557, IM, 0970 5570, ..
testo 557 · Digital manifold
Instruction manual
2
1 Contents
1
Contents
1
Contents ...................................................................................................3
2
Safety and the environment....................................................................4
3
4
2.1.
About this document ........................................................................4
2.2.
Ensure safety...................................................................................5
2.3.
Protecting the environment..............................................................5
Specifications ..........................................................................................6
3.1.
Use ..................................................................................................6
3.2.
Technical data .................................................................................6
Product description.................................................................................8
4.1.
Overview..........................................................................................8
5
First steps ..............................................................................................10
6
Using the product ..................................................................................12
6.1.
Preparing for measurement ...........................................................12
6.1.1.
6.1.2.
6.1.3.
6.2.
Connecting the temperature sensor ...............................................................12
Switching the instrument on ...........................................................................12
Choosing the measuring mode ......................................................................14
Performing the measurement ........................................................15
7
Maintaining the product ........................................................................17
8
Tips and assistance...............................................................................19
8.1.
Questions and answers .................................................................19
8.2.
Measurement parameters .............................................................19
8.3.
Error reports ..................................................................................20
8.4.
Accessories and spare parts .........................................................20
3
2 Safety and the environment
2
Safety and the environment
2.1.
About this document
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.
Symbols and writing standards
Representation Explanation
Warning advice, risk level according to the
signal word:
Warning! Serious physical injury may occur.
Caution! Slight physical injury or damage to
the equipment may occur.
> Implement the specified precautionary
measures.
Note: Basic or further information.
2. ...
Action: more steps, the sequence must be
followed.
> ...
Action: a step or an optional step.
-
Result of an action.
1. ...
4
...
Menu
Elements of the instrument, the instrument
display or the program interface.
[OK]
Control keys of the instrument or buttons of
the program interface.
... | ...
Functions/paths within a menu.
“...”
Example entries
2 Safety and the environment
2.2.
Ensure safety
> Do not operate the instrument if there are signs of damage at
the housing, mains unit or feed lines.
> Do not perform contact measurements on non-insulated, live
parts.
> Do not store the product together with solvents. Do not use any
desiccants.
> Carry out only the maintenance and repair work on this
instrument that is described in the documentation. Follow the
prescribed steps exactly. Use only original spare parts from
Testo.
> The objects to be measured or the measurement environment
may also pose risks: Note the safety regulations valid in your
area when performing the measurements.
> If the measuring instrument falls or another comparable
mechanical load occurs, the pipe sections of the refrigerant
hoses may break. The valve positioners may also be damaged,
whereby further damage to the interior of the measuring
instrument may occur that cannot be identified from the outside.
The refrigerant hoses must therefore be replaced with new,
undamaged refrigerant hoses every time the measuring
instrument falls or following any other comparable mechanical
load. Send the measuring instrument to Testo Customer
Service for a technical check for your own safety.
> Electrostatic charging can destroy the device. Integrate all the
components (system, manifold's valve block, refrigerant bottle
etc.) into the potential equalisation (earthing). Please see the
safety instructions for the system and the refrigerant used.
2.3.
Protecting the environment
> Dispose of faulty rechargeable batteries/spent batteries in
accordance with the valid legal specifications.
> 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.
> Refrigerant gases can harm the environment. Please note the
applicable environmental regulations.
5
3 Specifications
3
Specifications
3.1.
Use
The testo 557 is a digital manifold for maintenance and service
work on refrigeration systems and heat pumps. The device is only
to be used by qualified expert personnel.
With its functions the testo 557 replaces mechanical manifolds,
thermometers and pressure/temperature charts. Pressures and
temperatures can be applied, adapted, tested and monitored.
The testo 557 is compatible with most of the non-corrosive
refrigerants, water and glycol. The testo 557 is not compatible with
ammoniac refrigerants.
Then product must not be used in explosive environments!
3.2.
