Servicedocumentation

for

0632.0352 (300XXL) 0632.0351 (350 M) 0632.0350 (350 XL) V1.02/09.03

2

Introduction Service documents are confidential documents and are not allowed to be given to third persons. Service documents shall assist our service technicians all over the world in order to give utmost service to our customers. Service documents include drawings, circuit plans with documented testing points and spare parts lists. Service documents cannot replace service trainings. It rather serves as tool and paperwork for our service staff.

3

Contents 1.0 Electronic structure of gas analyzing boxes ...................................................................................................4

1.1 Automated logic diagram with description of signs .....................................................................................4 1.1.1 Connections of measuring box .............................................................................................................4 1.1.2 Voltage supply ......................................................................................................................................5 1.1.3 Digital part.............................................................................................................................................6 1.1.3 Analogue mux, SDA-MUX and ADC ....................................................................................................7 1.1.4 Fixed parameters..................................................................................................................................9 1.1.5 Gas parameters 1...............................................................................................................................10 1.1.6 Gas parameters 2...............................................................................................................................11 1.1.7 Peripheral connections .......................................................................................................................12

2.0 Measuring points of main circuit board .........................................................................................................13 3.0 Assembly plan of main circuit board .............................................................................................................14

3.1 Right side of module plug-in places ( > INDEX 7) ....................................................................................14 3.2 Left side of module plug-in places ( > INDEX 7) .......................................................................................15 3.3 Right side of component plug-in places ( > INDEX 7) ..............................................................................16 3.4 Right side of component plug-in places ( > INDEX 7) ..............................................................................17 3.5 Right side of module plug-in places (INDEX 7).........................................................................................18 3.6 Left side of module plug-in places (INDEX 7) ...........................................................................................19 3.7 Right side of component plug-in places (INDEX 7)...................................................................................20 3.8 Left side of component plug-in places (INDEX 7) .....................................................................................21

4.0 Circuit plan of main circuit board ..................................................................................................................22 4.01 Voltage supply (<INDEX 7) .....................................................................................................................22 Voltage supply (INDEX 7) .......................................................................................................................23 4.02 Peripheral connections (<INDEX 7) ........................................................................................................24 Peripheral connections (INDEX 7) ..........................................................................................................25 4.03 Temperature-measuring channels /SDA-MUX measuring modules (<INDEX 7) ..................................26 Temperature-measuring channels /SDA-MUX measuring modules (INDEX 7) ....................................27 4.04 Analogue-MUX and AD-converter (<INDEX 7) .......................................................................................28 Analogue-MUX and AD-converter (INDEX 7) .........................................................................................29 4.05 Data recorder, controler (<INDEX 7).......................................................................................................30 Data recorder, controler (INDEX 7).........................................................................................................31 4.06 Digital part (<INDEX 7)............................................................................................................................32 Digital part (INDEX 7)..............................................................................................................................33 4.07 Measuring channels of sensor modules (<INDEX 7)..............................................................................34 Measuring channels of sensor modules (INDEX 7) ................................................................................35 4.08 Measuring channel of NO modules (<INDEX 7) .....................................................................................36 Measuring channel of NO modules (INDEX 7) .......................................................................................37 4.09 Pellistor (<INDEX 7) ................................................................................................................................38 Pellistor (INDEX 7) ..................................................................................................................................39 4.10 CAN-interface (<INDEX 7) ......................................................................................................................40 CAN-interface (INDEX 7) ........................................................................................................................41 4.11 parts list of the main circuit board ...........................................................................................................42

5.0 Hosing plan (gas ways) ................................................................................................................................46 5.1 Testo 300 XXL...........................................................................................................................................46 5.2 Testo 350 M ..............................................................................................................................................47 5.3 Testo 350 XL .............................................................................................................................................48 5.4 Measuring block 0440.0330 (gas ways) ...................................................................................................49

6.0 General information ......................................................................................................................................51 6.01 Option gas cooler ....................................................................................................................................51 6.02 Condensation container (0440.0553)/ condensation trap (0554.0552) ..................................................52 6.03 Function zeroizing of the sensors with the flue gas probe in the flue gas ..............................................52 6.04 Option Fresh air valve .............................................................................................................................53 6.05 Option CO-dilution...................................................................................................................................54 6.06 Sensor heating ........................................................................................................................................56 6.07 Measuring cells .......................................................................................................................................57 6.08 Possible sensor combinations.................................................................................................................58 6.09 Warranty..................................................................................................................................................59 6.10 CAN-ID numbers .....................................................................................................................................59 6.11 Voltage-Management Of The Rechargeable Batteries ...........................................................................59

7.0 Calibration gases used by Testo Lenzkirch..................................................................................................61

4

1.0 Electronic structure of gas analyzing boxes 1.1 Automated logic diagram with description of signs 1.1.1 Connections of measuring box

