Testo 549, 550 Operating Manual

testo 549 - testo 550 . Digital manifold

Instruction manual

2

1 Contents

1 Contents

1 Contents ................................................................................................... 3

2 Safety and the environment .................................................................... 4

2.1. About this document ........................................................................ 4

2.2. Ensure safety................................................................................... 4

2.3. Protecting the environment .............................................................. 5

3 Product description ................................................................................. 5

3.1. Use .................................................................................................. 5

3.2. Overview ......................................................................................... 6

4 First steps ................................................................................................ 7

5 Using the manifold .................................................................................. 9

5.1. Preparing for measurement ............................................................. 9

5.1.1. Switching the instrument On ............................................................................... 9

5.1.2. Connecting temperature probe(s) .....................................................................11

5.1.3. Switching Bluetooth® on and off (only testo 550) ............................................11

5.1.4. Measuring mode ...............................................................................................12

5.2. Performing the measurement ........................................................ 13

6 Technical data ........................................................................................ 16

6.1.1. Bluetooth module (only testo 550) ....................................................................16

6.1.2. General technical data ......................................................................................17

7 Maintaining the product ........................................................................ 19

8 Tips and assistance............................................................................... 20

8.1. Questions and answers ................................................................. 20

8.2. Measurement parameters ............................................................. 20

8.3. Error reports .................................................................................. 21

8.4. Accessories and spare parts ......................................................... 21

9 EC declaration of conformity ................................................................ 22

3

2 Safety and the environment

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.

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 Safety and the environment

2.1. About this document

Use

> Please read this documentation 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 product.

Symbols and writing standards

2.2. Ensure safety

> Do not operate the instrument if there are signs of damage at

the housing, mains unit or hoses.

> 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.

> Dangers may also arise from the refrigeration systems being

measured or the measuring environment: Note the safety
regulations valid in your area when performing the
measurements.

4

> If the manifold falls or another comparable mechanical load

occurs, the pipe sections of the refrigerant hoses may break.
The valve stem shutoff may also be damaged, whereby further
damage to the interior of the manifold may occur that cannot be
identified from the outside. The refrigerant hoses must therefore
be replaced with new, undamaged refrigerant hoses every time
the manifold falls or following any other comparable mechanical
load. Send the manifold to Testo Customer Service for a
technical check for your own safety.

> To prevent damage from ESD (electro-static discharge) or

transient voltage spikes make sure that your refrigeration
system is properly grounded, as otherwise the manifold might
get damaged.

2.3. Protecting the environment

> Dispose of 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.

3 Product description

3 Product description

3.1. Use

Testo 549 and testo 550 are digital manifolds for maintenance and
service work on refrigeration systems and heat pumps. They are
intended for use by qualified personnel only.

The functions of the testo 549 and testo 550 are designed to
replace analog manifolds, thermometers and pressure/temperature
charts. Pressures and temperatures can be applied, adapted,
tested and monitored.

Testo 549 and testo 550 are compatible with most non-corrosive
refrigerants, water and glycol. Testo 549 and testo 550 are not
compatible with refrigerants containing ammonia.

The instruments must not be used in explosive environments!

5

3 Product description

Icon

Significance

Battery status

Bluetooth®

/ /

Measuring mode

3.2. Overview

Display and control elements

1 Mini-DIN probe socket for NTC temperature probe, with socket

cover
2 Foldable hanging hook (on rear)
3 Display. Instrument status icons:

6

4 Battery compartment. NOTE: Rechargeable batteries cannot

be charged inside the battery compartment.

4 First steps

Key

Function

[Set]

Set units

[R, ►, ■]

Select refrigerant/ Start/stop / Leakage test

[Mode]

Change measuring mode to Leak mode

[Min/Max/Mean]

Display min./max./mean values

[▲]

Up key: Scroll through menu

[P=0]

Pressure zeroing

Esc

Switches to the measurement / home view

[▼]

Down key: Scroll through menu

[ / ]

Switching the instrument on/off
Switch the display illumination on/off.

When not in use for long period: Remove batteries/rechargeable
batteries.

5 Control keys:

6 Sight glass for refrigerant flow
7 2 x valve stem shutoff
8 3 x hose holders for refrigerant hoses
9 3 x connections 1/4" SAE, brass

Left/right: Low pressure/high pressure, for refrigerant hoses
with quick connect fitting

Center: for charge / discharge of refrigerant
10 Mini-USB connection for firmware update, inside the battery

compartment.