Technical data
Feature
Values
Measurement
parameters
Pressure: psi/ kPa/MPa/bar
Temperature: °F/°C/K
Vacuum: Micron / inHg / inH2O / hPa / mbar/
Torr / Pa
Sensing element
Pressure: 2 x pressure sensors
Temperature: 2 x NTC
Measuring cycle
0.75 s
Interfaces
Pressure connections: 3 x 7/16" UNF,
1x 5/8" UNF
NTC measurement
Measurement
ranges
Pressure measurement range HP/LP:
-14.7…725 psi / -100…5000 kPa /
-0.1…5 MPa / -1…50 bar (rel)
Temperature measurement range:
-58…302 °F / -50…+150 °C
Measurement range vacuum (rel):
-14.7…0 psi / -1…0 bar
Overload
6
754 psi, 52 bar, 5200 kPa, 5.2 MPa
3 Specifications
Feature
Values
Resolution
Resolution pressure: 0.1 psi / 0.01 bar /
1 kPa / 0.001 MPa
Resolution temperature: 0.1 °F / 0.1 °C /
0.1 K
Vacuum resolution: 500 Micron / 0.02 inHg /
0.5 inH2O / 1 hPa / 1 mbar / 0.5 Torr / 100 Pa
Accuracy (nominal Pressure: ±0.5% of final value (±1 digit)
temperature 71.6 °F Temperature (-40…302 °F / -40…+150 °C):
/ 22 °C)
±0.9 °F (±1 digit), ±0.5 K (±1 digit), ±0.5 °C
(±1 digit)
Vacuum: 1% of final value (±1 digit)
No. of refrigerants
40
Selectable
refrigerants
No refrigerant, R12, R22, R123, R134a,
R227, R290, R401A, R401B, R402A, R402B,
R404A, R406A, R407A, R407C, R408A,
R409A, R410A, R411A, R413A, R414B,
R416A, R417A, R420A, R421A, R421B,
R422A, R422B, R422D, R424A, R427A,
R434A, R437A, R438A, R502, R503, R507,
R600, R600a, R718, R744 (only in
permissible measurement range up to
50 bar), R1234yf (Display: T8)
Measurable media
Measurable media: all media that is stored in
the testo 557. Not measurable: ammonia
(R717) and other refrigerants which contain
ammonia
Ambient conditions
Operating temperature: -4…122 °F /
-20…50 °C
Storage temperature: -4…140 °F / -20…60 °C
Humidity in area of use: 10… 90 %rF
Housing
Material: ABS / PA / TPE
Dimensions approx. 280 x 135 x 75 mm
Weight: approx. 1200 g (without batteries)
IP-class
42 (position in use hanging down)
Power supply
Current source: Rechargeable batteries /
batteries 4 x 1.5V type AA / Mignon / LR6
Battery lifetime: approx. 150 h (display
illumination off)
7
4 Product description
Feature
Values
Display
Type: Illuminated LCD
Response time: 0.5 s
Directives,
EC Directive: 2004/108/EC
standards and tests
Warranty
Duration: 2 years
Terms of warranty: see website
www.testo.com/warranty
4
Product description
4.1.
Overview
Display and control elements
1 Sensor socket Mini-DIN for NTC-temperature sensor, with
socket cover
2 Suspension attachment, foldable (backside).
3 Display. Instrument status icons:
8
4 Product description
Icon
Meaning
Battery capacity: >75% / >50% / >25% / <10%
/
/
Select measuring mode, see Choosing the
measuring mode page 14
4 Battery compartment. The rechargeable batteries cannot be
charged inside the instrument!
5
Control keys:
Key
Function
[Set]
Set units
[R, Start/Stop]
Select refrigerant / Start-Stop leak test
[Mode]
Switch between measuring modes
[Min/Max/Mean]
Show min, max, mean values
[▲]
Up-key: Change display view.
[p=0]
Pressure zeroing
Light key: switches display light on/off.
[▼]
Down-key: changes display view.
[
Switch the instrument on/off
]
6 Inspection glass for refrigerant flow.
7 4 x valve actuators
8 4 x hose brackets for refrigerant hoses
9 Connection 7/16" UNF, brass.
High pressure, for refrigerant hoses with quick release screw
fitting, passage for valve actuator lockable.
10 Connection 5/8" UNF, brass, for vacuum pump
11 Connection 7/16" UNF, brass, for e.g. refrigerant cylinders, with
screw cap.
12 Connection 7/16" UNF, brass.
Low pressure for refrigerant hoses with quick release screw
fitting, passage for valve actuator lockable.
9
5 First steps
5
First steps
Inserting batteries/rechargeable batteries
1. Unfold the suspension attachment and open the battery
compartment (clip lock).
