
0V 0V
5 5

4 4
Normal range
Vout/V
Vout/V

Normal range 3
3 2.3 ~ 3.8V
2.3 ~ 3.8V
2 2

1 1

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60

Time/sec. Time/sec.
Short circuit Water/electrolyte dried up

Figure 19 - Self diagnosis Vout response patterns

between 30ppm and 50ppm CO. As a solution, during the powering-on period. As a result, the
Figaro suggests the following three types of acceptable detection range of sensor output falls
circuits: between 0 and 3V.
1) Gain switching circuit (Fig. 20) 3) Change-baseline circuit (Fig. 21a)
The gain value of a second amplifier (IC2) is In the circuit shown in Figure x, the baseline
switched by the micro controller according to and gain values can be changed according to
the output signal of the micro controller. By application of voltage in V1 and V2. As shown in
setting a large gain value while the sensor is in Figure 21b, when Vcc of 3.0V and 0V are applied
low CO concentration range, adequate detection to V1 and V2 respectively during a short time,
resolution is achieved even if Vcc is 3.0V. the baseline of sensor output changes to lower
voltage. Gain value is also increased before
2) Opposite-baseline circuit (Fig. 10)
applying V1 and V2. Thus, by controlling both
In this circuit, the sensor is set up in the opposite
V1 and V2, a detector can achieve high detection
direction (i.e. the working electrode is connected
resolution when the detector is exposed to a low
to the positive input terminal of the op-amp
concentration of CO.
rather than the negative). Since the voltage
between the source and gate of the JFET is fixed 2-13 Proposed circuit for 5000ppm CO exposure test
at 3.0V only during power-on, the JFET can Most electrochemical CO sensors show very
make a short circuit for anti-polarization except long recovery time after high CO gas exposure.
Revised 07/15 10
 APPLICATION NOTES FOR TGS5042

 
Figure 20 - Gain switching circuit

As a result, detectors cannot meet the 5000ppm

CO exposure test of EN50291 (5.3.6) without
some countermeasure. TGS5042 displays faster
recovery time than other types of electrochemical
sensors, so it may be possible to pass the test.
However, if the amplified signal of the sensor
exceeds Vcc (max output level of op-amp) in
5000ppm CO due to large gain, the sensor output
in air after exposure of 5000ppm CO would drop
below the baseline for a while (undershoot),
temporarily causing reduced sensitivity to CO
which may lead to failure to meet ES50291.
As countermeasure to the phenomenon of   Figure 21b -Change of baseline sensor output
undershoot, the overflow current of the sensor using Vcc-3.0V on V1 and Vcc-0V on V2
should be canceled during the period when
the amplified sensor signal exceeds Vcc. For
example, by installing four diodes in the
amplifier circuit (see Figure 22), the overflow

  Figure 21a - Change baseline circuit Figure 22 - Basic circuit condition using a diode

Revised 07/15 11
 APPLICATION NOTES FOR TGS5042

current goes back to the sensor through the

diodes during the period when the amplified
signal exceeds 2.8V.
Alternatively, switching the gain of the amplified
output signal is also effective. Figure 23 shows
a sample circuit diagram which can change the
gain by using a FET.

A similar function can also done by “Change-

baseline circuit” as described in Item 2-12.3
 
above. In both of these cases, Figaro recommends Figure 23 - Circuit for changing gain using a FET

a gain value of 100,000 to 200,000-times when the

amplified output signal is higher than Vcc.

3. PCB and Housing Design

3-1 Position Dependency of the Sensor
TGS5042 has no position dependency in normal
usage such as in residential CO detectors.
However, for applications where ambient
temperature can change drastically and suddenly
to less than -20°C, it is recommended that the
sensor should be placed in a vertical position
with the working electrode upward. If the
sensor is positioned horizontally or vertically
with the working electrode down, the sensor
may be structurally damaged by large volume
expansion if water in the reservoir freezes.

3-2 Thermistor Location 1) Sensor compartment

It is recommended that a thermistor is located
as near to the sensor as possible in order to
accurately measure ambient temperature around
the sensor.

