TESTO REXS User manual

testo REXS
User Manual

Content
2
Content
1Declaration of Warranty ............................................................................................... 4
1.1. Type of Designation ....................................................................................................................... 4
1.2. Manufacturer ................................................................................................................................4
1.3. Warranty .......................................................................................................................................4
2Precautions ................................................................................................................... 5
2.1. Foreword.......................................................................................................................................5
2.2. Liabilities .......................................................................................................................................5
2.3. Copyright ©.................................................................................................................................... 5
3Safety ............................................................................................................................ 6
3.1. Risk Types......................................................................................................................................6
3.2. Labels and Explanations.................................................................................................................6
4System Overview........................................................................................................... 8
4.1. Soot Generation Principle of testo REXS .........................................................................................8
4.1.1. Principle...............................................................................................................................8
4.1.2. Applications .........................................................................................................................8
4.1.3. Functionality ........................................................................................................................ 9
4.2. The Benefits Are ............................................................................................................................ 9
4.3. Function Principle .......................................................................................................................... 9
4.4. The System....................................................................................................................................9
4.4.1. Soot Generator .................................................................................................................. 10
4.4.2. Input.................................................................................................................................. 10
4.4.3. Processing.......................................................................................................................... 10
4.4.4. Output ............................................................................................................................... 11
4.5. Front Panel Operational Elements................................................................................................ 12
4.6. Back Panel Operational Elements................................................................................................. 14
4.7. Back Panel Connectors................................................................................................................. 15
5Transportation, Unpacking and Extend of Delivery..................................................... 15
5.1. Transportation............................................................................................................................. 15
5.2. Unpacking.................................................................................................................................... 16
5.3. Storage, Acclimatisarion............................................................................................................... 17
5.4. Extent of Delivery ........................................................................................................................ 18
6Setting up and installation .......................................................................................... 20
6.1. Operation Environment Requirements......................................................................................... 20
6.2. Installation................................................................................................................................... 21
6.3. Test Stand Preparation................................................................................................................. 24
6.4. Operating Instructions ................................................................................................................. 24
6.5. Note ............................................................................................................................................ 25

Content
3
6.6. Warning....................................................................................................................................... 25
6.7. Test Bench Setup Examples.......................................................................................................... 25
7testo REXS Testing/Programming GUI......................................................................... 28
7.1. System Requirements .................................................................................................................. 28
7.2. Installation Procedure.................................................................................................................. 28
7.3. Uninstallation Procedure ............................................................................................................. 29
7.4. Serial Connection to testo REXS ................................................................................................... 29
7.5. Controls and Indicators................................................................................................................ 29
7.6. Operation of the testo REXS GUI .................................................................................................. 31
7.7. Errors/Troubleshooting................................................................................................................ 33
7.7.1. Communication Errors ....................................................................................................... 33
7.7.2. Testo REXS Errors............................................................................................................... 33
8Appendix ..................................................................................................................... 36
8.1. Specification, Technical Data........................................................................................................ 36
8.2. Service Guide............................................................................................................................... 37
8.2.1. Cleaning of the Burner Outlet............................................................................................. 37
8.2.2. Cleaning of the Spark Ignition Electrode ............................................................................. 38
8.2.3. Exchange of the HEPA Gas Filter Cartridges ........................................................................ 38
8.2.4. Exchange of the Spark Ignition Electrode ............................................................................ 38
8.2.5. Cleaning of the Optical Flame Detection Unit...................................................................... 38
8.3. Definitions, Units and Conversion Table ....................................................................................... 39