Sign in the automated logic diagram

Description

AT Probe connection for gas temperature measurement VT Probe connection for combustion air temperature

measurement TRIGGER / V24 Connections for external triggering and RS 232 CAN-Bus Three connections for CAN bus CNTR_RADIO Drive signal for activating the radio module Power-LED Three-colour luminous diode for indication of condition

of voltage supply Status-LED Three-colour luminous diode for indication of status

conditions RADIO-LED Three-colour luminous diode for indication of conditions

of radio modules

90 – 264 V≈

5

1.1.2 Voltage supply

(see circuit plan page 18) Sign in the automated logic diagram

Description

12V_NET Mains unit voltage 12.5V DGND Digitalground (0V) for power- and digital part KEIN_NET Drive signal for the µP, for recognition of net voltage 12V In net case: derived from 12V_NET

In accu case: derived from accu (Up controlled) 5V_2A 5V chargeable with 2A (Down controlled by accu or

12V in net operation) 10V Internal working point voltage (low chargeability) 5V_DIG Internal working point voltage, 5V for supply of digital

part (low chargeability) AVCC Internal working point voltage, 5V for supply of

analogue part (low chargeability) UREF Reference voltage for AD converter, referred to UM UM Reference voltage for measuring amplifier and ADC

(2.5V over AGND) AGND Analogue ground (0V) for analogue measuring part 8V_ISO Voltage supply Can-Bus 5V_ISO Driver voltage Can-Bus GND_ISO Ground of Can-Bus (0V)

10V 5V_DIG

KE

1

6

1.1.3 Digital part

(see circuit plan page 22, 23, 27) Sign in the automated logic diagram

Description

WP Write-Protection for Eeprom Additional eeprom Eeprom for customer-specific data Basic eeprom Eeprom for data of calibration and course of program

7

1.1.3 Analogue mux, SDA-MUX and ADC

(see circuit plan page 21, 20) Sign in the automated logic diagram

Description

TE_AT Thermo element signal of combustion gas temperature probe

TE_VT Thermo element signal of combustion air temperature probe

NTC_AT Signal of comparing place compensation for thermo- couple measurement AT

NTC_VT Signal of comparing place compensation for thermo- couple measurement VT

PDIFF_MEAS Signal of pressure measurement for finest draught, fine draught and Pdiff

PDIFF_CALIB Signal of pressure measurement for finest draught, fine draught and Pdiff (is needed for electr. calibration only)

10V Internal working point voltage (low chargeability) UMESS_ACCU Signal of accu voltage measurement NTC_ACCU Signal of temperature measurement of accus (is

measured by means of NTC) UM Reference voltage for measuring amplifier and ADC

(2.5V over AGND) PUMP_DR Signal of pump pressure measurement

(for calculation of pump capacity) SIGNAL_DR3 Signal connection of dilution pump pressure

measurement (is also used for electr. calibration) TE_GA Signal of thermo-couple measurement for the cold side

of Peltier element

8

GT_KTY Signal of instrument temperature measurement

(by means of KTY) I_AKKU Signal of accu current measurement (is not considered

by the measuring software) CELLS_TMP Signal of temperature measurement regarding gas

measuring cells (by means of NTC) SIGNAL_6 Signal of 6th measuring cell amplifier PEL_SIGNAL Signal of Pellistor amplifier SIGNAL_5 Signal of 5th measuring cell amplifier SIGNAL_4 Signal of 4th measuring cell amplifier H2_SIGNAL Signal of H2 branch of COH2 measuring cell CO_SIGNAL Signal of CO branch of COH2 measuring cell O2_SIGNAL Signal of O2 measuring cell SDA_MOD6 SDA-connection for 6th measuring cell plug-in place SDA_MOD5 SDA-connection for 5th measuring cell plug-in place SDA_MOD4 SDA-connection for 4th measuring cell plug-in place SDA_MOD3 SDA-connection for 3rd measuring cell plug-in place SDA_MOD2 SDA-connection of 2nd measuring cell plug-in place SDA_MOD1 SDA-connection of 1st measuring cell plug-in place

9

1.1.4 Fixed parameters

(see circuit plan page 20) Sign in automated logic diagram Description Fixed parameters Parameters that exist always AT Combustion gas temperature measurement VT Combustion air temperature measurement AKKU Accu voltage measurement UM_A_ON Circuit signal for accu voltage measurement GT Instrument temperature measurement COLD_SIDE Temperature measurement of cold side of Peltier

element ZT Measuring cell temperature measurement Finest draught, fine draught, PDiff Pressure measurement PWM_PDIFF Pulse-width modulated signal for adjustment of

working point of pressure measurement Pump pressure Pressure measurement for the pump capacity

10

1.1.5 Gas parameters 1

(see circuit plan pages 24, 25) Sign in the automated logic diagram

Description

Gas parameters Parameters which can be classified to the measuring cell plug-in places

DS_DT Drive signal for used-indication of gas measuring cells (is not considered by the software)

O2 O2-Measuring circuit COH2 Measuring circuit for the COH2 measuring cell NO Measuring circuit for the NO measuring cell CHANNEL_A Measuring circuit for the measuring cell plug-in place

No. 4 CHANNEL_B Measuring circuit for the measuring cell plug-in place

No. 5

11

1.1.6 Gas parameters 2

(see circuit plan page 26) Sign in automated logic diagram Description PELLISTOR Measuring circuit for measuring cell type Pellistor:

(here for measurement of CxHy) PEL_ON Drive signal for switch on resp. off of Pellistor sensor P4V Drive signal for adjustment of working voltage for a

Pellistor sensor (2V or 4.5V) S90 Micro switch for change-over of 6th measuring cell plug-

in place. Pellistor/electro-chemical CHANNEL_C Measuring circuit for the measuring cell plug-in place

NO. 6 (for electro-chemical measuring cell) DILUTION Plug-in place for a measuring gas dilution module

12

1.1.7 Peripheral connections

(see circuit plan page 19) Sign in the automated logic diagram

Description

Peltier Drive of Peltier element for gas cooling HPump Drive for main pump SPump Drive for rinsing pump U_SPUMP Drive signal for the voltage of rinsing pump 2.0V resp.