2. Insert the batteries (scope of delivery) or rechargeable batteries
(4 x 1.5 V, type AA / Mignon / LR6) into the battery
compartment. Observe the polarity!
3. Close the battery compartment.
When not in use for long period: Take out the batteries /
rechargeable batteries.
Recharge the rechargeable batteries completely before
using the instrument.
Switching the instrument on
> Press
-
[
].
Initializing phase:
•
All display segments light up (duration: 2 s).
-
Start mode ---- flashes.
-
Measurement view is opened.
Performing settings
1. Press [Set].
-
The configuration menu is opened and the adjustable
parameter flashes.
2. Set parameter:
Key functions
Representation
Explanation
[▲] or [▼]
Change parameter, select unit
[Set]
Select units/parameters
Adjustable parameters
Representation
Explanation
°C, °F
Set unit for temperature.
bar, kPa, MPa, psi Set unit for pressure.
10
5 First steps
Representation
Explanation
Pabs, Prel or psia, Depending on the chosen unit for pressure:
psig
Change between absolute and relative
pressure displays.
Micron, inHg, Pa,
hPa, Torr, inH2O,
mbar
Set pressure unit for vacuum.
Pabs, Prel or psia, Depending on the chosen unit for pressure:
psig
Change between absolute and relative
pressure displays in vacuum.
/
/
Select the measuring mode, see Choosing
the measuring mode page 14
 The settings will be accepted once the last selection has been
made.
Operating the valve actuators
With respect to the refrigerant flow path the digital manifold
behaves just like a conventional four-way manifold. The passages
are opened by opening the valves. The applied pressure is
measured with the valves closed and the valves opened.
> Open the valve: Turn valve actuator anticlockwise.
> Close the valve: Turn valve actuator clockwise.
WARNING
Tighten the valve actuator only hand-tight. Do not use any tools for
tightening, this could damage the thread.
11
6 Using the product
6
Using the product
6.1.
Preparing for measurement
6.1.1.
Connecting the temperature sensor
Sensors must be connected before the measuring
instrument is switched on, so that they are recognised by
the instrument.
Surface temperature sensor
An NTC temperature sensor (accessory) must be connected for
measuring the pipe temperature and for automatic calculation of
superheating and subcooling.
Deactivating the surface compensation factor for insertion and
air temperature sensor
A surface compensation factor has been set in the measuring
instrument to reduce the measuring errors in the main field of
applications. This reduces measuring errors when using surface
temperature sensors.
If the measuring instrument testo 557 is used in combination with
insertion or air temperature sensors (accessories), this factor must
be deactivated.:
> Press and hold the keys SET + MODE together and switch on
the measuring instrument [ ].
-
The instrument shows the message Fact off.
The surface compensation factor becomes active every
time the measuring instrument is switched on.
6.1.2.
Switching the instrument on
> Press [
].
Zeroing the pressure sensors
Zero the pressure sensors before every measurement.
✓ All connections must be pressureless (ambient pressure).
> Press key [P=0] and execute zeroing.
12
6 Using the product
Connecting the refrigerant hoses
Before each measurement check whether the refrigerant
hoses are in flawless condition.
✓ The valve actuators are closed.
1. Connect the refrigerant hoses for low-pressure side (blue) and
high-pressure side (red) to the measuring instrument.
2. Connect the refrigerant hoses to the system.
WARNING
The measuring instrument dropping down or any other comparable
mechanical load can cause breakage of the pipe pieces in the
refrigerant hoses. The valve actuators may also suffer damage,
which in turn could result in further damage inside the measuring
instrument, which may not be detectable from outside.
> For your own safety you should return the measuring
instrument to the Testo Service for technical inspection.
> You should therefore always replace the refrigerant hoses with
new ones after the measuring instrument has dropped down or
after any comparable mechanical loading.
Setting the refrigerant
1. Press [R, Start/Stop].
-
This opens the refrigerant menu and the currently selected
refrigerant flashes.
2. Setting the refrigerant:
Key functions
Representation
Explanation
[▲] or [▼]
Changing the refrigerant
[R, Start/Stop]
Confirm the setting and exit the refrigerant
menu.
Available refrigerants
Representation
Explanation
R...
Refrigerant number of refrigerant acc. to
ISO 817
T...
