TESTO 0699 6446 Series User manual

Compressed air counter
Instruction manual
0699 6446/xx Standard
0699 6447/xx With probe removal under pressure

2

Contents
3
Contents Page
1Introduction 4
1.1 Notes on the instruction manual 4
1.2 Receiving inspection, transport, storage 5
1.3 Scope of delivery 6
2Warranty 9
3Description of the instrument 10
3.1 Task and areas of application 10
3.2 Technical data 12
3.2.1 Measuring block 12
3.2.2 Thermal mass flow sensor 14
3.3 Accessories 17
3.3.1 Sealing cap (0699 6446/41) 17
3.3.2 Connecting cable with electrical isolator (0699 6446/42) 17
3.3.3 Replacement for electronic sensor assembly (0699 6446/31 or 0699 6447/31) 17
3.3.4 Additional ISO calibration points (0699 6447/22) 18
3.3.5 DAkkS calibration (0699 6447/23) 18
3.3.6 Additional DAkkS calibration points (0699 6447/24) 18
4Security measures 19
4.1 Intended purpose 19
4.2 Assembly, commissioning and operation 20
5Installation 21
5.1 Description of PBCOmpac®flange 21
5.2 Welded connection to pipeline with PBCOmpac®flange 22
5.3 Determining the installation point 22
5.3.1 Installation position 23
5.3.2 Required measurement route 23
5.3.3 Direction of flow 24
5.4 Installation of the electronic sensor assembly in the measuring block (version 0699 6446) 24
5.5 Installation of the electronic sensor assembly in the interchangeable fitting (version 0699 6447) 26
5.6 Electrical connection 27
5.6.1 4-wire pin assignment 27
5.6.2 5-wire pin assignment (accessory) 28
6Operation 29
6.1 Removal of the electronic sensor assembly under pressure (only 0699 6477) 29
6.1.1 Electronic sensor assembly in the measurement position (OPEN) 29
6.1.2 Remove electronic sensor assembly (CLOSE) 30
6.2 Thermal mass flow sensor 30
6.2.1 Operation and display elements 30
6.2.2 Types of operation 31
6.2.3 Programming 32
6.2.4 Adjustable parameters 33
6.2.5 Error messages 36
6.2.6 Menu overview 37
6.3 Changing the electronic sensor assembly (version 0699 6446) 38
6.4 Changing the electronic sensor assembly (version 0699 6447) 38
6.5 Cleaning the sensor 39
6.6 Cleaning agents 39
6.7 Calibration 39
7Troubleshooting 40
7.1 Service address 40
7.2 Exchange of damaged parts 40
7.3 Exchange of O-rings and sealing ring 40
7.4 Return shipment 40
7.5 Disposal 40

1 Introduction
4
1 Introduction
1.1 Notes on the instruction manual
This instruction manual offers you, the user of the compressed air counter,
0699 6446 / 0699 6447 support during the installation, operation and main-
tenance.
Characters and symbols
The following characters and symbols are used in this instruction manual to
emphasize text passages that need special attention.
Notes
This arrow points out specifics that must be observed during operation.
Warning
This character brings attention to text passages which, if not complied with
or not followed specifically, may lead to damages to or destruction of parts
of the system.
Caution!
This character is placed before text passages which may be hazardous to
one's health or life if not complied with.
Reference
The character points out further information in other handbooks, chapters
or sections.

1 Introduction
5
1.2 Receiving inspection,
transport, storage
•Take note of undamaged packaging!
Communicate damages to the packaging to your supplier.
Retain the damaged packaging until the matter is settled.
•Take note of undamaged contents!
Communicate damages to the contents to your supplier.
Retain the damaged goods until the matter is settled.
•Check the scope of delivery for completeness using the shipping docu-
ments and your order.
•The instrument is to be packaged for storage and transport in such a way
that it is secured against impact and protected from moisture. The original
packaging offers optimum protection. Furthermore, the permissible ambi-
ent conditions must be maintained (Section 3.2.1).
•Please direct any further questions to your supplier or their sales office.

