TESTO 549 User manual

testo 549 - testo 550 . Digital manifold
Instruction manual

2

1 Contents
3
1 Contents
1Contents ...................................................................................................3
2Safety and the environment....................................................................4
2.1. About this document........................................................................4
2.2. Ensure safety...................................................................................4
2.3. Protecting the environment..............................................................5
3Specifications ..........................................................................................5
3.1. Use ..................................................................................................5
3.2. Technical data .................................................................................6
4Product description.................................................................................9
4.1. Overview..........................................................................................9
5First steps ..............................................................................................10
6Using the product ..................................................................................12
6.1. Preparing for measurement ...........................................................12
6.1.1. Switching the instrument on........................................................................... 12
6.1.2. Connecting the temperature sensor...............................................................12
6.1.3. Switching Bluetooth® on and off (testo 550) ..................................................14
6.1.4. Selecting the measuring mode.......................................................................15
6.2. Performing the measurement ........................................................16
7Maintaining the product ........................................................................17
8Tips and assistance...............................................................................19
8.1. Questions and answers .................................................................19
8.2. Measurement parameters .............................................................19
8.3. Error reports ..................................................................................20
8.4. Accessories and spare parts .........................................................20
9Declarations ...........................................................................................21

2 Safety and the environment
4
2 Safety and the environment
2.1. About this document
Use
> Please read this documentation through carefully and
familiarize yourself with the product before putting it to use. Pay
particular attention to the safety instructions and warning advice
in order to prevent injuries and damage to the products.
> Keep this document to hand so that you can refer to it when
necessary.
> Hand this documentation on to any subsequent users of the
product.
Symbols and writing standards
Representation Explanation
Warning advice, risk level according to the
signal word:
Warning! Serious physical injury may occur.
Caution! Slight physical injury or damage to
the equipment may occur.
> Implement the specified precautionary
measures.
Note: Basic or further information.
Menu Elements of the instrument, the instrument
display or the program interface.
[OK] Control keys of the instrument or buttons of
the program interface.
2.2. Ensure safety
> Do not operate the instrument if there are signs of damage at
the housing, mains unit or feed lines.
> Do not perform contact measurements on non-insulated, live
parts.
> Do not store the product together with solvents. Do not use any
desiccants.

3 Specifications
5
> Carry out only the maintenance and repair work on this
instrument that is described in the documentation. Follow the
prescribed steps exactly. Use only original spare parts
from Testo.
> Dangers may also arise from the systems being measured or
the measuring environment: Note the safety regulations valid in
your area when performing the measurements.
> If the measuring instrument falls or another comparable
mechanical load occurs, the pipe sections of the refrigerant
hoses may break. The valve positioners may also be damaged,
whereby further damage to the interior of the measuring
instrument may occur that cannot be identified from the outside.
The refrigerant hoses must therefore be replaced with new,
undamaged refrigerant hoses every time the measuring
instrument falls or following any other comparable mechanical
load. Send the measuring instrument to Testo Customer
Service for a technical check for your own safety.
> Make sure that your refrigeration system is properly earthed, as
otherwise the measuring instrument might get damaged.
2.3. Protecting the environment
> Dispose of faulty rechargeable batteries/spent batteries in
accordance with the valid legal specifications.
> At the end of its useful life, send the product to the separate
collection for electric and electronic devices (observe local
regulations) or return the product to Testo for disposal.
> Refrigerant gases can harm the environment. Please note the
applicable environmental regulations.
3 Specifications
3.1. Use
testo 549 and testo 550 are digital manifolds for maintenance and
service work on refrigeration systems and heat pumps. They may
only be used by qualified authorized personnel.
The functions of the testo 549 and testo 550 mean they can replace
mechanical manifolds, thermometers and pressure/temperature
charts. Pressures and temperatures can be applied, adapted,
tested and monitored.