3.3V Ventilator Drive for instrument ventilator Hose pump Drive for hose pump Fresh air ventilator Drive for fresh air valve Net ventilator Drive for the ventilator of mains unit cooling Cell heatings Plug connections for cell heatings LED-driver Drive for the signalling LED Accu charging circuit Facility for loading the NIMH accus

(consists of hard and software)

13

2.0 Measuring points of m

ain circuit board Testing point

No.

Description

Measured value

Testing point on page

In circuit plan on page

1

Mains unit voltage 12V_N

ET 12.5V m

3% (D

GN

D)

2 12V-Supply according to Schottky 12V

ca. 12V_NETZ - 0.4V (D

GN

D)

3 5V-Supply for digital part 5V_D

IG

5V m 3%

(DG

ND

)

4

5V-Supply for analogue part AVCC

5V m

3% (AG

ND

)

5

5V-Supply for power parts 5V_2A

5V m 2%

, (DG

ND

) >10V if accu loads (D

GN

D)

6 G

round of Can-Buses G

ND

_ISO

0V (GN

D_ISO

)

7

Driver Voltage C

an-Bus 5V_ISO

5V m 3%

(GN

D_ISO

)

8

Voltage supply Can-Bus 8V_ISO

0V (G

ND

_ISO)

9 D

igital ground DG

ND

9V----12V (D

GN

D)

10 Analogue ground AG

ND

0V (AG

ND

)

11

Connection of m

ain pump 5V

approx. 4.2V (DG

ND

)

12

Connection of m

ain pump 3.3V

3.3V m 3%

(DG

ND

)

13

Connection of rinsing pum

p 3.3V 3.3V or 2.0V m

3% (D

GN

D)

14 Trigger input behind opto cable TR

IGG

ER

5V-level (DG

ND

)

15

Reference voltage for analogue part U

M

2.5V m 3%

(AGN

D)

16 R

eference voltage UR

EF 1.225V (R

ef. LM4041) (AG

ND

)

17

Working point for sw

itched capacitor IC36......N

5V approx. -5V (D

GN

D)

18 O

scillator voltage of IC36

Saw tooth approx. 1Vss , (D

GN

D)

approx. 300Hz

19 PW

M-signal for Pdiff PW

M_PD

IFF R

ectangular signal approx. 5Vss (DG

ND

) approx. 14 Khz

20 W

orking point for dilution and pump throughput

measurem

ent 10V m

2% (AG

ND

)

21 µP-R

eset RESET

5V-level (Low-Active) (D

GN

D)

22 W

orking point for O2-G

ambert

3.3V m 2%

(AGN

D)

23 W

orking point for NO

circuit 1.225V m

2% (AG

ND

)

24

PWM

-signal for Pellistor PEL_PWM

R

ectangular signal approx. 5Vss (DG

ND

) approx. 14 Khz

25 W

orking point Pellistor 1V / 2.13V m

2% (AG

ND

)

2

Accu voltage U_AC

CU

7V.......11V (D

GN

D)

14

3.0 Assembly plan of main circuit board 3.1 Right side of module plug-in places ( > INDEX 7)

Left

part

on n

ext p

age

15

3.2 Left side of module plug-in places ( > INDEX 7)

Rig

ht p

art o

n pa

ge

befo

re

16

3.3 Right side of component plug-in places ( > INDEX 7)

Left

part

on n

ext p

age

17

3.4 Right side of component plug-in places ( > INDEX 7)

Rig

ht p

art o

ne p

age

befo

re

18

3.5 Right side of module plug-in places (INDEX 7)

Left

part

on n

ext p

age

19

3.6 Left side of module plug-in places (INDEX 7)

Rig

ht p

art o

ne p

age

befo

re

20

3.7 Right side of component plug-in places (INDEX 7)

Left

part

one

page

be

fore

21

3.8 Left side of component plug-in places (INDEX 7)

Rig

ht p

art o

ne p

age

befo

re

22

4.0 Circuit plan of main circuit board 4.01 Voltage supply (<INDEX 7)

23

Voltage supply (INDEX 7)

24

4.02 Peripheral connections (<INDEX 7)

25

Peripheral connections (INDEX 7)

26

4.03 Temperature-measuring channels /SDA-MUX measuring modules (<INDEX 7)

27

Temperature-measuring channels /SDA-MUX measuring modules (INDEX 7)

28

4.04 Analogue-MUX and AD-converter (<INDEX 7)

29

Analogue-MUX and AD-converter (INDEX 7)