1 Introduction
6
1.3 Scope of delivery
Check the scope of delivery using the following table. The designations of
the individual components can also be found in the following exploded view.
The items 1, 3, and 4, marked in bold, are assembled and are to be
checked.
Item Assembled
at item Qty. Designation
1 1 Measuring block
nnn = Nominal width
material:
SVZ = Galvanized steel, 0699 6446/0x or
0699 6447/0x
EST = Stainless steel, 0699 6446/0x or
0699 6447/1x
1.10 1 2 Compac welding neck flange
nnn = Nominal width
material:
SVZ = Steel, 0699 6446/0x or 0699 6447/0x
EST = Stainless steel, 0699 6446/0x or
0699 6447/1x
1.11 1.10 2 DN 65: Viton 3.53 x 82.1
DN 80: Viton 3.53 x 94.8
DN 100: Viton 3.53 x 120.25
DN 125: Viton 3.53 x 136.12
DN 150: Viton 3.53 x 171.05
DN 200: Viton 3.53 x 274
DN 250: Viton 3.53 x 319.2
1.12 1.10 16
16
16
16
24
24
DN 65: M12 x 20 - 8.8 galv. DIN 931
DN 80: M12 x 22 - 8.8 galv. DIN 931
DN 100: M12 x 25 - 8.8 galv. DIN 931
DN 125 – DN 150 : M16 x 30 - 8.8 galv. DIN
912
DN 200: M16 x 30 - 8.8 galv. DIN 912
DN 250: M20 x 35 - 8.8 galv. DIN 912
1.20 1 1 Z alignment pin 4 x 10 DIN 7
1.30 1 1 0699 6446:
PBCOmpac conical nipple without groove
Interchangeable fitting WA140
material:
SVZ = Steel, 0699 6447/0x
EST = Stainless steel, 0699 6447/1x
1.40 1 1 O-ring, Viton 3.53 x 40.87
1.50 1.30 4 Socket head cap screw M10 x 12 - 8.8 galv.
2 1 Option Sealing cap and O-ring
2.10 2 Option O-ring, Viton 70 Shore, 30 x 2.5
3 1 Electronic sensor assembly
3.10 3 4 Roll pin
3.20 3.10 1 Hood
3.30 3 1 Protection cap for sensor tip during transport
4 Instruction manual
Please direct any further questions to your supplier or their sales office.

1 Introduction
7
0699 6446 Standard
(
1
)
(
1.10
)
(
1.20
)
(
1.30
)
(
1.40
)
(
3
)
(
3.10
)
+
(
3.20
)
(
1.50
)
(1.12)
(1.12)
(1.11)

1 Introduction
8
0699 6447 With probe removal under pressure
(
1
)
(
1.10
)
(
1.30
)
(
1.40
)
(
3
)
(
3.10
)
+
(
3.20
)
(
1.50
)
(1.12)
(1.12)
(1.11)

2 Warranty
9
2 Warranty
The instruments are built in compliance with the applicable regulations and
have left the factory in a properly-functioning state.
However, if our product should give you reason for complaint, we will rectify
deficiencies caused by errors in the factory free of charge. This is conditional
upon an immediate report of these deficiencies within our granted warranty
period.
Damages that have occurred as a result of improper use or non-compliance
with the instruction manual are excluded from this warranty.
The warranty period lasts 24 months. Unless otherwise stated, 12 months
are applicable for accessories. Warranty repairs do not extend the period of
warranty.
The warranty is voided if the interchangeable fitting or the electronic sensor
assembly has been opened (unless this is expressly described in the instruc-
tion manual for maintenance purposes) or if the serial numbers on the de-
vice have been changed, damaged or removed.
If repairs, adjustments or the like have been performed in addition to the
warranty repairs, the warranty repairs will be free of charge but the other
work will be charged as well as the transport and packaging.
Further or other claims are void, particularly for damages that have occurred
that do not pertain to the delivered components where liability is not ex-
pressly specified by law.
Services after the warranty period
Of course, we will remain at your service after the expiry of the warranty pe-
riod. In the event of malfunctions, send us your instrument with a brief de-
scription of the fault. Please also give us your telephone number for any in-
quiries.

