Operating instructions
Betriebsanleitung
Dead-weight tester in compact design, model CPB3800
Druckwaage in Kompaktausführung, Typ CPB3800
EN
DE
Dead-weight tester in compact design, model CPB3800
Operating instructions model CPB3800 Page 3 - 46
EN
Betriebsanleitung Typ CPB3800 Seite 47 - 90
DE
Further languages can be found at www.wika.com.
© 2013 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
®
WIKA
is a registered trademark in various countries.
®
WIKA
ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
2
WIKA operating instructions model CPB3800
14062232.04 03/2015 EN/DE
Contents
Contents
1. General information 4
2. Safety 6
2.1 Intended use 6
2.2 Personnel qualication 7
2.3 Personal protective equipment 7
2.4 Special hazards 8
2.5 Labelling, safety marks 10
3. Specications 11
4. Design and function 20
4.1 Description 20
4.2 Scope of delivery 20
4.3 Base unit 20
4.4 Piston unit 23
4.5 Function 23
5. Transport, packaging and storage 24
6. Commissioning, operation 25
6.1 Unpacking the dead-weight tester 25
6.2 Environmental requirement 25
6.3 Assembly of base units 25
6.4 Assembly of piston unit 26
6.5 Assembly of the dead-weight tester 27
6.6 Procedure 29
6.7 Completion 31
6.8 Pressure calculation computer software standard accuracy program 32
6.9 Temperature measurement of piston units 32
6.10 Cleaning gauges 33
7. Maintenance, cleaning and recalibration 34
7.1 Periodic maintenance 34
7.2 Corrective maintenance 34
7.3 Cleaning 38
7.4 Recalibration 39
8. Faults 41
9. Return and disposal 43
10. Accessories 45
Appendix: EC Declaration of conformity for model CPB3800 46
EN
Declarations of conformity can be found online at www.wika.com.
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WIKA operating instructions model CPB3800
3
1. General information
1. General information
■
EN
The model CPB3800 dead-weight tester in compact design described in the
operating instructions has been designed and manufactured using state-of-theart technology. All components are subject to stringent quality and environmental
criteria during production. Our management systems are certied to ISO 9001 and
ISO 14001.
■
These operating instructions contain important information on handling the
instrument. Working safely requires that all safety instructions and work instructions
are observed.
■
Observe the relevant local accident prevention regulations and general safety
regulations for the instrument’s range of use.
■
The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time. Pass
the operating instructions onto the next operator or owner of the instrument.
■
Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
■
The general terms and conditions contained in the sales documentation shall apply.
■
Subject to technical modications.
■
Factory calibrations / DKD/DAkkS calibrations are carried out in accordance with
international standards.
4
WIKA operating instructions model CPB3800
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1. General information
■
Further information:
DH-Budenberg
A division of WIKA Instruments Ltd.
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 31.06
- Application consultant:
WIKA Alexander Wiegand SE & Co. KG
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 31.06
- Application consultant:
Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious
injury or death, if not avoided.
Tel.: +44 844 4060086
Fax: +44 844 4060087
sales@dh-budenberg.co.uk
Tel.: +49 9372 132-0
Fax: +49 9372 132-406
info@wika.com
EN
CAUTION!
... indicates a potentially dangerous situation that can result in light
injuries or damage to equipment or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for ecient
and trouble-free operation.
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WIKA operating instructions model CPB3800
5
2. Safety
2. Safety
WARNING!
EN
2.1 Intended use
Pressure balances (dead-weight testers) are the most accurate instruments available
on the market for the calibration of electronic or mechanical pressure measuring
instruments. By direct measurement of the pressure as the quotient of force and area
(p = F/A), pressure balances (dead-weight testers) are approved as primary standards.
The core component of the CPB3800 is therefore a very precisely-manufactured pistoncylinder system, onto which a mass load is applied in order to generate the individual
test points. The mass load applied are proportional to the target pressure and this is
achieved through graduated disc weight. A maximum pressure of 1,200 bar must not be
exceeded.
