testo cu-2 · • installation of the testo cu-2 and accessories • handling, operation,...

testo CU-2

User Manual

Content

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Content 1 Declaration of Warranty ............................................................................................... 6

1.1. Type of Designation ....................................................................................................................... 6

1.2. Manufacturer ................................................................................................................................ 6

1.3. Warranty ....................................................................................................................................... 6

2 Precautions ................................................................................................................... 6

2.1. Foreword ...................................................................................................................................... 6

2.2. Liabilities ....................................................................................................................................... 6

2.2.1. Liability to Content............................................................................................................... 7

2.3. Copyright © .................................................................................................................................. 7

3 Safety ............................................................................................................................ 7

3.1. Risk Types...................................................................................................................................... 7

3.1.1. Electrical Safety ................................................................................................................... 7

3.2. Labels and Explanations ................................................................................................................. 7

4 System Overview .......................................................................................................... 8

4.1. Introduction .................................................................................................................................. 8

4.1.1. testo CU-2 Digital Control Unit ............................................................................................. 8

4.1.2. testo NanoMet Software ...................................................................................................... 8

4.2. Definitions ..................................................................................................................................... 8

4.3. Abbreviations, Units and Symbols .................................................................................................. 8

4.4. The System .................................................................................................................................. 10

4.4.1. Overview ........................................................................................................................... 10

4.4.2. Functionality ...................................................................................................................... 10

4.5. Control Elements and Connections .............................................................................................. 11

4.5.1. Front and Rear View .......................................................................................................... 11

4.5.2. Additional Analog and Digital In- and Output Connector 20) ............................................... 12

5 Installation and Setup ................................................................................................. 12

5.1. Hardware Setup........................................................................................................................... 12

5.2. Windows Embedded and Network Setup ..................................................................................... 12

5.2.1. Windows Embedded Login ................................................................................................. 12

5.2.2. Network Settings ............................................................................................................... 13

5.3. testo NanoMet Software Startup and Operation Mode Selection ................................................. 13

5.3.1. Manual Operation Mode .................................................................................................... 13

5.3.2. Software Control Mode ...................................................................................................... 14

5.3.3. Remote Computer Software Control Mode ........................................................................ 14

5.4. AK Host Remote Control Mode .................................................................................................... 15

6 testo NanoMet Operation ........................................................................................... 17

6.1. Main Measurement Tab .............................................................................................................. 17

6.1.1. Pause State ........................................................................................................................ 17

6.1.2. Standby State .................................................................................................................... 17

Content

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6.1.3. Measurement state ........................................................................................................... 18

6.1.4. Leak Test ........................................................................................................................... 18

6.1.5. Zero Test............................................................................................................................ 18

6.2. Measurement Configuration ........................................................................................................ 19

6.2.1. UN-ECE R83 Measurement and Test Cycle Definition .......................................................... 19

6.2.2. General Measurement Settings .......................................................................................... 20

6.3. System Configuration .................................................................................................................. 20

6.3.1. Measurement Instruments................................................................................................. 20

6.3.2. Dilution Instruments .......................................................................................................... 21

6.3.3. AK Interfaces ..................................................................................................................... 22

6.4. Analog Input and Output Signals Configuration ............................................................................ 22

6.4.1. Analog In ........................................................................................................................... 23

6.4.2. Analog Out......................................................................................................................... 23

6.4.3. Digital Out / Errors ............................................................ Fehler! Textmarke nicht definiert.

6.5. PNC Tab....................................................................................................................................... 24

6.6. testo NanoMet Control Panel and CPC Window ........................................................................... 24

6.6.1. testo NanoMet Control Panel ............................................................................................. 24

6.6.2. CPC Window ...................................................................................................................... 25

7 AK Host Operation ...................................................................................................... 25

7.1. AK Software Integration............................................................................................................... 25

7.2. AK Interfaces Specifications ......................................................................................................... 25

7.2.1. Serial Interface ................................................................................................................... 25

7.2.2. TCP/IP Interface ................................................................................................................. 26

7.3. AK Protocol Specification ............................................................................................................. 26

7.3.1. AK Command Telegram ...................................................................................................... 26

7.3.2. AK Response Telegram ....................................................................................................... 26

7.3.3. General AK Protocol Description ........................................................................................ 27

7.3.4. Handling of Certain Conditions ........................................................................................... 27

7.4. List of All AK Commands .............................................................................................................. 28

7.4.1. Control Commands – 'S' ..................................................................................................... 28

7.4.2. Write Commands – 'E' ........................................................................................................ 28

7.4.3. Read Commands – 'A' ........................................................................................................ 28

7.5. Descripton of All AK Commands ................................................................................................... 29

7.5.1. Control Commands – 'S' ..................................................................................................... 29

7.5.2. Write Commands – 'E' ........................................................................................................ 30

7.5.3. Read Commands – 'A' ........................................................................................................ 32

7.5.4. AK Errors List ..................................................................................................................... 34

8 Electrical Connections ................................................................................................. 35

8.1. Mains Supply ............................................................................................................................... 35

8.2. Dilution/Conditioning Devices...................................................................................................... 36

8.3. Analog/Digital Interface ............................................................................................................... 36

8.4. Standard Embedded Computer Ports ........................................................................................... 37

9 Maintenance and Calibration ...................................................................................... 38

Content

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9.1. Storage, Acclimatization .............................................................................................................. 38

9.2. Operation Environment Requirements......................................................................................... 38

10 Appendix ..................................................................................................................... 39

10.1. Extent of Delivery ........................................................................................................................ 39

10.2. Specification, Technical Data ....................................................................................................... 39

10.3. Designation of All testo CU-2 Digital Control Unit Operating Elements ......................................... 40

1 Declaration of Warranty

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1 Declaration of Warranty Manual Version History: Version: V1.03 Date: November 2018

1.1. Type of Designation This user manual refers to the instrument and software type and version as listed below. It replaces all previously dated user manuals for this instrument. Type: testo CU-2

1.2. Manufacturer Testo SE & Co. KGaA Tel: +49 7653 681 5062 Testo-Strasse 1 Fax: +49 7653 681 95062

79853 Lenzkirch web: www.testo.com Germany email: [email protected] For technical support contact your local service contractor or Testo techsupport.

email: [email protected]

1.3. Warranty Testo SE & Co. KGaA warrants that this product adheres to the specified properties for a period of twelve (12) months from the date of delivery. Excluded from the warranty are all parts subjected to normal wear as any fuses, batteries or other consumable parts. Also excluded are: Defects resulting from abnormal use, in particular outside the intended purpose; lack of maintenance; improper use or malicious damage. Warranty is void if actions are carried out which are not described in the documentation nor authorized by Testo SE & Co. KGaA. Testo SE & Co. KGaA does not provide any warranty on finished goods manufactured by others. Only the original manufacturer's warranty applies. There are no user-serviceable parts inside testo CU-2 and some very sensitive parts. Do not open your testo CU-2, as you may damage it. Warranty is voided if the case is opened and warranty-seal is broken. Parts repaired or replaced as a result of repair services are warranted to be free from defects in workmanship and material, under normal use, for 90 days from the date of shipment.

2 Precautions

2.1. Foreword This manual guides you through the installation, starting up, operation and maintenance procedures of the testo CU-2. In detail you will find information about the system as

• safety

• functionality of the testo CU-2, technical information and specifications

• installation of the testo CU-2 and accessories

• handling, operation, maintenance and troubleshooting Follow the instructions provided by this manual for safe and proper operation of the testo CU-2 Digital Control Unit.

Before installing and operating the testo CU-2, the operator or service has to read carefully this manual. For improper function, damages or injuries caused by ignoring the instructions by this manual no liabilities are accepted.

2.2. Liabilities Testo SE & Co. KGaA accepts no liability to improper function or injury caused by

• neglecting the instructions provided by this manual or instructed person.

• improper installation, operation, application, or maintenance.