30

4.05 Data recorder, controler (<INDEX 7)

31

Data recorder, controler (INDEX 7)

32

4.06 Digital part (<INDEX 7)

33

Digital part (INDEX 7)

34

4.07 Measuring channels of sensor modules (<INDEX 7)

35

Measuring channels of sensor modules (INDEX 7)

36

4.08 Measuring channel of NO modules (<INDEX 7)

37

Measuring channel of NO modules (INDEX 7)

38

4.09 Pellistor (<INDEX 7)

39

Pellistor (INDEX 7)

40

4.10 CAN-interface (<INDEX 7)

41

CAN-interface (INDEX 7)

42

4.11 parts list of the main circuit board 0220 2003 Pin board 10-pol St 70, 71, 72, 80, 91, 92 0222 2005 Pin board 2-pol R2.00 St 20 22 23 24 25 26 27 0222 2008 Pin board 4pol. R 2.00 St 21 0222 2009 Pin board 4pol. ST 11 0254 3505 Resistance 5.05K 0.1% R 308 309 317 318 326 0255 0000 Resistance 0.0 1% R 10.21, 10.53, 331 334 340 512 514 709

714 719 158 162 164 935 727 803 809 911 940

0255 0001 Resistance STK 0.01 Ohm R 10.22 0255 0499 Resistance 4,99 l% R 139, 156 0255 1221 Resistance 22,1 l% R 143 160 710 715 716 720 721 728 729

912 913 931 933 941 942 429 10,23 10,25 0255 2100 Resistance 100 l% R 405 818 926 10,2 10,41 10,44 0255 2162 Resistance 162 l% R 159 0255 2200 Resistance 200 l% R 138 222 226 10,33 0255 2365 Resistance 365 l% R 238 230 0255 2432 Resistance 432 l% R 342 0255 2562 Resistance 562 l% R 323, 425 0255 2750 Resistance 750 l% R 420 810 811 927 930 0255 2887 Resistance 887 l% R 157 0255 3100 Resistance 1,0K l% R 10,35 10,39 10,42 10,43 10,45 10,46

10,40 10,15 127 140 144 307 316 337419 711 724 732 733 800 819 820 908 937

0255 3130 Resistance 1,3K l% R 147 916 0255 3150 Resistance 1,5K l% R 718 723 731 915 944 0255 3215 Resistance 2,15K l% R 10.30, 325 923 0255 3432 Resistance 4,32K l% R 220 224 10.34 10,28 208 241 917 921 0255 3511 Resistance 5,11K l% R 105 161 242 306 338 339 0255 3634 Resistance 6,34K l% R 240 734 10,29 0255 3715 Resistance 7,15K l% R 128 0255 3806 Resistance 8,06K l% R 142 146 418 428 0255 4100 Resistance 10K l% R 209 210 213 229 243 246 247 322 333

336 341 402 403 409 R 416 503 504 603 604 712 713 725 726 801 821 909 910 R 928 929 938 939 10.17 10,1 10,14 10,48

0255 4124 Resistance 12,4K l% R 239, 427 0255 4150 Resistance 15K l% R 404 408 919 0255 4169 Resistance 16,9K l% R 918 0255 4200 Resistance 20K l% R 101 123 130 219 221 223 225 319 320

335 400 615 616 617 R 735 816 813 817 924 936

0255 4246 Resistance 24,6K l% R 141 249 0255 4365 Resistance 36,5K l% R 122 149 426 717 730 914 943 0255 4402 Resistance 40,2K l% R 202 204 206 211 214 217 231 245 401

808 0255 4511 Resistance 51.1K l% R 106 152 244 411 722 0255 4619 Resistance 61,9K l% R 129 145 814 0255 4715 Resistance 71,5K l% R 417 812 0255 4825 Resistance 82,5K l% R 407 0255 5100 Resistance 100K l% R 107 109 131 133 203 205 207 212 215

216 227 228 232 R 233 250 412 413 414 415 424 501 506 600 601 805 807 932 R 248 618 619 620 10,13 10,26

0255 5174 Resistance 174K l% R 102 103 108 132 150 151 0255 5249 Resistance 249K l% R 136 515 10-16 10-36 0255 5332 Resistance 332K l% R 121 148 0255 6100 Resistance 1M l% R 100 104 134 135 137 301 303 406 410

423 505 925 10,47 0256 7100 Resistance 10M 5% R 300 302 304 305 332 500 0286 0001 Condenser 100pF 50V 10% C 10,1 10,7 10,8

43

0286 0002 Condenser 033pF 50V C 10.5 10.6 126 127 128 219 220 221 222 223 400 413 414 430 510 511 C 444 445 446

0286 0004 Condenser 820pF 50V 10% C 113 431 0286 0017 Condenser 0.1uF 50V 20% C 10.16 10.18 10.19 10.22 10.4 100 102

118 120 131 201 C 202 203 204 205 207 209 210 211 212 224 225 318 319 3326 327 341 344 345 403 407 408 411 412 417 614 619 620 622 708 712 715 718 719 722 726 727 731 800 804 809 811 907 911 917 918 921 922 924 925 929 931 935 936

