Testo 557 Operating Manual

Page 1
testo 557 · Digital manifold
Instruction manual
Page 2
2
Page 3
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 ................................................................................................ 8
5 Using the manifold ................................................................................ 10
5.1. Preparing for measurement ........................................................... 10
5.1.1. Switching the instrument on ..............................................................................10
5.1.2. Connecting the temperature sensor .................................................................11
5.1.3. Connecting the vacuum probe ..........................................................................12
5.1.4. Switching Bluetooth® on and off.......................................................................12
5.1.5. Measuring mode ...............................................................................................13
5.2. Performing the measurement ........................................................ 13
6 Technical data ........................................................................................ 17
6.1.1. Bluetooth Modul ................................................................................................17
6.1.2. General technical data ......................................................................................18
7 Maintaining the product ........................................................................ 20
8 Tips and assistance............................................................................... 22
8.1. Questions and answers ................................................................. 22
8.2. Measurement parameters ............................................................. 22
8.3. Error reports .................................................................................. 23
8.4. Accessories and spare parts ......................................................... 23
9 EC declaration of conformity ................................................................ 24
3
Page 4

2 Safety and the environment

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

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
Menu
Elements of the instrument, the instrument display or the program interface.
[OK]
Control keys of the instrument or buttons of the program interface.

2.2. 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.
> 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
measures.
4
Page 5
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

2.3. Protecting the environment

get damaged.
> 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
3 Product description
applicable environmental regulations.

3 Product description

3.1. Use

Testo 557 is a digital manifold for maintenance and service work on refrigeration systems and heat pumps. It is intended for use by qualified personnel only.
The function of the testo 557 is designed to replace analog manifolds, thermometers and pressure/temperature charts. Pressures and temperatures can be applied, adapted, tested and monitored.
Testo 557 is compatible with most non-corrosive refrigerants, water and glycol. Testo 557 is not compatible with refrigerants containing ammonia.
The instruments must not be used in explosive environments!
5
Page 6
3 Product description
1
2
2 3 4
5
6 7 8
8
8
8
9
9
10
10
11
12 13

3.2. Overview

Display and control elements

1 Front connection for external vacuum probe 2 Mini-DIN probe socket for NTC temperature probe, with socket
cover 3 Foldable hanging hook (on rear) 4 Display. Instrument status icons:
Icon Meaning
/ /
Battery status
Bluetooth®
Select measuring mode
6
Page 7
3 Product description
5 Battery compartment. The rechargeable batteries cannot be
charged inside the instrument!
6 Control keys:
Ke y Function
[Set]
[R, ►, ■]
[Mode]
[Min/Max/Mean]
[▲]
[P=0]
Esc
[▼]
[ / ]
Set units
Select refrigerant / Start-Stop leak test
Switch between measuring modes
Display min, max, mean values
Up-key: Scroll through menu.
Pressure zeroing
Switches to the measurement/home view.
Down-key: Scroll through menu.
Switching the instrument on/off Switching display ilumination on/off.
7 Sight glass for refrigerant flow. 8 4 x valve stem shutoff 9 4 x hose holders for refrigerant hoses 10 2 x Connection 1/4" SAE, brass.
High pressure, for refrigerant hoses with quick release screw fitting, passage for valve actuator lockable.
11 Connection 3/8" SAE, brass, for vacuum pump 12 Connection 1/4" SAE, brass, for e.g. refrigerant cylinders 13 Mini-USB connection for firmware update, inside the battery
compartment.
7
Page 8

4 First steps

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

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.
Key Functions Description
[▲] or [▼]
[Set]
Selectable parameters
°C, °F
bar, kPa, MPa, psi
Pabs, Prel or psig
micron, inHg, Pa, hPa, mTorr,Torr, inH2O, mbar
/ /
Change parameters and select units
Confirm units / parameters
Description
Temperature unit
Unit for pressure.
Switch between absolute and relative pressure display
Unit for vacuum pressure.
Select measuring mode: heat pump / cooling / or Auto
8
Page 9
4 First steps
WARNING
Over tightening the valve stem shutoffs may cause:
Selectable
Description
parameters
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

- Settings will be applied following the final selection.