• operation by untrained staff.

http://www.testo.com

3 Safety

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• any technical modification not carried out by Testo SE & Co. KGaA or an authorized service partner.

For operating the testo MD19-3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube together with testo CU-2 Digital Control Unit, refer to the related user manuals.

2.2.1. Liability to Content The content of this manual is generated with most accurateness. Testo SE & Co. KGaA does not guarantee completeness, correctness and being up to date. Testo SE & Co. KGaA reserves the right to revise the content of the manual at any time and without notice.

2.3. Copyright © All work and contents done or generated by Testo SE & Co. KGaA are subject of the German copyright © and law for intellectual property. This copyright includes all specification data of the instrument or part of it, electrical and fluidic and mechanical schematics, pictures, diagrams and text. Copying, editing, publishing or any other utilisation requires a written agreement of Testo SE & Co. KGaA.

3 Safety

3.1. Risk Types The diagram in Fig. 3.1 shows typical risks that could cause damage or injury while handling the testo MD19-3E Rotating Disk Diluter or testo ASET15-1 Air Supply / Evaporation Tube. These risks may also occur if these or other devices are used in combination with testo CU-2.

Fig. 3.1: risk types

Refer to the user manuals of the devices connected to the testo CU-2 digital control unit to learn more about the risks which may occur operating them.

3.1.1. Electrical Safety When in operation any electrical equipment can produce dangerous voltages. Failure to observe the warnings may result in serious injury or damage. It is, therefore, mandatory that only suitably qualified personnel use this instrument. Satisfactory and safe operation of this instrument calls for proper handling in transportation, storage, installation as well as careful control and maintenance.

3.2. Labels and Explanations Listed labels, Caution and Warning are explained in general, and the further specific labels refer to type of hazard and danger.

4 System Overview

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Warning Warning means that improper operation could cause a serious human or instrument damage or injury with consequence of irrevocable instrument damage.

Electric Shock

Hazardous voltage. Contact may cause electric shock or burn. Turn off and lock out system power before servicing.

Electric Ground This sign indicates that the mains connector and cabinet ground are connected to protective earth PE.

4 System Overview

4.1. Introduction

4.1.1. testo CU-2 Digital Control Unit testo CU-2 Digital Control Unit is an accessory for the testo MD19-3E which is the Rotating Disk Diluter with external diluter head for performing the primary dilution as close as possible to the aerosol source. testo CU-2 is equipped with interfaces to control testo MD19-3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube and to read the digital signal of a condensation particle counter CPC. Besides, several analog and digital input and output signals can be handled.

4.1.2. testo NanoMet Software The testo NanoMet software is intended to control the testo CU-2 Digital Control Unit and therewith the connected particle measurement components like testo MD19-3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube. The testo NanoMet software also allows the user to read a digital signal from a CPC and to determine the functions of the analog ports of testo CU-2. The testo NanoMet software supports AK protocol. This permits the communication with an AK host computer and therewith the easy integration of the testo CU-2 controlled particle measurement system into a test rig.

4.2. Definitions testo MD19-3E third generation of Testo Rotating Disk Diluter with external diluter head

for primary dilution as close to the emission source as possible

testo ASET15-1 Testo Air Supply / Evaporation Tube unit supplies dilution air to the testo MD19-3E primary diluter and undertakes the thermal conditioning and secondary dilution of the aerosol

Raw gas undiluted aerosol from the emission source

Dilution air filtered and therewith particle free compressed or ambient air which is fed to the primary or secondary diluter

Measuring gas primary or secondary diluted aerosol from the emission source (combustion engine or CVS).

4.3. Abbreviations, Units and Symbols LED Light Emitting Diode

signal lamps at the front of testo MD19-3E, testo ASET15-1, and testo CU-2

CVS Constant Volume Sampler test rig component; combustion engine exhaust dilution tunnel

4 System Overview

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AK ArbeitsKreis VDA (working committee of German automotive industry alliance)

de facto standard communication protocol for test bench components

PND1 primary Particle Number Diluter (ECE R83 compliant abbreviation) Testo testo MD19-3E Rotating Disk Diluter

DFPND1 primary Dilution Factor dilution factor of PND1 (testo MD19-3E)

PND2 secondary Particle Number Diluter (ECE R83 compliant abbreviation) diluter part of testo ASET15-1

DFPND2 secondary Dilution Factor dilution factor of PND2 (testo ASET15-1)

PCRF Particle Concentration Reduction Factor (ECE R83 compliant abbreviation)

total dilution factor comprising DFPND1, DFPND2 and particle losses

fr overall dilution (= concentration reduction) factor used as equivalent of PCRF

PNC Particle Number Counter (ECE R83 compliant abbreviation) e.g. engine exhaust condensation particle counter EECPC from TSI

CPC Condensation Particle Counter product name of particle number counter manufactured by TSI

EECPC Engine Exhaust Condensation Particle Counter product name of ECE R83 compliant PNC manufactured by TSI

QMD primary diluted measuring gas flow from the testo MD19-3E primary diluter

QAS secondary dilution air flow from the air supply part of testo ASET15-1

QMG secondary diluted measuring gas flow to the connected instrumentation

QEX excess secondary diluted measuring gas gas flow

4 System Overview

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4.4. The System

4.4.1. Overview

Fig. 4.1 : testo ViPR system consisting of testo CU-2, testo MD19-3E, and testo ASET15-1

Fig. 4.1 shows a testo ViPR system consisting of testo CU-2 Digital Control Unit, testo MD19-3E Rotating Disk Diluter, testo ASET15-1 Air Supply / Evaporation Tube. Together with an engine exhaust condensation particle counter (e.g. TSI 3790 EECPC or GRIMM 5.431) this system meets PMP requirements and can be controlled via Ethernet.

4.4.2. Functionality testo CU-2 Digital Control Unit is built in a standard 19" case and therewith can be integrated into a 19" rack together with other devices like the controlled testo ASET15-1 with integrated testo MD19-3E. An embedded computer is built in with Windows Embedded Standard as operating system. This permits to operate the unit in different modes: Manual control, local software control, remote computer software control via Ethernet, or control by host computer via AK interface. Besides the Testo aerosol conditioning system consisting of testo MD19-3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube a TSI 3790 EECPC, GRIMM 5.431 or another CPC particle counter can be controlled via serial port and up to 5 analog signals from other external sources can be logged. Data logged by testo CU-2 can be saved on the integrated flash memory, a USB memory stick or to any network storage Windows Embedded can access via Ethernet.

4 System Overview

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4.5. Control Elements and Connections

4.5.1. Front and Rear View

Fig. 4.3: front view of testo CU-2

Fig. 4.3 shows the front of testo CU-2. There are no control elements except the power LED 1) indicating if the device is switched ON or OFF. All connectors and the mains switch are located at the rear side which is shown in Fig. 4.4. The testo CU-2 is either completely controlled via Ethernet or locally by using keyboard, mouse and VGA monitor which can be connected to the according ports.

Fig. 4.4: rear view of testo CU-2

1 Power LED

2 testo ASET15-1 Air Supply / Evaporation Tube (PND2 + VPR) interface 3 testo MD19-3E Rotating Disk Diluter (PND1) interface 4 male 25 pin D-Sub connector for analog and digital in- and output signals 5 USB connector of embedded computer

6 USB connector of embedded computer 7 USB connector of embedded computer used as default port for GRIMM 5.431 for PMP R-83 measurements 8 USB connector of embedded computer 9 not used 10 LAN 2 connector of embedded computer; default setting: DHCP

11 LAN 1 connector of embedded computer; default IP adress: 192.168.1.129 12 VGA monitor connector of embedded computer 13 Male serial connector 1 of embedded computer used as default port for EECPC 3790 for PMP R-83 measurements 14 Male serial 2 connector of embedded computer

15 not used 16 Female serial 3 connector to control testo CU-2 by AK host computer 17 Mains connector 18 Fuse holder; fuse: 250 V, 5.0 A, t

19 Mains switch

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5 Installation and Setup

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The properties of the devices connected to testo CU-2 are specified in appendix A.2

4.5.2. Additional Analog and Digital In- and Output Connector 20) testo CU-2 is delivered with a female connector 20) which is shown in Fig. 4.5. This connector can be plugged into the external signals port 4). It is equipped with solder pins which can be used as contacts for different analog and digital inputs and outputs:

• 5 analog input signals (–10...+10 VDC).