0286 0018 Condenser 10nF 50V 10% C 213 300 302 308 310 339 402 426 428 429 500 501 502 503 504 505 506 509 600 601 602 603 604 605 606 607 608 609 613 615 616 713 716 728 912 930 10,17 447 448 449

0286 0019 Condenser 1.8nF 50V 5% C 206 208 301 305 306 307 309 313 314 315 437 438 320 321 322 323 324 406 419 420 421 422 423 424 433 434 435 436 707 709 710 714 717 723 724 729 803 805 806 807 808 908 909 913 926 927 932

0286 0030 Condenser 0,47uF 50V 20% C 105 110 114 115 404 405 409 410 0287 0100 Foil condenser 63V 100 nF C 401 916 0288 0004 TAKO CHIP 4,7UF 16V +-20% C 101 103 316 317 340 418 439 440 711

725 730 910 928 0288 0005 TAKO Chip 10uF 16V +-20% C 10.21 132 214 215 216 217 218 10,23

937 0288 0006 Condenser 68uF/16V C 104 109 112 119 618 621 512 10,11 0288 0007 Condenser 68uF/20V C 116 129

44

0290 0008 Throttle-HF B82422 1.5UH L 10.1 10.2 20 21 22 23 30 31 32 33 34 35 36 37 40 41 42 43 70

0290 0013 Coil 47uH CDRH 125 L 10 12 0290 0019 Double throttle coil L 11 0305 0008 Quartz 1.8432 MHz Hcl8/u Q 40 0305 0021 Quartz 7.3728MHz Q 51 0305 0022 Quartz 32.768KHz 12.5pF Q 50 0305 0026 Quartz 8 MHz Q 10.1 0306 0002 Diode BYM10-600 D 20 21 22 23 24 25 26 27 28 29 0306 0003 Schottky-Diode PRL5817 D 18 0306 0004 Suppressor-Diode Z 30 31 0306 0006 Diode BAS 16 D 16 0306 0007 Diode 340 Schotthy-Diode D 10 13 14 0306 0008 Z.Diode 33V, 410mW D 15 0306 0010 Diode STK SS24 Schottky-Diode D 12 17 0306 0100 Diode LL4148 D 70 71 120 121 122 123 230 231 232

10,1 10,2 0306 4041 Ref.Diode LM4041 Z 32 80 0307 0054 Transistor NPN BCX 54-16 T 94 95 204 206 0307 0849 Transistor NPN BC 8493 T 41 42 83 96 101 105 106 108 111 113

115 209 216 217 0307 0859 Transistor PNP BC 859B T 10.1 40 44 100 210 211 212 213 214

215 0307 2510 DMOS FET P-channel TP2510N8 T 110 0307 9435 MOS FET P-channel SI9435 DY T 107 109 112 114 116 0307 9956 MOSFET 2 N-channel Si9956DY T 200 202 205 208 0307 0545 J-FET BF 545A TO-C T 70 73 75 92 97 0315 0007 OP 07 IC 33 40 75 76 92 93 96 97 98 0315 0316 OP-97F operation amplifier IC 72 0315 0027 OP TLC 27M2AID IC 41 42 46 80 95 0315 0340 OP AD8551 rail-to-rail IC 73 74 0315 1058 OP 2-fold LM358 IC 20 32 77 0316 1172 Switch regulator STK LT 1172 IC 10 11 0316 8125 Voltage regulator +5.OV Rg 10 11 12 13 0317 0472 MAX 47 2 CSA IC 10,15 0317 1043 Analogue switch LTC 1043 IC 36 0326 0000 4 x NAND SN74HCOO IC 602 620 0326 0032 OR - gate STK 74HC32 IC 614 615 616 0326 0138 Decoder (3 zu 8) 74HCl38 IC 611 0326 0373 8 Bit Latch 74HC373 IC 600 601 603 604 605 0326 4051 MUX laus8 74HC4051 IC 34 35 43 44 0326 4053 MUX 3x2 channels 74HC4053 IC 81 94 14 0327 0232 V24 sender/receiver MAX 232 IC 22 0327 0809 MCP 809-270 I / TT 2.7V IC 10.5 51 0335 7714 24-Bit A/D-U AD7714AR-5 IC 45 0345 0033 CAN Controller MCP2S1O-I/SO IC 10.6 0345 0031 Micro processor M37733S4 BFP IC 50

EEPROM AT24CO4AN IC 612 613 0346 0010 Flash 16MBit AT 49F 1614-9OTC IC 55

Data Flash At45 DO8I-RC IC 56 0346 5810 RAM 128 Kbyte 431000A-AIO IC 53 54 0347 0002 CAN-transreceiver PCA 82C250 IC 10.7 0351 2003 LED bi-color LED 10.1 20 21 0352 0201 Opto coupler Logic Gate IC 10,11 10,12 10,13 0352 0208 Opto coupler IL 208 A IC 10.4 10,10 21 0281 0601 FOKO 0,015uF 63V C 133 0281 0401 Foil condenser 0,1 uF 50 V C 130 134 0281 0406 FOKO 1uF 50V RM2,5 MKT C331 333, 335, 338 0283 0010 Elko 1000 uF 25 V C 106 117 0283 0022 Elko 2200 uF 16 V C 111 0200 0019 Push botton SMD S 50 0200 0508 Sliding switch 2pol. S 90

