TESTO 6457 User manual

testo 6457 COMPRESSED AIR METER
Instruction manual

Table of contents
1GENERAL INFORMATION ...........................................................................5
1.1 Incoming goods inspection, transportation and storage .........................5
•Make sure that the packaging is undamaged! ............................................5
•Make sure that the contents are not damaged!...........................................5
•If you have any questions, please contact your supplier or their sales
office........................................................................................................5
2SAFETY PRECAUTIONS ..............................................................................6
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. .........................................................................6
2.1 Intended use ..........................................................................................6
2.2 Installation, commissioning and operation..............................................7
As the user, you are responsible for compliance with all valid safety
regulations, including: ...........................................................................7
•The authorised personnel must have read and understood this
instruction manual and comply with the instructions set out in it. .....7
2.3 Exclusion of liability ................................................................................8
3DESIGN AND FUNCTION / SCOPE OF DELIVERY.....................................9
3.1 Electric sensor unit quick-change fitting ...............................................10
Absolute measuring range ...............................................................................10
3.2 Aluminium quick-change fitting with Compac flange ............................11
3.3 Compac welding neck flange (V flange) steel ......................................11
3.4 Dummy plug .........................................................................................11
3.5 Measuring station .................................................................................12
3.6 ISO calibration certificate .....................................................................12
4TECHNICAL DATA .....................................................................................13
4.1 Thermal mass flow sensor ...................................................................13
Output signals...................................................................................................13
4.2 Accessories..........................................................................................14
4.2.1 Replacement sensor..............................................................14
4.2.2 Connecting cable with electric isolation .................................14
4.2.3 Calibration options .................................................................14
•ISO certificate..............................................................................................14
•Sensor parameter setting for CO2 and N2 ................................................15
4.3 Function ...............................................................................................15
4.3.1 Processing the measuring signals .........................................15
4.3.2 Switching output ....................................................................16
4.3.3 Analog output ........................................................................17

Table of contents
4.3.4 Consumption quantity monitoring [ImP] ................................ 19
4.3.4.1 Meter reading....................................................... 19
4.3.4.2 Counter reset ....................................................... 19
4.3.4.3 Consumption quantity monitoring
via pulse signals................................................... 20
4.3.4.4 Consumption quantity monitoring
via preset counter ................................................ 20
4.3.5 Measuring value damping..................................................... 21
4.3.6 Low flow cut-off ..................................................................... 21
4.3.7 Simulation ............................................................................. 21
4.3.8 Colour of the characters in the display ................................. 22
5INSTALLATION .......................................................................................... 23
5.1 Determining the installation point......................................................... 23
•Well accessible with low vibration. ...........................................................23
5.2 Length measurements of the compressed air meter............................ 24
5.3 Installation position .............................................................................. 25
5.4 Required measuring section................................. 26
5.5 Direction of flow ................................................................................... 26
5.6 Installation of the compressed air meter .............................................. 27
5.6.1 Installation of the measuring station...................................... 27
5.6.2 Installing the sensor in the measuring station ....................... 28
28
5.7 Sensor replacement............................................................................. 29
5.8 Electrical connection............................................................................ 30
5.8.1 4-wire pin assignment ........................................................... 31
5.8.1.1 1 x pulse output, 1 x analog output
(condition on delivery) .......................................... 31
5.8.2 5-wire pin assignment (accessory)........................................ 32
6OPERATION ............................................................................................... 32
Thermal mass flow sensor........................................................................... 32
6.1 Operation and display elements .......................................................... 33
7MENU.......................................................................................................... 34
7.1 Process value display (RUN) ............................... 34
7.2 Main menu ........................................................................................... 35
7.3 Extended functions EF......................................................................... 36
7.4 Submenu OUT1................................................................................... 37
7.5 Submenu OUT2................................................................................... 39
7.6 Submenu CFG..................................................................................... 41
7.7 Submenu MEM, DIS ............................................................................ 42
Explanation submenu MEM......................................................................... 43

