TESTO 557 User manual

testo 557 · Digital manifold
Instruction manual

2

1 Contents
3
1Contents
1Contents...................................................................................................3
2Safety and the environment....................................................................4
2.1. About this document........................................................................4
2.2. Ensure safety...................................................................................5
2.3. Protecting the environment..............................................................5
3Specifications ..........................................................................................6
3.1. Use..................................................................................................6
3.2. Technical data.................................................................................6
4Product description...............................................................................10
4.1. Overview........................................................................................10
5First steps ..............................................................................................12
6Using the manifold ................................................................................14
6.1. Preparing for measurement...........................................................14
6.1.1. Switching the instrument on...........................................................................14
6.1.2. Connecting the temperature sensor...............................................................14
6.1.3. Connecting the vacuum probe.......................................................................16
6.1.4. Switching Bluetooth® on and off....................................................................16
6.1.5. Choosing the measuring mode......................................................................17
6.2. Performing the measurement........................................................17
7Maintaining the product........................................................................21
8Tips and assistance...............................................................................23
8.1. Questions and answers.................................................................23
8.2. Measurement parameters .............................................................23
8.3. Error reports ..................................................................................24
8.4. Accessories and spare parts .........................................................25
9Declarations...........................................................................................25

2 Safety and the environment
4
2Safety and the environment
2.1. About this document
Use
> Please read this documentation 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 product.
> 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.
1. ...
2. ... Action: more steps, the sequence must be
followed.
> ... Action: a step or an optional step.
- ... Result of an action.
Menu Elements of the instrument, the instrument
display or the program interface.
[OK] Control keys of the instrument or buttons of
the program interface.
... | ... Functions/paths within a menu.
“...” Example entries

2 Safety and the environment
5
2.2. Ensure safety
> Do not operate the instrument if there are signs of damage at
the housing, mains unit or hoses.
> Do not perform contact measurements on non-insulated, live
parts.
> Do not store the product together with solvents. Do not use any
desiccants.
> 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 refrigeration 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.
> Electrostatic charging can destroy the device. Integrate all the
components (system, manifold's valve block, refrigerant bottle
etc.) into the potential equalisation (earthing). Please see the
safety instructions for the system and the refrigerant used.
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
6
3Specifications
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3.1. Use
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The testo 557 is a digital manifold for maintenance and service
work on refrigeration systems and heat pumps. The device is only
to be used by qualified expert personnel.
With its functions the testo 557 replaces mechanical manifolds,
thermometers and pressure/temperature charts. Pressures and
temperatures can be applied, adapted, tested and monitored.
The testo 557 is compatible with most of the non-corrosive
refrigerants, water and glycol. The testo 557 is not compatible with
ammoniac refrigerants.
Then product must not be used in explosive environments!
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3.2. Technical data
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Feature Values
Measurement
parameters Pressure: psi/ kPa/MPa/bar
Temperature: °F/°C/K
Vacuum: micron / inHg / inH2O / hPa / mbar/
mTorr /Torr / Pa
Sensing element Pressure: 2 x pressure sensors
Temperature: 2 x NTC
Vacuum: via external probe
Measuring cycle 0,5s
Interfaces Pressure connections: 3 x 7/16" UNF,
1x 5/8" UNF
NTC measurement
External vacuum probe
Measurement
ranges Pressure measurement range
HP/LP: -14.7…870 psi / -100…6000 kPa
/ -0.1…6 MPa / -1…60 bar (rel)
Temperature measurement
range: -58…302 °F / -50…+150 °C
Measurement range vacuum: 0 ... 20.000
Mikron
Overload 940 psi, 65 bar, 6500 kPa, 6.5 MPa

3 Specifications
7
Feature Values
Resolution Resolution pressure: 0.1 psi / 0.01 bar /
1 kPa / 0.001 MPa
Resolution temperature: 0.1 °F / 0.1 °C /
0.1 K
Vacuum resolution: 1 Mikron (from 0 to 1000
Mikron) 10 Mikron (from 1000 to 2000
Mikron) 100 Mikron (from 2000 to 5000
Mikron) 500 Mikron (from 5000 to 10000
Mikron) 5000 Mikron (from 10000 to 20.000
Mikron)
Accuracy (nominal
temperature 71.6 °F
/ 22 °C)
Pressure: ±0.5% of final value (±1 digit)
Temperature (-40…302 °F/-40…+150 °C):
±0.9°F (±1 digit), ±0.5 °C (±1 digit)
Vacuum: ±(10 Mikron + 10% v. Mw.) (100 ...
1.000 Mikron)
No. of refrigerants 60