45

0217 0066 Socket contact Bu 20 21 22 23 24 25 20.1 21.1 22.1 23.1 24.1 25.1

0222 1008 Socket board 8-pol. Bu 10.1 61 0219 2006 Pin board 2-pol B2P-VH-B St 10 0219 2007 Pin board 4pol. B4P-VH-B St 30 0219 2127 Pin board 8pol R2.54 St 62 0219 2129 Pin board 12pol. Mico Match St 40 0220 2053 DIN-socket 8pol. P.B.T. Bu 30 31 0220 2086 Mini DIN socket 4polPower Bu 10 11 0220 2082 Mini-DIN socket 8pol. Bu 26 0192 0515 Receiver 0361 0001 SI temp.sensor KTY83 KTY,30 0380 0035 Pressure sensor 0-68mbar SXOIDD4 Sen 40 0380 0037 Pressure sensor 345mbar SCCO5DD4 Sen 41 0237 1003 HF-transmitter VP3-0084 Ue 10 0192 0109 Body-bound rivet, plastic-PA brown 0180 0274 Cooling aluminium sheet 0120 0111 Disk steel-MS nickeled 0360 0036 NTC R25= 5K UNI-K

46

5.0 Hosing plan (gas ways) 5.1 Testo 300 XXL

47

5.2 Testo 350 M

48

5.3 Testo 350 XL

49

5.4 Measuring block 0440.0330 (gas ways)

F2 E2 V1 Frischluftventil Fresh Air Valve

7 5 F1

6 E3 F3

V2 CO-Verdünnungsventiel CO-Dilution Valve

Hauptpumpe/ Main Pump testo 300XXL testo 350M/XL

Spülpumpe / Rinsing Pump

1 2 A3

50

A1 E2 A2

K1 12K2 10

9

11

51

6.0 General information Further information can be found in the market introduction files „testo 350 M/XL – 300 XXL – 454“. 6.01 Option gas cooler In order to get precise SO2 and NO2 measuring results it has to be avoided that SO2 and NO2 gets mixed up with the condensation in the combustion gas. It is an additional function to protect the measuring cells and the gas way against condensation (and dirt). Therefore the gas preparation is also useful for often measurements and for long-term measurements. The gas preparation is effective for combustion gases with a dew point up to 70°C. Usual temperature/nominal temperature of gas cooler – cold side. The electronic control of cold side is adjusted to the nominal temperature of 2°C (+/- 0,5°C). The cooling facility (Peltier element) of gas preparation provides a max. temperature difference of 20°C. If therefore 2°C cannot be reached the cooling is always active. Ventilator of warm side The ventilator of warm side is active always at the same time as the cooler. Readiness for operation The gas preparation is ready for operation if after 50 s the temperature difference between the sensor temperature and the cold side temperature is ≥ 6°C. The readiness for operation is not called off if the sensor temperature is below 10°C absolute. Puls relation of condensate pump The condensate pump gets its start signal if the main pump is switched on. By this it is ensured that at the beginning of a measurement possibly existing condensation is carried off. After that the pulse time is „on“ for 15 sec. and „off“ for 85 sec. Error conditions of gas preparation If 1 min. after switch on the readiness for operation has not been reached. If during operation the temperature difference of T-sensors/T-cold side is < 6°C. The readiness for operation is not called off if the sensor temperature is below 10°C absoute.

52

6.02 Condensation container (0440.0553)/ condensation trap (0554.0552) The condensation container and the condensation trap have different functions. The condensation trap is, as usual, at the gas way and serves for taking the humidity that had arisen during cooling down of combustion gas after having been taken out of the chimney. Because of this reason the condensation trap has to be air-proof. The condensation container is not at the gas way. It function serves only for containing the condensation arisen in the gas preparation. In the upper part of the condensation container there is a diaphragm. This diaphragm air-permeable and has the task to release the air pressure that arises by filling-in the condensation over the hose pump. If the condensation container is completely filled with condensation (i.e. overfilled) this diaphragm gets water-permeable as from a pressure of 200 mbar in order to protect the condensation container against cracking. Since with permanent measurements the condensation container may not be sufficient a hose can be adapted at the emptying piece. ATTENTION: The condensation trap and the condensation container are not allowed to be used arbitrarily because of different functions. This can result in damages of the measuring instrument resp. wrong measuring results. The condensation container differs from the condensation trap by the white air-permeable diaphragm below the metal clamp disc in the upper part of housing. 6.03 Function zeroizing of the sensors with the flue gas probe in the flue gas The analyser boxes of testo 300XXL and testo 350M/XL can effect zeroizing of the measuring cells even if the flue gas probe is located in the flue gas duct. Condition: -There is low pressure in the chimney. -The option CO-dilution is not equiped to the testo 350M. -The option solid matter measurement is not equiped to the testo 300XXL. During the calibration phase, the main pump is switched-off. The rinsing pump sucks fresh air via the outlets 1 and 2 and like this rinses the sensor with fresh air. This means that the CO-rinse (protection from overload of the sensor) is being used. In order to be able to rinse the remaining sensors, too, for a zeroizing, the two gas paths had to be connected by means of capillary K3 . Capillary K3 limits the flow to make sure that the measuring results of the other sensors in operation upon activated CO-rinse are not tampered.

