TESTO 6448 User manual

testo 6448 · Compressed air counter probe
Instruction manual

2

1 Contents
3
1Contents
1Contents...................................................................................................3
2Safety and the environment....................................................................5
2.1. About this document........................................................................5
2.2. Safety..............................................................................................5
2.3. Protecting the environment..............................................................7
3Specifications ..........................................................................................8
3.1. Use..................................................................................................8
3.2. Overview..........................................................................................9
3.3. Technical data...............................................................................10
3.3.1. Dimensions for the compressed air bar probe (mm) ......................................10
3.3.2. Technical data for the compressed air bar probe...........................................11
3.3.3. Description & technical data - accessories/service.........................................14
3.3.3.1. Tapping clamp.................................................................................14
3.3.3.2. Ball valve.........................................................................................15
3.3.3.3. Measurement fitting including ball valve ..........................................15
3.3.3.4. Drill unit ...........................................................................................16
3.3.3.5. Connecting cable.............................................................................16
3.3.3.6. Parameterisation/calibration:...........................................................16
4Initial operation......................................................................................17
4.1. Mechanical assembly....................................................................17
4.1.1. Preparation....................................................................................................17
4.1.2. Assembly of the clamp...................................................................................20
4.1.3. Assembly of the measurement fitting/ball valve .............................................21
4.1.4. Checking the clamp leak-tightness.................................................................22
4.1.5. Drilling holes in a compressed air line............................................................22
4.1.6. Assembly of the PBCOver reverse running protection unit.............................23
4.2. Electrical connection......................................................................24
5Operation................................................................................................27
5.1. Operation and display elements....................................................27
5.1.1. Types of operation.........................................................................................28
5.1.2. Menu overview...............................................................................................30
5.1.3. Programming.................................................................................................31
5.1.4. Adjustable parameters...................................................................................32
5.1.5. Setting the preset counter / pulse value (ImPS).............................................38
6Cleaning the sensor ..............................................................................43
6.1. Cleaning agents.............................................................................43

2 Safety and the environment
4
6.2. Calibration.....................................................................................43
7Troubleshooting....................................................................................44
7.1. Replacing damaged parts.............................................................44
7.2. Replacing O-rings and seal rings..................................................44
7.3. Error messages.............................................................................44

2 Safety and the environment
5
2Safety and the environment
2.1. About this document
Symbols and writing standards
The following characters and symbols are used in this instruction
manual to emphasise text passages that need special attention.
Symbol Explanation
Notes
This arrow points out specifics that must be
observed during operation.
Caution!
This symbol indicates text passages which, if not
complied with or not followed specifically, may
lead to the damage or destruction of system
parts.
Warning!
This symbol is placed in front of text passages
which may be hazardous to one’s health or life if
not complied with.
The symbol points out further information in
other manuals, chapters or sections.
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. Safety
The compressed air counter was built and checked reliably
according to state-of-the-art technology and left the factory in an
appropriately safe condition.
As the user, you are responsible for the compliance with all valid
safety regulations, including:
• Installation specifications
• Local standards and regulations

2 Safety and the environment
6
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.
The instruments are factory-tested and were delivered in a safe
condition.
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 authorised
personnel. The personnel must be authorised for the specified
tasks by the system operator.
• The authorised personnel must have read and understood
these operating instructions, and must comply with the
directions contained herein.
• Check that all connections are correct before commissioning
the complete measuring point.
• Do not commission damaged products and keep these from
being inadvertently commissioned. Mark the damaged products
as defective.
• Faults at the measuring point may only be corrected by
authorised 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 organisation.

2 Safety and the environment
7
Exclusion of liability
Liability of the manufacturer and its assistants exists only in the
event of deliberate 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 non-compliance with
the instruction manual or the operating conditions. Consequential
damages are excluded from the liability.
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.
2.3. Protecting the environment
• 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.

3 Specifications
8
3Specifications
3.1. Use
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 use with other gases.
Its design means that it can be operated in pressurised systems up
to PN16 and with a tapping clamp from DN250 up to PN10.
Use which deviates from that described endangers the safety of
people and of all 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 unless
expressly defined in this operating manual.
During operation, the sensors may only be changed by authorised
personnel.
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.

3 Specifications
9
3.2. Overview
1 Tapping clamp (optional)
2 Measurement fitting with quick-release coupling (optional)
3 PBCOver reverse running protection
4 Compressed air bar probe
5 Drilling tool (optional)

3 Specifications
10
3.3. Technical data
3.3.1. Dimensions for the compressed air bar probe (mm)

3 Specifications
11
3.3.2. Technical data for the compressed air bar probe
The thermal mass flow sensor for the compressed air volume flow
measurement is independent of the process pressure and the
media temperature.
Sensor
Sensor material Thermal, glass-coated ceramic sensor
Measurement
method Calorimetric
Accuracy For compressed air quality classes
(ISO 8573: particles to humidity to oil) 1-4-1:
±3% of meas. value, ±3% of final value
For compressed air quality classes
(ISO 8573: particles to humidity to oil) 3-4-4:
±6% of meas. value, ±6% of final value
Measuring
dynamics 1:150 or 1:300
Response time 〈0.1 s (where damping parameter = 0), can
be delayed via user menu (0 to 1 s)
Measurement parameters
Flow velocity
Selectable units m/s
Measuring range1160 m/s
Volumetric flow
Selectable units m³/h, m³/min, m³
Measuring range1The measuring range of the volumetric flow
depends on the inner pipe diameter
Temperature
Selectable units °C
Measuring range 0 to +60 °C / 32 °F ... +140 °F
1The measuring ranges refer to the standard volumetric flow as per DIN ISO 2533 (15 °C,
1013 mbar and 0% rel. humidity)