1 Declaration of Warranty
4
1Declaration of Warranty
Manual Version History:
Version: V4.0
Date: November 2016
1.1. Type of Designation
This user manual refers to the instrument type and version as listed below. It replaces all
previously dated user manuals for this instrument.
Type: testo REXS
1.2. Manufacturer
Testo SE & Co. KGaA Tel: [phone]
Testo-Strasse 1 Fax: [phone]
79853 Lenzkirch web: www.testo-particle.com
Germany email:[e-mail]
For technical support contact your local service contractor or Testo techsupport.
email: [e-mail]
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 MD19-3E and some very sensitive parts. Do not
open your testo MD19-3E, 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
5
2Precautions
2.1. Foreword
This manual guides you through the installation, starting up, operation and maintenance
procedures of the testo REXS. In detail you will find information about the system as
safety
functionality of the testo REXS, technical information and specifications
installation of the testo REXS and accessories
handling, operation, maintenance and troubleshooting
The instrument is not intended to be operated alone but integrated into a test
stand for filters or particle filter in industrial production and development.
Therefore the documentation and manual is not addressed to the end user but
rather to the test stand manufacturer. The test stand manufacturer has to
generate a self contained user manual.
Follow the instructions provided by this manual for safe and proper operation of the testo REXS
soot aerosol generator.
Before installing and operating the testo REXS, the operator or service
technician has to read and follow 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
any technical modification not carried out by Testo SE & Co. KGaA or an authorized
service partner
use of not genuine spare parts
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.
Follow the guidelines below to ensure proper operation of the instrument:
read this instruction manual before installation and operation
always use gas of specified quality and purity (propane and nitrogen) when operating this
aerosol generator
make sure that the compressed air supply pressure and gas never exceeds 8 bar
make sure that the maximum pressure at the compressed air inlet is always less than 8
bar, for propane and nitrogen less than 5 bar
do not restrict the aerosol outlet. The aerosol generator can only work against pressure up
to 500 mbar above atmospheric pressure
always use genuine replacement parts supplied by Testo SE & Co. KGaA
allow the instrument to cool off before performing any maintenance at the instrument
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 SE & Co.
KGaA.

3 Safety
6
3Safety
3.1. Risk Types
The following diagram shows typical risks that could cause damage or injury while handling the
testo REXS.
Fig. 3.1: Risk types
3.2. Labels and Explanations
When operating testo REXS, you are always operating under certain risk factors as electricity,
explosive and compressed gases, hot surfaces, moving parts and nanoparticles. Therefore testo
REXS includes several safety features. Nevertheless, some precautions still need to be taken to
ensure safe and reliable operation. Listed labels, Cautions, and Warnings are explained in
general, and the further specific labels refer to type of hazard and danger.
Note
Note
Note means this content describes important, useful and/or necessary
information to help guide you through the manual.
Caution and Warning
Caution
Caution means be careful. If you do not follow the manual instruction you might
cause an instrument or accessories damage, but no human injury. Also Caution
refers to important information about installation, operation and maintenance.
Warning
Warning means that improper operation could cause a serious human or
instrument damage or injury with consequence of irrevocable instrument
damage.

3 Safety
7
Warnings for testo REXS
Crush
Crush hazard. Keep hands clear of moving parts. Lockout/tagout before
servicing.
Electric Shock
Hazardous voltage. Contact may cause electric shock or burn.
Turn off and lock out system power before servicing.
Protection earth
The electroconductive terminal is connected to protection earth.
Skin Burn
Hot surface. Do not touch. To avoid possible skin burns, wear heat protection
gloves or turn heating off and allow surfaces to cool down before servicing.
Explosion
Explosion hazard. Inflammable gas. A gas leak may cause an explosion or burn.
Before turning on the instrument check gas leak tightness.
Gas filled cylinders
Compressed and explosive gas. Broken or leak cylinder may destroy the locality
and environment.
Soot Nanoparticles
Soot particles hazard. When breathed in, soot particles may cause adverse
carcinogenic health effects to organism. The human immune system is not able
to completely deflate inhaled nanoparticles; they may enter and remain in the
human body.
Toxic gas
Toxic gas hazard. The emission consists of toxic gas CO and CO2, that may
result in adverse health effects.
Safety dispositions
Gas cylinder support
Risk of tilting gas cylinder. Secure the standing gas cylinder with a chain or belt.
Eye protection
Eye hazard. Explosive gas surrounding, particles and bright flame may affect the
eyesight.
Ear protection
Ear protection. To fade out monotone sound location.

4 System Overview
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4System Overview
Fig. 4.1: testo REXS instrument
4.1. Soot Generation Principle of testo REXS
4.1.1. Principle
The soot aerosol generator is simulating the exhaust from a diesel combustion engine. The gas
fuel burner generates soot of selectable particle size and number concentration. The function
principle is based on a propane fuel diffusion flame that is quenched by air. From this follows that
propane (C3H8), nitrogen (N2) and air are transformed into carbon monoxide (CO), carbon dioxide
(CO2), water vapour, and soot nanoparticles.
4.1.2. Applications
Compared to a diesel combustion engine, testo REXS generates reproducible, constant and
stable exhaust gas flow and especially soot nanoparticles. This is a gain for the filter industries
regarding measurement of any particle filters of combustion engines as vehicles, ships,
locomotives, or cranes and calibration of engine test benches. Testo REXS may also be used to
test and certify air intake filters, cabin filters or dust absorbers.

