TESTO 523 User manual

Instruction manual en (international)
testo 523
Refrigeration System Analyzer

Safety and environment2
Safety and environment
On this document
iRead this document through carefully, and familiarize yourself with the
product before you put it to use. Keep this documentation close to hand in
order to be able to consult it if required. Pass this documentation on to later
users of the product.
iPay particular attention to information which is marked with the following
symbols:
· With the signal word Warning!:
Warns of dangers which can lead to serious injury if the prescribed safety
measures are not taken.
· With the signal word Caution!:
Warns of dangers which can lead to injury or material damage if the
prescribed safety measures are not taken.
· Important information
Avoiding personal injury/material damage
iUse the measuring instrument only for the purpose for which it is intended,
and within the parameters stated in the technical data. Do not use force.
iDo not carry out measurements on or near live parts with the measuring
instrument or the probes, if the instrument is not expressly approved for this!
iNever store the instrument together with solvents, do not use dessicants.
iCarry out only repair and maintenance work described in the instruction
manual. Observe the prescribed handling steps. Use only original spare parts
from Testo.

Specifications 3
Warning!
Danger of injury exists if highly pressurized hot, cold and/or toxic
refrigerants escape. For this reason, always wear protective glasses
and protective gloves when carrying out measurements and other
work on the refrigeration system.
If the measuring instrument falls down or is exposed to any other
comparable mechanical strain, the end connections of the refrigerant
hoses can break off. The valve knobs can also be damaged, which
can lead to further damage in the interior of the instrument, which is
not visible externally. For this reason, replace the refrigerant hoses
after any fall or comparable mechanical strain with new, undamaged
refrigerant hoses. For your own safety, send the instrument to Testo
customer service for technical testing.
Protecting the environment
iRefrigerant gases can damage the environment. Observe the relevant
environmental protection regulations.
iDispose of faulty rechargeable batteries/empty batteries at the proper
collection points.
iSend the product back to Testo at the end of its life. We will ensure that it is
disposed of in an environmentally friendly manner.
Specifications
Functions and application
The testo 523 is a refrigeration system analysis instrument for maintenace and
service work on refrigeration systems and heat pumps. It may only be used by
qualified staff.
The functions of the testo 523 enable it to replace mechanical manifolds,
thermometers and pressure/temperature tables. Pressures and temperatures
can be increased, adjusted, checked and monitored.
The testo 523 is compatible with most non-corrosive refrigerants, water and
glycol. The testo 523 is not compatible with refrigerants containing ammonia.
The product may nnot be used in areas where there is danger of explosion!
enfresitptsvnl????

Specifications4
Technical data
Measurement parameters
· Pressure: kPa / Mpa / bar / psi, temperature: °C / °F
Measurement sensor
· Pressure: 2x pressure sensor, temperature: Pt100
Measurement channels
· Number: 3
Interfaces
· Pressure connections: 3x 7/16" (1/4 SAE)
· Probes: 1x mini DIN socket for Pt100 temperature
probes
· Printer: IR for compatible Testo printer
Measurement ranges
· Meas. range pressure High Side: 0 to 50bar (rel) / 0 to
725psi (rel) / 0 to 5000kPa (rel) / 0 to 5MPa (rel)
· Meas. range pressure Low Side: 0 to 25bar (rel) / 0 to
362.5psi (rel) / 0 to 2500kPa (rel) / 0 to 2.5MPa (rel),
Overload limit 50bar / 725psi / 5000kPa / 5MPa
· Meas. range temp: -50 to +200°C / -58 to 392°F
Resolution
· Resolution pressure 0.1bar/1.45 psi/10 kPa/0.01MPa
· Resolution temperature: 0.1°C / 0.1°F
Accuracy (Nominal temperature 22°C/71.6°F, ±1 digit)
· Accuracy pressure: ±0.5% of full scale
Refrigerants
· Number: 30
· Measurable media: All refrigerants, nitrogen, water,
glycol. Not measurable: Ammonia (R717) and other
refrigerants containing ammonia
Ambient conditions
· Application temperature: -20 to 60°C / -4 to 140°F
· Storage temperature: -20 to 60°C / -4 to 140°F
Housing
· Material: ABS/PA/TPU
· Dimensions: 265 x 135 x75 mm (10.4 x 5.3 x 3.0“)
· Weight: approx 1200 g (2.7 lbs.)
· Protection class: IP54 / NEMA 3/3S
Current supply
· Current source:rechargeable or standard batteries
4x 1.5V, Type AA/Mignon/LR6
· Battery life: approx. 40h (display illumination off)
Display
· Type:Illuminated LCD
· Refresh rate: 1s
Guidelines, norms and tests
· EC guideline: 2004/108/EEC
Warranty
· Duration: 2 years
· warranty conditions: See web page
www.testo.com/warranty