• 3 analog output signals which are configured by the testo NanoMet software (0...+10 VDC).

• a digital input signal (0 or 5...25 VDC) which can be used to trigger data logging

• 2 digital alarm outputs delivering a 24 VDC signal in case of an error detected by the testo NanoMet software. These alarm signals are also configured individually by the testo NanoMet software.

Fig. 4.5: front and rear of external in- and output signals connector 20)

The pin assignment of the external signals port 4) and the specific connector 20) is described in chapter 8.3.

5 Installation and Setup Note: Numbers – e.g. 2) = testo ASET15-1 interface – refer to the operating elements illustrated in chapter 4.5 and appendix A.3.

5.1. Hardware Setup There are no big efforts to install testo CU-2 and combine it with testo MD19 Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube. Simply use standard 25 pin D-Sub cables to connect these devices to testo CU-2. The remote control interface connector of the stand-alone testo MD19-3E is located at the rear side of the testo MD19-3E laboratory case. If testo MD19-3E is integrated in an testo ASET15-1, the interface connectors of both components are situated at the rear of the testo ASET15-1 case. Both interfaces have to be connected to connectors 2) and 3) at the rear side of testo CU-2. If analog input signals should be recorded or provided by testo CU-2, these external devices might be connected to the external signals port 4), using a standard 25 pin D-Sub cable with female connector, or using the external signals connector 20). Two alarm voltage signals can also be tapped from the external signals port 4) and a trigger signal can be applied to start and stop data logging. The pin assignment of the external signals port 4) and therewith the connector 20) is described in chapter 8.3. Connect the testo CU-2 to your computer network or directly to a host computer using a crossover network cable, if the system should be remote controlled via Ethernet, use a 9 pin RS-232 cable to connect it to an AK host computer, or add a VGA monitor, keyboard and mouse to work directly on the testo CU-2. The different operation modes are described in chapters 5.3 and 5.4.

5.2. Windows Embedded and Network Setup

5.2.1. Windows Embedded Login testo CU-2 Digital Control Unit is delivered with Microsoft Windows Embedded installed. There are two Windows users predefined:

user name default password

windows user rights

remarks


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Admin Admin no restrictions only recommended for remote desktop operation and system setup e.g. integration in local network

CU-2 CU-2 limited rights recommended standard user, automatically logged after system boot up

For more detailed information or to integrate the testo CU-2 into your network please contact your network administrator. When the device is switched on, the embedded computer boots and the testo NanoMet software is automatically started. The duration of operation system and testo NanoMet software startup is about 100 seconds. After this time the system is ready for either manual operation of the dilution system, or testo NanoMet software control, or AK host computer control.

5.2.2. Network Settings testo CU-2 is equipped with two RJ45 sockets to connect the device to a Ethernet network. By default the LAN 1 connection has no fix IP address but is set to DHCP while LAN 2 has assigned the fixed IP address 192.168.1.129. LAN 1 connection using may be used to connect the device to a network equipped with a DHCP server. LAN 2 is intended to be used for a direct connection to a Windows PC using a crossover network cable.

As all other Windows settings the properties of both LAN connections can be changed in the Windows system control panel when logged in as administrator. The testo CU-2 can be found in the network either by using the IP address or the computer name. The default computer name consists of the part 'testo-' and the serial number of the individual device, e.g. 'testo-101999'.

5.3. testo NanoMet Software Startup and Operation Mode Selection Plug in the power cable to the mains connector 17) and switch on the testo CU-2 unit using the mains switch 19). Windows Embedded Standard boots and the testo NanoMet software is automatically started. The system is ready for measuring appr. 100 seconds after switching on the testo CU-2. If a monitor is attached or the system is controlled by Windows desktop connection the testo NanoMet user interface shown in Fig. 5.1 appears on the screen.

Fig. 5.1 : testo NanoMet user shell after system startup

5.3.1. Manual Operation Mode After startup, the testo NanoMet software runs in the manual operation mode. The software control menu contains the red 'Enable Software Control' button as shown in Fig. 5.2. Either the


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user can activate software control or the AK host computer can get control access via Ethernet or serial port.

Fig. 5.2 : testo NanoMet control menu after software startup

Otherwise it might be helpful to remain in manual operation mode if dilution parameters have to be determined like dilution factors or the total diluted measuring gas amount. Neither the testo NanoMet software nor the AK host computer controls testo MD19-3E and testo ASET15-1, even if they are physically connected to testo CU-2. The devices are locally operated by the control elements at their front panels according to the instructions in the specific user manuals. testo NanoMet software and AK host can read and log data provided by testo CU-2. Data logging by testo NanoMet software is started by pushing the 'start data logging' button. The AK interface is running in the background. Only AK read 'A' commands are possible. Control and write commands from AK host are responded with 'state = busy' and the AK system runs in 'manual mode'

5.3.2. Software Control Mode By clicking the software control button, the operator decides the testo NanoMet software to take control over the aerosol conditioning system, i.e. testo MD19-3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube. The software control button turns to grey and could now be used to disable software control and return to manual control mode. In software control mode, the system is operated via testo NanoMet user interface. The testo NanoMet software has prior access to the data acquisition modules. The AK interface is still running in the background. Only AK read 'A' commands are possible. Control and write commands from AK host are responded with 'state = busy' and and the AK system runs in 'manual mode'. Manual software control mode is mostly used for system configuration, field measurement, or if no other computer is available. It is possible to work directly on the embedded computer using monitor, mouse, and keyboard directly connected to the control unit testo CU-2.

5.3.3. Remote Computer Software Control Mode The system can be controlled by a remote-desktop connection. This is mostly used for measurements on test-benches if the user operates in a control room and the devices are mounted in a test cell. It is also used for system checks and configuration changes via Ethernet without the need of being personally present. The user directly works on the testo NanoMet software by using a remote-desktop connection. In this case the operator has the screen from the embedded computer on his workstation monitor and works on the embedded computer. The remote desktop connection can be established using the remote desktop connection software which is installed by default on Microsoft Windows XP professional or newer. Appropriate remote desktop protocol (RDP) clients are also available for a number of other operating systems like Windows 2000, 9x, and NT4, but also Mac OS X, Linux and others. After startup of the RDP software, the testo CU-2 can be found in the network either using its network computer name (e.g. 'matter-101999') or its IP address which are described in chapter 5.2.2. The Windows Embedded Standard log-in window appears which is shown in Fig. 5.3.


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Fig. 5.3: log-in window

Even if the testo CU-2 system is started by default with the standard user 'Matter' without a password needed, administrator rights are required for remote desktop operation. An administrator account is created by default with both user name and password: Administrator (mind the capital letter at the beginning of the password). If you try to log-in as 'Administrator' for the first time after system startup, i.e. if the standard user 'Matter' is logged in, the message shown in Fig. 5.4 appears.

Fig. 5.4 : standard user log-out message

Confirm by clicking 'Yes' to log-out 'Matter' and change the user to 'Administrator'. After logging in the testo NanoMet software is automatically started in the manual operation mode described in chapter 5.3.1 with the control menu shown in Fig. 5.2.

5.4. AK Host Remote Control Mode Using testo CU-2, the particle number measurement system can be integrated in a test rig. The testo CU-2 Digital Control Unit can then be controlled by a host computer connected by serial RS232 port or Ethernet connection. Communication protocol is AK over TCP/IP or RS232. Detailed AK protocol specifications can be found in chapter 7.