3 Description of the instrument
10
3 Description of the instrument
3.1 Task and areas of application
Measuring block with Compac welding neck flange
The measuring block with Compac welding neck flanges enables the me-
chanical and position-accurate fixture of the electronic mass flow sensor.
The measuring block is welded into the pipelines with the Compac welding
neck flanges. The nominal width of the measuring block and welding neck
flanges must coincide with the nominal width of the pipeline (Section 1.3).
The measuring block is designed for pipeline nominal widths from DN 65 up
to DN 250.
The operation of the pipeline without the electronic sensor assembly is made
possible with the 0699 6447 by using the interchangeable fitting. (Section
6.1.2).
With 0699 6446, only with the optional sealing cap (Section 3.3.1).
Electronic sensor
The sensor records the standard volumetric flow rate of the working com-
pressed air according to the calorimetric measurement principle. The meas-
urement value of the standard volumetric flow rate is calculated based on
the DIN ISO 2533 (1013 hPa, 15 °C and 0 % relative humidity).
The general operating conditions of compressed air systems apply. The air
quality of the working compressed air influences the accuracy of the meas-
urement:
Quality class acc. to
ISO8573-1
Particle – humidity - oil
Measurement inaccuracy
1-4-1 ± (3 % of meas. value + 0.3 % of meas. range final
value)
3-4-4 ± (6 % of meas. value + 0.6 % of meas. range final
value)
Analysis
•Current volumetric flow rate
•Current consumption quantity (pulse output module and totaliser)
Display
•Current volume flow in Nm³/min (Nl/min) (LED1) or Nm³/h (Nm³/h x
1000) (LED2) (4-digit display).
For nominal widths as of DN 65 Nm³/min are shown instead of Nl/min.
For nominal widths as of DN 125 Nm³/h x 1000 are shown instead of
Nm³/h.
•Current consumption quantity in Nm³ (4-digit display between 0.001 Nm³
and 4294*10³ Nm³). For values > 9999 Nm³, 1/1000 of the measurement
value is displayed and the 10³ (LED3) display indicates that the value
must be multiplied by a factor of 1000
•Consumption quantity before the last reset in Nm³. During the display of
this value, Nm³ (LED3) flashes

3 Description of the instrument
11
•The display °C (LED4) cannot be selected.
Signal output 1
•Switch signal is the limit value for volume flow, hysteresis or window
function as NO or NC contact
•Pulse sequence for consumption quantity with 1 pulse/standard litre
(pulse length 2 ms) and 1 pulse/Nm³ (pulse length 100 ms)
Signal output 2
•Switch signal is the limit value for volume flow, hysteresis or window
function as NO or NC contact
•Analog signal (4 - 20 mA) for corresponding volume flow
•Pulse sequence for consumption quantity with 1 pulse/standard litre
(pulse length 2 ms) and 1 pulse/Nm³ (pulse length 100 ms)
Measuring range Recording/display range
Relative meas.
range (%) 0,33% (0,4%) - 100%* 0% - 120%*
( ) : Value shown in display
* Absolute measuring range depends on the nominal width (see following
table)
Compressed air counter
The compressed air counter may only be used for measuring the volume
flow of working compressed air with up to 16 bar positive pressure.
Nominal width Meas. range* Recording/display range
DN 65 6,7 – 2000 m³/h 0 – 2400 m³/h
DN 80 9,2 – 2750 m³/h 0 – 3300 m³/h
DN 100 15 – 4440 m³/h 0 – 5320 m³/h
DN 125 23 – 7000 m³/h 0 – 8400 m³/h
DN 150 33 – 10,000 m³/h 0 - 12.0 (x 1000) m³/h
DN 200 58 – 17,500 m³/h 0 - 21.0 (x 1000) m³/h
DN 250 92 – 27,500 m³/h 0 - 33.0 (x 1000) m³/h
*Specifications acc. to DIN ISO 2533 (15 °C, 1013 hPa and 0 % rel. hu-
midity)
When using the totaliser function (consumption meter m³), the display value
must be multiplied by 1000.
As of DN 150 the display range with 4-digit representation of the m³/h is in-
sufficient. The display value is to be multiplied by 1000.
Based on the small size, the sensor only has a small contact surface. The
pressure loss is thus negligible (typ. 1 mbar).

3 Description of the instrument
12
3.2 Technical data
3.2.1 Measuring block
0699 6446 Standard
Material SVZ = Galvanized steel, 0699 6446/0x
EST = Stainless steel, 0699 6446/1x
Dimensions
Part no. Nominal
width L (mm) D1 (mm) D2 (mm) S (mm) H1 N SL W1* (kg)
0699 6446/01 DN 65 124 125 70.3 2.9 185 8 13 8.3
0699 6446/02 DN 80 160 141 82.5 3.2 201 8 13 10.6
0699 6446/03 DN 100 160 165 107.1 3.6 225 8 13 12.7
0699 6446/04 DN 125 172 205 131.7 4 265 8 17 20.6
0699 6446/05 DN 150 180 235 159.3 4.5 295 8 17 25.4
0699 6446/06 DN 200 180 290 207.3 5.9 350 12 17 36.0
0699 6446/07 DN 250 196 355 260.4 6.3 415 12 21 48.4
*W1: Weight of the mechanism, with sensor
Quantity:
Screws N
Ø screw holes SL
Ø D2
DN (see table)

