TESTO 6448 User manual

Compressed air counter probe
Instruction manual

2

1 Contents
3
1Contents
1Contents ...................................................................................................3
2Safety and the environment....................................................................4
2.1. About this document........................................................................4
2.2. Safety ..............................................................................................5
2.3. Protecting the environment..............................................................6
3Specifications ..........................................................................................7
3.1. Use ..................................................................................................7
3.2. Technical data .................................................................................8
3.2.1. Dimensions (mm).............................................................................................8
3.2.2. Thermal mass flow sensor ...............................................................................9
3.2.3. Accessories ...................................................................................................11
4Product description...............................................................................12
4.1. Overview........................................................................................12
5Initial operation......................................................................................16
5.1. Mechanical assembly ....................................................................16
5.1.1. Preparation ....................................................................................................16
5.1.2. Assembly of the clamp...................................................................................18
5.1.3. Assembly under pressure ..............................................................................21
5.1.4. Assembly of the PBCOver reverse running protection unit.............................21
5.1.5. Installation position of the sensor...................................................................24
5.2. Electrical connection......................................................................26
6Operation................................................................................................28
6.1. Operation and display elements ....................................................28
6.1.1. Types of operation .........................................................................................29
6.1.2. Programming .................................................................................................30
6.1.3. Adjustable parameters...................................................................................31
6.1.4. Setting the preset counter / pulse value (ImPS) .............................................36
6.1.5. Menu overview...............................................................................................41
7Cleaning the sensor ..............................................................................42
7.1. Cleaning agents.............................................................................42
7.2. Calibration .....................................................................................42
8Troubleshooting ....................................................................................43
8.1. Replacing damaged parts..............................................................43
8.2. Replacing O-rings and seal rings...................................................43
8.3. Error messages .............................................................................43

2 Safety and the environment
4
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.
Warning
This symbol indicates text passages which, if not
complied with or not followed specifically, may
lead to the damage or destruction of system
parts.
Caution!
This symbol is placed in front of text passages
which may be hazardous to one’s health or life if
not complied with.

Reference
The symbol points out further information in
other manuals, chapters or sections.
Menu Elements of the instrument, the instrument dis-
play or the program interface.
[OK] Control keys of the instrument or buttons of the
program interface.

2 Safety and the environment
5
2.2. Safety
The compressed air counter was built and checked reliably accord-
ing to state-of-the-art technology and left the factory in an appropri-
ately safe condition.
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 en-
sure safe operation. The user must ensure that the instruments are
set up and installed in such a way that their safe use is not af-
fected.
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 the-
se 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 be-
ing inadvertently commissioned. Mark the damaged products as
defective.
• Faults at the measuring point may only be corrected by author-
ised 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
6
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 manu-
facturer.
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 familiar-
ize yourself with the product before putting it to use. Pay par-
ticular 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.
Pos: 19 /TD/Überschr iften/2.3 Umwelt schüt zen @ 0\mod_1173780843645 _79.doc @ 375 @ 2 @ 1
2.3. Protecting the environment
Pos: 20.1 /TD/Sicher heit und Umwelt/Umwelt schü tzen/Akkus/Bat terien entsorgen @ 0\mod _1175693637007_79.doc @619 @ @ 1
• Dispose of faulty rechargeable batteries/spent batteries in ac-
cordance with the valid legal specifications.
Pos: 20.2 /TD/Sicher heit und Umwelt/Umwelt schü tzen/Produkt entsor gen @ 0\mod_11737803070 72_79.doc @ 357 @ @ 1
• At the end of its useful life, send the product to the separate col-
lection for electric and electronic devices (observe local regula-
tions) or return the product to Testo for disposal.

3 Specifications
7
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.
Thanks to the design, operation in systems that are under pressure
up to PN16 is possible.
Use which deviates from that described endangers the safety of
people and of all the measuring equipment and is thus not permis-
sible.
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 manipula-
tion using tools may occur on the measuring units unless expressly
defined in this operating manual.
Changing the sensors while in operation is possible.
Use authorised personnel when changing the sensors
during operation. Further details Assembly under
pressure, page 21.
The compressed air c ounter may only be operated under theambi ent conditions spec ified in the technic aldata. Otherwise, inaccu rate measurements occur orinstr ument malfunctions beco mepo ssible.
To ensure the safety of the user and the functionality of the instru-
ments, the commissioning steps, checks and maintenance work
recommended by the manufacturer are to be complied with and
carried out.