A second host computer can be connected via Ethernet optionally. Only one of the host computers can control the connected devices but the second one is able to read data using AK 'A' commands.

The testo NanoMet software has to be in the Manual Operation Mode which is the default mode after system start up. Then the AK master computer (Host A) can send remote command 'SREM' to get priority. The testo NanoMet user interface will then be deactivated (software control mode not available but data still can be read and recorded) and the second host (Host B) can only execute 'A' commands. This is illustrated in the flow chart of Fig. 5.5.


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Fig. 5.5: testo NanoMet operation modes flow chart

The command 'SMAN' ends priority state of the master computer (Host A), operator may then control the diluters manually, switch to software control and use the testo NanoMet software, or the other host computer (Host B) can get priority by sending 'SREM'. In this case Host A can only execute AK 'A' commands until Host B ends its priority by sending 'SMAN'.

6 testo NanoMet Operation

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6 testo NanoMet Operation The testo NanoMet user shell consists of the testo NanoMet main window, the testo NanoMet control panel, and the CPC control window. The testo NanoMet main window contains five tabs to set measurement parameters, to select operation mode and system state, to display the measured values and to do the data saving settings.

6.1. Main Measurement Tab The 'Measurement' tab shown in Fig. 6.1 includes the software control menu which was already described in chapter 5.3.1. It also displays the measured values, contains a chart where the selected values are plotted, and an error bar at the bottom of the window, where auto-detected errors are displayed.

Fig. 6.1: measurement tab

For every plotted signal it can be selected if the left or right y-axis should be used. In the chart settings area, minimum and maximum values of these axes can be set. This is done automatically if 'y auto scale' is selected. The set minimum and maximum values are useless then. The 'x scale interval' determines how many seconds should be plotted in the chart. Default value is 60 seconds, maximum is 1200 seconds = 2 hours. The system state buttons in the software control menu are active when the system is operated in the software control mode, as it is shown in Fig. 6.2. The system state is selected using these buttons. The actual system state is marked by the red button.

6.1.1. Pause State PAUSE state means that all pumps and heatings of testo MD19-3E and testo ASET15-1 are switched off.

6.1.2. Standby State STANDBY state means the system is ready for measurements. Pumps for sample gas and dilution air are switched on as well as the heaters of primary dilution head and the evaporation tube. Only the diluter disk is not rotating and therewith the dilution air passes the diluter without being added by any amount or raw gas.


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Fig. 6.2: testo NanoMet control menu in software control mode

6.1.3. Measurement state In the MEASUREMENT state the disk starts to rotate. The system is ready to measure.

6.1.4. Leak Test UN-ECE R83 reglementations require a system leakage test to be executed prior to each measurement test cycle. This leakage test is effected by feeding filtered air into the inlet of the entire particle sampling system. The particle counter shall then report a measured concentration of less than 0.5 #/cm3. This test can be performed automatically selecting the LEAK TEST state in the testo NanoMet control menu. In this state all parameters are set as in the measurement state except that the primary diluter disk is not rotating. This means no raw gas is added and therewith the filtered dilution air passes the dilution system instead of measuring gas. If the detected particle concentration does not recede to zero, either the secondary dilution air flow is set too low which leads to ambient air sucked through the excess air outlet port, or some leakage occurs, probably caused by a filter defect, by a failure at the diluter disk, an untight connection, or by a sensor defect. The leak test will start when 'start data logging' is clicked if the LEAK TEST state is selected. After 2 minutes test duration the system returns to the STANDBY state. The data logged during the leak test are saved in the selected data folder.

6.1.5. Zero Test A PNC zero test is required once a day for UN-ECE R83 applications. In terms of this test filtered air has to be feeded to the particle counter PNC. The PNC shall then report a measured concentration of ≤ 0.2 #/ cm3. The PNC shall show an increase in measured concentration to at least 100 #/ cm3 when challenged with ambient air and return to ≤ 0.2 #/ cm3 when filtered air is applied again. The ZERO TEST state of the testo NanoMet software cannot supply ambient air to the PNC but filtered air can be provided by the testo ASET15-1 when the primary dilution air supply is turned off and neither measuring gas nor dilution air passes the evaporation tube and only dilution air enters and leaves the secondary mixing chamber. If the amount of secondary dilution air exceeds the inlet flow of the PNC, it can only draw filtered air. Ambient air can be provided by manually pulling off the tube connector from the testo ASET15-1 measuring gas outlet.

If the PNC signal does not recede to zero during the zero test, either the secondary dilution air filter or the sensor might be faulty. The indicated particle concentration values during the zero test are recorded and saved in the selected data folder during 2 minutes when 'start data logging' is clicked. The ZERO TEST can also be used to isolate the reason for leakage found in a leak test. If the signal turns to zero in the zero test but not in the leak test, the leakage will probably be found in the primary dilution subsystem.


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6.2. Measurement Configuration The 'Config Measurement' tab shown in Fig. 6.3 serves to set the measurement parameters. It will be selected what should be calculated by the software out of the measured particle concentration values, how data logging will be started and stopped, and where the logged data should be saved.

Fig. 6.3: measurement configuration tab

6.2.1. UN-ECE R83 Measurement and Test Cycle Definition If the 'UN-ECE R83 measurement' button is activated, the measurements will follow a test cycle consisting of up to 5 parts. Each test of a cycle will be analyzed and particle number will be calculated in #/km according to UN-ECE R83. The results are saved in the header of the saved file. The desired test cycle is selected in the 'test cycle' menu. To change one of these predefined cycles, it first must be selected, then the cycle name has to be entered in the text field right from the 'test cycle' menu. The cycle part durations are entered in the fields below, and the newly defined cycle is saved by clicking on the 'OK and save' button. For the software to calculate the emissions in #/km, the 'cycle data information' window shown in Fig. 6.4 appears after the data logging is completed. In this window, the amout of exhaust gas volume and the virtually covered distance of the tested vehicle have to be entered for every cycle part for the testo NanoMet software to calculate the emitted particle number per kilometer #/km. The exhaust gas volume usually is the CVS total volume if the whole engine exhaust stream is fed to and the particle sample was drawn from the CVS.


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Fig. 6.4 : cycle data information window

6.2.2. General Measurement Settings On the 'Config Measurement' tab it is also set if data logging will be started by a trigger signal or manually and stopped manually or after a predetermined cycle time. Furthermore the sample rate can be set between 2 and 5 Hz, and the signal averaging interval is set. This setting will have a significant influence on the amount of data generated during the measurements.

By marking the 'include date in timestamp' control the date will also be saved in the first column of each entry in the data storage file. This option is usually used for long time and overnight measurements. In the bottom line of the 'Config Measurement' tab the path can be set where the logged data should be saved. This can either be locally on the internal memory of the embedded computer, an added USB storage device, or an accessible folder in the network where the testo CU-2 digital control unit is implemented. The default folder for the logged data to be saved by the testo NanoMet software is 'D:\MEASUREMENT DATA' on the internal flash memory of the embedded computer. The standard user 'CU-2' has no rights to access other folders.

6.3. System Configuration The system components must be specified in the 'Config System' tab shown in Fig. 6.5. The round check buttons can be activated independently of each other.

6.3.1. Measurement Instruments With the round check button, it is set if any testo NanoMet controllable particle detection sensor is attached and should be used for the measurements, or if just the dilution and conditioning components testo MD19 -3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube are controlled by the testo NanoMet software. The port where the sensor is attached to the testo CU-2 digital control unit can be set. Selectable sensors are TSI condensation particle counters CPC 3010, 37xx, engine exhaust condensation particle counter EECPC 3790, GRIMM 5.431 or the EcoChem PAH monitor PAS2000. The serial number and the measuring unit can be entered. Furthermore, a CPC correction factor k can be entered, according UN-ECE R83 regulations. This factor can be used to compensate a certain CPC signal deviation which possibly has been found when the sensor has been compared to a reference device.