3-3 Housing Design for Quick Response

For applications where quick response is
required, such as for simple CO analyzers, it is
recommended that the gas inlet of the sensor be 2) Slits
located at the detector slits or opening. It is also
recommended to make a small compartment
with slits in at least two sides (see Fig.24).

3-4 Sensor Lead Configuration

There are two lead configurations for TGS5042.
The best version will depend on the user ’s
application. Figure 24 - Sensor compartment design

Revised 07/15 12
 APPLICATION NOTES FOR TGS5042

TGS5042-A00: Sensor with SUS lead pins output corresponding to CO a concentration less
The hard pins enables the sensor to be mounted than 10ppm after subtracting detector output
directly to the PCB, simplifying the assembly without sensor.
process.
4-2 Calibration Using Individual Sensor Data
TGS5042-B00: Sensor with flexible nickel ribbon Using individual data printed on sensor, which
The flexible nickel ribbon allows for a variety of is measured at Figaro factory before shipping,
methods for connection to the PCB. This type can considerably simplify the calibration
is also suitable for insertion into a socket. The process. Though the expected accuracy of ±15%
flexible nickel ribbon may be broken by strong accuracy in this method is less than that for using
mechanical shock, drop, or vibration, so it is CO gas, this method can achieve significant
recommended that the sensor body be affixed reduction in handling costs while achieving
onto the PCB by using two-sided tape or wire, acceptable accuracy.
for example.
4-2-1 Input sensitivity data into microprocessor
Sensor data from the label can be read into the
4. Sensor Calibration
microprocessor in one of two ways:
4-1 Calibration Using CO Gas
1) Manually input the user readable value on the
1) After powering the circuit, wait 5 minutes to
label, located beneath the one dimensional bar
stabilize sensor output in clean air (see Note 1)
code (this value is nA/ppm and contains three
2) Measure sensor output in clean air (V0) (See
decimal places).
Note 2)
2) Using a barcode reader which can read Code-
3) Inject C1ppm of CO gas
128, read the one dimensional barcode and input
4) After stabilizing sensor output (e.g. 3 to 4 min),
directly to the microprocessor (this value is nA/
measure sensor output (V1)
ppm and contains three decimal places).
5) Calculate sensor sensitivity α from V0 and
V1 values:
4-2-2 Compensation of offset voltage (zero
α = (V1-V0) / C1 adjustment)
To compensate for offset voltage which is created
Using this method, accuracy of ±5% can be
by the sensor and operational amplifier, measure
obtained for display readings. Please note that
the offset voltage (V0) in clean air (0ppm of CO)
temperature should be in the range of 20°C±2°C
and write into an EEPROM or a microprocessor.
during the calibration process since the sensor
This value should be read from the finished
has dependency on temperature.
detector (after installation of sensor, op-amp,
Note 1: In principle, due to the nature of etc.).
electrochemical cells, pre-heating before
To obtain higher accuracy, keep ambient
calibration is not required. However, in actual
temperature in a range of 20±10°C and be sure
manufacturing, it is recommended to wait 5~10
that the ambient air is completely free of CO.
min. before calibration to stabilize sensor output
in the circuit.
4-3 Temperature Compensation
Note 2: If CO gas is present during the zero There are two methods for temperature
adjustment process, a correct zero adjustment compensation:
cannot be carried out. A detector should be
1) Using a microprocessor
checked in advance to verify that it generates
In case of using a microprocessor, it is necessary

Revised 07/15 13
 APPLICATION NOTES FOR TGS5042

to read the thermistor output and write it into 30

the microprocessor. Inside the microprocessor, NJU7034 AD708

temperature compensation is carried out by 20

using the compensation coefficiency table shown 10

in Appendix 1. Temperature compensated CO

sensitivity (αt) is calculated by the following 0

equation: Display reading (ppm)

αt= α/CF -10

where: CF = compensation coefficient at certain -20

temperature
2) Without using a microprocessor
-30
-20 -10 0 10 20 30 40 50 60 70
Temperature (˚C)

In case of not using a microprocessor, this Figure 25 - Temperature dependency of offset voltage
process can be eliminated. for op-amps