Explanation submenu DIS............................................................................43
7.8 Submenu COLR, SIM...........................................................................44
Explanation submenu COLR........................................................................45
Explanation submenu SIM ...........................................................................45
8COMMISSIONING .......................................................................................46
9PARAMETER SETTING..............................................................................46
9.1 General parameter setting....................................................................47
9.1.1 Select submenu .....................................................................47
9.1.2 Change to the process value display (RUN mode) ................47
9.1.3 Lock / unlock..........................................................................47
9.1.4 Timeout..................................................................................48
9.2 Settings for flow monitoring ..................................................................48
9.2.1 Limit value monitoring OUT1 or OUT2 / hysteresis function ..48
9.2.2 Limit value monitoring OUT1 or OUT2 / window function ......48
9.2.3 Analog signal flow OUT2 .......................................................49
9.3 Settings for consumption quantity monitoring.......................................49
9.3.1 Quantity monitoring by pulse signal OUT1 and OUT2...........49
9.3.2 Quantity monitoring by preset counter OUT1 or OUT2..........50
9.3.3 Manual counter reset .............................................................50
9.3.4 Time-controlled counter reset ................................................50
9.3.5 Deactivating counter reset .....................................................50
9.3.6 Counter reset using an external signal ..................................51
9.4 Settings for temperature monitoring .....................................................51
9.4.1 Limit value monitoring OUT1 or OUT2 / hysteresis function ..51
9.4.2 Limit value monitoring OUT1 or OUT2 / window function ......51
9.4.3 Analog signal temperature OUT2 ..........................................52
9.5 User settings (optional) ........................................................................52
9.5.1 Standard display ....................................................................52
9.5.2 Standard unit of measurement for flow ..................................53
9.5.3 Standard unit of measurement for temperature .....................53
9.5.4 Measuring value damping......................................................53
9.5.5 Switching logic for outputs .....................................................53
9.5.6 Low flow cut-off......................................................................53
9.5.7 Standard conditions ...............................................................54
9.5.8 Colour of the characters in the display...................................54
9.5.9 Switching/reset delay.............................................................54
9.5.10 Error behaviour of the outputs ...............................................55
9.5.11 Restore factory settings .........................................................55
9.6 Diagnostic functions .............................................................................56

Table of contents
9.6.1 Read min/max values............................................................ 56
9.6.2 Simulation ............................................................................. 56
10 OPERATION ............................................................................................... 57
11 TROUBLESHOOTING ................................................................................ 57
12 MAINTENANCE, REPAIR AND DISPOSAL............................................... 59
13 CONFIGURATION AND FACTORY SETTINGS ........................................ 60
13.1 Configuration of OUx on delivery ......................................................... 60
13.2 Factory setting ..................................................................................... 60

5
1 GENERAL INFORMATION
1.1 Incoming goods inspection, transportation and storage
•Make sure that the packaging is undamaged!
Inform your supplier of any damage to the packaging. Retain the damaged
packaging until the matter is settled.
•Make sure that the contents are not damaged!
Inform your supplier of any damage to the contents. 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 must also
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 pressurized
systems up to PN 16 (DN 200 14 bar)

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
3 DESIGN AND FUNCTION /
SCOPE OF DELIVERY
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
13
Aluminium interchangeable fitting
14
Flange adapter
The equipment is supplied loosely pre-assembled in 2 parts: sensor
and station. Also included in the scope of delivery:
• Calibration certificate

