TESTO 300 User manual

Next-Gen testo 300 - Combustion Analyzer
Instruction Manual

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Contents
Contents
1About this document ...........................................................................7
1.1 Symbols ................................................................................................. 7
1.2 Warning notices...................................................................................... 7
2Safety and disposal..............................................................................8
3Product-specific safety instructions ..................................................8
4Authorizations and certification .........................................................9
5Specifications.......................................................................................9
6Product description ...........................................................................11
6.1 Front view ............................................................................................. 11
6.2 Rear view ............................................................................................. 12
6.3 Connections ......................................................................................... 13
6.4 Compact flue gas probe ....................................................................... 13
6.5 Modular flue gas probe ......................................................................... 14
7First steps ...........................................................................................15
7.1 Commissioning ..................................................................................... 15
7.2 Power Supply / Battery ......................................................................... 15
7.2.1 Charging the Battery ............................................................................ 15
7.2.2 Connecting Power Supply ................................................................... 16
7.3 Touchscreen Operation ........................................................................ 16
7.4 Keypad ................................................................................................. 17
7.5 Switching the instrument on and off ..................................................... 18
7.6 Connect probes .................................................................................... 19
7.7 Connecting Smart Probes and testo Smart App ................................... 20
7.7.1 Attaching the testo Bluetooth® Connector (0554 3004) ........................ 20
7.7.2 Smart Probes compatible with the instrument ...................................... 22
7.7.3 Establishing a connection with the testo Smart App ............................. 22
7.7.3.1 App user interface ................................................................................ 23
7.7.3.2 Measurement menu – testo 300 Second Screeen ............................... 23
7.7.4 Connecting for the first time ................................................................. 24
7.7.5 Carrying out the measurement ............................................................. 25
7.7.6 Settings – language .............................................................................. 25
7.7.7 Help and Information ............................................................................ 26
7.7.7.1 Instrument information .......................................................................... 26
7.7.7.2 Tutorial ................................................................................................. 26

Contents
7.7.7.3 Exclusion of liability .............................................................................. 26
8Using the product.............................................................................. 27
8.1 User interface ...................................................................................... 27
8.1.1 List reading display type ...................................................................... 28
8.1.2 Graphics reading display type.............................................................. 29
8.1.3
8.2
Hotspot reading display type ...........................................................30
Overview of main menu ( ) ............................................................. 32
8.2.1 Customer / Measuring site ................................................................... 34
8.2.2 Tests ..... .............................................................................................. 36
8.2.3 Saved reports ...................................................................................... 38
8.2.4 Second Screen .................................................................................... 40
8.2.5 Gas path check .................................................................................... 40
8.2.6 Device settings .................................................................................... 40
8.2.6.1 Country version and language ............................................................. 40
8.2.6.2 Wi-Fi Connectivity................................................................................ 42
8.2.6.3 Date/Time ............................................................................................ 43
8.2.6.4 Own company address ........................................................................ 45
8.2.6.5 Hotspot ................................................................................................ 45
8.2.6.6 Rechargeable battery management ..................................................... 46
8.2.6.7 Display brightness ............................................................................... 46
8.2.6.8 Manage e-mail accounts ...................................................................... 46
8.2.6.9 CO/NO sensor protect ......................................................................... 47
8.2.6.10 NO2 addition ........................................................................................ 47
8.2.6.11 O2 reference ........................................................................................ 47
8.2.6.12 Alarm limits .......................................................................................... 48
8.2.7 Sensor diagnosis ................................................................................. 48
8.2.8 Error list ............................................................................................... 48
8.2.9 Device information ............................................................................... 48
8.2.10 Server information ............................................................................... 48
8.2.11 E-mail .................................................................................................. 49
8.2.12 My Apps ............................................................................................... 50
8.2.13 Help ..................................................................................................... 51
8.2.13.1 Device registration ............................................................................... 51
8.2.13.2 Tutorial ................................................................................................. 51
8.2.13.3 Setup Wizard ....................................................................................... 51