Before installation, commissioning and operation, ensure that the
appropriate dead-weight tester has been selected in terms of measuring
range, design and specic measuring conditions.
Non-observance can result in serious injury and/or damage to the
equipment.
Further important safety instructions can be found in the individual
chapters of these operating instructions.
The pressure is set via an integrated, nely-adjustable, precision dual area spindle
pump. As soon as the measuring system reaches equilibrium, there is a balance of
forces between the pressure and the mass load applied.Then the test item can be
calibrated or adjustments can be carried out.
Due to its stand-alone operation (integrated pressure generation and the pure
mechanical measuring principle), the model CPB3800 is ideal for on-site use for
maintenance and service.
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specications contained in these operating instructions must be
observed. Improper handling or operation of the instrument outside of its technical
specications requires the instrument to be taken out of service immediately and
inspected by an authorised DH-Budenberg/WIKA service engineer.
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WIKA operating instructions model CPB3800
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2. Safety
Handle mechanical precision measuring instruments with the required care (protect
from humidity, impacts, strong magnetic elds, static electricity and extreme
temperatures, do not insert any objects into the instrument or its openings).
If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in instrument malfunction. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
The manufacturer shall not be liable for claims of any type based on operation contrary
to the intended use.
2.2 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to
equipment.
■
The activities described in these operating instructions may only be
carried out by skilled personnel who have the qualications described
below.
■
Keep unqualied personnel away from hazardous areas.
EN
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and
knowledge of country-specic regulations, current standards and directives, are capable
of carrying out the work described and independently recognising potential hazards.
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
DH-Budenebrg/WIKA can provide dedicated training courses on the correct use of our
products. Please contact your local oce for further details.
2.3 Personal protective equipment (P.P.E.)
The personal protective equipment is designed to protect the skilled personnel from
hazards that could impair their safety or health during work. When carrying out the
various tasks on and with the instrument, the skilled personnel must wear personal
protective equipment.
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WIKA operating instructions model CPB3800
7
2. Safety
Follow the instructions, displayed in the work area, regarding personal
protective equipment!
EN
The required personal protective equipment must be provided by the operating
company.
Wear safety goggles!
Protect eyes from ying particles and liquid splashes.
Wear protective gloves!
Protect hands from contact with aggressive media.
2.4 Special hazards
WARNING!
To ensure safe working on the instrument, the operating company must
ensure
■
that suitable rst-aid equipment is available and aid is provided
whenever required.
■
that the operating personnel are regularly instructed in all topics
regarding work safety, rst aid and environmental protection and
knows the operating instructions and, in particular, the safety
instructions contained therein.
WARNING!
Residual media at the dead-weight tester can result in a risk to persons,
the environment and the equipment. Take sucient precautionary
measures.
2.4.1 Mineral oils health and safety information
DH-Budenberg/WIKA provide hydraulic mineral oil in 500 ml containers labelled “ISO
VG 22” for use up to 4,000 bar in dead-weight testers. It is no more hazardous than other
common lubricating oils.
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WIKA operating instructions model CPB3800
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2. Safety
It is the nature of the way in which this equipment is used, that there
could be frequent and/or prolonged skin contact; in a few individuals this
could give rise to skin irritation (Keratosis or Dermatitis). The use of an
eective barrier cream and/or protective gloves will greatly reduce this
possibility.
Description
Closed ash point greater than 120 °C
Storage not above 30 °C
Oral LD 50 15 g per kg body weight
Threshold limit value 5 mg/m³
Fire extinguishing media CO
Spillage Soak with absorbent clay or proprietary absorbent
Waste disposal Burn or dump in approved area
Emergency treatment of acute eects
Ingestion Do not induce vomiting.
Aspiration Send to hospital immediately
Inhalation Remove to fresh air, if nausea persists seek medical
Eye contact Wash with copious amounts of water for at least 10 minutes.
