TESTO 6446 User manual
testo 6446 compressed air meter
Instruction manual
Contents
1GENERAL INFORMATION ...........................................................................5
1.1Incoming goods inspection, transportation and storage ....................................... 5
2SAFETY PRECAUTIONS..............................................................................6
2.1Intended use ......................................................................................................... 6
2.2Installation, commissioning and operation............................................................ 7
2.3Exclusion of liability...............................................................................................8
3DESIGN AND FUNCTION .............................................................................9
3.1Electric sensor unit.............................................................................................. 10
3.2Compac stainless steel sealing cone.................................................................. 12
3.3Compac welding neck flange (V flange) steel..................................................... 12
3.4Dummy plugs included as standard.................................................................... 13
3.5Measuring station................................................................................................ 14
3.6ISO calibration points.......................................................................................... 14
4TECHNICAL DATA .....................................................................................15
4.1Thermal mass flow sensor .................................................................................. 15
4.2Accessories......................................................................................................... 16
4.2.1Connecting cable with electric isolation ....................................................16
4.2.2Replacement sensor.................................................................................16
4.2.3Calibration options ....................................................................................16
5INSTALLATION...........................................................................................17
5.1Determining the installation point........................................................................ 17
5.2Length measurements of the compressed air meter .......................................... 18
5.3Installation position ............................................................................................. 19
5.4Required measuring section ...............................................................................20
5.5Direction of flow ..................................................................................................20
5.6Installation of the compressed air meter ............................................................. 21
5.6.1Installation of the measuring station .........................................................21
5.6.2Installing the sensor in the measuring station ..........................................22
22
5.7Sensor replacement............................................................................................ 23
5.8Electrical connection ........................................................................................... 24
5.8.14-wire pin assignment...............................................................................24
5.8.25-wire pin assignment (accessory) ...........................................................25
Contents
6OPERATION ............................................................................................... 26
6.1Operation and display elements ......................................................................... 26
6.2Types of operation.............................................................................................. 28
6.2.1Run mode 28
6.2.2Display mode 28
6.2.3Programming mode – parameter configuration........................................ 28
7MENU.......................................................................................................... 29
7.1Menu overview ................................................................................................... 29
7.2Menu explanation ............................................................................................... 30
8PROGRAMMING AND PARAMETRISATION ............................................ 31
8.1Programming ...................................................................................................... 31
8.2Parametrising scenarios ..................................................................................... 33
8.2.1Settings for flow monitoring ...................................................................... 33
8.2.2Settings for consumption quantity monitoring .......................................... 34
8.2.3Settings for temperature monitoring ......................................................... 36
8.2.3.1Configuring the analogue value for temperature ...................................... 36
8.2.4User settings (optional) ............................................................................ 37
8.2.5Service functions ...................................................................................... 39
8.2.6Pulse setting 40
8.2.7Hysteresis function ................................................................................... 41
8.2.8Window function ....................................................................................... 41
8.2.9Scaling the measuring range.................................................................... 42
9REPAIR....................................................................................................... 43
9.1Error messages .................................................................................................. 43
9.2Cleaning the sensor............................................................................................ 43
9.2.1Cleaning agents ....................................................................................... 43
9.3Recalibration....................................................................................................... 44
10TROUBLESHOOTING ................................................................................ 45
10.1Replacing damaged parts................................................................................... 45
10.2Replacing O-rings and sealing rings................................................................... 45
10.3Return shipment ................................................................................................. 45
10.4Disposal.............................................................................................................. 45
5
1
GENERAL INFORMATION
1.1 Incoming goods inspection, transportation and storage
• Take note of undamaged packaging!
Communicate damages to the packaging to your supplier. Retain the
damaged packaging until the matter is settled.
• Make sure there is no damaged 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 by referring to the
shipping documents and your order.
• The instrument is to be packaged for storage and transport in a way
that protects it from impacts and moisture. The original packaging
offers optimum protection. The permissible ambient conditions are also to
be observed ( see 4 Technical data).
• If you have any questions, please contact your supplier or their
sales office.
6
2
SAFETY PRECAUTIONS
Read this instruction manual before commissioning the
compressed air meter. Store this instruction manual in a location
that is accessible for all users at all times.
2.1 Intended use
The compressed air meter is intended exclusively for use in pipe
systems for working compressed air, provided that the calibration
certificate does not explicitly allow use with other gases.
WARNING
ATTENTION
The compressed air meter may only be operated under the ambient
conditions specified in the technical data. Otherwise, inaccurate
measurements will occur and instrument malfunctions cannot be ruled out.
To ensure the safety of the user and the functionality 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.
Any use other than that described will compromise the
safety of persons and the entire measuring system and is
therefore not permitted.
The manufacturer shall accept no liability for damages that
occur as a result of improper or inappropriate use or
installation.