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Fig. 6.5: system configuration tab

6.3.2. Dilution Instruments As secondary dilution unit PND2 only the testo ASET15-1 Air Supply / Evaporation Tube can be selected or not. The testo MD19-3E is intended as primary dilution unit PND1. testo MD19-3E supports extended remote control functions like to control the primary diluter temperature and the raw gas pump by the testo NanoMet software as well as it is possible to read raw gas temperature and pressure and several error informations by testo CU-2 Digital Control Unit. The testo NanoMet control panel is added by these additional functions if testo MD19-3E is selected as primary diluter. Along with the Rotating Disk Diluter version the rotating disk type has to be selected. The 10 cavities disk serves to realize lower dilution factors while higher dilution factors are achieved using the 8 cavities disk, as it is described in the testo MD19-3E user manual. The 'use fr or standard calibration' menu in the system configuration tab shown in Fig. 6.5 allows to set if measurements should be performed using the attached devices applying their standard calibrations, or if PMP compliant calibrations according UN-ECE R83 should be applied. By clicking the 'change' button the calibration factors settings window shown in Fig. 6.6 can be opened to insert the calibration data out of the documents delivered with the dilution components to the testo NanoMet software. As standard, the instruments are calibrated individually. The more extensive and more detailed PMP calibration is done with the components combined to one system.

For setting up the system according UN-ECE R83, the nominal primary and secondary dilution factors have to be approximately determined. The best fitting dilution settings out of the calibration certificate have to be selected and entered into the corresponding fields of the calibration factors window, together with the PCRF determined in line with these values during the calibration procedure.


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Fig. 6.6: calibration factors settings window

To use the standard calibration, simply the two calibration factors determined for both testo MD19-3E diluter disks must be entered in the specific field. There is no need for testo ASET15-1 calibration figures because in terms of its calibration this device has been adjusted to meet exactly its nominal dilution factors.

6.3.3. AK Interfaces An AK host computer may either connect to the testo CU-2 Digital Control Unit via serial connection or via TCP/IP using one of the two LAN connectors of the device. If a serial connection should be used, COM4 is set by default. This port is equipped with a female connector while COM1...COM3 have male connectors. This is done because in this case testo CU-2 is connected to the AK server as a slave while the other COM ports are used to connect other slave devices to testo CU-2 Digital Control Unit as master. Another AK host may connect to testo CU-2, but this one can only execute AK 'A' (read) commands because only one instance may control the system and therewith execute 'S' (control) and 'E' (write) commands. The detail parameters of the connection to the AK host can be set in the 'AK interfaces' section of the 'Config System' tab.

6.4. Analog Input and Output Signals Configuration On the 'Config AI/AO' tab shown in Fig. 6.7 the 5 analog inputs can be specified and the functions of the 4 analog outputs can be selected out of the referring menus. Besides it is set if one digital output signals should be used for all errors or if the two available signals should indicate CPC and dilution system errors separately.


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Fig. 6.7: analog input and output signals configuration tab

6.4.1. Analog In Using the round check buttons, every analog input and output channel can be activated or deactivated individually. Active input signals will be recorded in the measurement file during data logging and will be available for being displayed on the 'Measurement' tab. For every channel an analog DC voltage range within –10 V DC...+10 V DC can be specified to equate a certain signal range. Furthermore, the signal can be named and serial number and signal unit can be entered which will also be saved during data logging.

6.4.2. Analog Out

Fig. 6.8: analog and digital output signal menues

The 4 analog output signals can also be enabled individually. For every voltage output, one signal can be selected from the menu which is opened by clicking on the signal selection bar. The output voltage range is 0...+10 V DC. The signal range corresponding to this voltage limits is set by the operator.


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6.5. PNC Tab The informations provided by the attached particle number counter PNC, i.e. TSI condensation particle counter CPC are shown on the 'PNC tab' shown in Fig. 6.9.

Fig. 6.9: particle number counter PNC tab

If a TSI 37xx or GRIMM 5.431 particle counter is used, these informations are the detected particle concentration which is also displayed at the CPC front display, the ambient conditions of the CPC, the temperatures inside the sensor which are relevant for correct operation, the serial number, any errors, and some operation parameters. The TSI 3010 model only sends the vacuum information to the control device. This value is important to ensure sufficient flow through its critical nozzle. It is also possible to send certain commands to the particle number counter. These are to enable or disable the automatic functions autofill and water removal for TSI 37xx models and the butanol fill button for TSI 3010.

6.6. testo NanoMet Control Panel and CPC Window

6.6.1. testo NanoMet Control Panel The testo NanoMet control panel is shown in Fig. 6.10. It serves to set dilution and conditioning parameters like primary and secondary dilution factors and temperatures of primary diluter and evaporation tube of testo ASET15-1. This window also allows to control the testo ASET15-1 pumps and the raw gas pump of testo MD19-3E and it provides information about the hardware status, i.e. if the set dilution factor and temperatures are reached, if the pump flows are within their specifications, and if the rotating disk motor works correctly.

Fig. 6.10: testo NanoMet control panel with testo MD19-3E control field

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The testo NanoMet control panel will be deactivated and its background color will change from black to grey, if software control is disabled i.e. the system runs in manual or AK host control mode. It gets active when software control is enabled.

6.6.2. CPC Window If a 3010 or 37xx condensation particle counter CPC from TSI or GRIMM 5.431 is used as particle number counter PNC, the actually measured value of this sensor is displayed in the CPC window shown in Fig. 6.11 as well as the CPC status and a short description of automatically detected CPC errors.

Fig. 6.11: CPC status window

7 AK Host Operation

7.1. AK Software Integration The testo NanoMet operation modes are described in chapter 5.3 and 5.4 and illustrated in Fig. 5.5. An AK host computer can simply take control over the system by sending the 'SREM' command after the software start up if testo NanoMet software control has not been activated before. The testo NanoMet software is started and therewith the system including AK module is ready appr. 100 seconds after the testo CU-2 is switched on.

7.2. AK Interfaces Specifications

7.2.1. Serial Interface The RS232 V24 9-pin male connector at the back of the unit is used to connect a master computer with the following pin assignment: Pin 3 = Txd (transmit)

Pin 2 = Rxd (receive) Pin 5 = Gnd (ground) All serial parameters fo the AK communication can be configured in the testo NanoMet software:

parameter selectable values default settings

baud rate 1200, 2400, 4800, 9600, 19'200, 38'400 9600

start bit 1 1

data bits 7 or 8 8

stop bits 1 or 2 1

parity even, odd, none none

handshake Xon/Xoff Xon/Xoff

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7.2.2. TCP/IP Interface There are two RJ45 connector at the back of the unit for the TCP/IP communication. Both ports may be used to connect one or two host computers to the testo CU-2. There are two parameters necessary for the AK communication:

• IP addresses of the computer. These can be changed when logged in as administrator on the embedded computer. Default value for LAN2: 192.168.1.129, LAN1 is set to DHCP by default. These addresses may have to be changed to connect the testo CU-2 to a network. The embedded computer can be identified in a network by its network name. Default name of testo CU-2 is 'MATTER-[Serial number]', e.g.: 'MATTER-101999'

• The AK port addresses can be configured in the testo NanoMet software. Each port must be a number between 0 and 65535. Default values are 49152 (Host A) and 49153 (Host B). Both ports are used at the two IP addresses, respectively LAN ports. Numbers from 0 up to 49151 should not be used, because they are officially registered and reserved.