Skin contact Where skin rashes or other abnormalities occur as a result
/dry chemical foam or water fog
2
Administer 250 ml milk or olive oil.
The main hazard following accidental ingestion is aspiration
of liquid into lungs.
attention.
If irritation results or persists, obtain medical advice.
of prolonged or repeated contact, medical advice should be
obtained as soon as possible.
EN
2.4.2 Other liquids
For some very particular applications we supply specially constructed liquids. Copies of
manufacturer’s data can be sent on request.
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WIKA operating instructions model CPB3800
9
2. Safety
2.4.3 Lifting of masses
WARNING!
EN
2.5 Labelling, safety marks
Product label
Care must be taken when lifting the masses onto the dead-weight tester.
Each mass must be lifted individually and never attempt to lift stack of
masses on or o the dead-weight tester.
For an explanation of
symbols, see below.
Serial No.
Pressure range
Date of manufacture
Explanation of symbols
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
CE, Communauté Européenne
Instruments bearing this mark comply with the relevant European
directives.
10
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WIKA operating instructions model CPB3800
3. Specications
3. Specications
Piston-cylinder systems (standard)
Measuring range
Required masses kg 41 50 58 50
Smallest step
(Standard mass set)
Nominal eective area of the
piston
Measuring range
Required masses kg 47 47 58 47
Smallest step
(Standard mass set)
Nominal eective area of the
piston
Accuracies
Standard
Option
3) 4)
3) 4)
Pressure transmission medium Hydraulic uid based on VG22 mineral oil (0.5 l included in scope
Material
Piston Tungsten carbide
Cylinder Tungsten carbide
Mass set Stainless steel, non-magnetic
Weight
Piston-cylinder system kg 2.4
BAR mass set incl. mass carrier kg 41.5 50.5 58.5 50.5
lb/in² mass set incl. mass carrier kg 47.5 47.5 58.5 47.5
Storage case for mass set
(optional, 2 pieces required)
Dimensions
Storage case for mass set
(optional)
1) Theoretical starting value; corresponds to the pressure value generated by the piston or the piston and its make-up weights (by
their own weight). To optimise the operating characteristics more masses should be loaded.
2) The smallest pressure change value that can be achieved based on the standard mass set. To reduce this, a set of ne
increment masses is also available.
3) The accuracy from 10 % of the measuring range is based on the measured value. In the lower range, a xed error based on
10 % of the range applies.
4) Measurement uncertainty assuming reference conditions (ambient temperature 20 °C, atmospheric pressure 1,013 mbar,
relative humidity 40 %). For operation without a CalibratorUnit, corrections must be made if required.
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1)
2)
bar 1 … 120 2.5 ... 300 5 ... 700 10 ... 1,200
bar 1 2.5 5 10
in² 1/16 1/40 1/80 1/160
1)
2)
lb/in² 10 … 1,600 25 ... 4,000 50 ... 10,000 100 ... 16,000
lb/in² 10 25 50 100
in² 1/16 1/40 1/80 1/160
0.05 % of reading
0.025 % of reading
of delivery)
kg 5.8
400 x 310 x 310 mm (W x H x D) and
215 x 310 x 310 mm (W x H x D)
EN
WIKA operating instructions model CPB3800
11
3. Specications
Base
Connections
EN
Connection for piston-cylinder
system
Test item connection G ½ female thread, loose union connection
Material
Wetted parts Austenitic stainless steel, high tensile brass, nitrile rubber
Pressure transmission
medium
Reservoir 170 cm³
Weight
Base 13.5 kg
Storage case for the base
(optional)
Permissible ambient conditions
Operating temperature 18 ... 28 °C
Dimensions
Base 401 x 397 x 155 mm ) (W x D x H), for details, see technical drawings
5) Other pressure transmission media on request.