3 Description of the instrument
13
0699 6447 With probe removal under pressure
Material SVZ = Galvanized steel, 0699 6447/0x
EST = Stainless steel, or 0699 6447/1x
Dimensions 0699 6447
Part no. Nominal
width L (mm) D1 (mm) D2 (mm) S (mm) H1 N SL W1* (kg)
0699 6447/01 DN 65 124 125 70.3 2.9 279 8 13 9.3
0699 6447/02 DN 80 160 141 82.5 3.2 295 8 13 11.6
0699 6447/03 DN 100 160 165 107.1 3.6 319 8 13 13.7
0699 6447/04 DN 125 172 205 131.7 4 359 8 17 21.6
0699 6447/05 DN 150 180 235 159.3 4.5 389 8 17 26.4
0699 6447/06 DN 200 180 290 207.3 5.9 444 12 17 37.0
0699 6447/07 DN 250 196 355 260.4 6.3 509 12 21 49.4
*W1: Weight of the mechanism, with electronic sensor assembly
Quantity:
Screws N
Ø screw holes SL
Ø D2
DN (see table)

3 Description of the instrument
14
3.2.2 Thermal mass flow sensor
The thermal mass flow sensor for the compressed air volume flow meas-
urement is independent of the process pressure and the media temperature.
The electronic sensor assembly is adjusted to the data of the measurement
block (diameter/medium). For this reason, only an identically adjusted model
can be used when replacing the component. When ordering spares, the data
of the measurement block must be stated.
Sensor Thermal, glass passivated ceramic sensor
Media Compressed air, with special calibration also CO2, N2
Accuracy for compressed air quality classes (ISO 8573:
Particle - humidity - oil) 1-4-1: ±3 % of reading ±0.3 % of final
value
for compressed air quality classes (ISO 8573:
Particle - humidity - oil) 3-4-4: ±6% of reading ±0.6% of final
value
Display, operation 4-digit alphanumeric display, two operating buttons, operation
menu, LED (4x green for phys. units, 3x yellow for "Display x
1000" and switch statuses)
Display units* Nm³/min (Nl/min), Nm³/h, Nm³
Measuring dynamics 1:300
Response time < 0.1 s
Pressure-tight up to 16 bar positive pressure
Media contact V2A (1.4301), glass passivated ceramic, PEEK, polyester,
Viton, anodized aluminium
Housing materials PBT-GF 20, PC (APEC), Makrolon, V2A (1.4301), Viton
Protection class IP65 / III
Medium temperature 0 - +60 °C (rel. humidity max. 90 %)
Perm. ambient temperature 0 - +60 °C
Perm. storage temperature -25 - +85 °C
Electrical connection M12 x 1 connector, can be loaded to 250 mA, short-circuit-proof
Voltage supply 19 - 30 VDC, power consumption < 100 mA
Output signals
Analog output 4 - 20 mA, measuring range scaleable
max. load 500 ohm
Switch output 2 switch signals can be parameterized (dependent on volume
flow, hysteresis or window function as NO or NC contact)
Pulse output DN 65 – DN 80: 1 pulse/m³
DN 100 – DN 250: 1 pulse/10 m³
Current carrying capacity 2 x 250 mA, short-circuit-proof, protected against polarity rever-
sal, overload-proof
Readiness delay 0.5 s
CE
EU Directive 2004/108/EC
* The measurement, display and adjustment ranges are related to the stan-
dard volumetric flow according to DIN ISO 2533 (15 °C, 1013 mbar and 0 %
rel. humidity) if not otherwise entered in the calibration protocol of the elec-
tronic sensor assembly

3 Description of the instrument
15
Dimensions 0699 6446 Standard
Item 1 Sensor display
Item 2 Sensor probe component
Item 3 Threaded pin
Item 4 O-ring
Item 5 Cylindrical pin for alignment in the direction of the flow
Sensor weight 428 g
Direction of flow
WAF 36
Section A-A

3 Description of the instrument
16
Dimensions 0699 6447 With probe removal under pressure
Item 1 Head of the electronic sensor assembly
Item 2 Extension
Item 3 Threaded pin
Item 4 O-ring
Item 5 Cylindrical pin for alignment in the direction of the flow
Item 6 Sensor
Electronic sensor assembly
weight 560 g
Section A-A
Direction of flow

3 Description of the instrument
17
3.3 Accessories
3.3.1 Sealing cap (0699 6446/41)
Only for 0699 6446 Standard version.
The sealing cap with internal thread is used for operating the pipeline without
the mass flow sensor.
3.3.2 Connecting cable with electrical isola-
tor (0699 6446/42)
Uniform for all versions.
A connecting cable with an electrical isolator integrated into the connector is
available as an accessory. The cable is 5 m long and is used for the galvanic
isolation of the signal output to the electronics to which it is attached. The
cable is delivered with an appropriate connector for the mass flow sensor on
one side and with open cable ends on the other side.
3.3.3 Replacement for electronic sensor as-
sembly (0699 6446/31 or 0699 6447/31)
The electronic sensor assembly is adjusted to the data of the measurement
block (diameter/medium). For this reason, only an identically adjusted model
can be used when replacing the component. When ordering spares, the data
of the measurement block must be stated.
The replacement for the electronic sensor assembly is used as a backup in
the event of damage to or loss of the original mass flow sensor or the entire
assembly.
When ordering, the nominal width must be given for the calibration of the
electronic sensor assembly.
Sealing cap mounted on
measuring block.