Special Testo designation for certain
refrigerants (T8 = T1234yf)
13
6 Using the product
Representation
Explanation
---
no refrigerant selected.
Example: Setting refrigerant R401B
1. Press [▲] or [▼] several times, until R401B flashes.
2. Press [R, Start/Stop] to confirm the setting.
Quitting the refrigerant selection
> Press [R, Start/Stop] or automatically after 30 s, if no other key
has been pressed.
6.1.3.
Choosing the measuring mode
1. Press [Set] several times
2. Press [▲] or [▼] to select the function.
3. Saving settings: Press [Set].
-
The measuring mode is displayed.
Display
14
Mode
Function
Refrigeration
system
Normal function of the digital
manifold
Heat pump
Normal function of the digital
manifold
Automatic mode
When automatic mode is
activated the digital manifold
testo 557 automatically
reverse the display of high
and low pressure. This
automatic reversal occurs
when the pressure in the low
pressure side is 1 bar higher
than the pressure in the high
pressure side. This switching
over is indicated by ---flashing in the display. This
mode is particularly suitable
for air conditioning systems
that provide cooling and
heating.
6 Using the product
6.2.
Performing the measurement
WARNING
Risk of injury caused by pressurized, hot, cold or toxic
refrigerants!
> Wear protective goggles and safety gloves.
> Before applying pressure to the measuring instrument: Always
fasten the measuring instrument on the suspension attachment
to prevent it from falling down (danger of breakage)
> Before each measurement check the refrigerant hoses for
flawless condition and correct connection. Do not use any tools
to connect the hoses, tighten hoses only hand-tight (max.
torque 5.0 Nm / 3.7 ft*lb).
> Comply with the permissible measuring range (-14.7…725 psi /
-1…50 bar). Pay particular attention in systems with refrigerant
R744, since these are frequently operated with higher
pressures.
Measuring
✓ The actions described in the chapter “Preparing for
measurement” have been performed.
1. Apply pressure to the measuring instrument.
2. Read the measuring values.
With zeotropic refrigerants, the evaporation temperature
to/Ev is displayed after the complete evaporation / the
condensation temperature tc/Co is displayed after complete
condensation.
The measured temperature must be assigned to the
superheating or subcooling side (toh <--> tcu). Dependent on
this assignment, the display will show toh/T1 resp. Δtoh/SH
or tcu/T2 resp. Δtcu/SC, depending on the selected display.
-
Reading and display illumination are flashing.
•
12 psi/1 bar before the critical pressure of the refrigerant is
reached,
•
when the max. permissible pressure of 754 psi/52 bar is
exceeded.
15
6 Using the product
Key functions
> [▲] or [▼]: Change the readings display.
Possible display combinations:
Evaporation pressure
Refrigerant evaporation
temperature to/Ev
Condensation pressure
Refrigerant condensation
temperature tc/Co
or (only with inserted temperature sensor)
Evaporation pressure
Condensation pressure
Measured temperature toh/T1 Measured temperature tcu/T2
or (only with inserted temperature sensor)
Evaporation pressure
Superheating Δtoh/SH
Condensation pressure
Subcooling Δtcu/SC
With two inserted NTC sensors Δt is additionally displayed.
> [Mean/Min/Max]: Hold readings, min. / max. readings, show
mean values (since switching on).
Leak test / pressure drop test
The temperature compensated leak test can be used to
check the leak tightness of systems. For this purpose both
the system pressure and the ambient temperature are
measured over a defined period of time. For this purpose
a temperature sensor to measure the ambient temperature
may be connected (recommendation: Deactivate the
surface compensation factor (see page 12) and use NTC
air sensors Art.-No. 0613 1712). This provides information
about the temperature compensated differential pressure
and about the temperature at the beginning/end of the test
as a result. If no temperature sensor is connected, you may
also perform the leak test without temperature
compensation.
✓ The actions described in the chapter “Preparing for
measurement” have been performed.
1. Press [Mode]
-
The leak test view is opened. ΔP is displayed.
2. Start the leak test: Press [R, Start/Stop].
3. End the leak test: Press [R, Start/Stop].
-
The result is displayed.
4. Confirm the message: Press [Mode].
16
7 Maintaining the product
-
Automatic jump to the evacuation / vacuum display.
Evacuation / vacuum display
The measurement takes place in the low pressure side.