Operating the 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.
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.
9
Page 10

5 Using the manifold

WARNING
5 Using the manifold

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.
> Press [P=0] key for 3 seconds to execute zeroing.
Connecting the refrigerant hoses
Before each measurement check whether the refrigerant hoses are in flawless condition.
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.
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.
10
Page 11
5 Using the manifold
Choosing the refrigerant
1. Press [R, ►, ■].
- It activates the refrigerant menu and the currently selected refrigerant flashes.
2. Setting the refrigerant:
Key functions Description
[▲] or [▼]
[R, ►, ■]
Selectng another refrigerant
Confirm the selection and exit the refrigerant menu
Available refrigerants
Representation Description
R...
Refrigerant number of refrigerant acc. to ISO 817
---
no refrigerant selected.
Example: Setting refrigerant R401B
1. Press [R, ►, ■] to activate refrigerant menu.
2. Press [▲] or [▼] several times, until R401B flashes.
3. Press [R, ►, ■] to confirm the setting.
Exiting the refrigerant selection
> Press [R, ►, ■] or automatically after 30 s, if no other key has
been pressed.

5.1.2. Connecting the temperature sensor

Surface temperature sensor
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 sensor
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:
to Off.
fac
fac
is displayed.
1. Press [Set] repeatedly until T
2. Press [▲] or [▼] to set T
11
Page 12
5 Using the manifold
3. Press [Set] to continue through the settings menu until the
measurement/home view is displayed.
is shown on the display if T
- T
fac
is disabled.
fac

5.1.3. Connecting the vacuum probe

> Open the front cover of the connector and connect up the

5.1.4. Switching Bluetooth® on and off

vacuum probe.
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 get the App for iOS instruments in the App Store or for Android instruments in the Play Store.
Information about compatibility can be found in the relevant app store.
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.
Display Description
flashes
is permanently
There is no Bluetooth connection, or a potential connection is being searched for.
There is a Bluetooth connection.
displayed
is not displayed
Bluetooth is disabled.
12
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.
Page 13

5.1.5. Measuring mode

pressure. This automatic change occurs
WARNING
Display Mode Function
Refrigeration system
Heat pump Normal function of the digital manifold
Automatic mode
5 Using the manifold
Normal function of the digital manifold
If the automatic mode is activated, the testo 557 digital manifold automatically changes the display of the high and low
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).

5.2. Performing the measurement

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.
13
Page 14
5 Using the manifold
Refrigerant evaporation
(psi/bar)
Refrigerant condensation
(psi/bar)
Measured temperature T1/t
(psi/bar)
Measured temperature T2/
(psi/bar)
Superheating SH/Δt
(°F/°C)
(psi/bar)
Subcooling SC/Δt
(°F/°C)
(psi/bar)

Measuring

1. Connect and apply pressure to the manifold.
2. See readings.
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..
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
> Press [▲] Possible display combinations:
or [▼] to change the reading in the display.
temperature Ev/to (°F/°C) Evaporation pressure
(°F/°C)
Evaporation pressure
Evaporation pressure
14
temperature Co/tc (°F/°C) Condensation pressure
oh
tcu (°F/°C) Condensation pressure
oh
cu
Condensation pressure
Page 15
5 Using the manifold
Changeable
- Evaporation Temperature (Ev)
- Measured Temperature (T1)
- Superheating
(SH)
Changeable
- Condensation Temperature (Co)
- Measured Temperature (T2)
- Subcooling (SC)
Evaporation pressure
Condensation pressure
With both NTC temperature probes connected, Δt is also shown. > Press [Mean/Min/Max]: to display min. / max. readings and
mean values.