10
3.1 Electric sensor unit quick-change fitting
The sensor records the standard volumetric flow of working compressed
air based on the calorimetric measuring principle. It detects the four
process parameters flow velocity, flow quantity, consumption quantity and
media temperature.
All specifications apply to standard volumetric flow according to DIN ISO
2533 (1013 mbar, 15 °C, 0% relative air humidity). The sensor can be set
to different standard conditions.
Observe the general operating conditions for compressed air
systems. The air quality of the working compressed air influences the
measuring accuracy as follows:
Absolute measuring range
WARNING
Nominal width
Measuring range
Recording/disp
lay range
DN 65
8 –1877 m³/h
0 –2252 m³/h
DN 80
11 –2635 m³/h
0 –3162 m³/h
DN 100
19 –4533 m³/h
0 –5436 m³/h
DN 125
29 –6923 m³/h
0 –8307 m³/h
DN 150
43 –10190 m³/h
0 –12230 m³/h
DN 200
73 –17350 m³/h
0 –20820 m³/h
DN 250
115 –27450 m³/h
0 –32950 m³/h
Specifications according to DIN ISO 2533 (15 °C, 1013.25 mbar and 0% rel.
humidity).
Quality classes according to
ISO 8573-1
particles/humidity/oil
Measurement errors
1-5-1
± (3.1% of measured value
+ 0.5% of full scale value)
3-4-4
± (6% of measured value +
0.6% of full scale value)
The compressed air meter may be used to measure the
volume flow of working compressed air with up to 16 bar
(> DN 200, PN 14) overpressure.

11
3.2 Aluminium quick-change fitting with
Compac flange
The aluminium quick-change fitting accommodates the sensor unit and
enables maintenance without interrupting the flow, with reproducible
positioning of the measuring point.
The upper closure of the quick-change fitting is provided by a sealing
cone.
The Compac flange in the lower section forms the interface between the
quick-change fitting and the measuring station.
3.3 Compac welding neck flange (V flange)
steel
The connection between the measuring point interface and the pipe
system is made via the Compac welding neck flanges.
Note
An alternative to the welding neck flange (V flange) is to fit a Compac threaded
flange (G flange).
3.4 Dummy plug
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.
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.

12
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 pipelines with the Compac welding neck flanges
in line with the direction of flow (see engraved direction arrow). The
nominal width of the measuring station and welding neck flanges
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 certificate
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 is included in the delivery.

13
4 TECHNICAL DATA
4.1 Thermal mass flow sensor
The thermal mass flow sensor for compressed air volume flow
measurement works independently of the process pressure and media
temperature.
Sensor Thermal glass-coated ceramic sensor
Media Compressed air, with special calibration also CO2, N2
Accuracy Class 1-5-1:
± (3.1% of measured value + 0.5% of full scale value)
Class 3-4-4:
± (6% of measured value + 0.6% of full scale value)
Air quality according to ISO 8573 –1.2010;
at media temperature 23 °C
Temperature monitoring ± 2 °C
Repeat accuracy ±1.5% of measured value
Display, operation Colour display 1.44", 128x128 pixels, 2x LED, yellow
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 overpressure
(> DN 200 up to 14 bar overpressure)
Media temperature -10 °C to + 60 °C
Perm. ambient temp. 0 °C to 60 °C
Maximum permissible
relative humidity 90% relative humidity
Perm. storage
temperature -20 °C to + 85 °C
Media contact V2A (1.4301), glass-coated ceramic, FKM,
PPS GF40, acrylate
Housing materials PBT + PC-GF 30, PPS GF40
Protection class IP65, IP 67 / III
Electrical connection M12 x 1 connector, can be loaded to 150 mA,
short-circuit-proof
Power supply 18 to 30 VDC, current consumption < 80 mA*
Readiness delay 1 s
* according to EN 80178 SELV/PELV
Output signals
Analog output 4-20 mA, measuring range scaleable
max. load 500 Ω
Current carrying
capacity 2 x 150 mA, short-circuit-proof, protected against polarity
reversal

14
Switching and
pulse signal
- overload-proof
EMC DIN EN 60947-5-9
4.2 Accessories
4.2.1 Replacement sensor
The replacement sensor serves as a replacement in case of damage to or
loss of the original mass flow sensor.
Note
4.2.2 Connecting cable with electric isolation
A suitable connection cable is available as an accessory. The cable is
5 m long and is used for the electrical connection of the transmitter to the
customer's control system. 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.
Optionally, a cable with additional electrical isolation is also available;
with this cable, the electrical isolation is built into the instrument
connector and is used for the galvanic electrical isolation of the sensor
output from the electronics connected to it.
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.