3 Specifications
8
3.2. Technical data
3.2.1. Dimensions (mm)

3 Specifications
9
3.2.2. Thermal mass flow sensor
The thermal mass flow sensor for the compressed air volume flow
measurement is independent of the process pressure and the me-
dia temperature.
Feature Values
Sensor Thermal, glass-coated ceramic sensor
Media Compressed air (CO2, N2also possible with
special calibration)
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:
particles to humidity to oil) 3-4-4: ±6 % of
reading, ±0,6 % of final value
Display, operation Four-digit alphanumeric display, two operat-
ing buttons, operation menu, LEDs (6x green
for physical units, 2x yellow for switch status-
es)
Display units1m³/min, m³/h, m/s, m³, °C
Measurement
dynamics
1:150 or 1:300
Measuring range
(1:300)
0.25 to 75 Nm³/h
Response time < 0.1 s
Pressure-tight Up to 16 bar overpressure
Protection class IP65 / III
Media contact V2A (1.4301), glass-coated ceramic, PEEK,
polyester, Viton, anodised aluminium
Housing materials PBT-GF 20, PC (APEC), Makrolon, V2A
(1.4301), Viton
Protection class IP65 / III
Electrical
connection
M12 x 1 connector, can be loaded to 250 mA,
short-circuit-proof
1The measurement, display and adjustment ranges are related to the standard
volume flow according to DIN ISO 2533 (15 °C, 1013 mbar and 0 % rel. humidi-
ty) if not otherwise stated in the calibration protocol of the sensor

3 Specifications
10
Feature Values
Voltage supply 19 to 30 V DC, power consumption < 100 mA
Readiness delay 0.5 s
Analogue output 4 to 20 mA, measuring range scalable for
m³/min, m³/h, m/s and °C
max. load = 500 Ohm
Pulse output Pulse speed 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)
Current carrying
capacity
2 x 250 mA, short-circuit-proof, protected
against polarity reversal, overload-proof
Medium
temperature
0 to +60 °C (rel. humidity max. 90 %)
Ambient
temperature
0 to +60 °C
Storage
temperature
-25 to +85 °C
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 conditions see
www.testo.com/warranty

3 Specifications
11
3.2.3. Accessories
• Sensor parameterisation for CO2and N2: Six measuring points
are paramaterised with specified nominal widths, standard tem-
peratures 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 paramaterised 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 indi-
cates six measuring points with m³/min (incl. standard condi-
tions). The six ISO calibration points are required for this.
• Measurement fitting: The measurement fitting is nickel-plated
brass and has a DN 20 female pipe clamp connection, plus a
DN 15 quick-release connection for additional measuring points
(e.g. pressure or pressure dew point).
• Tap: The tap is nickel-plated brass and has a DN 20 female
pipe clamp connection.
• Tapping clamp: Material: Stainless steel tapping clamp
(304/A2), Perbunan (NBR) insert, stainless steel screws and
nuts. The tapping clamp allows the sensor to be installed pre-
cisely using the drill unit without the need for welding. The cor-
responding supply line may be under pressure (normal operat-
ing conditions) when installing the tapping clamp or when
repairing/replacing the sensor.
• Connecting cable with electrical isolator (item no. 0699 3393):
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 Product description
12
4Product description
4.1. Overview
1 Electronic sensor
2Tapping clamp (optional)
3Measurement fitting with quick-release coupling (optional,
Accessories, page 11)
4PBCOver reverse running protection unit

