TESTO CU-2 User manual

testo CU-2
User Manual

2

Content
3
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 toContent............................................................................................................... 7
2.3. Copyright © ..................................................................................................................................7
3 Safety............................................................................................................................7
3.1. Risk Types...................................................................................................................................... 7
3.1.1. Electrical Safety ...................................................................................................................7
3.2. Labelsand 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 NetworkSetup..................................................................................... 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 ControlMode ........................................................................ 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
4
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. DilutionInstruments.......................................................................................................... 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 ResponseTelegram....................................................................................................... 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
5
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 ControlUnit Operating Elements......................................... 40

1
Declaration of Warranty
6
1Declaration 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: [phone]
Testo-Strasse 1 Fax: [phone]
79853 Lenzkirch web: www.testo.com
Germany email:[email protected]
For technical support contact your local service contractor or Testo techsupport.
email: su[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.
2Precautions
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.

3
Safety
7
•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.
3Safety
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
8
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.
4System 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
9
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
DF
PND1
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
DF
PND2
secondary Dilution Factor dilution factor of PND2 (testo ASET15-1)
PCRF Particle Concentration Reduction Factor (ECE R83 compliant
abbreviation)
total dilution factor comprising DF
PND1
, DF
PND2
and particle losses
f
r
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
Q
MD
primary diluted measuring gas flow from the testo MD19-3E primary
diluter
Q
AS
secondary dilution air flow from the air supply part of testo ASET15-1
Q
MG
secondary diluted measuring gas flow to the connected instrumentation
Q
EX
excess secondary diluted measuring gas gas flow

4
System Overview
10
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.