Product description 5
Product description
At a glance
enfresitptsvnl????
IR interface for connection to Testo report
printer
Display: low pressure side (blue), high
pressure side (red)
Display symbols
: Battery capacity ( : full, : empty)
: Print function: data are being transmitted
Probe socket mini DIN for Pt100
temperature probes, with socket cover
Operating buttons
Button functions
: On/Off button: switches instrument on/off.
: Function buttons (4x, orange): respective
function is shown in display.
: Up/Down buttons: change display view.
: Light button: switches display/sight glass
illumination on/off.
: Printer button: transmits data to Testo report
printer
Sight glass for refrigerant flow.
2x valve knobs, with two valve positions
(see ).
3x connections 7/16“ UNF (1/4 SAE), brass.
Left/right: low pressure /high pressure,
for refrigerant hoses with fast screw
connection, flow-through can be closed
with valve.
Centre: for e.g. refrigerant bottles, with
sealing cap.
2x Unlocking buttons for valve knobs
Battery compartment. Rechargeable
batteries cannot be charged in the
instrument!
Fold-away suspension hook, with eye for
a padlock (see ).
Plastic protector
Warning!
Do not remove fitting protector
during measurement and trans-
port. It protects the fittings at the
base of the instrument from un-
due strain or potential breakage.

First steps6
First steps
²Inserting bbatteries/rechargeable bbatteries:
1Fold out the suspension hook and open battery compartment (clip
fastening).
2Insert batteries (included in delivery) or rechargeable batteries (4x 1.5V,
Type AA /Mignon/LR6) into the battery compartment. Observe polarity!
3Close battery compartment.
At longer periods of disuse: Remove batteries.
²Switching iinstrument oon:
iPress .
- Initialization phase:
· All display sements light up (duration: 2s).
· Instrument type, serial number and Firmware version are displayed (duration: 2s).
- The measurement view is opened
-or-
- When switched on for the first time after battery replacement:
StAndArd bAtt flashes.
The battery type used must be entered so that the battery capacity is
correctly displayed. The instrument switches off after one minute, if no
setting is made.
1Press or several times to set the battery type used:
StAndArd bAtt = Standard batteries, rEchArGE bAtt = Rechargeable
batteries.
2Press function button OK to confirm the setting.
- The configuration menu is opened.
3Continue with Making ssettings, step 2.
²Making ssettings:
1Press function button Set.
- The configuration menu is opened and the settable parameter flashes.

First steps 7
2Setting parameters:
Button functions
· : Alter parameter.
· : Change to next parameter.
·OK : Store settings and leave configuration menu.
·esc : Leave configuration menu (without storing).
Settable parameters
·P=0: Set pressure sensors to zero
·bar,kPa,MPa,psi: Set pressure unit.
·Pabs,Prel or psia,psig(depending on pressure unit selected): Switch between display of absolute and
relative pressure.
·°C,°F : Set temperature.
·AutoOff off,on : Automatic switch-off (20min after the last time a button was pressed) switch on/off.
·24hr,am/pm : Switch between 24h and 12h time display.
·88:88 : Set time (hours, minutes).
·day,month,year : Set date (day, month, year).
Example “Set pressure unit”
1 Press function button or several times, until bar,kPa,MPa or psi flashes.
2 Press or several times, until the desired pressure unit appears.
3 Press function button or several times to switch to the next parameter
3Press function button OK to store the settings and leave the configuration
menu.
²Switching iinstrument ooff:
iPress .
²Operating vvalve kknobs:
The function of the valve knobs is independent of the valve position. For
easier operation, unlocking the knobs is recommended. For transport,
stowing the valve knobs is recommended.
iUnlock valve knobs: Press unlocking button.
iStow valve knobs: Press valve knobs into the housing.
The refrigeration system analyzer acts like a conventional two-way manifold
with respect to the refrigerant path: The passage is opened by opening the
valves. The connected pressure is measured measured independently of
whether the valves are open or closed.
iOpen valve: Turn the valve knob anti-clockwise.
iClose valve: Turn the valve knob clockwise.
Warning!
Tighten valve positioner only hand-tight. Do not use tools to tighten
the valve positioner, as the thread may be damaged thereby!
enfresitptsvnl????