4 Product description
13
PBCOver reverse running protection unit
The PBCOver combines three functions in one instrument:
• Reverse running protection, meaning the sensor can only be
moved in one direction during assembly.
• Process seal, meaning compressed air cannot escape during
assembly thanks to an enclosed O-ring.
• Adjustable fixation, so that a precise immersion depth and
alignment is possible (similar to the pressure point on a car
clutch). 360° alignment is possible at any time (rotation of the
sensor).
The PBCOver reverse running protection unit must not
be disassembled (loss of functionality) and can be used
at an overpressure up to 16 bar.
Tapping clamp
The tapping clamp allows the sensor to be installed precisely using
the drill unit without the need for welding. The corresponding supply
line may be under pressure (normal operating conditions) when in-
stalling the tapping clamp or when repairing/replacing the sensor.
Assembly of the tapping clamp under pressure should
only be made by trained personnel, and is permitted for
a maximum pressure of 16 bar (up to DN 200) and 10
bar (DN 250 and DN 300, Assembly under pressure,
page 21).
Tolerance range for outer diameter of the pipeline when using tap-
ping clamps:
Nominal width Tolerance range
DN 40 52 – 58 mm
DN 50 59 – 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
DN 300 315 – 335 mm

4 Product description
14
Electronic sensor
The sensor records the standard volume flow rate of the working
compressed air according to the calorimetric measurement princi-
ple. The measurement value of the standard volume flow rate is
calculated based on DIN ISO 2533 (1013 hPa, 15 °C and 0 % rela-
tive humidity).
The electronic sensor may only be used for measuring
the volume flow of working compressed air up to an
overpressure of 16 bar.
Set the pipeline diameter on the instrument and any
deviating standard temperatures and pressures
(Programming, page 30). Read out and set the ana-
logue end point (20 mA).
Observe the general operating conditions for compressed air sys-
tems. The air quality of the working compressed air influences the
accuracy of the measurement as follows:
Quality class acc. to
ISO 8573-1
Particles to humidity to oil
Measurement inaccuracy
1-4-1 ± (3 % of reading, + 0.3 % of end
measurement value)
3-4-4 ± (6 % of reading, + 0.6 % of end
measurement value)
Score
• Current flow rate
• Current consumption quantity (pulse output and totaliser)
Display
• Current volume flow in m³/min (l/min = LED 1 and 10³ = LED 6
both light up) and m³/h (LED 2).
• Current average flow speed in m/s (LED 3).
• Current consumption quantity in Nm³ (LED 4 = four-digit display
between 0.001 Nm³ and 4294 x 10³ Nm³). For values
> 9999 Nm³, 1/1000 of the measurement value is displayed and
the 10³ (LED 6) display indicates that the value must be multi-
plied by a factor of 1000.
• Consumption quantity before the last reset in Nm³. During the
display of this value, Nm³ (LED 4) flashes.

4 Product description
15
• The °C display (LED 5) indicates the gas temperature in °C.
Switch output 1
• Switch signal as the limit value for volume flow, hysteresis or
window function as NO or NC contact.
• Pulse sequence for adjustable consumption quantity, e.g.
1 pulse/m³ (pulse length 100 ms) or quantity monitoring via pre-
set counter (Setting the preset counter / pulse value (ImPS),
page 36).
Switch output 2
• Switch signal as the limit value for volume flow, hysteresis or
window function as NO or NC contact.
• Analogue signal (4 to 20 mA) for corresponding volume flow.
Sensor type Measuring range2Recording/display range2
Sensor up to 80 m/s 0.33 % – 50 % 0 % – 60 %
Sensor up to 160 m/s 0.33 % – 100 % 0 % – 120 %
Nominal width Measuring range
(80 m/s)3
Measuring range* (160 m/s)3
DN 40 0.03 – 5.2 m³/min 0.03 – 10.4 m³/min
DN 50 0.06 – 8.3 m³/min 0.06 – 16.7 m³/min
DN 65 0.11 – 16.7 m³/min 0.11 – 33.3 m³/min
DN 80 0.15 – 22.9 m³/min 0.15 – 45.8 m³/min
DN 100 0.24 – 36.7 m³/min 0.24 – 73.3 m³/min
DN 125 0.39 – 58.3 m³/min 0.39 – 116.7 m³/min
DN 150 0.55 – 83.3 m³/min 0.55 – 166.7 m³/min
DN 200 0.9(7) – 145.8 m³/min 0.9(7) – 291.7 m³/min
DN 250 1.5(3) – 229.2 m³/min 1.5(3) – 458.3 m³/min
Based on the small size, the sensor only has a small
contact surface. The pressure loss is thus negligible
(typically 1 mbar).
2Absolute measuring range depends on the nominal width (see following table)
3Specifications acc. to DIN ISO 2533 (15 °C, 1013 hPa and 0 % rel. humidity).
Initial measuring range is different to display resolution