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6.04 Option Fresh air valve By means of option „fresh air valve“ (testo 350M/XL only), you can also do zeroizing of the sensors with the flue gas probe inside the flue gas, even if there is overpressure in the chimney. The funktion is not affected by any other option. If the option „fresh air valve“ is installed, the ambient air is sucked-in via the fresh air inlet during the zeroizing phase. In this case, the main pump (instead of the rinsing pump) forwards fresh air to the sensors for zeroizing.

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6.05 Option CO-dilution Specifikation Dilution steps : 0, 2, 5, 10, 20, 40 Drive of dilution valve l(3/2-way valve ): without current measuring gas Triggered Dilution air Accuracy: ± 2.5 % of meas. value (dilution)

additionally ± 5 % of meas. value (sensors)

CO-Measuring ranges with different dilution steps

Dilution operation

Recommended CO-measuring ranges for COH2 (0...10 000 ppm)

Dilution step CO-concentration at sensor

Measuring range CO Accuracy

from........up to from........up to 2 300 1500 600 3000 5 300 1500 1500 7500 10 300 1500 3000 15000 +- 7.5 % of meas.

value 20 300 1500 6000 30000 40 300 1500 12000 60000

Recommended CO-measuring ranges for COH2 Low (0...500 ppm)

Dilution step CO-concentration

at sensor Measuring range CO Accuracy

from........up to from........up to 2 100 500 200 1000 5 100 500 500 2500 10 100 500 1000 5000 +- 7.5 % of meas.

value 20 100 500 2000 10000 40 100 500 4000 20000

Hints: The indicated measuring ranges are recommendations in order to reach highest possible accuracy with the dilution. Out of these measuring ranges it has to be counted with a higher deviation. Attention: With CO concentrations over 40 000 ppm CO the toxic sensors can be damaged. In order to avoid this please dismount the toxic sensors with such applications. With the O2 sensor it can be measured in this range. With CO concentrations over 10.8 % (108 000 ppm) in connection with air the lower explosion limit of CO is reached.

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Calibration of CO dilution with test gas

If the CO measured value is beyond the indicated tolerance with active CO dilution it first has to be checked whether a reasonable dilution step had been chosen. Please see the table on the last page. After this it has to be ensured, by means of test gas, that the CO measuring cell delivers possibly accurate measured values without activated CO dilution. Maybe a calibration should be effected. Then a suitable test gas and a reasonable dilution step is selected. For this purpose the tabe on page 36 is helpful. E.g. 5000 ppm (for CO/H2 high) and dilution step 5. Procedure: - Starting the CO dilution with a suitable dilution step. - Starting, effecting and finishing the gas calibration. - Controlling the measured value with switched on CO dilution. The calibration data are registered in a Eeprom and are only effective with switched on dilution. The calibration has an effect on all dilution steps. This calibration has no influence on the measuring accuracy with inactive dilution. With flue gas analyzers with installed CO dilution also the dilution should be checked at the same time of gas test.

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6.06 Sensor heating The sensor heating fulfills the purpose to put an undercooled combustion gas analyzing instrument faster into readiness for operation. The heating of sensors serves also as protection against condensation at sensors. Nominal voltage 12 V DC Heating performance at 12 V 0.6 W Current input at 12 V 50 mA Electronic resistances 240 Ω ± 24 Ω (± 10%) The control of sensor heating happens in 2 variants: 1. with gas cooler and 2. without gas cooler. The sensor temperature“ZT“ is generally measured at the CO sensor with an NTC sensor. Additionally to the HC Pellistor all sensor are heated. 1. Sensor heating with gas cooler Value Remarks Usual temperature/nominal temperatur Cell temperature ZT

8.0°C Absolute temperature NTC as T-probe at CO-sensor. ambient temperature range -5°C up to 50°C

Heating on, if Sensor temperature ZT < 7.8 °C 0.2°C Hysterese Heating off, if Sensor temperature ZT > 8.0 °C 2. Sensor heating without gas cooler Value Remarks Usual temperature/nominal temperature Cell temperature ZT

15.0°C Absolute temperature NTC as T-probe at CO-sensor. ambient temperature range -5°C up to 50°C

Heating on, if Sensor temperature ZT < 14.8 °C 0.2°C Hysterese Heating off, if Sensor temperature ZT > 15.0 °C