7.3. AK Protocol Specification

7.3.1. AK Command Telegram

protocol: hex: description

1. Byte STX

HEAD

02 start byte

2. Byte DON'T CARE (30) any byte, configurable in testo NanoMet software default = 30 h = '0'

3. Byte FUNCT.CODE1

function code, 4 bytes 4. Byte FUNCT.CODE2

5. Byte FUNCT.CODE3

6. Byte FUNCT.CODE4

7. Byte BLANK

VARIABLE DATA (length depending on functional code)

20 blank (space, 20 h)

8. Byte 'K' 4B K for channel / device with following number

9. Byte NUMBER device number, always = 0, 1 byte

DATA data depending on functional code

n. Byte ETX END 03 end byte

7.3.2. AK Response Telegram protocol: hex: description

1. Byte STX

HEAD

02 start byte

2. Byte DON'T CARE (30) any byte, configurable in testo NanoMet software default = 30 h = '0'

3. Byte FUNCT.CODE1 function code, 4 bytes

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4. Byte FUNCT.CODE2

5. Byte FUNCT.CODE3

6. Byte FUNCT.CODE4

7. Byte BLANK

FIXED DATA

20 blank (space, 20 h)

8. Byte ERROR STATUS 0 when no error, 1...9, +1 every error status change

DATA VARIABLE DATA

(length depending on functional code)

data depending on functional code, can also disappear

n. Byte ETX END 03 end byte

7.3.3. General AK Protocol Description • Every transfer always starts with 'STX', each 'STX' starts a new transfer

• The 'don't care' byte can take any content, excluding control signs or signs reserved by AK commands. Default value is 0 (30 hex)

• Every function code always includes 4 bytes. A list of all codes can be found in the following chapters.

• The function code may not contain blanks.

• If the command message contains no error, the response message contains the echo of the function code and the error status number (0 to 9).

• The echo will be four question marks (????), if the function code has an error or is unknown, or the command telegram has not a minimum length of 10 bytes.

• There are three groups of function codes: S = Control commands A = Read commands E = Write commands (S, A, E stands for the German words: 'Steuerbefehle', 'Abfragen', 'Einstellbefehle')

• The particle measurement system is a measurement device and not a functional engine. Therefore, the identification respectively the channel number is always K0.

• Error status is '0' for an error free running of the system. The error status number will be counted up from 1 to 9 with each change in the error status. The error status number will be zero again after all errors are removed.

• The data set is variable. Each data set will begin with a blank (20 h) . A blank is also used to separate characters of data. The separation with <CR><LF> will only be done, if the following complete data will have more than 60 digits.

• The long and variable floating point or the E- format are allowed to display the digits of numbers in the data set. You can find the used formats for all functional codes in the following chapters. '+/-' may only be used for negative numbers. Digits without physical meaning have to be removed.

• Every transfer always stops with 'ETX'

7.3.4. Handling of Certain Conditions • If transfer of a data value is not possible, e.g. a device in the system is missing or it

cannot send a signal, the data will be replaced by a '#'

• The date is only valid with restrictions, e.g. temperature of CPC is not ready. Then data will begin with '#'

• If a control or adjusting command is sent while the measuring device is in 'Manual' mode, resp. not set to 'Remote', then response data set = 'OF' (offline)

• If the system is not able to send a response. The host computer has to realize the missing response by 'time out'

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• If the system is occupied by executing a previous function, the new start of a control command will lead to the response 'BS' (busy) in the data block of the response. The running function will not be disturbed. Exception: The command was a software reset.

• If the system is operated in manual operation mode, also the command 'remote' will be responded with 'BS'. In this mode only read commands can be used. All control and write commands will be responded with 'BS'.

• If the data or parameters transfer is not complete (i.e. not expected format) in the command telegram of the system, the host computer will get a 'SE' (Syntax Error) in the data block of the response.

• If the system doesn't work with data or parameters of the command (data error, parameter error) the host computer will get a 'DF' (Data Failure) in the data block of the response.

• All setpoints set with write 'E' commands will be saved when testo CU-2 will be shut down and they will be restored after rebooting and set to standby or measurement mode.

7.4. List of All AK Commands

7.4.1. Control Commands – 'S' CODE: description:

SREM REMOTE – set system to AK host remote control mode

SMAN MANUAL – disable remote control and set system to manual operation

SRES RESET – reset all functions and restart system

SPAU PAUSE – set system to pause state

STBY STAND BY – set system to stand by state

SMGA MEASURE – set system to STAND BY state

SNGA ZERO TEST – start automatic PNC zero concentration test

SLEC LEAK TEST – start automatic system (VPR+PNC) leak test

SINT INTEGRATOR START – start integration, integral avarage

SINA INTEGRATOR STOP – stop integration started with SINT

7.4.2. Write Commands – 'E' CODE: description:

ENOR set standard conditions temperature and pressure

ETD1 set PND1 temperature range: 20...150°C

EVD1 set PND1 dilution factor range: 15...300 (10 cav.) or 150...3000 (8 cav.)

EVD2 set PND2 dilution factor range: 1...11

ETET set ET temperature range: 20...400°C

EDST set PND1 diluter disk type and if secondary dilution PND2 shall be used or

7.4.3. Read Commands – 'A' CODE: description:

ASTZ STATUS – read the current operation mode and system state

ASTF ERROR STATUS – read the numbers of all current failures

AKON read the current diluted and undiluted particle number concentrations

APRF read current particle concentration reduction factor PCRF

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CODE: description:

AIKG concentration integral average calculated since the command SINT

AIKO concentration integral average calculated since command SINT or last AIKO

ANGA read the result of the last ZERO TEST

ALEC read the result of the last LEAK TEST

ANOR read the currently set standard conditions: standard temperature and

ATD1 read PND1 temperature

AVD1 read setpoint and actual value of primary dilution factor DFPND1

AVD2 read setpoint and actual value of secondary dilution factor DFPND2

ATET read evaporation tube ET temperature

AFD2 read the secondary dilution air supply flow QAS in PND2

7.5. Descripton of All AK Commands

7.5.1. Control Commands – 'S' SREM REMOTE – set system to AK host remote control mode

command: SREM K0 response: SREM E

E: error status 0...9

SMAN MANUAL – disable remote control and set system to manual operation mode

command: SMAN K0 response: SMAN E


SRES RESET – reset all functions and restart system system status after reset is MANUAL mode and PAUSE state

command: SRES K0 response: SRES E


SPAU PAUSE – set system to pause state: resting state after system start or RESET

PND1 disk stopped, sample gas pump off, dilution air pumps off, PND1 and ET heatings off

command: SPAU K0 response: SPAU E


STBY STAND BY – set system to stand by state: ready for measurements PND1 disk stopped, sample gas and dilution air pumps on, PND1 and ET heating on

command: STBY K0 response: STBY E


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SMGA MEASURE – change from STAND BY to measurement state PND1 disk rotates, diluted gas flows to PNC

command: SMGA K0 response: SMGA E


SNGA

ZERO TEST – start automatic PNC zero concentration test, duration: 2 min during SNGA mode other S and E commands will be responded with 'BS' (busy) exceptions: 'SRES', 'STBY' or 'SPAU' will stop running zero test according the UN-ECE R83 regulation the number concentration should be < 0.2 #/ccm

the result of this test can be read with the command ANGA

command: SNGA K0 response: SNGA E


SLEC

LEAK TEST – start automatic system (VPR+PNC) leak test, duration: 2 min during SNGA mode other S and E commands will be responded with 'BS' (busy) exceptions: 'SRES', 'STBY' or 'SPAU' will stop the running leak test according the UN-ECE R83 regulation the number concentration should be < 0.5 #/ccm the result of this test can be read with the command ALEC

command: SLEC K0 response: SLEC E


SINT

INTEGRATOR START – start integration, integral avarage integration of values runs until stopped with SINA or restarted with SINT again the avarage values can be read with AIKG or AIKO

command: SINT K0 response: SINT E


SINA INTEGRATOR STOP – stop integration started with SINT

command: SINA K0 response: SINA E


7.5.2. Write Commands – 'E'

ENOR set standard conditions temperature and pressure (system default: 273.15 K, 1013.25 mbar)

command: ENOR K0 TTT PPP

response: ENOR E

E: error status 0...9 TTT: absolute temperature [K] format: floating point example: '273.15' PPP: pressure [mbar] format: floating point example: '1013.25'