3 Description of the instrument
18
3.3.4 Additional ISO calibration points
(0699 6447/22)
Uniform for all versions.
Other measurement points are calibrated for the ISO basic calibration. You
must specify the number of required additional calibration points when order-
ing.
3.3.5 DAkkS calibration (0699 6447/23)
Uniform for all versions.
The mass flow sensor receives a 2-point calibration from a DAkkS certified
calibration laboratory. This is documented on the electronic sensor assembly
by means of an inspection label.
3.3.6 Additional DAkkS calibration points
(0699 6447/24)
Uniform for all versions.
Other measurement points are calibrated in addition to the DAkkS basic cali-
bration. You must specify the number of additional calibration points when
ordering.

4 Security measures
19
4 Security measures
4.1 Intended purpose
The compressed air counter is intended exclusively for use in pipe systems
for working compressed air, provided that the calibration certificate does not
explicitly allow using for other gases.
Thanks to the design, operation in systems that are under pressure up to
PN16 is possible.
The system must be depressurized before beginning the drilling and welding
work.
0699 6446: Before assembling or dismantling the sensor or the sealing cap
(available as an accessory), the system status must be at zero pressure.
Use which deviates from that described endangers the safety of people and
of all of the measuring equipment and is thus not permissible.
The manufacturer accepts no liability for damages that occur as a result of
improper or inappropriate use or installation.
To avoid damage to the instrument or health hazards, no manipulation using
tools may occur on the measuring units that is not expressly defined in this
operating manual.
0699 6446: Changing the sensors while in operation is not possible.
0699 6447: If all necessary operation steps are observed, changing the elec-
tronic sensor assembly while in operation is possible thanks to the inter-
changeable fitting.
The compressed air counter may only be operated under the ambient condi-
tions specified in the technical data. Otherwise, inaccurate measurements
occur or instrument malfunctions become possible.
To ensure the safety of the user and the operability of the instruments, the
commissioning steps, checks and maintenance work recommended by the
manufacturer are to be complied with and carried out.
These instructions do not contain complete detailed information for the sake
of transparency.
Should you require further information or should a specific problem occur
that is not comprehensively handled in the instructions, you can request the
required information directly from the manufacturer.
Read these operating instructions before commissioning the fitting. Store
these operating instructions in a location that is accessible for all users at all
times. Please support us in improving these operating instructions. We are
grateful for any ideas you may have.

4 Installation
20
4.2 Assembly, commissioning
and operation
The compressed air counter was reliably built and checked according to
state-of-the-art technology and left the factory in a properly secure state.
As the user, you are responsible for the compliance with all valid safety
regulations, including:
•Installation specifications
•Local standards and regulations.
The manufacturer has undertaken all necessary measures to ensure safe
operation. The user must ensure that the instruments are set up and in-
stalled in such a way that safe use is not impacted.
The instruments are factory-tested and were delivered in a reliable state.
These operating instructions contain information and warnings that must be
followed by the user in order to ensure safe operation.
•Assembly, commissioning, operation and maintenance of the measuring
unit may only be performed by trained authorized personnel. The person-
nel must be authorized for the named functions by the system operator.
•The authorized personnel must have read and understood these operat-
ing instructions and comply with the directions in these operating instruc-
tions.
•Check all connections for correctness before the commissioning of the
complete measuring point.
•Do not commission damaged products and keep these from being inad-
vertently commissioned. Mark the damaged products as defective.
•Faults at the measuring point are only to be corrected by authorized and
specially trained personnel.
•If faults cannot be corrected, the products must be taken out of operation
and secured from inadvertent commissioning.
•Repairs that are not described in these operating instructions may only
be carried out directly by the manufacturer or by the service organization.
Exclusion of liability:
Liability of the manufacturer and its assistants exists only in the event of de-
liberate acts or gross negligence. The extent of liability is limited to the value
of the respective order placed with the manufacturer.
The manufacturer accepts no liability for damages that occur due to non-
observance of the safety instructions or noncompliance with the instruction
manual or the operating conditions. Consequential damages are excluded
from the liability.