3 Specifications
12
Inputs and outputs
Analog outputs
Output type 4 to 20 mA (4-wire), freely scalable between
zero and the end of the measuring range for
m³/min, m³/h, m/s and °C
Load Max. 500 Ω
Further outputs
Pulse output Pulse valence adjustable in increments of 1
m³ (recommended increments are 1 m³, 10
m³, 100 m³ and 1,000 m³, or preset counter
up to 1,000,000 m³)
Switching output 2 switching outputs, programmable
(dependent on consumption or volumetric
flow, NC or NO contact, hysteresis, window),
switch statuses are displayed via 2 LEDs
Capacitance Can each carry a load of max. 18 to 30 V DC
or 250 mA
Supply
Voltage supply 18 to 30 V DC, power consumption < 100 mA
Current
consumption <100 mA
Connection M12 x 1 plug, load capacity up to 250 mA,
short-circuit-proof (synchronised), protected
against polarity reversal, overload-proof
General technical data
Housing design
Housing material PBT-GF 20, PC (APEC), Makrolon, V2A
(1.4301), Viton
Weight 850 g
Media contact V2A (1.4301), glass-coated ceramic, PEEK,
polyester, Viton, anodised aluminium
Protection class IP65 / III
Display
Display 4-digit alphanumeric display, two operating
buttons, operation menu, LEDs (6x green for
physical units, 2x yellow for switch statuses)
Display units m³/min, m³/h, m/s, m³, °C

3 Specifications
13
Operation
Parameterisation 2 operating buttons
Standard reference Volumetric flow conversion with manual input
option for temperature, humidity and pressure.
Factory setting: 15 °C, 1013.25 hPa, 0%RH.
Miscellaneous
Protection class IP65
EMC EN 6126-1:2006 class B/EN 6126-1:2006
table 2
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
Warranty 2 years, for warranty terms, see
www.testo.com/warranty
Compressed air (CO2, N2also possible with
special calibration)
Operating conditions
Humidity (sensors) Rel. humidity 〈90 %RH
Ambient
temperature 0 to +60 °C
Medium
temperature 0 to +60 °C (rel. humidity max. 90%)
Storage
temperature -25 to +85 °C
Pressure-tight Up to 16 bar overpressure

3 Specifications
14
Measuring range for volumetric flow as per DIN2533
depending on pipe diameter
Version Inner pipe
diameter in
mm
Measuring range
(160 m/s)
DN 40 40.9 0 to 600 m³/h
DN 50 53.1 0 to 1000 m³/h
DN 65 70.3 0 to 1880 m³/h
DN 80 82.5 0 to 2600 m³/h
DN 100 107.00 0 to 4400 m³/h
DN 125 131.7 0 to 6700 m³/h
DN 150 159.3 0 to 9950 m³/h
DN 200 207.3 0 to 17000 m³/h
DN 250 260.4 0 to 25600 m³/h
3.3.3. Description & technical data - accessories/service
3.3.3.1. Tapping clamp
The tapping clamp allows the sensor to be installed precisely
without the need for welding. Using the drill unit enables installation
under pressure. The sensor can be installed & dismantled under
pressure when the tapping clamp and the measurement fitting
described below are used.
Technical data for the tapping clamp
Tapping clamp
material Stainless steel 304/A2, Perbunan (NBR) 70 Shore insert, stainless steel A2 nuts and
stainless steel screws.
Pressure resistance PN16 for DN40 to DN200, PN10 for DN250

3 Specifications
15
Tapping clamp
material Stainless steel 304/A2, Perbunan (NBR) 70 Shore insert, stainless steel A2 nuts and
stainless steel screws.
Nominal widths/
tolerance ranges Nominal width: Tolerance range:
DN 40/50 47 – 67 mm
DN 65 73 – 80 mm
DN 80 86 – 106 mm
DN 100 107 – 127 mm
DN 125 128 – 148 mm
DN 150 149 – 171 mm
DN 200 216 – 238 mm
DN 250 260 – 280 mm
3.3.3.2. Ball valve
The integrated ball valve enables the compressed air line to be
isolated from the measuring instrument.
Measurement fitting
material Brass, nickel-plated
Connections DN15 internal thread for sensor
DN20 union nut for tapping clamp/welding
socket
3.3.3.3. Measurement fitting including ball valve
The measurement fitting has a pipe clamp connection and a DN8
connection for a quick-release coupling. The integrated ball valve
enables the compressed air line to be isolated from the measuring
instrument.
The quick-release coupling is used to integrated an additional
measuring point (e.g. the Testo dewpoint transmitter)
Technical data for the measurement fitting
Measurement fitting
material Brass, nickel-plated
Connections DN15 internal thread
DN8 connection for quick-release coupling
7.2 mm