To prevent damage to the instruments or health risks occurring
the measuring units must never be manipulated with tools
unless expressly defined in this instruction manual.
The structural design allows for operation in pressurised
systems up to PN 16 (DN 65 bis DN 200) and PN 14 (DN 250)
7
2.2 Installation, commissioning and operation
The compressed air meter was built and tested reliably according to
state-of-the-art technology and left the factory in an appropriately safe
condition.
As the user, you are responsible for 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 installed in such a way that their safe use is not affected.
This instruction manual contains information and warnings that must
be followed by the user in order to ensure safe operation.
• Installation, commissioning, operation and maintenance of the
measuring unit may only be performed by trained, authorised
personnel.
The personnel must be authorised for the specified tasks by the
system operator.
• The authorised personnel must have read and understood this
instruction manual and comply with the instructions set out in it.
• Check all connections for correctness before commissioning the
complete measuring station.
• Do not commission damaged products and keep these from being
inadvertently commissioned. Mark the damaged products as
defective.
• Faults at the measuring point are only to be corrected by authorised
and specially trained personnel.
• If faults cannot be corrected, the products must be taken out of
operation and be safeguarded from inadvertent commissioning.
• Repairs that are not described in this instruction manual may only be
carried out directly by the manufacturer or by the service organisation.
8
2.3 Exclusion of liability
Liability of the manufacturer and its vicarious agents shall exist only in the
event of deliberate acts or gross negligence. The extent of liability shall be
limited to the value of the respective order placed with the manufacturer.
The manufacturer shall accept no liability for damages that occur due to
non-observance of the safety instructions or non-compliance with the
instruction manual or the operating conditions. Consequential damages
are excluded from the liability.
Note
Use the components only in the supplied combination.
Due to the design, they are not necessarily compatible
with older compressed air meters.
9
3DESIGN AND FUNCTION
Overview of components
1 Sensor unit 2 Straight pin as alignment aid
3 Hexagon socket head screw M 10 4 Dummy plug
5 Dummy plug holder both sides 6 Direction of flow arrow
7 Measuring station 8 Brass sealing plug
9 Hexagon screw depending on DN 10 Viton O-rings
11 Compac steel welding
neck flange
12 Compac stainless steel sealing
cone
10
The equipment is supplied loosely pre-assembled in 2 parts:
sensor and station. Also included in the scope of delivery:
•
Calibration certificate in compliance with ISO/IEC 17025
3.1 Electric sensor unit
The sensor records the standard volumetric flow of the working
compressed air according to the calorimetric measurement principle.
The standard volumetric flow is calculated on the basis of DIN ISO 2533
(1013.25 mbar, 15 °C and 0% relative humidity), unless otherwise stated
on the calibration certificate. The relevant unit is Nm³/h or Nl/min.
Observe the general operating conditions for compressed air
systems. The air quality of the working compressed air influences the
measuring accuracy as follows:
Measuring signals
The instrument shows the current process values on a display. It
generates 2 output signals according to the parametrization.
•
Current flow rate
•
Current consumption quantity (pulse output module and totaliser)
Display
•
Current volume flow in Nm³/h or Nl/min
•
Current consumption quantity in Nm³
•
Current average speed in Nm/s
•
Current media temperature in °C
•
Switching states of the respective outputs
Quality classes according to
ISO 8573-1 particle/humidity/oil
Measurement errors
1-4-1 ± (3% of reading + 0.3% of final
value of measuring range)
3-4-4 ± (6% of reading, + 0.6% of final
value of measuring range)
11
Sensor output 1
•
Switch signal as the limit value for volume flow or flow velocity, hysteresis or
window function as N/O or N/C contact.
•
Quantity monitoring using the preset counter.
Sensor output 2
•
Switch signal as the limit value for volume flow, flow velocity or
temperature, hysteresis or window function as N/O or N/C contact.
•
Analogue signal (4-20 mA) for volume flow, flow velocity or temperature.
Relative measuring range (%)
Measuring range Recording/
display range
0.33% (0.4%) - 100% 0% to 120%
The absolute measuring range depends on the nominal width (see
following table).
Absolute measuring range
WARNING
Nominal width Measuring range Recording/
display range
DN 65 6.7-2,000 m³/h 0.11-2,400 m³/h
DN 80 9.2-2,750 m³/h 0.15-3,300 m³/h
DN 100 15-4,400 m³/h 0.24-5,280 m³/h
DN 125 23-7,000 m³/h 0.39-8,400 m³/h
The compressed air meter may be used to measure the
volume flow of working compressed air with up to 16 bar
(DN 65 to DN 200) or 14 bar (DN 250) overpressure.
12
Nominal width Measuring range Recording/
display range
DN 150 33-10,000 m³/h 0.55-12,000 m³/h
DN 200 58-17,500 m³/h 0.97-21,000 m³/h
DN 250 92-27,500 m³/h 1.53-33,000 m³/h
Specifications according to DIN ISO 2533 (15 °C, 1013 mbar and 0%
rel. humidity).