4-4 Calculation of CO Concentration

Power ON
CO concentration can be calculated by using
sensor output (Vout), offset voltage (V0), Alarm dalay againt
temperature compensated CO sensitivity (t), and polarity of sensor

gain (A) in the following formula:

Generate trouble Yes
C = (Vout-Vo)/A/αt Equation 1 signal
Sensor trouble
detection

Depending on the op-amp, offset voltage has No

a large temperature dependency as shown Sensor output

sampling
in Fig.25. To compensate the temperature
dependency, it is recommended to make a table Thermistor
output sampling
of offset voltage at different temperatures Vo(T)
in the microprocessor, and Vo in Equation 1 CO calculation

should be replaced to Vo(T) in Equation (1’). Display CO

C = (Vout-Vo)/A/αt Equation 1’ concentration

Actual gain (A) should be measured instead Convert to COHb

concentration
of calculated or specified at a theoretical value
since such value may not be obtained in actual
Yes
measurement. Activate CO alarm Alarm
determination

Fig.26 shows basic flow chart of signal processing. No

Suppress CO alarm

5. Manufacturing Process
Figure 26 - Signal processing
5-1 Handling and storage of sensors flowchart

Prior to usage, sensors should be stored in

condition, resulting in sensor polarization. The
Figaro’s original sealed bag under conditions
sensor will require a warm up period of about
of 5~30˚C, 30~80%RH, and avoiding dew
one hour to stabilize output.
condensation for a maximum period of 6
months. Do NOT use a moisture proof bag (such 5-2 PCB assembly
as an aluminum coated bag) for prevention of Flux should be sufficiently dried before sensors
dew condensation. When the sensor is shipped are assembled onto the PCB to avoid any
from Figaro, the sensor is in an open circuit contamination of the sensor by flux vapors.

Revised 07/15 14
 APPLICATION NOTES FOR TGS5042

Soldering Material Flux

No.
Company Model Composition Melting Temp Company Model

ULF-20
1 H63E Sn/37Pb 183˚C Tamura Kaken Corp
(Cl free)

Asahi Chemical Research

2 H63E Sn/37Pb 183˚C AGF-780R
Laboratory Co., Ltd.
Solder Coat
Co. Ltd. Asahi Chemical Research
3 H63A Sn/37Pb 183˚C AGF-550BK
Laboratory Co., Ltd.

LLS219A-
Sn/3.0Ag/0.5CuNi/ Soldus line: 271˚C
4 B18 Tamura Kaken Corp EC-19S-8
Ge Liquidus line: 221˚C
(Pb free)

Table 1 - Wave soldering materials

5-3 Sensor assembly 5-4 Final assembly

The sensor electrodes of model -B00 are short- Avoid any shock or vibration which may be
circuited by the Nickel ribbon when the sensors caused by air driven tools. This may cause
are shipped. Before mounting the sensors on a breakage of the sensor’s lead wires or other
PCB, the Nickel ribbon of model -B00 should physical damage to the sensor.
be cut. Model -A00 is shipped in an open-
circuited condition, so the sensor output should 5-5 Gas test
be stabilized by shorting the sensor (refer to FAQ Test all finished products in the target gas
for advice on short-circuiting). Both models -A00 under normal operating conditions. Keep the
and -B00 can be directly soldered onto a PCB. atmospheric conditions in the chamber stable,
utilizing a user-defined standard test condition
In case the –B00 model is inserted into a socket, which is based on applicable performance
it is recommended to cut Ni ribbon as short as standards and on anticipated usage for detectors.
possible from the welded part. Do NOT peel Remove any traces of smoke, adhesives, gases,
away the Nickel ribbon with strong force at the or solvents from the chamber.
working electrode side. The mechanical force
may damage the sensor electrode. Do NOT use Nitrogen balanced CO gas. Oxygen
molecules are required for the reaction of the
The metal ribbon of the -B00 model is for sensor with CO (refer to Sec. 2-Operation Principle
electrical connection and therefore should not of TGS5042 Technical Info).
be used to affix the sensor to a PCB. For securing
the sensor to a PCB and to prevent disconnection During exposure to a mixture of CO and N2,
of the Ni leads, the sensor should be attached to the sensor reacts to CO by consuming oxygen
a PCB using wire, two-sided tape, etc. molecules inside sensor. After consuming all the
oxygen molecules inside sensor, the sensor will
Recommended conditions for manual not react to CO.
soldering:
Temperature of soldering copper head: 380°C Dry/bottled CO gas can be used since the
Period: < 10 sec. sensor’s humidity dependency is very small.
Figaro has confirmed that wave soldering can NOTE: Without testing after final assembly,
be done by using the materials shown in Table detectors have no guarantee of accuracy or
1. When different materials will be used, a test reliability.
should be conducted before production starts
to see if there would be any influence to sensor 5-6 Storage of Finished Products
characteristics. Detectors should be stored in a clean air