3 Specifications
6
testo 549 and testo 550 are compatible with most non-corrosive
refrigerants, water and glycol. testo 549 and testo 550 are not
compatible with refrigerants containing ammonia.
The instruments must not be used in explosive environments!
3.2. Technical data
Characteristic Values
Parameters Pressure: kPa / MPa / bar / psi
Temperature: °C/°F/K
Sensor Pressure: 2 x pressure sensor, temperature:
2 x NTC
Meas. cycle 0,5 s
Measurement
channels
Quantity: 4
Interfaces Pressure connections: 3 x 7/16" UNF
NTC measurement
Measuring ranges HP/LP pressure measuring range: -100 to
6000 kPa / -0.1 to 6 Mpa / -1 to 60 bar (rel)
/ -14.7 to 870 psi
Temperature measuring range: -50 to
+150 °C / -58 to 302°F
Vacuum measuring range (rel): -1 to
0 bar / -14.7 to 0 psi
Overload 65 bar, 6500 kPa, 6,5 Mpa, 940 psi
Resolution Pressure resolution: 0.01 bar/0.1 psi/
1 kPa/0.001 MPa
Temperature resolution: 0.1 °C/0.1 °F
Accuracy (nominal
temperature
22 °C/71.6 °F)
Pressure: ±0,5 % of full scale (±1 digit)
Temperature (-40…150°C): ±0.5 °C (±1 digit)
/0,9°F (±1 Digit)
No. of refrigerants 60

3 Specifications
7
Characteristic Values
Selectable
refrigerants in the
instrument
R114 R407C R444B
R12 R407F R448A
R123 R407H R449A
R1233zd R408A R450A
R1234yf R409A R452A
R1234ze R410A R452B
R124 R414B R453a
R125 R416A R454A
R13 R420A R454B
R134a R421A R454C
R22 R421B R455A
R23 R422B R458A
R290 R422C R500
R32 R422D R502
R401A R424A R503
R401B R427A R507
R402A R434A R513A
R402B R437A R600a
R404A R438A R718 (H2O)
R407A R442A R744 (CO2)
Refrigerants that
can be updated via
testo Service (only
testo 549)
R11 R227 R417A
FX80 R236fa R417B
I12A R245fa R417C
R1150 R401C R422A
R1270 R406A R426A
R13B1 R407B R508A
R14 R407D R508B
R142B R41 R600
R152a R411A RIS89
R161 R412A SP22
R170 R413A

3 Specifications
8
Characteristic Values
Refrigerants that
can be updated via
testo Service (only
testo 550)
R11 R227 R417A
FX80 R236fa R417B
I12A R245fa R417C
R1150 R401C R422A
R1270 R406A R426A
R13B1 R407B R508A
R14 R407D R508B
R142B R41 R600
R152a R411A RIS89
R161 R412A SP22
R170 R413A
Measurable media Measurable media: All media that are stored
in the testo 549 and testo 550 Not
measurable: Ammonia (R717) and other
refrigerants which contain ammonia
Ambient conditions Operating temperature: -20 to 50 °C/
-4 to 122 °F
Storage temperature: -20 to 60 °C/
-4 to 140 °F
Housing Material: ABS/PA/TPU
Dimensions: 265 x 135 x 75 mm
Weight: approx. 1000 g (without batteries)
IP class 42
Power supply Current source: Rechargeable
batteries/batteries 4x 1.5 V, type
AA/mignon/LR6
Battery life: approx. 250h
(display light off, Bluetooth off)
Display Type: Illuminated LCDResponse time: 0.5 s
Directives,
standards and tests
EU Directive: 2014/30/EU
You can find the EU declaration of
conformity on the Testo homepage
www.testo.com under the product-
specific downloads.

4 Product description
9
4 Product description
4.1. Overview
Display and control elements
1 Mini-DIN probe socket for NTC temperature probe, with socket
cover
2 Foldable suspension device (on rear)
3 Display. Instrument status icons:
Icon Significance
Battery capacity
Bluetooth®, (see Switching Bluetooth® on and
off (testo 550), page 14)
//
Select measuring mode (see Selecting the
measuring mode, page 15)
4 Battery compartment. It is not possible to charge rechargeable
batteries in the instrument!