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ETD1 set PND1 temperature the range: 20...150°C setpoints out of range are rounded to the next lowest respectively highest possible temperature

command: ETD1 K0 TTT response: ETD1 E

E: error status 0...9 TTT: temperature [°C] range: 20...150°C ECE R83: 150°C format: floating point example: '150.0'

EVD1

set PND1 dilution factor range: 15...300 (10 cav.) or 150...3000 (8 cav.) range: 15...300 for 10 cavities disk or 150...3000 for 8 cavities disk (nominal values) setpoints out of range are rounded to the next lowest respectively highest possible dilution factor

command: EVD1 K0 DDD response: EVD1 E

E: error status 0...9 DDD: dilution factor DF PND1 [ - ] range: 15...300 or 150...3000 format: floating point example: '20.0'

EVD2 set PND2 dilution factor range: 1...11 setpoints out of range are rounded to the next lowest respectively highest possible temperature

command: EVD2 K0 DDD response: EVD2 E

E: error status 0...9 DDD: dilution factor DF PND2 [ - ] range: 1...11 format: floating point example: '10.0'

ETET set evap. tube ET temperature range: 20...400°C

command: ETET K0 TTT response: ETET E

E: error status 0...9 TTT: temperature [°C] range: 20...400°C ECE R83: 300...400°C format: floating point example: '300.0'

EDST

set PND1 diluter disk type and if secondary dilution PND2 shall be used or not choose 8 or 10 cavities disk. The disk selection but not the PND2 setting will be stored and used after reset or system restart. If PND2 is disabled, air supply pump is switched off and DFPND2

= 1

command: EDST K0 CC D response: EDST E

E: error status 0...9 CC: used rotating disc format: integer, 2 digits '10' for 10 cavities or '08' for 8 cavities disk D: '0' for PND2/pump off '1' for PND2/pump on

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7.5.3. Read Commands – 'A'

ASTZ

STATUS – read the current operation mode and system state three modes inform if the system is manually or remote controlled by current or another host if system is remote operated by current host, system state is indicated

command: ASTZ K0 response: ASTZ E OOOO SSSS

E: error status 0...9 OOOO: operation mode: 'SREM': remote operation, current host 'SMAN': manual operation only read commands possible 'SRBS': remote busy another host is in remote mode (SREM) SSSS: system state: 'SPAU' pause state 'STBY' standby state 'SMGA' measurement state 'SNGA' zeroing state 'SLEC' leak test mode

ASTF ERROR STATUS – read the numbers of all current failures

command: ASTF K0 response: ASTF E a b c d ...

E: error status 0...9 a, b, c, d ... sequence of the numbers of current system errors which are listed in chapter ??. example: '11 13 20' means: – ET temperature wrong – CPC not ready – CPC liquid level too low

AKON read the current diluted and undiluted particle number concentration: concentration is corrected to the currently set standard conditions (ENOR)

command: AKON K0 response: AKON E CCC RRR FFF

E: error status 0...9 CCC: particle concentration corrected to std. cond. [#/ccm] E-format: example: '3.26E3' = 3'260 #/ccm response is not affected by stopped disk rotation RRR: concentration CCC multiplied by PCRF E-format: example: '3.26E5' = 326'000 #/ccm if disk rotation is stopped, response will be 'NaN' FFF: particle concentration reduction factor PCRF format: floating point example: '100.0' if disk rotation is stopped, response will be 'Inf'

APRF read current particle concentration reduction factor PCRF

command: APRF K0 response: APRF E FFF

E: error status 0...9 FFF: particle concentratio reduction factor PCRF format: floating point example: '100.0' if disk rotation is stopped, response will be 'Inf'

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AIKG concentration integral average calculated since the command SINT

command: AIKG K0 response: AIKG E CCC RRR FFF


AIKO concentration integral average calculated since command SINT or last AIKO

command: AIKO K0 response: AIKO E CCC RRR FFF


ANGA

read the result of the last ZERO TEST (started by SNGA command before) if no zero test has been done since start-up of the system, response is 'NaN' according UN-ECE R83 the number concentration must be < 0.2 #/ccm

command: ANGA K0 response: ANGA E CCC MMM

E: error status 0...9 CCC: corrected particle concentration [#/ccm] E-format: example: '0.05E0' = 0.05 #/ccm MMM: duration in minutes since zero test has been done format: integer example '125' = 125 min

ALEC read the result of the last LEAK TEST (started by SLEC command before) if no leak test has been done since start-up of the system, response is 'NaN' according UN-ECE R83 the number concentration must be < 0.5 #/ccm

command: ALEC K0 response: ALEC E CCC MMM

E: error status 0...9 CCC: corrected particle concentration [#/ccm] E-format: example: '0.08E0' = 0.08 #/ccm MMM: duration in minutes since leak test has been done format: integer example '125' = 125 min

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ANOR read the currently set standard conditions: standard temperature and pressure

command: ANOR K0 response: ANOR E TTT PPP

E: error status 0...9 TTT: temperature [K] format: floating point example: '273.15' PPP: pressure [mbar] format: floating point example: '1013.25'

ATD1 reads PND1 temperature

command: ATD1 K0 response: ATD1 E TTT

E: error status 0...9 TTT: temperature [°C] for ECE R83: 150°C format: floating point example: '150.8'

AVD1 read setpoint and actual value of primary dilution factor DFPND1 if PND1 rotating disk is stopped and therefore DFPND1 is infinite, response is 'Inf'

command: AVD1 K0 response: AVD1 E DDD RRR

E: error status 0...9 DDD: DFPND1 primary dilution factor setpoint 15...300 or 150...3000, depenting on used disk format: floating point example: '20.0' RRR: DFPND1 primary dilution factor actual value format: floating point example: '20.2'

AVD2 read setpoint and actual value of secondary dilution factor DFPND2

command: AVD2 K0 response: AVD2 E DDD RRR

E: error status 0...9 DDD: DFPND2 setpoint range: 1...11 format: floating point example: '10.0' RRR: actual DFPND2 format: floating point example: '10.05'

ATET read evaporation tube ET temperature

command: ATET K0 response: ATET E TTT

E: error status 0...9 TTT: temperature [°C] range: 20...400°C ECE R83: 300...400°C format: floating point example: '300.5'

AFD2 read the secondary dilution air supply flow QAS in PND2

command: AFD2 K0 response: AFD2 E FFF

E: error status 0...9 FFF: flow in lN/min range: 0...15.0 lN/min format: floating point example: '3.0'

7.5.4. AK Errors List There are a number of errors which can be detected by the system and read out using the 'ASTF' command. These error codes are listed below:

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35

# error notation description

1 Status PND1 not ready

2 PND1 temperature error

3 Dilution error failure in dilution factor

4 Motor error Rotating disk is blocked

5 Pump error raw gas pump not running

6 Dilution air flow PND1 failure

10 Dilution air flow PND2 failure flow failure or flow too low

11 Temperature ET wrong Temperature of the evaporation tube differs 10°C or more from setpoint

12 DF PND2 failure deviation >10%

13 CPC status not ready

14 Saturator temp out of range

15 Condenser temp out of range

16 Optics temp out of range

17 Inlet flow rate out of range Orifice pressure is < 10 or > 90 kPa. Apply sufficient external vacuum.

18 Aerosol flow rate out of range

19 Laser power low

20 Liquid level low

21 Concentration out of range value detected by CPC > 1.0E4 #/ccm

22 Multiple Error at CPC

23 No CPC communication CPC is not connected, switched off or cable broken


8.1. Mains Supply Connect the power cord plug to a grounded power socket. The IEC mains connector 17) on the rear side of the testo CU-2 case includes the mains switch 19) and the fuse holder 18). The one phase power cord delivered with the instrument is equipped with a country-specific plug and protective earth. Mains supply voltage: 90 ... 240 VAC, 50/60 Hz, max. 140 VA Fuse type: slow switching fuse 250 V, 5 A, t, 5 x 20 mm


36

Warning In case of a blown fuse, replace it only with the specified type of fuse. If the fuse is repeatedly blown, the unit must be sent to the manufacturer or to an instructed service station for checking and repair.