5. Press [Mode].
-
The display shows VAC
6. Press [Mode].
-
Main menu display.
Vacuum measurement
In order to achieve optimal measuring accuracy in vacuum
measurement, the measuring instrument must be zeroed at
ambient pressure.
Zeroing at ambient pressure must be performed for each
vacuum measurement.
✓ The desired units have been set, see Performing settings
page 10.
1. Press [
].
2. Zero the measuring instrument at ambient pressure [p=0].
3. Press [Mode] 2 times.
-
The instrument is in vacuum mode Vac.
4. Start evacuation.
7
Maintaining the product
Cleaning the instrument
> If the housing of the instrument is dirty, clean it with a damp
cloth.
Do not use any aggressive cleaning agents or solvents! Weak
household cleaning agents and soap suds may be used.
Keeping connections clean
> Keep screw connections clean and free of grease and other
deposits, clean with a moist cloth as required.
17
7 Maintaining the product
Removing oil residues
> Carefully blow out oil residues in valve block using compressed
air.
Ensuring the measuring accuracy
Testo Customer Service would be glad to further assist you if you
so wish.
> Check instrument regularly for leaks (recommended: annually).
Keep to the permissible pressure range!
> Calibrate instrument regularly (recommended: annually).
Changing batteries/rechargeable batteries
✓ Instrument is switched off.
1. Fold out the suspension device, loosen the clip and remove the
cover of the battery compartment.
2. Remove empty batteries/rechargeable batteries and insert new
batteries/rechargeable batteries (4x 1.5 V, type AA, Mignon,
LR6) in the battery compartment. Observe the polarity!
3. Set on and close cover of the battery compartment (clip must
engage).
4. Switch the instrument on.
Changing the valve or valve positioner handle
WARNING
Change of the valve positioners and valves by the customer is not
permissible.
> Send the measuring instrument to the Testo Customer Service.
18
8 Tips and assistance
8
Tips and assistance
8.1.
Questions and answers
Question
Possible causes/solution
Batteries are almost empty.
flashes
> Change batteries.
The instrument switches
off automatically.
Residual capacity of the batteries is
too low.
> Change batteries.
uuuu lights up instead of
the parameter display
The permissible measuring range has
been undershot.
> Keep to the permitted measuring
range.
oooo lights up instead of
the parameter display
The permissible measuring range has
been exceeded.
> Keep to the permitted measuring
range.
8.2.
Measurement parameters
Name
Description
Δtoh
SH
Superheating, evaporation pressure
Δtcu
SC
Subcooling, condensation pressure
to
Ev
Refrigerant evaporation temperature
tc
Co
Refrigerant condensation temperature
toh
T1
Measured temperature, evaporation
tcu
T2
Measured temperature, condensation
19
8 Tips and assistance
8.3.
Error reports
Question
Possible causes/solution
---- is lit up instead of
measurement parameter
display
Sensor or cable defective
Display EEP FAIL
Eeprom defective
> Please contact your dealer or
Testo Customer Service
> Please contact your dealer or
Testo Customer Service
If you have any questions, please contact your dealer or Testo
Customer Service. The contact details can be found on the back of
this document or on the Internet at www.testo.com/servicecontact.
8.4.
Accessories and spare parts
Description
Article no.
Clamp probe for temperature measurement
at pipes
0613 5505
Pipe wrap probe with Velcro tape for pipe
diameters of up to max. 75 mm, Tmax.
+75 °C, NTC
0613 4611
Watertight NTC surface probe
0613 1912
Precise, robust NTC air probe
0613 1712
For a complete list of all accessories and spare parts, please refer
to the product catalogues and brochures or look up our website at:
www.testo.com
20
Testo Inc.
Testo Pty. Ltd
40 White Lake Road
Sparta, N. J. 07871
Unit 11,
114-118 Merrindale Drive
Croydon South 3136
Phone:
+1 862 354 5001
Fax: +1 862 354 5020
Email: [email protected]
www.testo.us
Phone: +61 3 87 61 61 08
Fax:
+61 3 87 61 61 09
Email: [email protected]
www.testo.com.au
Testo Ltd
Newman Lane ALTON,
HAMPSHIRE GU34 2QJ
Phone:
01420 54 44 33
Fax: 01420 54 44 34
Email: [email protected]
www.testo.co.uk
0970 5570 en 02 V01.00
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