G ¾ B (male)
Hydraulic uid based on VG22 mineral oil (0.5 l included in scope of
delivery)
8.5 kg
5)
CE conformity and certicates
CE conformity
Pressure equipment directive 97/23/EC (Module A)
Certicate
Calibration Calibration certicate
Approvals and certicates, see website
For further specications see WIKA data sheet CT 31.06 and the order documentation.
12
Option: UKAS calibration certicate (pressure calibration with a mass
set) for CPB3800 standard models
Option: UKAS calibration certicate (area and mass calibration) for
CPS/CPM5800 only
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3. Specications
Tables of masses
The following tables show, for the respective measuring range, the number of masses
within a mass set, with their resulting nominal pressures.
Should the instrument not be operated under reference conditions (ambient temperature
20 °C, atmospheric pressure 1,013 mbar, relative humidity 40 %), relevant corrections
must be made.
The disc weights are manufactured, as standard, to standard gravity of 9.80665 m/s².
As an optional extra, mass sets can be manufactured for customer local gravity value.
Standard mass sets
EN
Measuring range
[bar]
1 ... 120 2,5 ... 300
Quantity Nominal
Quantity Nominal
pressure per
piece
[bar] [bar]
Piston and make-up weight 1 1 1 2.5
Piston, mass carrier and mass carrier
make-up weight
Masses (stackable on mass carrier ) 3 20 3 50
Masses (stackable on piston)
Measuring range
[bar]
1 20 1 50
1 20 1 50
1 10 1 25
2 4 2 10
1 2 1 5
1 1 1 2.5
5 ... 700 10 ... 1.200
Quantity Nominal
Quantity Nominal
pressure per
piece
[bar] [bar]
Piston and make-up weight 1 5 1 10
Piston, mass carrier and mass carrier
make-up weight
Masses (stackable on mass carrier) 4 100 3 200
Masses (stackable on piston)
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1 100 1 200
1 100 1 200
1 50 1 100
2 20 2 40
1 10 1 20
1 5 1 10
pressure per
piece
pressure per
piece
WIKA operating instructions model CPB3800
13
3. Specications
Measuring range
[lb/in²]
10 ... 1,600 25 ... 4,000
Quantity Nominal
Quantity Nominal
pressure per
EN
Piston 1 10 1 25
Mass carrier and mass carrier make-
up weight
Masses (stackable on mass carrier) 5 200 5 500
Masses (stackable on piston)
Measuring range
[lb/in²]
1 190 1 475
1 200 1 500
1 100 1 250
2 40 2 100
1 20 1 50
1 10 1 25
50 ... 10,000 100 ... 16,000
Quantity Nominal
piece
[lb/in²] [lb/in²]
Quantity Nominal
pressure per
piece
[lb/in²] [lb/in²]
Piston 1 50 1 100
mass carrier and mass carrier make-
up weight
Masses (stackable on mass carrier) 7 1,000 5 2,000
Masses (stackable on piston)
1 950 1 1,900
1 1,000 1 2,000
1 500 1 1,000
2 200 2 400
1 100 1 200
1 50 1 100
pressure per
piece
pressure per
piece
14
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WIKA operating instructions model CPB3800
3. Specications
Transport dimensions for complete instrument
The complete instrument, in its standard version and standard scope of delivery,
consists of three packages on a single pallet.
The dimensions are 1,200 x 800 x 500 mm.
The overall weight is dependant on the measuring range.