Revised 07/15 15
 APPLICATION NOTES FOR TGS5042

environment at room temperature. Storage in Acceptance of sensor Acceptance of components

dirty or contaminated environments should be
avoided. Also, void storage in extremely low
humidity--sensor life may be shortened. Please Read out PCB Assembly Repair
sensitivity data
refer to Sec. 6-Notes in TGS5042 Technical Info for
additional information.
NG
Circuit test
5-7 Packaging
OK
When a plastic clam shell is used for packaging
Input sensitivity data to
of a CO detector, a small charcoal filter should EEPROM

be placed inside to avoid potential influence by

organic vapors generated from the package. Sensor Assembly

Never expose the sensor to a vacuum. Sudden Zero adjust

exposure to a vacuum may temporarily damage

Final Assembly
the sensor. (PCB,Casing,etc.)

6. Quality Control Re-calibration

(Zero, Gas)
1) A sample of finished products from each
production lot should be tested to confirm alarm NG
Function check
Gas test
concentration. Check whether these samples are
OK
acceptable for shipment and maintain a record
Packaging
of these tests.
2) Periodically sample a certain number Storage

of finished products to confirm the alarm Shipping

concentration under extreme conditions (e.g.
-10°C or 40°C/85%RH) and maintain a record Figure 27 - Manufacturing flow chart
of these tests. Q. How long is the expected life of TGS5042?
3) Periodically sample a certain number of A: Unlike some electrochemical sensors which are
completed products periodically to confirm their short-lived, the expected sensor life is more than 10
long-term characteristics and maintain a record years under normal operating condition.
of such tests. Q: Is it true that the accuracy of two-electrode
electrochemical CO sensors is less than that of three-
7. Expected Performance electrode type sensors?
Considering sensor variation as well as the A: While this may be true for sensors whose electrode
tolerances of electric components such as the op- potentials are unstable, the TGS5042 exhibits good
amp and thermistor, display accuracy of ±20% accuracy. With an optimized sensor structure and
can be expected when individual bar code data electrodes, TGS5042 maintains very stable electrode
of TGS5042 is used for calibration. This level potentials. As a result, the sensor shows excellent long
of accuracy may not be obtained if low quality term stability, drifting by only 2% over 2000 days.
components are used. For higher accuracy, gas
Q: Where does CO gas enter into the sensor?
calibration for each sensor is recommended.
A: There are three pin holes in the working electrode
which act as a gas inlet. Refer to Figure 1 on page 2
8. Frequently Asked Questions
of the TGS5042 Technical Information.
Q: What approvals does TGS5042 have?
A: The sensor has received UL2034 component Q: Does the sensor comply to RoHS restrictions?
recognition. A: Yes.