5 First steps
10
5 Control keys:
Key Function
[Set] Set units
[R, ►, ■] Select refrigerant/ Start/stop / Tightness
test
[Mode] Switching measuring mode
[Min/Max/Mean] Display min./max./mean values
[▲] Up key: Change display view
[P=0] Pressure zeroing
Esc Switches to the measurement/home view
[▼] Down key: Change display view
[/] Switching the instrument on/off
Switch the display illumination on/off.
6 Sight glass for refrigerant flow
7 2 x valve positioner
8 3 x hose parkers for refrigerant hoses
9 3 x connections 7/16" UNF, brass
Left/right: Low pressure/high pressure, for refrigerant hoses
with quick connect fitting, passage can be locked via valve
positioner. Centre: for refrigerant bottles, for example, with
sealing cap.
10 On the back below the battery compartment cover, mini-USB
connection for firmware update.
5 First steps
Inserting batteries/rechargeable batteries
1. Fold out the suspension device and open the battery
compartment (clip lock).
2. Insert batteries (included in delivery) or rechargeable batteries
(4x 1.5 V, type AA/Mignon/LR6) in the battery compartment.
Observe the polarity!
3. Close the battery compartment.
- After inserting the batteries, the instrument switches on
automatically and goes into the settings menu.
When not in use for long period: Remove
batteries/rechargeable batteries.

5 First steps
11
Performing settings
1. Press [Set] repeatedly,
2. Press [▲]or [▼]to select the unit/parameter.
 The settings will be accepted once the last selection has been
made.
Key functions
Representation Explanation
[▲]or [▼]Change parameter, select unit
[Set] Select units/parameters
Adjustable parameters
Representation Explanation
°C, °F Set temperature unit.
bar, kPa, MPa, psi Set unit of pressure.
Pabs, Prel or psig Depending on the selected unit of pressure:
Switch between absolute and relative
pressure display.
14.7 psi
1.013 bar
(Pamb)
Set current absolute pressure
/ / Select measuring mode
AUTO OFF Automatic switch-off time, instrument
switches off after 30 minutes if no
temperature probe is connected and there is
no pressure apart from ambient pressure.
Tfac Temperature compensation factor, icon is
shown on the display if the function is
disabled.
 Settings will be applied following the final selection.
Operating valve positioner
The digital manifold acts like a conventional two-way manifold with
regard to the refrigerant path: The passages are opened by
opening the valves. The adjacent pressure is measured with valves
closed as well as with them open.
> Open valve: Turn valve positioner anticlockwise.
> Close valve: Turn valve positioner clockwise.

6 Using the product
12
WARNING
Valve positioner tightened too tightly.
• Damage to the PTFE seal (1).
• Mechanical deformation of the valve piston (2) leading to the
PTFE seal (1) falling out.
• Damage to the thread of the threaded spindle (3) and the valve
screw (4).
• Broken valve knob (5).
Tighten the valve positioner only hand-tight. Do not use any tools
to tighten the valve positioner.
6 Using the product
6.1. Preparing for measurement
6.1.1. Switching the instrument on
> Press [].
Zeroing the pressure sensors
Zero the pressure sensors before every measurement.
✓There must be ambient pressure at all connections. >.
> Press for 3 seconds key [P=0] and execute zeroing.
6.1.2. Connecting the temperature sensor
Sensors must be connected before the measuring
instrument is switched on, so that they are recognised by
the instrument.

6 Using the product
13
Surface temperature sensor
An NTC temperature sensor (accessory) must be connected for
measuring the pipe temperature and for automatic calculation of
superheating and subcooling.
Deactivating the surface compensation factor for insertion and
air temperature sensor
A surface compensation factor has been set in the measuring
instrument to reduce the measuring errors in the main field of
applications. This reduces measuring errors when using surface
temperature sensors.
If the measuring instrument testo 550 is used in combination with
insertion or air temperature sensors (accessories), this factor must
be deactivated:
1. Press [Set] repeatedly until Tfac is displayed.
2. Press [▲]or [▼]to set Tfac to Off.
3. Press [Set] to continue through the settings menu until the
measurement/home view is displayed.
- Tfac is shown on the display if Tfac is disabled.
Connecting the refrigerant hoses
Before each measurement check whether the refrigerant
hoses are in flawless condition.
✓The valve actuators are closed.
1. Connect the refrigerant hoses for low-pressure side (blue) and
high-pressure side (red) to the measuring instrument.
2. Connect the refrigerant hoses to the system.
WARNING
The measuring instrument dropping down or any other comparable
mechanical load can cause breakage of the pipe pieces in the
refrigerant hoses. The valve actuators may also suffer damage,
which in turn could result in further damage inside the measuring
instrument, which may not be detectable from outside.
> For your own safety you should return the measuring
instrument to the Testo Service for technical inspection.
> You should therefore always replace the refrigerant hoses with
new ones after the measuring instrument has dropped down or
after any comparable mechanical loading.