Standard CPB3800 units
Weight in kg Weight in kg
Version in bar net gross Version in lb/in² net gross
1 … 120 bar 71 89 10 ... 1,600 lb/in² 68 86
2.5 … 300 bar 71 89 25 ... 4,000 lb/in² 68 86
5 … 700 bar 71 89 50 ... 10,000 lb/in² 68 86
10 … 1,200 bar 71 89 100 ... 16,000 lb/in² 68 86
Optional CPS/CPM5800 units with CPB3800 base
Weight in kg Weight in kg
EN
Version in bar net gross Version in psi net gross
Single-piston measuring ranges
1 … 120 bar 77 95.5 10 … 1,600 psi 73 91.5
2 … 300 bar 77 95.5 30 … 4,000 psi 72.5 91
Dual-piston measuring ranges Dual-piston measuring ranges
1 … 60 bar /
10 … 700 bar
1 … 60 bar /
20 … 1,200 bar
1 … 60 bar /
20 … 1,400 bar
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WIKA operating instructions model CPB3800
85.5 104 10 … 800 psi /
77.5 96 10 … 800 psi /
85.5 104 10 … 800 psi /
Single-piston measuring ranges
84.5 103
100 … 10,000 psi
73 91.5
200 … 16,000 psi
84.5 103
200 … 20,000 psi
15
3. Specications
Dimensions in mm
(without disc weigths)
Front view
EN
Side view
16
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WIKA operating instructions model CPB3800
3. Specications
Top view
6
5
(1) Test item connection
(2) High-pressure shut-o valve
(3) Low-pressure shut-o valve
(4) Dual-area spindle pump with star handle
(5) Piston-cylinder system
(6) Rotatable feet
(7) Reservoir with screwed sealing plug
(8) Pressure generation control schematic
2
EN
7
3
8
1
4
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17
3. Specications
Standard connection piston-cylinder system
EN
Test connection
O-ring 8.9 x 1.9
Oil collecting tray
Adapter, see scope
of delivery
Sealing ring
USIT 10.7 x 18 x 1.5
18
Oil collecting tray
When using thread adapters, the thread adapter has to be connected
pressure tight to the test item rst.
After that the test item with mounted adapter can be inserted into the test
connection and can be oriented.
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WIKA operating instructions model CPB3800
3. Specications
Liquids used
A hydraulic mineral oil viscosity 20 ... 37 cSt at 40 °C viscosity grade VG20 to VG37
to ISO 3448 (BS 4231) is used for the CPB3800 base unit. Most users will be able to
obtain locally suitable oil (see below) as used in hydraulic machinery. However, for the
convenience of users we can supply a 500 ml bottle of oil, viscosity grade VG22.
Oils suitable for dead-weight testers
The following oils are the commercially available oils suitable for use in the dead-weight
testers.
EN
ISO 3448
viscosity
grade
VG22 -- Tellus 22
VG32 10W Tellus V32
VG37 -- Tellus 37
Other liquids
The dead-weight tester model CPB3800 is manufactured for use on mineral oil only. If
an end user wishes to use it on another uid, it is the end user responsibility to ensure
that the uid is compatible with high tensile brass, stainless steel, mild steel, and nitrile
rubber, which are the materials that will come into contact with the uid.
Approx. SAE
Shell Esso Mobil
viscosity clas-
sication
Nuto H22 DTE 22
Tellus R22
Nuto H32 DTE Oil Light
DTE 24
-- -Tellus R37
Tellus T37
Tellus V37
Fluids, which attack ABS, should be used with caution. Continual
immersion of the cover in such uids will cause deterioration. Spillages
should be wiped o immediately.
Wear safety goggles!
Protect eyes from ying particles and liquid splashes.
Wear protective gloves!
Protect hands from contact with aggressive media.
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WIKA operating instructions model CPB3800
19
4. Design and function
4. Design and function
4.1 Description
EN
The model CPB3800 dead-weight tester in compact design provides optimum features
for laboratory use whilst being rugged enough for industrial requirements. It provides a
highly accurate measurement of pressure.
The piston unit is screwed on to the left hand side pressure block of the base unit and
the test item is connected to the right hand pressure block.