Leak test / pressure drop test

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.
1. Press [Mode] ΔP is displayed.
2. Start the leak test: Press [R, ►, ■]. ΔP is now flashing and
hh:mm timer is on.
3. End the leak test: Press [R, ►, ■]. ΔP stops flashing and
hh:mm timer stops.
- Result is displayed. Note: Leak test time duration and ΔP value
4. Confirm the message: Press [Mode] to exit leak mode.
15
Page 16
5 Using the manifold
Duration of test
Differential pressure start compared to actual
Measured pressure beginning of test
Actual measured pressure

Vacuum measurement

The vacuum probe is plugged into the front connection of the
manifold and connected to the system.
1. Press [Mode] the vacuum mode is displayed. If ambient pressure is applied to the vacuum probe, then oooo is
shown on the display.
2. Start the vacuum pump.
- Once the measuring range 0 to 20,000 microns is reached, the current vacuum value is shown on the instrument display. The instrument also displays the current ambient temperature, the water evaporation temperature, which corresponds to the vacuum reading, and the delta between these two temperatures.
3. To leave vacuum mode, remove the vacuum probe from the testo 557 or switch to the standard measurement view using the
[Mode] button.
16
Page 17
6 Technical data
6.1.1. Bluetooth Modul
The Bluetooth® option may only be operated in countries in
which it is type approved.
Feature Values
Bluetooth Range >20 m (free field)
Bluetooth type
LSD Science & Technology Co., Ltd
L Series BLE Module (08 Mai 2013) based on TI CC254X chip
Qualified Design ID B016552
Bluetooth radio
Class 3
class
Bluetooth company 10274
European Union
Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, United Kingdom.
EFTA countries
Island, Suisse, Norway, Lichtenstein.
Other countries
USA, Turkey, Hong Kong, Canada
Information from the FCC (Federal Communications Commission) This device complies with part 15 of the FCC Rules. Its
commissioning is subject to the two following conditions: (1) This instrument must not cause any harmful interference and (2) this instrument must be able to cope with interference, even if this has undesirable effects on 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.

6 Technical data

17
Page 18
6 Technical data
5000 micron (from 10000 to 20.000 micron)

6.1.2. General technical data

Feature Values
Pressure: psi / kPa / MPa / bar
Parameters
Sensors
Measuring cycle 0.5 s
Interfaces
Measuring ranges
Overload 940 psi, 65 bar, 6500 kPa, 6.5 MPa
Resolution
Temperature: °F / °C / K Vacuum: micron / inHg / inH
mTorr /Torr / Pa
2 Pressure: sensors, 2 Temperature (NTC Thermistors)
Pressure connections: 3 x 1/4" SAE, 1x 3/8" SAE NTC measurement External vacuum probe
Pressure measurement range HP/LP: -14.7…870 psi / -100…6000 kPa / -0.1…6 MPa / -1…60 bar (rel)
Temperature measurement range: -58…302 °F / -50…+150 °C
Measurement range vacuum (abs): 0 … 20.000 micron
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:
1 micron (from 0 to 1000 micron) 10 micron (from 1000 to 2000 micron) 100 micron (from 2000 to 5000 micron) 500 micron (from 5000 to 10000 micron)
O / hPa / mbar /
2
Accuracy (nominal temperature
71.6 °F / 22 °C)
No. of refrigerants
18
Pressure: ±0.5% FS (±1 digit) Temperature: -58 to 302°F (0.9°F ± 1 digit) / -50
to 150°C (±0.5 °C ±1 digit) Vacuum: ±10% of rdg +10 microns (100 to 1.000
microns)
60
Page 19
Feature Values
R422C, R422D, R424A, R426A, R427A, R434A,
All refrigerants that are stored in the testo 557
, vacuum probe not
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, Selectable refrigerants
R410A, R411A, R412A, R413A, R414B, R416A,
R417A, R420A, R421A, R421B, R422A, R422B,
R437A, R438A, R502, R503, R507, R508A,
R508B, R600, R600a, R718 (H2O), R744 (CO2)
(only in permissible measurement range up to
60 bar), R1234yf
6 Technical data
Measurable media
Ammonia (R717) and other refrigerants which
contain ammonia will damage the manifold
Operating temperature: -4…122°F / -20…50°C
Ambient conditions
14…122°F / -10…50°C (vacuum probe)
Storage temperature: -4…140°F / -20…60°C
Humidity in area of use: 10… 90%rF
Bluetooth Range >20 m / 65 ft (unobstructed field)
Material: ABS / PA / TPE Housing
Dimensions approx. 280 x 135 x 75 mm
Weight: approx. 1200 g (without batteries)
IP-class 42
4 x 1.5 V, type AA/mignon/LR6 rechargeable or
standard batteries Power supply
Battery life: approx. 250h
(display light off, Bluetooth off
connected)
Display
Directives,
Type: Illuminated LCD
Response time: 0.5 s
EC Directive: 2014/30/EC standards and tests
Duration: 2 years Warranty
Terms of warranty: see website
www.testo.com/warranty
19
Page 20

