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TESTO 6446 Instruction Manual

Compressed air meter
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  • Page 1   testo 6446 compressed air meter Instruction manual  ...

  • Page 3: Table Of Contents

    Contents     GENERAL INFORMATION ................5     Incoming goods inspection, transportation and storage ........5   SAFETY PRECAUTIONS ................6       Intended use ......................6     Installation, commissioning and operation ............7     Exclusion of liability ....................8  ...
  • Page 4 Contents   OPERATION ....................26       Operation and display elements ................. 26     Types of operation ....................28     Run mode 6.2.1     Display mode 28 6.2.2     Programming mode – parameter configuration ........28 6.2.3  ...

  • Page 5: General Information

    GENERAL INFORMATION 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.

  • Page 6: Safety Precautions

    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. 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.

  • Page 7: Installation, Commissioning And Operation

    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: •...

  • Page 8: Exclusion Of Liability

    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.

  • Page 9: Design And Function

    DESIGN AND FUNCTION Overview of components Sensor unit Straight pin as alignment aid Hexagon socket head screw M 10 Dummy plug Dummy plug holder both sides Direction of flow arrow Measuring station Brass sealing plug Hexagon screw depending on DN Viton O-rings 11 Compac steel welding Compac stainless steel sealing...

  • Page 10: Electric Sensor Unit

    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 Electric sensor unit The sensor records the standard volumetric flow of the working compressed air according to the calorimetric measurement principle.
  • Page 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.

  • Page 12: Compac Stainless Steel Sealing Cone

    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). Compac stainless steel sealing cone The Compac sealing cone makes up the intersection between the measuring station and sensor.

  • Page 13: Dummy Plugs Included As Standard

    Sealing principle of the Compac flange 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.

  • Page 14: Measuring Station

    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).

  • Page 15: Technical Data

    TECHNICAL DATA 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...

  • Page 16: Accessories

    Output signals Analog output 4-20 mA, measuring range scaleable max. load 500 Ω pulse 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 IEC 1000/4/2 ESD 4/8 kV...

  • Page 17: Installation

    INSTALLATION 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 WARNING qualified electrician. To install and remove the sensor the line must be depressurized.

  • Page 18: Length Measurements Of The Compressed Air Meter

    Length measurements of the compressed air meter Inch Ø D1 Ø D2 2½" 70.3 3" 82.5 4" 107.1 5" 131.7 6" 159.3 8" 207.3 10" 260.4...

  • Page 19: Installation Position

    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. Diagrams: 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,...

  • Page 20: Required Measuring Section

    Required measuring section 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 Note pipeline length downstream of the compressed air meter, as seen in the direction of flow for the medium.

  • Page 21: Installation Of The Compressed Air Meter

    Installation of the compressed air meter 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. Note To install and remove the compressed air meter the line must be depressurized.

  • Page 22: Installing The Sensor In The Measuring Station

    3. Screw the measuring station between the flanges according to the direction of flow. Fix the screws in diagonal order for even force distribution. Installing the sensor in the measuring station 5.6.2 Make sure that the pipeline is depressurized before installing the sensor.

  • Page 23: Sensor Replacement

    Fix the sensor to the measuring station with the union nut and without tools. The mechanical installation of the compressed air meter is now complete. Sensor replacement The removal of the mounted sensor may be necessary for maintenance, cleaning and calibration purposes. Never remove the sensor or the dummy plug from the sealing cone when the line is under pressure –...

  • Page 24: Electrical Connection

    Electrical connection Disconnect the system from the power supply when connecting. The instrument may only be installed by a qualified electrician. Follow the national and international regulations regarding the installation of electrical engineering systems. The voltage supply is to be laid out in accordance with EN50178, SELV, and PELV.

  • Page 25: 5-Wire Pin Assignment (Accessory)

    5.8.1.1 1 x pulse output, 1 x analog output (condition on delivery) The OUT1 output is used as a PNP signal output (pulse) and the OUT2 output is used as an analog output. This is the configuration in which the sensors are delivered.

  • Page 26: Operation

    The potential-free pulse output OUT1 is specified for this connecting cable as follows: Line type LiYCY Length Switching capacity 500 mA Max. switching voltage 36 V Min. switching voltage Switch contact resistance 0.21 Ω Insulation voltage 5.3 kV Protected against polarity reversal OPERATION Thermal mass flow sensor...
  • Page 27 Type Description Illuminated LED = display unit set ① Indicator LEDs Current flow rate (Nl/min) ⑧ When the LED lights up, displayed value x 1000 Current flow rate (Nm When the LED lights up, displayed value x 1000 Current flow velocity (Nm/s) Current consumption quantity since last reset (Nm Consumption quantity before the last reset in (Nm flashing...

  • Page 28: Types Of Operation

    Types of operation Run mode 6.2.1 After switching on the supply voltage, the instrument is in run mode. It carries out its measurement and evaluation functions and provides output signals according to the set parameters. The display shows the current measurement values and the yellow LEDs show the switch status of the outputs.

  • Page 29: Menu

    MENU Menu overview In the menu overview, indicates the Set button and Mode button on the sensor. Nl/min Nm/s °C (Nm³)* = volume flow amount before the last reset The parameter values given in digits represent factory settings or random examples.