6 Using the product
14
Setting the refrigerant
1. Press [R, ►, ■].
- This opens the refrigerant menu and the currently selected
refrigerant flashes.
2. Setting the refrigerant:
Key functions
Representation Explanation
[▲]or [▼]Changing the refrigerant
[R, ►, ■] Confirm the setting and exit the refrigerant
menu.
Available refrigerants
Representation Explanation
R... Refrigerant number of refrigerant acc. to
ISO 817
--- no refrigerant selected.
Example: Setting refrigerant R401B
1. Press [▲]or [▼]several times, until R401B flashes.
2. Press [R, ►, ■]to confirm the setting.
Quitting the refrigerant selection
> Press [R, ►, ■]or automatically after 30 s, if no other key has
been pressed.
6.1.3. Switching Bluetooth® on and off
(testo 550)
In order to be able to establish a connection via Bluetooth,
you need a tablet or smartphone with the Testo app
Refrigeration already installed on it.
You can get the App for iOS instruments in the App Store
or for Android instruments in the Play Store.
Information about compatibility can be found in the
relevant app store.

6 Using the product
15
1. Press [▲]and [▼]simultaneously and hold down for
3 seconds.
- Once the Bluetooth icon is shown on the display, Bluetooth is
switched on.
Display Explanation
flashes There is no Bluetooth connection, or a
potential connection is being searched for.
is permanently
displayed
There is a Bluetooth connection.
is not displayed Bluetooth is disabled.
2. Press [▲]and [▼]simultaneously and hold down for
3 seconds.
- Once the Bluetooth icon is no longer shown on the display,
Bluetooth is switched off.
6.1.4. Selecting the measuring mode
1. Press[Set] several times.
2. Select function with[▲] or [▼].
3. Save setting: press [Set].
- Measuring mode is dsplayed.
Display Mode Function
Refrigeration
system
Normal functionality of the digital
manifold
Heat pump Normal functionality of the digital
manifold
Automatic
mode
If the automatic mode is activated, the
testo 549 und testo 550 digital
manifold automatically changes the
display of the high and low pressure.
This automatic change occurs when
the pressure on the low-pressure side
is 1 bar higher than the pressure on
the high-pressure side. During the
change, Load (2 s) is shown in the
display.
This mode is especially suited to air
conditioning systems which cool and
heat.

6 Using the product
16
6.2. Performing the measurement
WARNING
Risk of injury caused by refrigerant that is at high pressure,
hot, cold, or poisonous!
> Wear safety goggles and protective gloves.
> Before pressurizing the measuring instrument: Always fasten
the measuring instrument at the suspension device in order to
prevent it from falling (risk of breakage)
> Check if the refrigerant hoses are intact and connected
correctly before each measurement. Do not use a tool to
connect the hoses. Only tighten the hoses by hand (max.
torque 5.0 Nm/3.7 ft*lb).
> Maintain permissible measuring range (0 to 60 bar). Pay
particular attention with systems with refrigerant R744, as
these are often operated with higher pressures.
Measuring
1. Pressurize the measuring instrument.
2. Read off readings.
With zeotropic refrigerants, the evaporation temperature
to/Ev is displayed after the complete evaporation/the
condensation temperature tc/Co is displayed after the
complete condensation.
The measured temperature must be assigned to the
superheating or the subcooling side (toh <--> tcu).
Depending on this assignment, toh/T1 or ∆toh/SH or
tcu/T2 or ∆tcu/SC is shown depending on the selected
display.
- Reading and display illumination flash:
• 1 bar before reaching the critical pressure of the refrigerant,
• upon exceeding the max. permissible pressure of 60 bar.
Key functions
> [▲]or [▼]: Change the reading display.
Possible display combinations:
Evaporation pressure
Refrigerant evaporation
temperature to/Ev
Condensation pressure
Refrigerant condensation
temperature tc/Co