3.2 Compac stainless steel sealing cone
The Compac sealing cone makes up the intersection between the
measuring station and sensor. Please note the following design details for
correct positioning of the components after welding in the pipeline
according to the direction of flow: The straight pin of the measuring station
engages in the one-sided bore of the Compac sealing cone.
This is designed with a slot that receives the sensor pin in the downstream
direction of flow.
3.3 Compac welding neck flange (V flange) steel
The connection between the measuring point interface and the pipe
system is made by the Compac welding neck flanges. These seal twice –
both metal-wise and against an O-ring made of Viton in a circumferential
groove in the measuring station. The advantages of these flanges in
comparison to standard DIN flanges with flat seals are the significantly
smaller construction volume and thus material volume and weight, lower
bolt tightening forces and the prevention of overstraining of the seal (with
regard to deformation and compression) – with higher density efficiency
and leakage reliability. Slight scratches in the contact surfaces are
tolerated without loss of function due to the high compressive force.
Example: DN 250 at PN 100
•
Compac flange weight 15 kg
• Previous DIN flange weight 81 kg
Note
An alternative to the welding neck flange (V flange) is to fit a Compac threaded
flange (G flange).
To avoid a mixed seam in the welded joint to the pipeline,
make sure that the Compac flanges are made of steel or
stainless steel according to the pipeline.
13
Sealing principle of the Compac flange
P
3.4 Dummy plugs
included as standard
The dummy plug is made of stainless steel and has a bright red plastic
protective cap to stop it unintentionally loosening.
It secures the measuring point interface while the sensor is uninstalled,
e.g. when changing the sensor for recalibration. For this purpose, it is
screwed onto the sealing cone (Fig. 1) when the line is
depressurized.
The dummy plug seals both metal-wise and redundantly via an O-ring.
A significant advantage over simple dummy plugs is that the trapped
compressed air can escape safely under pressure during
(unintentional) disassembly. When turning the union nut, enough
thread turns remain to prevent it "shooting off". If the sensor is
installed, the dummy plug is stored near the device in one of the
holders (tapped bore) – as shown in Figure 2.
1
2
14
3.5 Measuring station
The measuring station with Compac welding neck flanges is used to
precision-mount the electronic volume flow sensor. The measuring station
is welded into the pipelines with the Compac welding neck flanges in line
with the flow direction (see engraved direction arrow). The nominal width
of the measuring station and welding neck flange must match the
nominal pipe width ( see 3). To prevent a mixed seam during welding,
the material of the parts must also be the same.
The compressed air meter is designed for nominal pipe widths from
DN 65 to DN 250.
3.6 ISO calibration points
The compressed air meter is supplied calibrated to its nominal width.
A minimum of six measuring points are parametrised with specified
nominal widths, standard temperatures and pressures, then moved to the
test stand where the standard volume is tested. The calibration certificate
in compliance with ISO/IEC 17025 is included in the scope of delivery.
15
4TECHNICAL DATA
4.1 Thermal mass flow sensor
The thermal mass flow sensor for the compressed air volume flow
measurement is independent of the process pressure and the media
temperature.
Sensor Thermal glass-coated ceramic sensor
Media Compressed air
Accuracy For compressed air quality classes (ISO 8573:
particles to humidity to oil) 1:4:1: ±3% of
reading, ±0.3% of final value for compressed air
quality classes (ISO 8573) 3:4:4: ±6% of
reading, ±0,6% of final value
Temperature monitoring ±2 °C
Reproducibility ±1.5% of reading
Display, operation 4-digit, alphanumerical display, two operating
buttons, user menu, operating menu, 5 x green
LED (measurement units), 1 x green LED
(function display 103), 2 x yellow LED (switching
status)
Display units* Nl/min, Nm³/h, Nm/s, Nm³, °C
Measuring dynamics 1:300
Response time < 0.1 s
Pressure-tight up to 16 bar (DN 250 to 14 bar)
Media temperature 0 to + 60 °C (rel. humidity max. 90%)
Perm. ambient temp. 0 to + 60 °C
Perm. storage temp. -20 to + 85 °C
Media contact V2A (1.4301) or galvanised steel, glass-coated
ceramic, PEEK, polyester, Viton, anodised
aluminium
Housing materials PBT-GF 20, PC (APEC), Makrolon, V2A
(1.4301) or galvanised steel, Viton
Protection class IP65 / III
Electrical connection M12 x 1 connector, can be loaded to 250 mA,
short-circuit-proof
Power supply 19 to 30 VDC, voltage supply < 100 mA
Readiness delay 1 s
Note
* The measurement, display and adjustment ranges are related to the
standard volume flow according to DIN ISO 2533 (15 °C, 1013 mbar and 0%
rel. humidity) if not otherwise stated in the calibration protocol of the sensor.