Contents
8.2.13.4 Update via USB .................................................................................... 52
9Performing the measurement............................................................53
9.1 Prepare for measurement .................................................................... 53
9.2 Zeroing phases..................................................................................... 53
9.3 Carry out gas path check ..................................................................... 54
9.4 Use of flue gas probe ........................................................................... 54
9.5 Overview of measurement types ( ) ............................................. 55
9.5.1 Flue gas Analysis ................................................................................. 56
9.5.2 Draft Measurement ............................................................................... 59
9.5.3Solid fuel measurement ........................................................................ 60
9.5.4CO Air Free .......................................................................................... 61
9.5.5Smoke number ..................................................................................... 62
9.5.6Differential pressure ............................................................................. 62
9.5.7Differential temp. .................................................................................. 63
9.5.8 O2 Air (EU Regulation).......................................................................... 65
9.5.9 Gas flow ............................................................................................... 66
9.5.10Oil flow rate .......................................................................................... 66
9.5.11CO ambient .......................................................................................... 67
9.5.12Pipe Commissioning (EU Regulation) .................................................... 67
9.5.13Pressure Drop Test (EU Regulation) .....................................................69
9.5.14Pretest (EU Regulation ) ........................................................................ 70
9.6 Overview of options ( ) .................................................................. 72
9.6.1 Edit view ............................................................................................... 73
9.6.2 Zeroing Gas Sensors ........................................................................... 75
9.6.3
9.7
Mean value calculation ......................................................................... 75
Overview of protocols ( ) ............................................................... 76
9.7.1 Print data .............................................................................................. 77
9.7.2 Save ..................................................................................................... 77
9.7.3 Finish protocol ...................................................................................... 78
10 Maintenance........................................................................................81

Contents
10.1 Service ................................................................................................. 81
10.2 Calibration ........................................................................................... 81
10.3 Check instrument status ...................................................................... 81
10.3.1 Sensor diagnosis ................................................................................. 81
10.3.2 Error list ............................................................................................... 81
10.4 Clean the measuring instrument .......................................................... 81
10.5 Drain condensate container ................................................................. 82
10.6 Open the measuring instrument........................................................... 83
10.7 Replace sensors .................................................................................. 85
10.7.1 Replace O2 sensor .............................................................................. 86
10.7.2 Change CO, CO H2 and NO sensor .................................................... 87
10.8 Clean modular flue gas probe .............................................................. 87
10.9 Replace the probe module ................................................................... 89
10.10 Check/replace particle filter ................................................................. 89
10.11 Replace thermocouple ......................................................................... 89
11 Technical data.................................................................................... 91
12 Contact and support..........................................................................94

1 About this document
7
1About this document
•The instruction manual is an integral part of the instrument.
•Keep this documentation to hand so that you can refer to it when necessary.
•Please read this instruction manual through carefully and familiarize yourself
with the product before putting it to use.
•Hand this instruction manual on to any subsequent users of the product.
•Pay particular attention to the safety instructions and warning advice in order
to prevent injury and damage to the product.
1.1 Symbols
Display Explanation
Note: basic or further information
1
2
…
Action: several steps, the sequence must be followed.

Result of an action

Requirement
1.2 Warning notices
Always pay attention to any information marked with the following warning
notices along with warning pictograms. Implement the specified precautionary
measures!
DANGER
Risk of death!
WARNING
Indicates possible serious injury.
CAUTION
Indicates possible minor injury.
CAUTION
Indicates possible damage to equipment.

2Safety and disposal
8
2Safety and disposal
Please observe the Testo information document (enclosed with the product).
3Product-specific safety instructions
CAUTION
The condensate may be acidic.
Risk of burns to the hands!
-
Wear acid-resistant safety gloves, glasses and overalls to empty the
condensate.
•Make sure that the condensate has been fully emptied out of the condensate
trap before the measuring instrument is stored for a long time.
•Before disposing of the product, the condensate trap must be emptied and
the condensate in the crude gas tube disposed of in a suitable container.
•When testing a gas pipe, pay attention to the following:
WARNING
Dangerous mixture of gases
Danger of explosion!
-
Make sure there are no leaks between the sampling point and the measuring
instrument.
-
Do not smoke or use naked flames during the measurement.
CAUTION
Acid in the sensors.
May cause chemical burns.
-
Do not open the sensors.
Eye contact: Rinse the affected eye thoroughly under running water for 10
minutes, keeping the eyelids wide open and protecting the unaffected eye.
Remove contact lenses wherever possible.

4 Authorisations and certification
9
CAUTION
Acid in the sensor filters.
May cause irritation to the skin, eyes or respiratory tract.
-
Do not open the sensor filters.
Eye contact: Rinse the affected eye thoroughly under running water for 10
minutes, keeping the eyelids wide open and protecting the unaffected eye.
Remove contact lenses wherever possible.
Skin contact: Remove the injured person’s contaminated clothing, ensuring
self-protection. Rinse affected skin areas under running water for at least 10
minutes.
Inhalation: Move to fresh air and make sure that breathing is unrestricted.
Ingestion: Rinse mouth out and spit out liquid. If conscious, drink 1 glass of
water (approx. 200 ml). Do not induce vomiting.
4Authorizations and certification
Please find the current country approvals in the Approval and Certification
document which is enclosed with the product.
5Specifications
The Next-Gen testo 300 is a measuring instrument which enables the
professional flue gas analysis of combustion systems, such as
•small combustion plants (oil, gas, wood, coal)
•low-temperature and condensing boilers
•gas heaters.
.
Using the instrument, these systems can be adjusted and checked for
compliance with the applicable limit values.
The instrument has been verified as a short-term measuring instrument and
should not be used as a safety (alarm) device. It is intended for indoor use only.
The following tasks can also be carried out using the instrument:
•Regulating the O2, CO and CO2, NO, NOx values in combustion plants to
ensure optimum operation.
•Draft measurement.
•4Pa measurement.
•Measuring and regulating the gas flow pressure in gas heaters.
•Measuring and optimizing the flow and return temperatures of heating
systems.
•Measuring the CO concentration in the ambient air.