4.2 Scope of delivery
■
Base
■
Dual-area spindle pump for lling, pressure generation and ne pressure adjustment
■
Piston connection with G ¾ B male thread
■
Test item connection with G ½ female thread, loose union connection
■
Adapter set for test item connection selectable from 3 dierent sets:
- Adapter set “BSP” G ½ male on G ⅛, G ¼, G ⅜ and G ½ female
- Adapter set “NPT” G ½ male on ⅛ NPT, ¼ NPT, ⅜ NPT and ½ NPT female
- Adapter set “metric” G ½ male on M12 x 1.5 and M20 x 1.5 female
■
Piston-cylinder system
■
Mass set manufactured to standard gravity (9.80665 m/s²)
■
VG22 mineral oil (0.5 litre)
■
Tool and maintenance set consisting of:
1 hexagon wrench key 3 mm A/F
2 x 30 mm A/F open-ended spanners
1 spirit level
4 level plates
1 bag of seals
1 G ½ (½” BSP) angle connection
1 pointer press-on tool
1 pointer remover
1 test item connection
■
Operating instructions in German and English language
■
Factory calibration certicate
Cross-check scope of delivery with delivery note.
4.3 Base unit
The model CPB3800 series base unit consists of a solid aluminium base plate mounted
on four adjustable levelling feet, a spindle pump, reservoir, control valves, pipework to
20
WIKA operating instructions model CPB3800
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4. Design and function
two stainless steel pressure connection blocks. The pipework and above mentioned
assemblies are covered by an easy to clean ABS cover.
4.3.1 Spindle pump
The spindle pump is bolted to the reservoir/high pressure cylinder block fastened to the
base unit. A sectioned view of the pump is shown. The rotating handwheel (C) which
is operated by the spokes (D) is attached to a threaded spindle (E). The spindle is
supported in a sintered bearing (F). As the spindle (E) is rotated, it drives a non-rotating
ram (E and K) forward, the thrust being taken by a needle thrust bearing (G). The large
diameter of the ram (H) in the barrel of the pump (J) primes the pressure system and
provides the low pressure up to approximately 140 bar (2,000 lb/in²). The small diameter
of the ram (K) in the reservoir/ high pressure cylinder block provides the higher test
pressures up to 1,200 bar (16,000 lb/in2).
4.3.2 Reservoir
A liquid reservoir is provided on the top of reservoir/high pressure cylinder block.
The reservoir is provided with a translucent cover to enable the reservoir level to be
monitored. A plug in the middle of the reservoir cover to allow the reservoir to be lled
or topped up (the plug is removed whilst the dead-weight tester is in use). The reservoir
contains enough liquid (approximately 150 cm³) to enable normal operation of the
dead-weight tester to be carried out.
Low pressure ram displacement = 60 cm³
High pressure ram displacement = 10 cm³
4.3.3 Control valves
Two control valves are provided on the top of reservoir/high pressure cylinder block.
The valve mechanisms are built into the reservoir/high pressure cylinder block and they
control the ow of liquid through internal drillings in the reservoir/high pressure cylinder
block. The rear valve is referred to as valve A and is used to control the output from the
larger diameter ram of the spindle pump. The front valve is referred to as valve B and is
used to control the ow of liquid to and from the reservoir.
EN
4.3.4 Connection blocks
Pressure supply pipes from the spindle pump are terminated at two pressure blocks
mounted on the base unit. The pressure blocks are tted with threaded bosses
projecting up through the cover plate of the base unit. These threaded bosses enable
piston units to be directly screwed on to them or connections for various sizes of gauge
connections to be screwed on to them. Oil cups are tted to the unit cover around the
threaded bosses of the connection blocks to catch any oil drips from the gauge stand
during gauge tting and removal.
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WIKA operating instructions model CPB3800
21
4. Design and function
Sectioned view of spindle pump
EN
K
22
H
J
G
D
F E
C
WIKA operating instructions model CPB3800
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4. Design and function
4.4 Piston unit
The piston unit of the model CPB3800 is a single range piston unit, which covers the
range up to 1,200 bar (16,000 lb/in²).
Masses are loaded directly onto the piston head for low pressure calibration points. A
coloured band indicates when the piston is oating.
For higher pressure points, a mass carrier is tted directly to the piston head, and disc
weights located at the bottom of the mass carrier or located on top of it. A machined
groove on the main piston body indicates when the piston is oating.