4 First steps

Inserting batteries / rechargeable batteries

1. Fold out the hanging hook and open the battery compartment
by squeezing the clip lock.

2. Insert batteries (included in delivery) or rechargeable batteries
(4x 1.5 V, type AA/Mignon/LR6) in the battery compartment.
Observe the polarity!

3. Close the battery compartment.

- After inserting the batteries, the instrument switches on
automatically and goes into the settings menu.

7

4 First steps

Key functions

Description

[▲] or [▼]

Change parameters and select units

[Set]

Confirm units / parameters

Selectable
parameters

Description

°F, °C

Temperature unit

Psi, bar, kPa, MPa

Unit of pressure

Psig or Pabs, Prel

Switch between absolute and relative
pressure display

Pamb

Set current absolute pressure in inches of HG
or bar

/ /

Select measuring mode: heat pump / cooling
/ or Auto

AUTO OFF

Activate or deactivate Automatic power-off.
Instrument switches off after 30 minutes if no
temperature probe is connected and there is
no pressure apart from ambient pressure

T

fac

Activate or deactivate surface temperature
compensation factor, icon is shown on the
display if the function is deactivated

Units / Parameter selection

1. Press [Set] to confirm or change unit parameter settings

2. Press [▲] or [▼] to change the units / parameters.
 The settings will be accepted once the last selection has been

made.

 Settings will be applied following the final selection.

Operating valve stem shutoffs

The digital manifold acts like a conventional two-way manifold with
regard to the refrigerant path: The passages are opened by
opening the valves. The adjacent pressure is measured with valves
closed as well as with them open.

> Open valve: Turn valve positioner counterclockwise.
> Close valve: Turn valve positioner clockwise.

8

WARNING

Over tightening the valve stem shutoffs may cause:

• Damage to the PTFE seal.

• Mechanical deformation of the valve piston leading to the

PTFE seal falling out.

• Damage to the thread of the threaded spindle and the valve
screw.

• valve knobs to brake.

Lightly tighten the valve knob. Do not use tools to tighten the valve
stem shutoffs.

5 Using the manifold

Before each measurement check whether the refrigerant hoses are
in flawless condition.

5.1. Preparing for measurement

5.1.1. Switching the instrument On

> Press [ / ].

Zero the pressure sensors before every measurement.
✓ All connections must be at ambient pressure.

5 Using the manifold

> Press [P=0] key for 3 seconds to execute zeroing.

Connecting the refrigerant hoses

✓ Make sure the valve stem shutoffs are closed.

1. Connect the refrigerant hoses to the low-pressure side (blue)
and high-pressure side (red).

2. Connect the refrigerant hoses to the AC/R system.

9

5 Using the manifold

WARNING

Dropping this instrument or any other comparable mechanical
shock can damage the refrigerant pipes and hoses. The valve
actuators may also suffer damage, which in turn could result in
further damage inside the instrument and may not be detectable
from outside.

> For your own safety you should return the manifold to the

Testo Service Department for technical inspection.

> You should therefore always replace the refrigerant hoses with

new ones after an accidental drop has occurred or after any
visible wear and tear.

Key functions

Description

[▲] or [▼]

Selecting another refrigerant

[R, ►, ■]

Confirm the selection and exit the refrigerant
menu

Representation

Description

R...

Refrigerant number of refrigerant acc. to
ISO 817

---

no refrigerant selected.

Choosing the refrigerant

1. Press [R, ►, ■].

- It activates the refrigerant menu and the currently selected

2. Setting the refrigerant:

refrigerant flashes.

Available refrigerants

Example: Selecting refrigerant R401B

1. Press [R, ►, ■] to activate refrigerant menu.

2. Press [▲] or [▼] several times, until R401B flashes.

3. Press [R, ►, ■] to confirm the selection.

Exiting the refrigerant selection

> Press [R, ►, ■] or automatically after 30 s, if no other key has

been pressed.

10

5 Using the manifold

In order to to establish a connection via Bluetooth, on an Android
or iOS device, the Testo App Refrigeration must be already
installed.

You can download the App for iOS in the Apple App Store or for
Android in Google Play.