5Specifications
10
•The instrument can be used for measurements on CHP plants in accordance
with the first German Federal Immission Control Ordinance (BImschV).
•In principle, the CO sensor can also be used for measurements on CHP
plants. If you carry out more than 50 measurements on CHP plants per year,
please contact your nearest Testo service center or send the instrument to
Testo Service for checking.
An NOx filter for the CO sensor can be ordered as a spare part to replace a
used filter.
The Next-Gen testo 300 is a measuring instrument which enables the
professional flue gas analysis of combustion systems, such as
•small combustion plants (oil, gas, wood, coal)
The solid fuel measurement adapter (0600 9765) is required for
measurements on solid fuel systems. The adapter protects the
measuring instrument from harmful substances (dust, organic
compounds, etc.).
•low-temperature and condensing boilers
•gas heaters.
.
Using the instrument, these systems can be adjusted and checked for
compliance with the applicable limit values.
The instrument has been verified as a short-term measuring instrument and
should not be used as a safety (alarm) device.
The following tasks can also be carried out using the instrument:
•Regulating the O2, CO and CO2, NO, NOx values in combustion plants to
ensure optimum operation.
•Draft measurement.
•4Pa measurement.
•Measuring and regulating the gas flow pressure in gas heaters.
•Measuring and optimising the flow and return temperatures of heating
systems.
•Measuring the CO concentration in the ambient air.
•The instrument can be used for measurements on CHP plants in accordance
with the first German Federal Immission Control Ordinance (BImschV).
•In principle, the CO sensor can also be used for measurements on CHP
plants. If you carry out more than 50 measurements on CHP plants per year,
please contact your nearest Testo service centre or send the instrument to
Testo Service for checking.
An NOx filter for the CO sensor can be ordered as a spare part to replace a used
filter.

6 Product description
11
6Product description
6.1 Front view
1
USB interface /
Power connection
4
User interface
2
Gas outlet
5
Condensate container
3
On/Off button
6
Connections

6Product description
12
6.2 Rear view
1
Attachment point for carrying
strap
2
Magnets
Explanation of icons
IMPORTANT
Magnetic field
Damage to other devices!
-Keep a safe distance away from products that could be
damaged by the effects of magnetism (e.g. monitors,
computers or credit cards).
At the end of its useful life, deliver the product to the separate
collection point for electric and electronic devices (observe local
regulations) or return the product to Testo for disposal.
Next-Gen testo 300 complies with the Korean safety
standard.
Next-Gen testo 300 is Bluetooth-enabled

6 Product description
13
China RoHS
6.3 Connections
1
Probe connections for additional
probes and testo Bluetooth®
Connector
3
Flue gas socket
2
Integrated ambient air probe
4
Differential pressure
measurement connection
There must be no more than one extension lead (0554 1201, 0554
1202) connected between flue gas socket and flue gas probe.
6.4 Compact flue gas probe
1
Removable filter chamber with
window and particle filter
3
Connector plug for measuring
instrument
2
Probe handle
4
Connection cable

6Product description
14
6.5 Modular flue gas probe
1
Removable filter chamber with
window and particle filter
4
Connector plug for measuring
instrument
2
Lock release
5
Probe handle
3 Probe module 6 Connection cable
1 Removable filter chamber with
window and particle filter
4 Connector plug for measuring
instrument
2
Lock release
5
Probe handle
3 Probe module 6 Connection cable

7 First steps
15
7First steps
7.1 Commissioning
Take the information in the testo information document (included with the
product) into account for this.
7.2 Power Supply / Battery
The measuring instrument is supplied with an energy storage unit.
Fully charge the battery before using the measuring instrument.
If the measuring instrument is completely discharged, allow at least 30
minutes to charge before switching the measuring instrument on and
using it again.
If the power supply is connected, the measuring
instrument is automatically powered via the power supply.
Only charge the battery at an ambient temperature of
32 to 95 °F (0 to 35 °C).
Storage conditions for the battery:
•Ambient temperature from 50 to 68 °F (10 to 20 °C)
•Charge level of 50 to 80%
7.2.1 Charging battery
1
2
Connect the instrument plug of the charging cable to the USB socket
on the measuring instrument.
Connect the charging cable of the power supply to a power socket.