4.5 Function
Operation of the dead-weight tester is controlled by the two valves A and B on the top
of the reservoir/high pressure cylinder block. When initially priming the system valves A
and B are opened to ll the system with oil from the reservoir. Valve B is then closed with
valve A left open and the spindle pump operated to provide the lower test pressures.
To provide the higher pressures valve A is closed to seal o the test circuit from the low
pressure part of the spindle pump and valve B is opened to allow the liquid in the low
pressure part of the spindle pump to return to the reservoir as the pump is operated.
This ensures that the pump can be operated without having to put large forces on the
spindle pump handwheel. To release the test pressure the spindle pump is wound out
and valve A is opened.
EN
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WIKA operating instructions model CPB3800
Hand pump
Valve A
Reservoir
Valve B
23
5. Transport, packaging and storage
5. Transport, packaging and storage
5.1 Transport
EN
Check the model CPB3800 dead-weight tester for any damage that may have been
caused by transport. Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change
in installation site, sending for repair or recalibration).
Disc weights are shipped in cardboard and not in their respective
wooden cases, if ordered.
Wooden cases are not suitable for use as shipping cases.
5.3 Storage
Permissible conditions at the place of storage:
■
Storage temperature: -10 ... +50 °C
■
Humidity: 35 ... 85 % relative humidity for instrument base and mass set
35 ... 65 % relative humidity for piston-cylinder system (no condensation)
Avoid exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
■
Potentially explosive environments, ammable atmospheres
■
Corrosive liquids
Store the model CPB3800 dead-weight tester in its original packaging in a location that
fulls the conditions listed above. If the original packaging is not available, pack and
store the instrument as described below:
1. Wrap the instrument in an antistatic plastic lm.
2. Place the instrument, along with shock-absorbent material, in the packaging.
3. If stored for a prolonged period of time (more than 30 days), place a bag, containing a
desiccant, inside the packaging.
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WIKA operating instructions model CPB3800
14062232.04 03/2015 EN/DE
6. Commissioning, operation
6. Commissioning, operation
6.1 Unpacking the dead-weight tester
As soon as possible after delivery open the packaging of the deat-weight tester and
check that you have all the items detailed in the packing list (see chapter 4.2 “Scope
of delivery”). As you are unpacking the items, examine them for signs of damage or
breakage during transit.
If any items are missing get in touch immediately with DH-Budenberg/WIKA to inform us
of the shortage.
6.2 Environmental requirement
When siting the dead-weight tester if not in a temperature controlled laboratory look for
an area that satises the following criteria as much as possible:
■
A constant temperature area free from draughts and sources of heat or cold
■
An area free from noise and vibration, constantly used pathways
■
A clean dry area free from corrosive liquids or vapours
A strong, stable, level table or workbench with the capability of supporting the system
with sucient space to operate is required.
6.3 Assembly of base units
Fastening base to bench
The base is to be mounted on a rm, level table or bench about 0.9 m high. The centre
line of the front adjustable feet of the unit should be about 40 mm from the front edge of
the bench to allow adequate clearance for the handwheel.
EN
1. Mark the position of the adjustable feet of the unit on the top of the bench.
2. Position a level plate at the centre of each of the adjustable feet of the unit and screw
the plate to the bench to ensure that the dead-weight tester is rigid.
3. Fit the base unit on the bench with the adjustable feet on the level plates and the
handwheel shaft projecting over the front of the bench.
4. Screw in the four handwheel spokes into the hub.
5. Using the spirit level provided, level the unit in both the front/rear axis and the side
to side axis by adjusting the four knurled feet, by placing the spirit level on top of the
piston-cylinder system.
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WIKA operating instructions model CPB3800
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6. Commissioning, operation
6.4 Assembly of piston unit
The piston unit of the CPB3800 has its own transportation box that should be used for
storing the unit when not in operation, and if the customer ever has to send the unit
back for recalibration. The following details show how the piston is to be assembled/
EN
disassembled to the main body.