The App is compatible with devices using iOS 7 or higher /
Android 4.3 or 4.4.

Display

Description

flashes

There is no Bluetooth connection, or a
potential connection is being searched for.

is permanently

displayed

There is a Bluetooth connection.

5.1.2. Connecting temperature probe(s)

Note: The testo 549 does not include temperature probes in the
initial scope of delivery.

Surface temperature probe

At least one NTC temperature probe must be connected to
measure the pipe temperature, for automatic calculation of
superheating and subcooling.

Deactivating the surface compensation factor for insertion and
air temperature probes

A surface compensation factor has been set in the measuring
instrument to improve the measuring accuracy of surface
temperature readings.

If the manifold is used in combination with insertion or air
temperature probe (optional), this factor must be deactivated:

1. Press [Set] repeatedly until T

2. Press [▲] or [▼] to set T

to Off.

fac

fac

is displayed.

3. Press [Set] to continue through the settings menu until the
measurement/home view is displayed.

- T

is shown on the display if T

fac

is disabled.

fac

5.1.3. Switching Bluetooth® on and off (only testo 550)

1. To turn on the Bluetooth press [▲] and [▼] simultaneously and
hold down for 3 seconds.

- Once the Bluetooth icon is shown on the display, Bluetooth is
switched on.

11

5 Using the manifold

Display

Description

is not displayed

Bluetooth is disabled.

Display

Mode

Function

Refrigeration
system

Normal functionality of the digital
manifold

Heat pump

Normal functionality of the digital
manifold

Automatic
mode

If the automatic mode is activated, the
testo 549 und testo 550 digital
manifolds automatically changes the
display of the high and low pressure.
This automatic change occurs when
the pressure on the low-pressure side
is 1 bar (15 psi) higher than the
pressure on the high-pressure side.
During the change, Load (2 s) is
shown in the display.

This mode is especially suited to air
conditioning systems which cool and
heat (heat pumps).

2. To turn off the Bluetooth press [▲] and [▼] simultaneously and

hold down for 3 seconds.

- Once the Bluetooth icon is no longer shown on the display,

Bluetooth is switched off.

5.1.4. Measuring mode

12

WARNING

Risk of injury caused by refrigerant that is at high pressure,
hot, cold, or poisonous!

> Wear safety goggles and protective gloves.
> Before pressurizing the measuring instrument: Always fasten

the measuring instrument at the hanging hook in order to
prevent it from falling (risk of breakage)

> Check if the refrigerant hoses are intact and connected

correctly before each measurement. Do not use a tool to
connect the hoses. Only tighten the hoses by hand (max.
torque 5.0 Nm/3.7 ft*lb).

> Do not exceed the permissible measuring range (0 to 870 psi /

0 to 60 bar). Pay particular attention with systems with
refrigerant R744, as these are often operated with higher
pressures.

Note: With refrigerants that have a temperature glide, “Zeotropes”
the evaporation temperature Ev/to and condensation temperature
Co/tc are displayed after evaporation and condensation are
complete.

Zeotropes (refrigerants blends mix together) can separate from
each other, unlike azeotropes which mix together to become one.

Zeoptropes often blend refrigerants with different boiling points
(saturation temps), where one will change from liquid to vapor
before the other as they go through the evaporator.

The glide is the difference between the lowest boiling point and the
highest boiling point. If they are 3 degrees apart, for example, the
blend has a 3 degree glide.

5.2. Performing the measurement

Measuring

1. Connect and apply pressure to the manifold.

2. See readings.

5 Using the manifold

13

5 Using the manifold

Refrigerant evaporation
temperature Ev/to (°F/°C)

Evaporation pressure
(psi/bar)

Refrigerant condensation
temperature Co/tc (°F/°C)

Condensation pressure
(psi/bar)

Measured temperature T1/t

oh

(°F/°C)

Evaporation pressure
(psi/bar)

Measured temperature T2/t

cu

(°F/°C)

Condensation pressure
(psi/bar)

Superheating SH/Δtoh (°F/°C)

Evaporation pressure
(psi/bar)

Subcooling SC/Δt

cu

(°F/°C)

Condensation pressure
(psi/bar)

Changeable

- Evaporation
Temperature (Ev)

- Measured
Temperature (T1)

- Superheating (SH)

Changeable

- Condensation
Temperature (Co)

- Measured
Temperature (T2)

- Subcooling (SC)

Condensation
pressure

Evaporation
pressure

- The display illumination will flash if:

• The critical pressure of the refrigerant is within 15 psi (1 bar) of
the highest pressure (and temperature) where the refrigerant can
still condense

• The maximum. permissible pressure of 870 psi (60 bar) is
exceeded.