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6.07 Measuring cells The expected life time is, according to data sheet is 2 years each (also HC and H2S). The new exclusive sensors probably behave in their expected life time similar like the analogue standard sensors in testo 350 old (valid for SO2, NO2). As formerly this statement is valid that the life time considerably depends on the conditions of application. Depending on how much a sensor was used in applications, how much sensitivity and reaction time have changed, a sensor has to be exchanged earlier or can be used longer. e.g.: exchange if loss of sensitivity > 30 %. or if the reaction time t90 (20s) => 45s or if the baseline has increased considerably. or if the inboard filter is already exhausted (valid for: CO / COlow (against NOx/SO2), NO / NOlow (against SO2), HC (against NOx/SO2) The recommendation for the calibration interval (control and if necessary re-adjustment of sensitivity by means of test gas) is 6 months. Function principle of HC module The Testo HC module in testo 360 works according to the principle of heat tone. The principle can be explained in a simple way as follows: The electronic current flows through a platinum wire and by this it heats up the wire and the catalytic material to an operation temperature of approx. 500°C. Burnable gases in combustion gas (e.g. CyHy, H2, Co) are burnt at the catalyst surface as long as enough oxigen is available. This burning increases the temperature (Ü) of catalyst and therefore of the platinum wire. By this the electric resistance of platinum wire is changed. The change of resistance at the platinum wire is determined over a so-called „Wheatstone bridge circuit“ and provides the necessary measuring signal. IMPORTANT: The HC sensor needs an oxygen part of at least 2 % O2 (at 1000ppm Methan; the required oxygen increases limearly). Otherwiese the sensor burns down. This leads to loss of signal or to complete break-down of sensor. The testo 350 M/XL disposes about a security mechanism that switches off the sensor in case of oxigen share < 2% O2.

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6.08 Possible sensor combinations

O2

CO

/H2

CO

/H2-low

NO

2 SO

2 1) H

2S 3) N

O

NO

-low

HC

2) Inscription of the sockets

Typ 1 (O2)

O

2

Typ 2 (2-channel)

CO

Typ 3 (NO

)

NO

Typ 4 (channel A)

Typ A

Typ 2 (channel B)

Typ A

Typ 2 (channel C/H

C)

H

C / Typ A

= equipm

ent electronically not possible

Type A = NO

2, SO2, H

2S

= equipm

ent for reasons of m

easuring technique impossible

1) For calculation of the cross sensivity, the N

O2- and C

O/H

2-cells are required

2) For calculation of the cross sensivity, the CO

/H2-Zelle is required, for the protection sw

itch-off, the O

2-cell must be available!

3) For calculation of the cross sensivity, the NO

2- und SO2- cells are

required!

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6.09 Warranty Flue-gas analyser box 2 years (except for wearing parts and measuring cells) CO/ NO/ NO2/ SO2/ HC/ H2S: 1 year O2 1 ½ years Probes 1 year Rechargeable batteries 1 year Accessory ½ year 6.10 CAN-ID numbers Every Bus participants needs a CAN Bus address of identification. As Testo standard each participant has a CAN address. Per instrument type a sector of numbers has been fixed by production. Instrument type CAN-address range Operation part 1 9 PC CAN-card 2 9 Combustion gas analyzing box

10 19

Climate box 20 29 Analogue box 30 39 Powerbox 40 49 Radio box 50 59 The CAN address, given by production, is given always in dependance of serial number. Example: Analogue box (0554.0845) with serial number 00536920 has the CAN address 30. ATTENTION: Participants with the same CAN address are not recognized in the system. Because of this reason the CAN address of each participant can be modified over the operation part, the PC software or the service software. Modified CAN addresses are taken over with new starting of system. 6.11 Voltage-Management Of The Rechargeable Batteries Voltage: Action: <7.9V Status LED changes from green/blinking into

yellow/blinking <7.0V Gasanalyser switched off.

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7.0 Calibration gases used by Testo Lenzkirch Nr. Abgleichgase Toleranz in % rel. Abgleichgas für Gerät No. Calibration Gas Tolerance Range In

% Calibration Gas For Instrument

1 1000 ppm CO 1,4 % O2

2 2

Testo 346,342,300 (all types),350 (all types),360

2 400 ppm CO 300 ppm H2

5 % O2

2 2 2

3 5000 ppm Co 2 Testo 350 (all types),360,325I 2,5 % O2 2 (40000 ppm CO-Zelle/CO-high) 4 80 ppm NO 2 Testo 300 (all types),

342,350 (all types),360,325I 5 800 ppm NO

(+gas No.8) 2

6 40 ppm NO 2 Testo 350 M/XL

(for NOlow) 7 300 ppm NO

(+gas No. 8) 2

8 100 ppm NO2

Rest: Syntetic Air 2 Testo 350 (all types),360

9 1000 ppm SO2

(+ gas No. 1, No. 8)

3 Testo 350 (all types),360, 300I, 325I

10 700 ppm CO 2 Testo 325 (all types) , 325I, 315 2,5 % O2 2 11 80-100 ppm CO 2 0632.1247 12 200 ppm H2S 3 Testo 350 XL (+ gas No. 1 or No.15

depending to the CO module, No. 8)

13 100 ppm SO2 (or gas No. 9)

3

14 5000 ppm CH4 2 Testo 350 XL 21 % O2 15 300 ppm CO,

1,4% O2 (+ gas No. 2)

2 Testo 350 XL (for CO/H2low)

16 200ppm CO,

5.0% 02, Rest N2 2 Testo 305-1

17 17 % CO2

(+ gas with no CO2) 2 Testo 350 M/XL

18 40 % CO2 2 Testo 350 M/XL

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