3 Specifications
8
Feature 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
APP
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
9
Feature Values
Measurable media Measurable media: all media that is stored in
the testo 557. Not measurable: ammonia
(R717) and other refrigerants which contain
ammonia
Ambient conditions Operating temperature: -4…122°F
/ -20…50°C
-10 ... 50°C / 14 ... 122 °F (Vacuum)
Storage temperature: -4…140°F / -20…60°C
Humidity in area of use: 10… 90%rF
Housing Material: ABS / PA / TPE
Dimensions approx. 280 x 135 x 75 mm
Weight: approx. 1200 g (without batteries)
IP-class 42
Power supply Current source: Rechargeable batteries /
batteries 4 x 1.5V type AA / Mignon / LR6
Battery lifetime: approx. 250 h (Bluetooth off,
vacuum probe not connected)
Display Type: Illuminated LCD
Response 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
10
4Product description
4.1. Overview
Display and control elements
1 Front connection for external vacuum probe
2 Sensor socket Mini-DIN for NTC-temperature sensor, with
socket cover
3 Suspension attachment, foldable (backside).
4 Display. Instrument status icons:
Icon
Meaning
Battery status
Bluetooth®
/ /
Select measuring mode
5 Battery compartment. The rechargeable batteries cannot be
charged inside the instrument!

4 Product description
11
6 Control keys:
Key Function
[Set] Set units
[R, ►, ■]
Select refrigerant / Start-Stop leak test
[Mode]
Switch between measuring modes
[Min/Max/Mean]
Display min, max, mean values
[▲] Up-key: Scroll through menu.
[P=0] Pressure zeroing
Esc Switches to the measurement/home view.
[▼] Down-key: Scroll through menu.
[ / ] Switching the instrument on/off
Switching display ilumination on/off.
7 Inspection glass for refrigerant flow.
8 4 x valve stem shutoff
9 4 x hose holders for refrigerant hoses
10 Connection 1/4" SAE, brass.
High pressure, for refrigerant hoses with quick release screw
fitting, passage for valve actuator lockable.
11 Connection 3/8" SAE, brass, for vacuum pump
12 Connection 1/4" SAE, brass, for e.g. refrigerant cylinders, with
screw cap.
13 Connection 1/4" SAE, brass.
Low pressure for refrigerant hoses with quick release screw
fitting, passage for valve actuator lockable.
14 Mini-USB connection for firmware update, inside the battery
compartment.

5 First steps
12
5First steps
Inserting batteries/rechargeable batteries
1. Fold out the hanging hook and open the battery compartment
by squeezing the 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: Take out the batteries /
rechargeable batteries.
Performing settings
1. Press [Set] to confirm or change unit parameter settings
2. Press [▲] or [▼] to change the units / parameters.
- The settings will be accepted once the last selection has been
made.
Key functions
Key Functions Description
[▲] or [▼] Change parameters and select units
[Set] Confirm units / parameters
Adjustable parameters
Representation Explanation
°C, °F
Set unit for temperature.
bar, kPa, MPa, psi
Set unit for pressure.
Pabs, Prel or psig Depending on the chosen unit for pressure:
Change between absolute and relative
pressure displays.
micron, inHg, Pa,
hPa, mTorr,Torr,
inH2O, mbar
Set pressure unit for vacuum.
/ /
Select the measuring mode

5 First steps
13
Representation Explanation
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.
Operating the valve stem shutoffs
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 counterclockwise.
> Close valve: Turn valve positioner clockwise.
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 manifold
14
6Using the manifold
6.1. Preparing for measurement
6.1.1. Switching the instrument on
> Press [ ].
Zeroing the pressure sensors
Zero the pressure sensors before every measurement.
✓All connections must be pressureless (ambient pressure).
> Press for 2 seconds key [P=0] and execute zeroing.
6.1.2. Connecting the temperature sensor
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.
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.