Key functions for 550 or 549 when used with optional probes

> Press [▲] or [▼] to change the reading in the display.
(The temperature probes must be connected.)

Possible display combinations:

With both NTC temperature probes connected, Δt is also shown.
> Press [Mean/Min/Max] to display min./max. readings and

14

mean values.

5 Using the manifold

Systems can be tested for tightness with the temperature­compensated leak test. The system pressure and the ambient
temperature are measured over a defined period of time, typically
with an inert gas such as Nitrogen. A temperature probe can be
connected that measures the ambient temperature. : Optional air
temperature probe, part. no. 0613 1712) is recommended.

Measurement data of the temperature-compensated differential
pressure and temperature, from start to the end of the test, is
displayed. It is possible to perform a leak test without connecting a
temperature probe.

Differential
pressure start
compared to
actual

Measured
pressure
beginning
of test

Duration
of test

Actual
measured
pressure

Leak test / pressure drop test

1. Press [Mode] ΔP is displayed.

2. Start the leakage test: Press [R, ►, ■].ΔP is now flashing and

hh:mm timer is on.

3. End the leakage test: Press [R, ►, ■]. ΔP stops flashing

and hh:mm timer stops.

- Result is displayed. Note: Leak test time duration and ΔP value

4. Confirm message: Press [Mode] to exit leak mode.

15

6 Technical data

The Bluetooth® option may only be operated in countries
in which it is approved.

Feature

Values

Bluetooth type

LSD Science & Technology Co., Ltd
L Series BLE module (08 May 2013) based

on TI CC254X chip
Qualified Design ID

B016552

Bluetooth radio
class

Class 3

Bluetooth listing
company

10274

6 Technical data

6.1.1. Bluetooth module (only testo 550)

European Union

Germany (DE), Belgium (BE), Netherlands (NL), Spain (ES),
Sweden (SE), Italy (IT), Denmark (DK), United Kingdom (GB),
France (FR), Austria (AT), Poland (PL), Hungary (HU),
Romania (RO), Czech Republic (CZ), Finland (FI),

EFTA countries

Switzerland (CH), Norway (NOR)

Other countries

Turkey (TR), India (IN), Australia (AUS), New Zealand (NZL),
USA (US), Argentina (AR), Hong Kong (HK)

Information from the FCC (Federal Communications Commission)
This device complies with part 15 of the FCC Rules. Its

commissioning is subject to the following two conditions: (1) This
device may not cause harmful interference and (2) this device must
be able to accept interference, even if this could have undesired
effects on the operation.

Changes
The FCC demands that the user be informed that any changes or

modifications to the instrument that are not explicitly approved by
testo AG may void the user's right to use this instrument.

16

6.1.2. General technical data

Characteristic

Values

Parameters

Pressure: kPa / MPa / bar / psi
Temperature: °C / °F / K

Sensors

2 Pressure: sensors, 2 Temperature (NTC
Thermistors)

Meas. cycle

0.5 s

Interfaces

Pressure connections: 3 x 1/4" SAE
2 Temperature NTC measurement channels

Measuring ranges

HP/LP pressure measuring range: -100 to
6000 kPa / -0.1 to 6 MPa / -1 to 60 bar (rel)
/ -14.7 to 870 psi

Temperature measuring range: -50 to
+150 °C / -58 to 302°F

Vacuum measuring range (rel): -1 to
0 bar / -14.7 to 0 psi

Overload

65 bar, 6500 kPa, 6.5 MPa, 940 psi

Resolution

Pressure resolution: 0.01 bar / 0.1 psi /
1 kPa / 0.001 MPa

Temperature resolution: 0.1 °C/0.1 °F

Accuracy (nominal
temperature
22 °C/71.6 °F)

Pressure: ± 0.5 % FS
Temperature 58 to 302°F (0.9°F ± 1 digit)

0 to 150°C (±0.5 °C ±1 digit)