Using the product8
Using the product
Preparing measurement
²Connecting ttemperature pprobe:
For the measurement of the line temperature and the automatic calculation
of super-heating and sub-cooling, a Pt100 temperature probe (accessory)
must be connected.
Probes must be connected before switching the instrument on, in order for
them to be recognized.
1Open the socket cover on the left-hand side of the instrument.
2Plug the connection plug of the temperature probe into the probe socket.
3Depending on the measurement task, position the probe at the end of the
evaporator (Superheat) or condenser (Sub-cooling).
²Switching iinstrument oon:
iPress .
²Zeroing ppressure ssensors:
Carry out a zeroing of the pressure sensors before each measurement.
The measurement values can be falsified by a change in the position of
the measuring instrument. After zeroing, the position of the measuring
instrument must not be changed. Carry out zeroing before every measure-
ment in order to compensate faulty positioning or long-term zero-point
drift. Zeroing is only possible in a range of ±1bar(rel)/ ±14.5psi (rel) and
0...2bar(abs)/ ±29psi (abs) resprectively.
The connections on the low and high pressure sides must be depres-
surized (ambient pressure).
1Press function button Set.
-p=0 flashes.
2Press OK to carry out zeroing.
²Connecting rrefigerant hhoses:
The valve knobs are closed.
1Connect refrigerant hoses for low pressure side (blue) and high pressure
side (red) to the instrument.
2Connect refrigerant hoses to the system.

Using the product 9
Warning!
If the measuring instrument falls down or is exposed to any other
comparable mechanical strain, the end connections of the refrigerant
hoses can break off. The valve knobs can also be damaged, which
can lead to further damage in the interior of the instrument, which is
not visible externally. For this reason, replace the refrigerant hoses
after any fall or comparable mechanical strain with new, undamaged
refrigerant hoses. For your own safety, send the instrument to Testo
customer service for technical testing.
²Setting rrefrigerant:
1Press right-hand function button (R..., ...T or ---) .
- The refrigerant menu is opened and the selected refrigerant flashes.
2Set refrigerant:
Button functions
· : Change refrigerant.
·OK : Confirm setting and leave refrigerant menu.
·esc : Leave refrigerant menu without applying setting.
Settable refrigerants
·R... : R-number of the refrigerant according to ISO817.
·...T : Special Testo description of certain refrigerants: 1T = R1270, 2T = R407D, 3T = R422D.
·--- : No refrigerant selected.
Example “Setting refrigerant R401B”
1 Press or several times, until R401B flashes.
2 Press function button OK to confirm the setting.
enfresitptsvnl????

Using the product10
Carrying out a measurement
Warning!
Danger oofiinjury ddue ttohhighly ppressurized hhot, ccold oorppoisonous
refrigerants!
iAlways secure the measuring instrument with the carabiner
suspension hook before pressurizing the instrument, in order to
prevent falls (danger of breakage).
iBefore each measurement, ensure that the refrigerant hoses are
intact and correctly connected. Do not use tools to connect the
hoses. Connect the hoses only hand-tight (max. torque 5.0Nm/
3.7ft*lb).
iWear protective glasses and protective gloves.
iObserve permitted pressure range!
²Measuring:
The handling steps from the chapter “Preparing measurement” have been
carried out.
1Pressurize the instrument.
2Read off measurement values:
For Zeotropic refrigerants (those with temperature glide), the tempera-
tures to/tc displayed are those at the end of the phase change
(evaporation or condensation) of the last component.
The temperature measured must be allocated to the super-heating or
sub-cooling side (function button toh <--> tcu). Dependent on this
allocation, toh or Δtoh /tsh,or tcu or Δtcu /tsc is displayed.