6 Using the manifold
15
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.
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 Using the manifold
16
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6.1.3. Connecting the vacuum probe
> Open the front cover of the connector and connect up the
vacuum probe.
- The instrument automatically switches to the vacuum
measurement mode.
6.1.4. Switching Bluetooth® on and off
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.
1. Press [▲] and [▼] simultaneously and hold down for
3 seconds.
- Once the Bluetooth icon is shown on the display, Bluetooth is
switched on.
Display
Description
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 Using the manifold
17
6.1.5. Choosing the measuring mode
1. Press [Set] several times
2. Press [▲] or [▼] to select the function.
3. Saving settings: Press [Set].
- The measuring mode is displayed.
Display Mode Function
Refrigeration
system Normal function of the digital manifold
Heat pump Normal function of the digital manifold
Automatic
mode When automatic mode is activated the
digital manifold testo 557 automatically
reverse the display of high and low
pressure. This automatic reversal
occurs when the pressure in the low
pressure side is 1 bar higher than the
pressure in the high pressure side. This
switching over is indicated by ----
flashing in the display. This mode is
particularly suitable for air conditioning
systems that provide cooling and
heating.
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 applying pressure to the measuring instrument: Always
fasten the measuring instrument on the suspension attachment
to prevent it from falling down (danger of breakage)
> Before each measurement check the refrigerant hoses for
flawless condition and correct connection. Do not use any tools
to connect the hoses, tighten hoses only hand-tight (max.
torque 5.0 Nm / 3.7 ft*lb).
> Comply with the permissible measuring range (-14.7…870 psi
/ -1…60 bar). Pay particular attention in systems with
refrigerant R744, since these are frequently operated with
higher pressures.

6 Using the manifold
18
Measuring
✓The actions described in the chapter “Preparing for
measurement” have been performed.
1. Apply pressure to the measuring instrument.
2. Read the measuring values.
With zeotropic refrigerants, the evaporation temperature
to/Ev is displayed after the complete evaporation / the
condensation temperature tc/Co is displayed after complete
condensation.
The measured temperature must be assigned to the
superheating or subcooling side (toh <--> tcu
). Dependent on
this assignment, the display will show toh/T1 resp. Δtoh/SH
or tcu/T2 resp. Δtcu/SC, depending on the selected display.
- Reading and display illumination are flashing.
• The critical pressure of the refrigerant is within 15 psi (1 bar)
of the highest pressure (and temperature) where the
refrigerant can still condense.
• The maximum. permissible pressure of 870 psi (60 bar) is
exceeded.
Key functions
> Press [▲] or [▼] to change the reading in the display.
Possible display combinations:
Evaporation pressure
Refrigerant evaporation
temperature to/Ev
Condensation pressure
Refrigerant condensation
temperature tc/Co
or (only with inserted temperature sensor)
Evaporation pressure
Measured temperature
toh/T1
Condensation pressure
Measured temperature
tcu/T2
or (only with inserted temperature sensor)
Evaporation pressure
Superheating Δtoh/SH Condensation pressure Subcooling Δtcu/SC

6 Using the manifold
19
With both NTC temperature probes connected, Δt is also shown.
> Press [Mean/Min/Max]: to display min. / max. readings and
mean values.
Leak test / pressure drop test
The temperature compensated leak test can be used to
check the leak tightness of systems. For this purpose both
the system pressure and the ambient temperature are
measured over a defined period of time. For this purpose
a temperature sensor to measure the ambient temperature
may be connected (recommendation: Deactivate the
surface compensation factor (see page 14) and use NTC
air sensors Art.-No. 0613 1712). This provides information
about the temperature compensated differential pressure
and about the temperature at the beginning/end of the test
as a result. If no temperature sensor is connected, you may
also perform the leak test without temperature
compensation.
✓The actions described in the chapter “Preparing for
measurement” have been performed.
1. Press [Mode]
- The leak test view is opened. ΔP is displayed.
2. Start the leak test: Press [R, ►, ■].
3. End the leak test: Press [R, ►, ■].
- The result is displayed.
4. Confirm the message: Press [Mode].
- Main menu display.
Changeable
-
Evaporation
Temperature (Ev)
-
Measured
Temperature (T1)
-
Superheating (SH)
Changeable
-
Condensation
Temperature (Co)
-
Measured
Temperature (T2)
-
Subcooling (SC)
Condensation
pressure
Evaporation
pressure

6 Using the manifold
20
Evacuation / vacuum display
5. Connect Vakuum probe
Vacuum measurement
✓The vacuum probe is plugged into the front connection of the
manifold and connected to the system.
1. [Mode] 2 x press.
- The vacuum measurement menu appears. If ambient pressure
is applied to the vacuum probe, then oooo is shown on the
display.
2. Start the vacuum pump.
- Once the measuring range 0 to 20,000 microns is reached, the
current vacuum value is shown on the instrument display. The
instrument also displays the current ambient temperature, the
water evaporation temperature, which corresponds to the
vacuum reading, and the delta between these two
temperatures.
3. To leave vacuum mode, remove the vacuum probe from the
testo 557 or switch to the standard measurement view using the
[Mode] button.
Differential
pressure start
compared to
actual
Measured
pressure
beginning
of test
Duration
of test
Actual
measured
pressure