No. of refrigerants

60

Selectable
refrigerants

No refrigerant, R11, R12, R22, R123,
R1234ze, R125, R13B1, R134a, R14,
R142B, R152a, R161, R23, R227, R290,
R32, R401A, R401B, R401C, R402A,
R402B, R404A, R406A, R407A, R407B,
R407C, R407D, R407F, R408A, R409A,
R410A, R411A, R412A, R413A, R414B,
R416A, R417A, R420A, R421A, R421B,
R422A, R422B, R422C, R422D, R424A,
R426A, R427A, R434A, R437A, R438A,
R502, R503, R507, R508A, R508B, R600,
R600a, R718 (H2O), R744 (CO2) (only in
measuring range up to 870 psi (60 bar),
R1234yf

6 Technical data

17

6 Technical data

Measurable media

All refrigerants that are stored in the testo
549 and testo 550

Ammonia (R717) and other refrigerants
which contain ammonia will damage the
manifold

Ambient conditions

Operating temperature: -4 to 122 °F
(-20 to 50 °C)

Storage temperature: -4 to 140 °F
(-20 to 60 °C)

Bluetooth

Range >20 m / 65 ft (unobstructed field)

Housing

Material: ABS/PA/TPU
Dimensions: 7.87 x 4.29 x 2.48 in.

(265 x 135 x 75 mm)
Weight: approx. 2.83 lbs.

1060 g (without batteries)

IP class

42

Power supply

4 x 1.5 V, type AA/mignon/LR6 rechargeable
or standard batteries

Battery life: approx. 250h
(display light off, Bluetooth off)

Display

Type: Illuminated LCD Response time: 0.5 s

Directives,
standards and tests

EC Directive: 2014/30/EC

Warranty

Duration: 2 years
Warranty conditions: see website

www.testo.com/warranty

18

7 Maintaining the product

Do not use harsh cleaning agents or solvents! Mild soap and
water may be used.

Cleaning the instrument

> Clean instrument using a damp cloth.

Keeping connections clean

> Keep screw connections clean and free of grease and other

deposits, clean with a moist cloth as required.

Removing oil residues

> Carefully blow out oil residues in valve block using compressed

air.

To ensure measuring accuracy

> Check instrument regularly for leaks (recommended: annually).

Do not exceed the pressure range!

> Calibrate instrument regularly (recommended: annually).

Changing batteries/rechargeable batteries

✓ Instrument is switched off.

7 Maintaining the product

1. Fold out the hook, loosen the clip and remove the cover of the
battery compartment.

2. Remove discharged 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.

19

8 Tips and assistance

DO NOT ATTEMPT to change the valve stems. Changing the
valve stem shutoff or valves themselves will void the warranty.

Send the measuring instrument to Testo Customer Service.

Question

Possible causes/solution

flashes

Batteries are nearly discharged.
> Replace batteries.

The instrument switches
off automatically.

Batteries are discharged.
> Replace batteries.

uuuu lights up instead of

the parameter display

The maximum measurement range
has been exceeded.

oooo lights up instead of

the parameter display

Under range value has been
exceeded.

bar, °C

psi, °F

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

Changing the valve or valve stem shutoff

8 Tips and assistance

8.1. Questions and answers

8.2. Measurement parameters

20

8.3. Error reports

Question

Possible causes/solution

---- is lit up instead of

measurement parameter
display

Sensor or cable defective
> Please contact your dealer or

Testo Customer Service

Display EEP FAIL

Electronics (Hardware Fault)
> Please contact Testo Customer

Service

Description

Article no.

Temperature clamp probe - 4.9 ft. cable length (1.5m)

0613 5505

Temperature clamp probe - 14 ft. cable length (5m)

0613 5506

Pipe wrap probe with Velcro tape

0613 4611

Watertight NTC surface probe

0613 1912

Precise, robust NTC air probe

0613 1712

Transport case for measuring instrument, probe and
hoses

0516 0012

8.4. Accessories and spare parts

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

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/service-

contact.
Click onto your country’s flag for local support.

8 Tips and assistance

21

9 EC declaration of conformity

9 EC declaration of conformity

22

9 EC declaration of conformity

23

Testo Inc.
40 White Lake Road

Sparta, N. J. 07871
Phone: [phone]

Fax: [phone]
Email: [e-mail]

www.testo.com

0970 5502 en-US 01 V02.00