7 Maintaining the product
17
or (only with connected temperature probe)
Evaporation pressure
Measured temperature toh/T1
Condensation pressure
Measured temperature tcu/T2
or (only with connected temperature probe)
Evaporation pressure
Superheating ∆toh/SH.
Condensation pressure
Subcooling ∆tcu/SC
With two connected NTC probes, ∆t is also shown.
> [Mean/Min/Max]: Record readings, display min./max. readings,
mean values (since switching on).
Tightness test/pressure drop test
Systems can be tested for tightness with the
temperature-compensated tightness test. The system
pressure and the ambient temperature are measured
over a defined period for this. A temperature probe can
be connected that measures the ambient temperature
for this (recommendation: NTC air probe, art. no. 0613
1712). Information about the temperature-compensated
differential pressure and about the temperature at the
beginning/end of the test exists as a result. If no
temperature probe is connected, the tightness test can
be performed without temperature compensation.
1. Press [Mode] (leakage test view).
- Leakage test view is opened. ∆P is displayed.
2. Start the leakage test: Press [R, ►, ■].
3. End the leakage test: Press [R, ►, ■].
- Result is displayed.
4. Confirm message: Press [Mode].
7 Maintaining the product
Cleaning the instrument
Do not use any aggressive cleaning agents or solvents!
Mild household cleaning agents and soap suds may be
used.
> If the housing of the instrument is dirty, clean it with a damp
cloth.

7 Maintaining the product
18
Keeping connections clean
> Keep screw connections clean and free of grease and other
deposits, clean with a moist cloth as required.
Removing oil residues
> Carefully blow out oil residues in valve block using compressed
air.
Ensuring the measuring accuracy
Testo Customer Service would be glad to further assist you if you
so wish.
> Check instrument regularly for leaks (recommended: annually).
Keep to the permissible pressure range!
> Calibrate instrument regularly (recommended: annually).
Changing batteries/rechargeable batteries
✓Instrument is switched off.
1. Fold out the suspension device, loosen the clip and remove the
cover of the battery compartment.
2. Remove empty batteries/rechargeable batteries and insert new
batteries/rechargeable batteries (4x 1.5 V, type AA, Mignon,
LR6) in the battery compartment. Observe the polarity!
3. Set on and close cover of the battery compartment (clip must
engage).
4. Switch the instrument on.

8 Tips and assistance
19
8 Tips and assistance
8.1. Questions and answers
Question Possible causes/solution
flashes Batteries are almost empty.
> Change batteries.
The instrument switches
off automatically.
Residual capacity of the batteries is
too low.
> Change batteries.
uuuu lights up instead of
the parameter display
The permissible measuring range has
been undershot.
> Keep to the permitted measuring
range.
oooo lights up instead of
the parameter display
The permissible measuring range has
been exceeded.
> Keep to the permitted measuring
range.
8.2. Measurement parameters
Name Description
bar, °C psi, °F
∆toh SH Superheating, evaporation pressure
∆tcu SC Subcooling, condensation pressure
to Ev Refrigerant evaporation temperature
tc Co Refrigerant condensation temperature
toh T1 Measured temperature, evaporation
tcu T2 Measured temperature, condensation

8 Tips and assistance
20
8.3. Error reports
Question Possible causes/solution
---- lights up instead of the
temperature value display
(T1/T2 or toh/tcu)
Sensor or cable faulty
> Please contact your dealer or Testo
Customer Service
---- lights up instead of the
display of the value for
superheating/subcooling
(SH/SC or ∆toh/∆tcu)
- There is no
superheating/subcooling.
- No theoretical condensation or
evaporation temperature can be
calculated based on the pressure
measured.
EEP FAIL displayed Electronics faulty
> Please contact your dealer or
Testo Customer Service
8.4. Accessories and spare parts
Description Article no.
Clamp probe for temperature measurement
at pipes (1,5m cable length)
0613 5505
Clamp probe for temperature measurement
at pipes (5m cable length)
0613 5506
Pipe wrap probe with Velcro tape for pipe
diameters of up to max. 75 mm, Tmax.
+75 °C, NTC
0613 4611
Watertight NTC surface probe 0613 1912
Precise, robust NTC air probe 0613 1712
Transport case for measuring instrument,
probe and hoses
0516 0012
For a complete list of all accessories and spare parts, please refer
to the product catalogues and brochures or look up our website at:
www.testo.com
If you have any questions, please contact your dealer or Testo
Customer Service. The contact details can be found on the back of
this document or on the Internet at www.testo.com/service-
contact..