TESTO CU-2 User Manual

testo CU-2

User Manual

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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: [phone]
Testo-Strasse 1 Fax: [phone]
79853 Lenzkirch web: www.testo.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 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 CU­2 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.

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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

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

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

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

5 Installation and Setup

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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