Based on the small size, the sensor only has a small contact
surface. The pressure loss is thus negligible (typically
1 mbar).
16
Output signals
Analog output 4-20 mA, measuring range scaleable
max. load 500 Ωpulse output
DN 65 - DN 80: 1 pulse/1 Nm³
DN 100 – DN 250: 1 pulse/10 Nm³
Current carrying capacity 2 x 250 mA, short-circuit-proof, protected against
polarity reversal, overload-proof
EMC
IEC 1000/4/2 ESD 4/8 kV
IEC 1000/4/3 HF radiated 10 V/m
IEC 1000/4/4 burst 2 kV
IEC 1000/4/6 HF grid-bound 10 V
4.2 Accessories
4.2.1 Connecting cable with electric isolation
A connecting cable with an electrical isolator integrated into the connector
is available as an accessory. The cable is 5 metres long and is used for
the galvanic isolation of the sensor 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.
4.2.2 Replacement sensor
The replacement sensor serves as a replacement in case of damage to or
loss of the original mass flow sensor.
Note
4.2.3 Calibration options
• ISO certificate
An ISO certificate from the manufacturer documents six measuring points
including the measuring conditions.
When ordering a new sensor, please indicate the certificate
number of the old sensor in order to take account of
customer-specific measuring conditions directly during
calibration.
17
5
INSTALLATION
WARNING
WARNING
5.1 Determining the installation point
Please always observe the technical data see 4.1). The place of
installation is to meet the following criteria:
• Medium does not condense at the place of installation, i.e. measuring
location only behind a suitable compressed air dryer, which ensures
an appropriate pressure dew point. Otherwise the specified measuring
accuracy cannot be guaranteed.
• Ambient temperature of maximum + 60 °C (note any potential thermal
radiation).
• Take account of the inflow and outflow section ( see 5.4).
• Take account of the direction of flow ( see 5.5).
• Well accessible with low vibration.
• A min. 200 mm space is needed to remove the sensor.
Installation may only be carried out by authorised, qualified
staff, e.g. pipeline engineers. Please observe the relevant
national regulations.
The electrical connections are to be performed by a
qualified electrician.
To install and remove the sensor the line must be
depressurized. Ensure that the line section cannot be
inadvertently used (lockout-tagout).
18
5.2 Length measurements of the compressed air meter
L
Inch DN L
mm
Ø D1
mm
Ø D2
mm
S
mm
H1
mm
N SL
mm
LK
mm
2½" 65 148 125 70.3 2.9 184 8 13 106
3" 80 160 141 82.5 3.2 198 8 13 118
4" 100 160 165 107.1 3.6 223 8 13 144
5" 125 172 205 131.7 4 255 12 13 168
6" 150 180 235 159.3 4.5 284 8 17 200
8" 200 180 290 207.3 5.9 336 12 17 252
10" 250 196 355 260.4 6.3 396 12 21 315
19
6:
5.3 Installation position
Do not install the sensor in the crossed-out installation positions
shown in the following graphic in point 6. Otherwise, in the event of a
limited flow rate, the specified accuracy cannot be maintained.
The arrow shows the direction of flow for the medium.
1: Vertical installation position, direction of flow horizontally to the left,
probe downwards
2: Horizontal installation position, direction of flow vertically downwards,
probe to the rear
3: Horizontal installation position, direction of flow horizontally to the rear,
probe to the left (heated sensor element upwards)
4: Vertical installation position, direction of flow horizontally to the right,
probe upwards
5: Horizontal installation position, direction of flow vertically upwards, probe
to the rear
Horizontal installation position, direction of flow horizontally to the rear,
probe to the right (heated sensor element downwards, problems
possible at low flow rates)
Diagrams:
1.
2. 3.
4.
5. 6.
20
5.4 Required measuring section
Note
Total measurement section = inflow section + outflow section
Outflow section = 5 x D
Inflow route = 15 x D + B
D = pipe diameter [mm]
B = additional calming section
Changes to the
pipe diameter B = 5 x pipe diameter
90° elbow B = 5 x pipe diameter
Two 90° elbows, one level
B = 10 x pipe diameter
Two 90° elbows, two levels
B = 15 x pipe diameter
Valve, slider B = 35 x pipe diameter
5.5 Direction of flow
Note
Take account of the required inflow and outflow section in
order to achieve the specified measuring accuracy. The
inflow section refers to the pipeline length upstream of the
compressed air meter and the outflow section to the
pipeline length downstream of the compressed air meter,
as seen in the direction of flow for the medium.
Always take the direction of flow into account when
installing the measuring station. This is indicated by the
arrow engraved on the side of the measuring station. The
arrow points in the direction that the medium flows in the
pipeline.
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