4 System Overview
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4.1.3. Functionality
Testo REXS is built up in a mobile 19'' rack. The straightforward design and clear layout ease its
operation. Indicators, display and software enable control and monitoring of the control
parameters.
4.2. The Benefits Are
Soot aerosol generator, simulating exhaust from a modern diesel combustion engine.
Real soot nanoparticles, reproducible in size and concentration.
Aerosol output flow approx. 700 lN/min.
Adjustable particle sizes of approx. 60, 80 and 100 nm.
Soot nanoparticles mass output of 1.5 g/h at 80 nm.
Capable to work against back pressure up to 500 mbar.
Flexible and simple operation.
Simple test bench integration.
Local and/or remote control.
Very low maintenance effort needed, low down-time.
4.3. Function Principle
Fig. 4.2: Function principle
4.4. The System
To operate testo REXS, only propane, nitrogen, compressed air, and one phase electricity is
required.
Gas and air supply, power supply and test bench devices mounted to the burner outlet have to be
provided and installed by test bench manufacturer. The block diagram in Fig. 4.2 shows the testo
REXS system design with all electrical and gas lines, by inputs and outputs.

4 System Overview
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4.4.1. Soot Generator
testo REXS is controlled by a microcontroller. It supervises gas pressures, gas flows, remote
control signal, flame status and aerosol temperature, and it drives automatic ignition, display and
LED indicators. Furthermore it controls the operating point change, start-up, gas mass flow
controller, valves and shut down. With only the two buttons Burner ON/OFF and Operating Point
at the front panel testo REXS is controlled. Communication to the remote operation software is
done by a protocol over a EIA-232 serial interface.
4.4.2. Input
Gas supply unit, propane and nitrogen
Compressed propane and nitrogen supply with the matching technical requirements are
connected to testo REXS by encoded quick couplings. Precision pressure regulators adjust the
gas pressures, before the gases are purified through HEPA filters. Pressure switches and safety
shut-off valves control the minimal required pressure for safe operation. Mass flow controllers set
the nominal gas flows depending on the selected operating point. Propane and nitrogen are
mixed downstream of the MFC and lead into the burner.
Compressed air
Oxidation air:
The compressed oxidation air is supplied through an encoded quick coupling. It is purified
through a prefilter and a HEPA filter. Oxidation air pressure is controlled by a precision pressure
regulator. Pressure switch and safety shut valve controls the minimal required operation
pressure. A mass flow controller sets the nominal oxidation air flow depending on the selected
operating point. Oxidation air is then lead to the bottom part of the burner.
Note
Oxidation air is feeded internally from quench air in standard setup. A separate
oxidation air supply may be used if necessary.
Quench air:
The quench air is supplied through an encoded quick coupling. It is prefiltered and the pressure is
controlled by a precision pressure regulator. A HEPA filter purifies the quench air before it flows
into the MFC. Quench air is controlled depending on the selected operating point. The quench air
is lead to the mid part of the burner.
Operation elements:
Burner ON/OFF starts and stops production procedure.
Operation button switches over into the different aerosol production point.
Emergency stop immediately shuts down the process.
Communication interfaces:
RS232 is the communication interface between Microcontroller and external Notebook or PC
Desktop. Ethernet connects the internal interface from the notebook to the user ethernet.
4.4.3. Processing
Ignition unit
The flame is ignited with a high voltage spark ignition unit. The ignition energy is provided by high
voltage transformer with a capacity of 15 kV. During the ignition procedure a carriage moves the
spark ignition electrode into the combustion chamber and ignites the injected combustion gas. As
soon as the optical flame sensor detects the flame the electrode carriage is refracted to its initial
position, as well as after 5 unsuccessful spark ignition sequences.
Optical flame detector
The optical flame sensor detects the flame, observing the combustion chamber from the bottom
and reports the flame status to the microcontroller.
Power supply unit
The power supply unit provides 24 VDC power to the several subsystems of testo REXS. Input
voltage may be in a range of 90 to 250 VAC (wide-range input). Fuses values may change
depending on the actual supply voltage.