7 Maintaining the product

7 Maintaining the product

Cleaning the instrument

Do not use harsh cleaning agents or solvents! Mild soap and water may be used.
> 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).
Keep to the permissible pressure range!
> Calibrate instrument regularly (recommended: annually).

Changing batteries/rechargeable batteries

Instrument is switched off.
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.
20
Page 21
7 Maintaining the product
> Remove the vacuum probe from the testo 557!

Changing the valve or valve stem shutoff

Replacement of valve stem shutoffs or valves must be performed by a qualified technician. Warranty coverage with respect to valve stem shut-offs and valves will NOT apply to miss-use or damage and is only applicable if failure is attributable to defective parts and workmanship.
Send the measuring instrument to Testo Customer Service.

Cleaning the vacuum probe

Contaminants such as oil may impair the accuracy of the vacuum sensor.
CAUTION
Carrying out cleaning with the probe connected may result in damage to the probe!
CAUTION
Damage to the sensor due to sharp objects!
> Do not insert any sharp objects into the probe!
1. Remove the vacuum probe from the testo 557.
2. Put a few drops of rubbing alcohol into the sensor opening.
3. Seal the opening by placing your finger on it and shake the vacuum probe briefly.
4. Remove all the alcohol from the probe.
5. Repeat this process at least twice.
6. Leave the probe to dry for at least 1 hour. To dry the sensor faster, you can connect the probe directly to a vacuum pump and draw vacuum.
21
Page 22

8 Tips and assistance

8 Tips and assistance

8.1. Questions and answers

Question Possible causes/solution
flashes
The instrument switches off automatically.
Batteries are almost empty. > Change batteries.
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
bar, °C psi, °F
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
22
Page 23

8.3. Error reports

Question Possible causes/solution
---- is lit up instead of
measurement parameter display
Display EEP FAIL
Sensor or cable defective > Please contact your dealer or
Testo Customer Service
Eeprom defective > Please contact your dealer or
Testo Customer Service
Display BT ERR
No BT module connected or BT module defective.
> Please contact your dealer or Testo
Customer Service
Display ERR 1-5
Vac-Probe defect > Please contact your dealer or
Testo Customer Service

8.4. Accessories and spare parts

Description Article no.
Clamp probe for temperature measurement at pipes (1,5m)
Clamp probe for temperature measurement at pipes (5m)
Pipe wrap probe with Velcro tape for pipe diameters of up to max. 75 mm, Tmax. +75 °C, NTC
Watertight NTC surface probe 0613 1912
Precise, robust NTC air probe 0613 1712
External vacuum probe 0638 1557
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
0613 5505
0613 5506
0613 4611
23
Page 24

9 EC declaration of conformity

9 EC declaration of conformity
24
Page 25
Page 26
Testo Inc.
40 White Lake Road Sparta, N. J. 07871
Phone: +1 862 354 5001 Fax: +1 862 354 5020
Email: info@testo.com www.testo.com
Headquarter testo AG
Testo-Straße 1 79853 Lenzkirch Germany Tel.: +49 7653 681-0 Fax: +49 7653 681-7699 Email: info@testo.de Internet: www.testo.de
0970 5571 en-US 01 V01.13
Loading...