1. Unscrew the knurled retaining cap from the main body.
2. Place the piston head on a at surface, with the piston facing vertically.
3. Fit the knurled retaining cap to the piston via the eccentric hole.
4. Place the main piston body with the external thread in a vertical position.
5. Lubricate the piston with the pressure medium, and insert the piston into the cylinder
in the main body in a vertical direction only.
WARNING!
Do not apply any transverse force. Excess force is not required.
6. Tighten the knurled retaining cap to the main body.
7. Lift the piston head until it engages against its internal stop. This movement should
be free.
Mass carrier
Main body
Piston head
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14062232.04 03/2015 EN/DE
WIKA operating instructions model CPB3800
6. Commissioning, operation
6.5 Assembly of the dead-weight tester
1. Fit the piston unit to the left hand connection. Ensure that the mating faces are clean
and the 12 mm diameter O-ring seal correctly located. Excess force is not required
to achieve an eective seal.
2. Check the level of the system base with the spirit level on the piston-cylinder
system. Level if necessary by using the levelling screws. If using as a comparator, t
additional loose union connection (order number 14031251) to port that piston unit
would be tted to.
3. Fit the appropriate connection to the gauge stand, using a bonded seal to make the
joint and screw a test gauge (for installation use a known gauge) into position, also
with a bonded seal.
If preferred, a copper or leather washer can be substituted for the bonded seal at
the gauge. The loose nut on the dead-weight tester base enables the gauge to be
positioned as required and for back connection gauges the angle connection is
screwed into the loose union connection.
When using thread adapters, the thread adapter has to be connected
pressure tight to the test item rst.
After that the test item with mounted adapter can be inserted into the test
connection and can be oriented.
EN
6.5.1 Filling the base unit with liquid
1. Remove ller plug from reservoir by prising plug out. (This plug should be left out
whilst in use).
2. Open valves A and B.
3. Wind spindle pump handle fully clockwise.
4. Fill reservoir with appropriate liquid. Use the oil supplied or an approved substitute
for oil systems. Do not use other liquids. Castor based oils, Skydrol, solvents or
similar liquids will attack the seals tted in the dead-weight tester.
5. Wind spindle pump handle fully anti-clockwise.
6. Top up reservoir if necessary.
Wear safety goggles!
Protect eyes from ying particles and liquid splashes.
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WIKA operating instructions model CPB3800
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6. Commissioning, operation
Wear protective gloves!
Protect hands from contact with aggressive media.
EN
6.5.2 Post assembly test
1. Carry out a test calibration of a known instrument (see chapter 6.6 “Procedure”) to
ensure that the unit is working correctly.
2. Release the pressure and remove the test instrument.
To remove the instrument from the system, use the appropriate size
of spanners on the top section of the pressure connection and on the
body of the instrument only. Ensure that the lower part of the pressure
connection is not rotated as this may release it from the base.
3. The system is now ready for use.
CAUTION!
If the volume required to be lled is very large requiring the use of an
additional pump and reservoir to be connected to the model CPB3800,
it is ESSENTIAL to ensure that valve B is kept open and valve A closed
at all times otherwise a high pressure can be built up on the low pressure
ram of the screw press and damage caused. To ensure this does not
happen we can supply the system tted with a relief valve, which will
release at a set pressure, should the valve operation be incorrect.
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Alternatively, we can supply a modied system and hand pump for this
operation. For further information on both items contact DH-Budenberg/
WIKA.
When testing equipment with a large volume, the capacity of the spindle
pump (65 cm³) may be insucient to reach the pressure required. In this
case, the equipment should be lled as far as possible with the liquid
before connecting it to the system, so that the displacement needed is
reduced.
Dirty or chemically contaminated test items should not be tted as they
contaminate the system unless they are rst cleaned.
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WIKA operating instructions model CPB3800
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