15
•Sensor parameter setting for CO2 and N2
Six measuring points are parametrised 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.
4.3 Function
▪The flow is monitored by a calorimetric measuring system, the
measuring signals are evaluated by the electronics.
▪The instrument records the media temperature during flow as an
additional process value.
▪The instrument displays the current process values.
▪The instrument has extensive self-diagnostic capabilities.
▪A simulation mode enables simple commissioning of the sensor.
4.3.1 Processing the measuring signals
The instrument generates 2 output signals according to the parameter
settings:
OUT1: 5 options
- Switching signal for flow quantity limit value
- Switching signal for temperature limit value
- Switching signal for preset counter
- Pulse signal for quantity counter
- OFF (output switched to high impedance)
OUT2: 9 options
- Switching signal for flow quantity limit value
- Switching signal for temperature limit value
- Switching signal for preset counter
- Switching signal for quantity counter
- Analog signal for flow quantity
- Analog signal for temperature
- Input for external counter reset signal (InD)

16
- OFF (output switched to high impedance)
- Pulse output
4.3.2 Switching output
OUTx changes its switching status if it is above or below the set
switching limits (flow or temperature). Hysteresis or window function
can be selected.
Example of flow monitoring:
SP = Switching point FH = Upper limit value
rP = Reset point FL = Lower limit value
HY = Hysteresis FE = Window
Hno / Fno = NO (normally open) Hnc / Fnc = NC (normally closed)
Note
Note
When the hysteresis function is set, the switching point (SP) is
defined first, then the reset point (rP), which must be a lower value.
If only the switching point is changed, the reset point is changed
automatically, the previously set gap remains constant.
When set to the window function, the upper limit value (FH) and
lower limit value (FL) have a fixed hysteresis of 0.25% of the full
scale value. This keeps the switching status of the output stable if
the flow fluctuates very slightly.
Hysteresis function
Window function

17
4.3.3 Analog output
The instrument provides an analog signal that is proportional to the flow
quantity or the media temperature.
Within the measuring range, the analog signal is between 4 and 20 mA.
The measuring range is scalable:
▪[ASP2] determines at which measured value the output signal is
4 mA.
▪[AEP2] determines at which measured value the output signal is
20 mA.
Note
If the measured value is outside the measuring range or if there is an
internal error, the current signal indicated in Figure 1 | p. 18 is output.
For measured values outside the display range or in the event of an error,
messages are displayed (cr.UL, UL, OL, cr.OL, Err; 11).
The analog signal in the event of an error is adjustable ( 9.5.10):
▪[FOU] = On determines that the analog signal goes to the upper end
value (21.5 mA) in the event of an error.
▪[FOU] = OFF determines that the analog signal goes to the lower end
value (3.5 mA) in the event of an error.
▪[FOU] = OU determines that the analog signal behaves as specified by
the current parameters in the event of an error.
Minimum distance between [ASP2] and [AEP2] = 20% of the
FS value.

18
Fig. 1
Analog output characteristic according to standard IEC 60947-5-7.
1
Analog signal
2
Measured value (flow or temperature)
3
Detection range
4
Display range
5
Measuring range
6
Scaled measuring range
Q:
Flow
T:
Temperature
MAW:
Zero/lower range value for non-scaled measuring range.
(When a low flow cut-off is set for Q: Signal output starting at
MAW + LFC ( 4.3.6)
MEW:
Full scale value/upper range value for non-scaled measuring
range
ASP:
Analog starting point with scaled measuring range
AEP:
Analog end point with scaled measuring range
UL:
Below the display range
OL:
Above the display range
cr.UL:
Below the detection range (error)
cr.OL:
Above the detection range (error)