3 Specifications
16
3.3.3.4. Drill unit
The special drill unit, when used in conjunction with a ball valve and
tapping clamp, enables the compressed air bar probe to be
installed under pressure. An additional instruction manual is
available for this and is provided with the drill.
3.3.3.5. Connecting cable
The connecting cable (article no. 0699 3393) is used for the power
supply and to transfer measurement data
Technical data for the connecting cable:
Length 5 m
Connection 4-pin, galvanically isolated,
M12x1 socket/open cable end
3.3.3.6. Parameterisation/calibration:
• Sensor parameterisation for CO2and N2: Six measuring points
are parameterised with specified nominal widths, standard
temperatures and pressures for nitrogen or carbon dioxide, then
moved to the test stand where the standard volume is tested.
• ISO calibration points: For the purpose of basic characteristics
and accuracy, six measuring points are parameterised with
specified nominal widths, standard temperatures and pressures,
then moved to the test stand where the standard volume is
tested.
- ISO certificate: An ISO certificate from the manufacturer
indicates six measuring points with m³/min (incl. standard
conditions). The six ISO calibration points are required for this.

4 Initial operation
17
4Initial operation
4.1. Mechanical assembly
4.1.1. Preparation
Determining the installation point
The installation point should be easily accessible and experience
only low vibrations. The ambient temperature must not exceed the
values specified in the technical data (pay attention to possible heat
radiation).
Please note that a clearance of at least 400 mm is required for
deinstallation of the sensor. When planning the measuring point,
this is in addition to the space required for the measurement fitting
or tap of at least 95 mm, or the space for the existing fittings (also
including possible reductions to DN 15).
During assembly, consider the flow direction and required
inflow/outflow routes.
Also consider the installation point with regard to the specified
technical data. The medium may not be in a condensed state at the
installation point. For this reason, the location in a working
compressed air network can only be behind a suitable compressed
air dryer which provides a suitable pressure dew point; otherwise
the specified measurement accuracy is not guaranteed.
Do not install the sensor in the crossed-out installation positions
shown in the following graphic. In the event of a limited flow, the
specified accuracy cannot be maintained.
Schematic diagram (the arrow shows the direction of flow for the
medium):

4 Initial operation
18
Vertical installation
position, direction of flow
horizontally to the left,
sensor downwards
Horizontal
installation
position, direction
of flow vertically
downwards,
sensor to the rear
Horizontal installation
position, direction of flow
horizontally to the rear,
sensor to the left (heated
sensor element upwards)
Vertical installation
position, direction of flow
horizontally to the right,
sensor upwards
Horizontal
installation
position, direction
of flow vertically
upwards, sensor
to the rear
Horizontal installation
position, direction of flow
horizontally to the rear,
sensor to the right (heated
sensor element
downwards, problems
possible at low flow rates)

4 Initial operation
19
Direction of flow
The direction of flow must be taken into account when installing the
measurement fitting. This is shown on the tapping clamp by means
of an arrow (Compac-Air system). The arrow points in the direction
in which the medium in the pipeline flows.
If only the electronic sensor with PBCOver reverse running
protection is used, then make sure the sensor display points
against the direction of flow.
The sensor must be parallel to the direction of flow.
Angular displacement leads to severe measurement
errors.
Required measurement route
Bear in mind the required inflow and outflow routes in order to
achieve the specified measurement accuracy. The inflow route
refers to the pipeline length in front of the mass flow sensor and the
outflow route to the pipeline length behind the mass flow sensor, as
seen in the direction of flow for the medium.
The length of inflow route E depends on the design of the pipeline
upstream of the sensor, vertical (see table below). The outflow
route depends on the pipe diameter. Inflow and outflow routes are
calculated as follows:
Total measurement route = inflow route + outflow route
Outflow route = 5 x D
Inflow route = E (see table below)
D = pipe diameter [mm]
Changes to the pipe
diameter E = 20 x D
90° manifold E = 20 x D
Two 90° manifolds, one
level E = 25 x D
Two 90° manifolds, two
levels E = 30 x D
Valve, slider E = 50 x D

4 Initial operation
20
On-site preparations
The installation point must be freely accessible and there must be
enough space to work around the pipes.
A stable stepladder is required for all assembly work carried out up
to 3.5 metres off the floor (height of the pipe). A working platform
must be provided for work at greater heights. If the measuring point
cannot be accessed by a platform, then scaffolding or other
equipment must be used to provide a safe working platform.
Any cladding or insulation covering the pipes must be removed
around the measuring point (clearance of at least 0.6 metres.
Necessary grinding work in the case of corroded pipes must be
carried out before montage.
4.1.2. Assembly of the clamp
1 Clamp
2 Seal
3 Cap
4 Threaded bolt
5 Nut
6 Delrin® washer
7 Retaining bracket
8 Screw yoke
9 Side bracket