5 Initial operation
16
5Initial operation
5.1. Mechanical assembly
5.1.1. 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 de-
installation 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 in-
cluding possible reductions to DN 15).
During assembly, consider the flow direction and required in-
flow/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 com-
pressed 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.
Required measurement route
Bear in mind the required inflow and outflow routes in order to
achieve the specified measurement accuracy. The inflow route re-
fers 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.
Total measurement route = inflow route + outflow route
Outflow route = 5 x D
Inflow route = 5 x D + B
D = pipe diameter [mm]
B = additional cushioning route

5 Initial operation
17
Changes to the pipe diameter B = 15x pipe diameter
90° manifold B = 15x pipe diameter
Two 90° manifolds, one level B = 20x pipe diameter
Two 90° manifolds, two levels B = 25x pipe diameter
Valve, slider B = 45x pipe diameter
Assembly of the tapping clamp
1 Clamp
2 Seal
3 Cap
4 Threaded bolt
5 Nut
6 Delrin® washer
7 Retaining bracket
8 Screw yoke
9 Side bracket
10 Slide plate

5 Initial operation
18
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 equip-
ment 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). Any
grinding work required in the event of corroded pipes must be car-
ried out carefully so that the surface curvature is not destroyed.
5.1.2. Assembly of the clamp
Assembly recommendations
• Compare the pipe diameters and check the correct size of the
clamp.
• Eliminate all traces of dirt, rust and grease from the assembly
point of the clamp so that the surface is smooth and clean. The
seals and slide plate should be wetted to achieve better adhe-
sion. Seals, nuts and bolts must not be greased!
• Before assembly, mark the position of the clamp to ensure a
correct fit.
• During assembly, ensure that the seals and holder lips remain
clean and that no foreign bodies are found between the seal
and pipe.
• The correct tools (long wrench and/or torque wrench) make as-
sembly easier.
• The bolt threads must not be contaminated.
• If a torque wrench is not used, then the nuts must not be tight-
ened excessively. Always pay attention to the shape of the
Delrin® washer.
• Always carry out a pressure test before closing the clamp. In
the event of leaks, adjust the torque and check again after 20
minutes.

5 Initial operation
19
Installation
The pipe must be completely free of any dirt, rust or grease at the
assembly point of the clamp. Cleaning with soapy water is best for
this, as it also improves the functionality of the clamp.
Seals, nuts and bolts must not be greased!
Remove the caps on the threaded bolts and unscrew the nuts up to
the end of the threaded bolt (do not remove them).
Unfold the pipe clamp and place the upper clamp part around the
pipe.
Hang the retaining bracket correctly over the screw yoke on one
side.
Feed the loose bottom clamp part underneath the pipe and hang it
loosely on the other screw yoke using the free retaining bracket.
When doing this, ensure that both holder lips are inserted smoothly
under the seals.
The clamp must no longer be moved radially from this position.
Check that the seals and holder lips are positioned on the pipe and
that the sharp ends are positioned smoothly over the seals. Tighten
the nuts by hand on the retaining bracket attached loosely to the
screw yoke until the bracket is under tension.

5 Initial operation
20
Using the wrench, rotate further until the retaining bracket slips
over the screw yoke and clicks into place.
Tighten the nuts uniformly using a wrench (min. 300 mm long) until
the Delrin® washers curve slightly around the nuts. The shape of
the Delrin® washer does not affect the clamp functionality.
The following torques are set when using a torque wrench:
M12: 65 Nm
M14: 85 Nm
M16: 110 Nm
The Delrin® washers must also curve slightly around the nuts in
this case.
Check the torque after 20 minutes and adjust if neces-
sary.
The attached clamp must be checked for leaks before it
is pressurised!
To do this, apply a test pressure from the outside
through the tap or measurement fitting and check for
leaks using leak spray.