Electric Shock Make sure that the protecting ground pin of the country specific plug is correctly connected to the protecting ground contact of your socket. If the plug is replaced, ensure the yellow/green ground wire of the cable is properly connected to the new ground pin or the case is otherwise connected to

protective earth which is usually indicated by the sign.

8.2. Dilution/Conditioning Devices The testo ASET15-1 interface 2) and testo MD19-3E interface 3) may exclusively be used to connect these devices to the testo CU-2 digital control unit. The pin assignment of these interfaces is adapted to the specific analog and digital input and output signals of the testo MD19-3E Rotating Disk Diluter and testo ASET15-1 Air Supply / Evaporation Tube.

8.3. Analog/Digital Interface The pin assignment of the external analog and digital in- and output signals interface 4) and connector 20) is shown in Fig. 8.1.

Fig. 8.1: external in- and output signals connector 20)

The analog and digital inputs and outputs have the following properties and requirements:

• Digital trigger input: high level: 5...25 VDC low level: max. 1 VDC pull up current: 0.5 mA / load resistance Rin

= 10...50 kΩ

• Digital outputs: high level: 24.0 +/- 0.2 VDC low level: < 0.5 VDC, maximum load is 30 mA

The analog DC voltage signals are as follows:

• Analog inputs: signal range –10...+10 VDC input impedance Rin = 20.0 MΩ

• Analog outputs: signal range 0...+10 VDC 12 bit signal output impedance Rout

= 0.5 Ω.

D-sub pin

signal description pola-rity

analog

/ digital input / output

signal range

1 analog input 0 + A I –10...+10 VDC





6 PNC error (if multiple DO ports error is set)

+ D O +24 VDC

7 dilution system error (or single port error) + D O +24 VDC

8 digital input: trigger signal + D I 5...25 VDC

10 analog output 0 + A O 0...+10 VDC



37

D-sub pin

signal description pola-rity

analog

/ digital input / output

signal range



14 analog input 0 – A I –10...+10 VDC





20 ground for digital in- and outputs – D 0 VDC

25 ground for analog outputs – A O 0 VDC

8.4. Standard Embedded Computer Ports The USB ports 5)...8), the LAN connectors 10) and 11), the VGA monitor connector 12), and the serial ports 13) 14) and16) are standard peripherals connections of the embedded computer. However some of them are used to connect some measuring components to the system. A TSI CPC 3010 or 37xx or EECPC 3790 or a PAH monitor PAS2000 can be attached to serial port 1 13).

A GRIMM CPC 5.431 should be connected to USB-Port 7). AK host computer(s) can be connected via Ethernet on the LAN connectors 10) and 11) or via COM port 4 16). USB storage devices may be plugged into the USB ports 5)...6) to save recorded data directly. All other standard computer ports can be used to attach peripherals like mouse, keyboard, monitor, and printer.

9 Maintenance and Calibration

38

9 Maintenance and Calibration

9.1. Storage, Acclimatization Fast ambient temperature changes may result in condensed water on and inside the instrument. This may cause serious damage of electronic parts, e.g. the controller or safety devices.

• Do not store the instrument outdoor, the storage environment must be clean and dry.

• After long time storage or transport with cold ambient conditions or thermal fluctuation, the instrument requires to adapt slowly to the local ambient conditions before starting up.

• If condensed water has formed, wait at least 12 hours before installation and starting up.

• Avoid mechanical damage and agitation.

• Storage temperature range: -10°C to +60°C.

9.2. Operation Environment Requirements

Caution Read this section carefully before setting up testo CU-2 Digital Control Unit. Testo SE & Co. KGaA is not liable if the instrument is damaged, caused by the operation environment not meeting the requirements.

Caution The testo CU-2 Digital Control Unit is designed to be installed in a laboratory, test stand or a temporary test set-up. The instrument is not intended to be used outdoor or in a dusty or wet environment.

IP protection degree

IP 20. testo CU-2 is protected against accidental contact to dangerous parts of the instrument. It is not protected against intrusion of sand, dust or water. Avoid operation in dusty or wet environment for safe and reliable operation.

operating tempe-rature range

The operating ambient temperature range is +10°C to +40°C if free air circulation around the device is ensured.

humidity range The ambient relative humidity range (RH) is 0% to 90%

shocks and vibrations

Avoid operation under any kind of shock or vibration.

10 Appendix

39

10 Appendix

10.1. Extent of Delivery testo CU-2 delivery consists of the following items:

item # description

1 testo CU-2 Digital Control Unit

2 testo CU-2 accessories box, containing:

3 user manual to testo CU-2 Digital Control Unit

4 IEC power cord for Switzerland

or for Germany, France, Italy, Korea, etc.

or for USA, Canada, Japan, etc.

or for United Kingdom, etc.

5 1 crossover Ethernet cable

6 2 D-Sub cables for connecting testo MD19-3E and testo ASET15-1 to testo CU-2

7 1 external signals connector 20)

10.2. Specification, Technical Data compatible measurement devices

• Testo testo MD19-3E Rotating Disk Diluter • Testo testo ASET15-1 Air Supply / Evaporation Tube • GRIMM 5.431; TSI CPC 3010 or 37xx or EECPC 3790 or Eco Chem PAS2000 PAH monitor • sensors providing analog DC voltage signals –10...+10 VDC

operation modes

• manual control: only data acquisition via testo CU-2 • local software control: mouse, keyboard and monitor attached to testo CU-2 • remote software control via Windows remote desktop connection • AK control via Ethernet or serial communication

peripherals standard computer peripherals using serial ports, USB, PS/2 sockets, VGA monitor connector

power supply 90...240 VAC, 50/60 Hz, max. 140 VA

assembly 3U-19" case for rack mounting with handles dimensions (w ∙ h ∙ d): 485 ∙ 146 ∙ 470 mm

weight ca. 6.5 kg

operating conditions

Tamb: 10 ... 40 °C 0...90% relative humidity

Conformity testo CU-2 Digital Control Unit is not CE-conform

10 Appendix

40

10.3. Designation of All testo CU-2 Digital Control Unit Operating Elements 1 Power LED

2 testo ASET15-1 Air Supply / Evaporation Tube (PND2 + VPR) interface 3 testo MD19-3E Rotating Disk Diluter (PND1) interface 4 male 25 pin D-Sub connector for analog and digital in- and output signals 5 USB connector of embedded computer

6 USB connector of embedded computer 7 USB connector of embedded computer used as default port for GRIMM 5.431 for PMP R-83 measurements 8 USB connector of embedded computer 9 not used 10 LAN 2 connector of embedded computer; default setting: DHCP

11 LAN 1 connector of embedded computer; default IP adress: 192.168.1.129 12 VGA monitor connector of embedded computer 13 Male serial connector 1 of embedded computer used as default port for EECPC 3790 for PMP R-83 measurements 14 Male serial 2 connector of embedded computer

15 not used 16 Female serial 3 connector to control testo CU-2 by AK host computer 17 Mains connector 18 Fuse holder; fuse: 250 V, 5.0 A, t

19 Mains switch

Fig. 4.3 : front view of testo CU-2

Fig. 4.4: rear view of testo CU-2

Fig. 4.5: external signals connector

8

10 Appendix

41

Testo SE & Co. KGaA Testo-Strasse 1 79853 Lenzkirch Germany phone: +49 7653 681 5062 fax: +49 7653 681 95062 e-mail: [email protected]

testo cu-2 · • installation of the testo cu-2 and accessories • handling, operation,...

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