Using the product 11
Button functions
· : Change measurement value display. Possible display combinations:
- or (only with connected temperature probe) -
- or (only with connected temperature probe) -
· Function button Hold/Min/Max : Freeze measurement values, display min./max. values (since switch-
on, last reset or last switch-over toh <--> tcu).
· Function button RESET : Reset min./max. values. Only available when min./max. values are displayed.
· Function button toh <--> tcu : Allocation of the temperature probe measurement value to the low
pressure side (blue) or high pressure side (red). Only available when a temperature probe is connected
and the measured temperature or sub-cooling/super-heating is displayed.
- When the critical pressure of the refrigerant is reached: Measurement
value and display illumination flash.
________________________________________________________________ ________________________________________________________________
Evaporation pressure Condensation pressure
Super-heating Δtoh / tsh Sub-cooling Δtcu / tsc
________________________________________________________________ ________________________________________________________________
________________________________________________________________ ________________________________________________________________
Evaporation pressure Condensation pressure
Measured line temperature. toh Measured line temperature. tcu
________________________________________________________________ ________________________________________________________________
________________________________________________________________ ________________________________________________________________
Evaporation pressure Condensation temperature
Refrigerant evaporation temperature. toRefrigerant condensation temperature. tc
________________________________________________________________ ________________________________________________________________
enfresitptsvnl????

Maintaining the product12
Maintaining the product
±Cleaning tthe hhousing:
iIf dirty, clean the housing with a damp cloth (soap solution). Do not use
aggressive cleaning products! Immediately remove oils, refrigerants and
solvents from the housing.
±Keep cconnections cclean:
iKeep screw connections clean and free of grease and other deposits, if
necessary clean with a damp cloth.
±Regularly rreplace rrefrigerant hhoses
Warning!
If the measuring instrument falls down or is exposed to any other
comparable mechanical strain, the end connections of the refrigerant
hoses can break off. The valve knobs can also be damaged, which can lead to
further damage in the interior of the instrument, which is not visible externally.
For this reason, replace the refrigerant hoses after any fall or comparable
mechanical strain with new, undamaged refrigerant hoses. For your own safety,
send the instrument to Testo customer service for technical testing.
±Removing ooil ttraces:
iCarefully blow any oil traces out of the valve block with compressed air.
±Ensuring mmeasurement aaccuracy:
If required, Testo customer service is happy to help you.
iRegularly check the instrument for leakage (recommended annually).
Observe maximum pressure ratings!
iCalibrate the instrument regularly (recommended annually).
±Changing bbatteries/rechargeable bbatteries:
Instrument is switched off.
1Fold out the suspension hook and open battery compartment (clip
fastening).
2Remove empty batteries and insert new batteries or rechargeable
batteries (4x 1.5V, Type AA /Mignon/LR6) into the battery compartment.
Observe polarity!

Maintaining the product 13
3Close battery compartment.
4Set battery type and check/set date/time, see chapter First ssteps,
handling objective Switching iinstrument oon.
±Replacing tthe vvalve oortthe ppositioner kknob:
Warning!
Replacing of the positioner knob and the valve by the customer is not
allowed. Send the instrument to Testo customer service.
enfresitptsvnl????

Tips and assistance14
Tips and assistance
Questions and answers
Question Possible causes Possible solution
flashes · Batteries are nearly empty. · Change batteries.
The instrument switches · Function Auto Off is switched on. · Switch function off.
off automatically. · Remaining battery capacity is too low. · Change batteries.
---- lights up 4x, · Instrument error. · Please contact your dealer or
all other displays Testo customer service.
are not lit.
uuuu lights up instead of · Value under permitted · Observe permitted
meas. parameter display. measurement range. measurement range.
oooo lights up instead of · Value over permitted · Observe permitted
meas. parameter display. measurement range. measurement range.
---- lights up instead of · Probe not connected. · Connect probe.
meas. parameter display. · Probe breakage. · Exchange probe.
Refrigerant escaping · Valve positioner not tight · Please contact your dealer
from valve positioner or Testo cutomer service.
If we were not able to answer your question, please contact your dealer or
Testo customer service. For contact data, see back of this document or web
page www.testo.com/service-contact
Accessories and spare parts
Description Part no.
Probes
Air probe, PT100 0609 1773
Surface probe, PT100 0609 1974
Immersion / penetration probe, PT100 0609 1273
Pipe wrap probe, PT100, with Velcro, 2.9m / 9.5ft wire 0609 5602
Pipe wrap probe, PT100, with spring clamp 0609 5605
Miscellaneous
Report pinter, IrDA 0554 0547
Spare paper for report printer, 6 rolls, long life paper 0554 0568
A complete list of all accessories and spare parts can be found in the product
catalogues and brochures or on the internet at: www.testo.com

Notes 15
en
enfresitptsvnl????

0973 5231 en 08 V02.02 en-GB