The charging process starts. LED in
the condensate trap flashes red.
The charging process stops
automatically when the energy
storage unit is fully charged. LED in
the condensate trap has a continuous
red light.
If the battery has discharged completely, the charging time at room
temperature is approx. 5-6 hrs.

7First steps
16
7.2.2 Power Supply Operation
1
2


Connect the instrument plug of the Power Supply to the mini USB on
the measuring instrument.
Connect the power supply into a power supply.
The measuring instrument is powered via the power supply.
If the instrument is switched off and a battery is inserted, the charging
process will start automatically. Switching the measuring instrument
on stops the charging of the battery and the measuring instrument is
powered via the power supply.
For longer measurements involving mains operation, Testo
recommends using a combustion air temperature probe with
connection cable. Self-heating of the instrument during power supply
operation may influence the combustion air temperature measurement
using a mini ambient air probe.
7.3 Touchscreen Operation
Familiarize yourself with the touchscreen operating concept before you use the
measuring instrument.
Actions are mostly carried out by:
Description
Tapping
To open applications, select menu symbols,
press buttons on the display or enter characters
with the keypad, in each case tap these with a
finger.
Swiping
Swipe to the right or left on the display to show
further views, e.g. to switch from the list view to
the graphic view.

7 First steps
17
Description
Zooming
In order to make a section of the display larger
or smaller, touch the display with two fingers
and move them apart or together.
Dragging
You can move an element by touching it,
holding it and dragging it to the required
position.
Example: Changing the display sequence of the
measurement parameters.
7.4 Keypad
Some functions require values (figures, numerical value, unit, characters) to be
entered. The values are entered via a keypad.

Input field is enabled (flashing cursor)
1
Enter value: tap the required value
on the display (figures, numerical
value, unit, characters).
2
Confirm entry: Press .
3
Repeat steps as required.

7First steps
18
7.5 Switching the instrument on and off
Current
status
Action Function
Instrument
off
Press the side
button for 3 seconds
Instrument is switched on.
When the measuring instrument is started for the first time, the setup
wizard guides you through the following setting parameters step by
step:
-Country version
-Language
-Wi-Fi
-Date and Time
-Own company address
-E-mail account
A tutorial can be started after the setup wizard.
The tutorial demonstrates the general operation and the most important
functions of the measuring instrument using examples.
Instrument
on
Press the side
button briefly
(< 1 s)
Instrument is switched to standby mode.
The instrument is re-activated when the
button is pressed again.
Instrument
off
Press the side
button for a long
time (>1 s)
Selection: [OK] Instrument is switched
off or cancel the instrument being
switched off with [Cancel].
Standby mode has 3 time-dependent functions:
•Standby time up to 1 min: Immediate restart after pressing the key.
•Standby time up to 1 hour: After pressing the key, a restart takes
place after 5 seconds.
•Standby time more than 1 hour: Next-Gen testo 300 is in power
save mode. After pressing the key, a restart takes place after the
zeroing phase.
Unsaved readings are lost when the measuring instrument is switched
off.

7 First steps
19
7.6 Connect probes
Flue gas probes

Instrument is switched on.
1
Insert the connector plug into the flue
gas socket and lock it in place by
turning it slightly clockwise (bayonet
lock).
There must be no more than one extension line (0554 1202) between
measuring instrument and flue gas probe.
Temperature adapter

Instrument is switched on.
1
Insert the connector plug of the
probe into the probe socket.

System recognizes the probe (info is displayed).
The parameter which is measured with an external probe is identified
on the display by "ext.".

7First steps
20
7.7 Connecting Smart Probes and testo
Smart App
The Next-Gen testo 300 has the option of establishing a Bluetooth® connection
with wireless probes via the testo Bluetooth® Connector as well as a
connection to the testo Smart App at the same time.
If the Next-Gen testo 300 is used with Smart Probes, they must be at
least 8 inches (20 cm) apart.
7.7.1 Attaching the testo Bluetooth®Connector
(0554 3004)
Once the testo Bluetooth® Connector is plugged in, all the warning
and safety instructions for the Next-Gen testo 300 apply.
WARNING
Danger of suffocation!
The testo Bluetooth
® Connector is a small part that can be swallowed.
Keep out of reach of children.
1
Connect the testo Bluetooth®
Connector to the TUC 1 or TUC 2
socket on the Next-Gen testo 300.


When connected, a testo Bluetooth® Connector icon appears in
the Next-Gen testo 300 status display.
You can now connect up to 4 Smart Probes to the Next-Gen testo
300 at the same time.