  • Page 30: Menu Explanation

    Menu explanation SP1/rP1 Switching point or Return switching point Upper/lower limit value for flow rate ImPS Pulse value ImPR Repeat pulse yes = active = pulse output or no = not active = preset counter function Initial function for OUT1 (flow rate or consumption quantity): - Switching signal for limit values: Hysteresis function Hno and Hnc or window function Fno and Fnc o = normally open = N/O contact;...

  • Page 31: Programming And Parametrisation

    SEL2 Standard measurement parameter for evaluation using OUT2: Limit value signal or analogue signal for flow rate Limit value signal or analogue signal for temperature rEF.P Standard pressure measurement and display values refer to for the flow rate rEF.T Standard temperature measurement and display values refer to for flow rate Low flow cut-off Reset –...
  • Page 32 * To reduce the value: Allow the display to run through to the maximum setting value. After this, the run-through starts again from the minimum setting value. Set the display unit Uni before you set the values for the SPx, rPx, ASP and AEP parameters.

  • Page 33: Parametrising Scenarios

    Parametrising scenarios Settings for flow monitoring 8.2.1 Configuring limit monitoring with OUT1 8.2.1.1 select and specify unit of measurement ( see 8.2.4). select and set the switching function. Hno = hysteresis function/NO contact Hnc = hysteresis function/NC contact Fno = window function/NO contact Fnc = window function/NC contact select and set value with which the output switches.

  • Page 34: Settings For Consumption Quantity Monitoring

    Configuring the analogue value for flow rate 8.2.1.3 select and specify unit of measurement ( see 8.2.4). SEL2 select and FLOW set. select and set the function. I = flow-proportionate current signal (4 to 20 mA) select and set value with which the minimum value is output.
  • Page 35 Configuring program-controlled reset 8.2.2.3 select; continue with a) or b) a) reset counter manually Press until rES.T is displayed, then briefly press Mode/Enter. b) enter value for time-controlled reset Press until the required value is displayed (intervals of 1 hour to 8 weeks), then briefly press Mode/Enter. Press until rES.T is displayed, then briefly press Mode/Enter.

  • Page 36: Settings For Temperature Monitoring

    Settings for temperature monitoring 8.2.3 Configuring limit monitoring with OUT2 8.2.3.1 SEL2 select and set. TEMP select and set the switching function. Hno = hysteresis function/NO contact Hnc = hysteresis function/NC contact Fno = window function/NO contact Fnc = window function/NC contact select and set value with which the output switches.

  • Page 37: User Settings (Optional)

    User settings (optional) 8.2.4 Specifying the standard unit of measurement for flow rate 8.2.4.1 select and specify unit of measurement. Lmin = flow volume per standard litre/minute nm3h = flow volume per standard cubic metre/hour nmS = flow velocity per standard metre/second The setting only affects the flow rate value.
  • Page 38 Configuring the error characteristics of the outputs 8.2.4.4 FOU1 select and specify value On = output 1 switches ON in the event of an error. OFF = output 1 switches OFF in the event of an error. > With both values – ON and OFF – the meter no longer runs in the event of an error.

  • Page 39: Service Functions

    Setting the standard pressure which measurement and display 8.2.4.5 values refer to for flow rate rEF.P select and set the required standard pressure. Setting range: 950 to 1050 hPa in 1 hPa increments. Setting the standard temperature which measurement and display 8.2.4.6 values refer to for flow rate rEF.T...

  • Page 40: Pulse Setting

    Resetting all parameters to factory setting 8.2.5.2 After resetting to factory setting, the memory value is zero. Note select. press and hold it down until [----] is displayed. Press Mode/Enter briefly. It is recommended noting down the individual settings before carrying out this function.

  • Page 41: Hysteresis Function

    - Set OU1 to ImP - Press Mode/Enter until ImPS is displayed. Press and hold Set. > The current numerical value flashes for 5 seconds, then one of the four digits is active (digit flashes; can be changed). - Setting the required pulse value: - First select the required setting range (1, 2, 3, etc.): Press and hold the Set button until the setting range has the required value.

  • Page 42: Scaling The Measuring Range

    Scaling the measuring range 8.2.9 - With the analog starting point parameter ASP, you determine at which measuring value the output signal is 4 mA. - With the analog end point parameter AEP, you determine at which measuring value the output signal is 20 mA. - Minimum distance between ASP and AEP = 25% of final value of measuring range MEW = final value of measuring range...

  • Page 43: Repair

    REPAIR Error messages Display Description Measuring value < -20% of final value of measuring range (temperature) Recording range exceeded (Flow rate > 120% of final value of measuring range) Flashing: short-circuit in switching output 1* Flashing: short-circuit in switching output 2* Flashing: short-circuit in both switching outputs* Flashing: Malfunction in probe * The affected output is switched off as long as the short-circuit lasts.

  • Page 44: Recalibration

    Clean the sensor with approved cleaning agents only. Do not use any chafing (abrasive) cleaning agents. These can lead to irreparable damages to the sensor. Carry out a new inspection after the cleaning, as required. During cleaning, take care not to mechanically stress the ATTENTION sensor plates, as they may break, causing irreparable damage to the sensor.

  • Page 45: Troubleshooting

    To order spare parts please contact our Service team, either by phone on +49 7653 6810 or email to info@testo.de. Replacing O-rings and sealing rings 10.2 • Keep the sealing surfaces clean.
  • Page 48   0970 6446 en 03...

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