Revised 07/15 16
 APPLICATION NOTES FOR TGS5042

Q: How long does it take to stabilize sensor output the sensor is easily influenced by external electric
after storage when the sensor electrodes are open- noise since sensor output current is very small.
circuited? Power-supply noise should be minimized, an anti-
A: According to Figaro’s test results, short-circuiting electrical noise circuit pattern should be made, and
the sensor for one hour should be sufficient to stabilize a CR circuit should be used to prevent influence of
sensor output after as much as 6 months storage in electrical noise.
fresh air. Nevertheless, the period to reset the sensor’s
If incoming noise is too large to be prevented by
polarization depends on the type(s) of gases existing
the above measures, these additional steps should
in ambient air, ambient conditions, storage period,
be taken:
and the customer’s circuit. For achieving the best
- coat the detector case with a copper board
results, Figaro recommends that users conduct tests
- use anti-EMI material
at their production facility to determine the optimal
- place metal mesh around the electric circuit
stabilization period for sensor output in air.
Q: Are any special precautions needed to use
TGS5042 for a simple CO analyzer? Figaro USA Inc. and the manufacturer, Figaro
A: To obtain quick response, the gas inlet of sensor Engineering Inc. (together referred to as Figaro)
of the sensor should be located nearest to the detector reserve the right to make changes without notice
to any products herein to improve reliability,
slits or opening. For this application, TGS5042-B00 is
functioning or design. Information contained in
recommended. Please cut the Nickel ribbon as short this document is believed to be reliable. However,
as possible and connect an insulated copper wire by Figaro does not assume any liability arising out of the
soldering. In addition, it is recommended to make application or use of any product or circuit described
small compartment with slits at least in two sides herein; neither does it convey any license under its
around the sensor. Refer to Sec. 3-3 Housing Design patent rights, nor the rights of others.
for Quick Response.
Figaro’s products are not authorized for use as critical
Q: How can electric noise be prevented? components in life support applications wherein a
A: Since sensor impedance is 10Ω or less, the sensor failure or malfunction of the products may result in
itself will not be a source of electric noise. However, injury or threat to life.

FIGARO GROUP

HEAD OFFICE OVERSEAS

Figaro Engineering Inc. Figaro USA Inc.
1-5-11 Senba-nishi 121 S. Wilke Rd. Suite 300
Mino, Osaka 562-8505 JAPAN Arlington Heights, IL 60005 USA
Tel.: (81) 72-728-2561 Tel.: (1) 847-832-1701
Fax: (81) 72-728-0467 Fax.: (1) 847-832-1705
email: [email protected] email: [email protected]
www.figaro.co.jp

Revised 07/15 17
 APPLICATION NOTES FOR TGS5042

Appendix 1 - Temperature Compensation Coefficients

Temp CF Temp CF Temp CF
(˚C) (I/Io) (˚C) (I/Io) (˚C) (I/Io)
-40 0.453 0 0.844 40 1.105
-39 0.463 1 0.852 41 1.109
-38 0.473 2 0.861 42 1.112
-37 0.483 3 0.870 43 1.115
-36 0.493 4 0.878 44 1.118
-35 0.503 5 0.887 45 1.121
-34 0.513 6 0.895 46 1.124
-33 0.523 7 0.903 47 1.126
-32 0.534 8 0.911 48 1.128
-31 0.544 9 0.919 49 1.130
-30 0.554 10 0.927 50 1.132
-29 0.564 11 0.935 51 1.134
-28 0.574 12 0.943 52 1.135
-27 0.584 13 0.950 53 1.136
-26 0.594 14 0.958 54 1.137
-25 0.605 15 0.965 55 1.138
-24 0.615 16 0.972 56 1.139
-23 0.625 17 0.980 57 1.139
-22 0.635 18 0.987 58 1.139
-21 0.645 19 0.994 59 1.139
-20 0.655 20 1.000 60 1.139
-19 0.664 21 1.007 61 1.139
-18 0.674 22 1.013 62 1.139
-17 0.684 23 1.020 63 1.139
-16 0.694 24 1.026 64 1.139
-15 0.704 25 1.032 65 1.139
-14 0.714 26 1.038 66 1.139
-13 0.723 27 1.044 67 1.139
-12 0.733 28 1.050 68 1.139
-11 0.742 29 1.055 69 1.139
-10 0.752 30 1.060 70 1.139
-9 0.761 31 1.066
-8 0.771 32 1.071
-7 0.780 33 1.076
-6 0.789 34 1.080
-5 0.799 35 1.085
-4 0.808 36 1.089
-3 0.817 37 1.094
-2 0.826 38 1.098
-1 0.835 39 1.101

Revised 07/15 18