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Operating instructions |
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Betriebsanleitung |
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Dead-weight tester in compact design, model CPB3800 |
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Druckwaage in Kompaktausführung, Typ CPB3800 |
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Dead-weight tester in compact design, model CPB3800
EN |
Operating instructions model CPB3800 |
Page |
3 |
- 46 |
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DE |
Betriebsanleitung Typ CPB3800 |
Seite |
47 |
- 90 |
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!
14062232.04 03/2015 EN/DE
2 |
WIKA operating instructions model CPB3800 |
14062232.04 03/2015 EN/DE
Contents
Contents
1.General information
2.Safety
2.1Intended use
2.2Personnel qualification
2.3Personal protective equipment
2.4Special hazards
2.5Labelling, safety marks
3.Specifications
4.Design and function
4.1Description
4.2Scope of delivery
4.3Base unit
4.4Piston unit
4.5Function
5.Transport, packaging and storage
6.Commissioning, operation
6.1Unpacking the dead-weight tester
6.2Environmental requirement
6.3Assembly of base units
6.4Assembly of piston unit
6.5Assembly of the dead-weight tester
6.6Procedure
6.7Completion
6.8Pressure calculation computer software standard accuracy program
6.9Temperature measurement of piston units
6.10Cleaning gauges
7.Maintenance, cleaning and recalibration
7.1Periodic maintenance
7.2Corrective maintenance
7.3Cleaning
7.4Recalibration
8.Faults
9.Return and disposal
10.Accessories
Appendix: EC Declaration of conformity for model CPB3800
Declarations of conformity can be found online at www.wika.com.
4 EN
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WIKA operating instructions model CPB3800 |
3 |
1. General information
1. General information
■■ The model CPB3800 dead-weight tester in compact design described in the EN operating instructions has been designed and manufactured using state-of-the-
art technology. All components are subject to stringent quality and environmental criteria during production.Our management systems are certified 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 modifications.
■■ Factory calibrations / DKD/DAkkS calibrations are carried out in accordance with international standards.
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4 |
WIKA operating instructions model CPB3800 |
1. General information
■■ Further information: |
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DH-Budenberg |
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A division of WIKA Instruments Ltd. |
www.wika.de / www.wika.com |
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- Internet address: |
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- Relevant data sheet: |
CT 31.06 |
844 4060086 |
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- Application consultant: |
Tel.: |
+44 |
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Fax: |
+44 |
844 4060087 |
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sales@dh-budenberg.co.uk |
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WIKA Alexander Wiegand SE & Co. KG |
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- Internet address: |
www.wika.de / www.wika.com |
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- Relevant data sheet: |
CT 31.06 |
9372 132-0 |
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- Application consultant: |
Tel.: |
+49 |
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Fax: |
+49 |
9372 132-406 |
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info@wika.com |
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Explanation of symbols
EN
WARNING!
... indicates a potentially dangerous situation that can result in serious injury or death, if not avoided.
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 efficient and trouble-free operation.
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WIKA operating instructions model CPB3800 |
5 |
2. Safety
2. Safety
WARNING!
EN Before installation, commissioning and operation, ensure that the appropriate dead-weight tester has been selected in terms of measuring range, design and specific 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.
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.
The pressure is set via an integrated, finely-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 specifications contained in these operating instructions must be observed. Improper handling or operation of the instrument outside of its technical specifications requires the instrument to be taken out of service immediately and inspected by an authorised DH-Budenberg/WIKA service engineer.
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6 |
WIKA operating instructions model CPB3800 |
2. Safety
Handle mechanical precision measuring instruments with the required care (protect |
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from humidity, impacts, strong magnetic fields, static electricity and extreme |
EN |
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.
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2.2 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient!
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 qualifications described below.
■■ Keep unqualified personnel away from hazardous areas.
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-specific 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 office 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.
WIKA operating instructions model CPB3800 |
7 |
2. Safety
Follow the instructions, displayed in the work area, regarding personal EN protective equipment!
The required personal protective equipment must be provided by the operating company.
Wear safety goggles!
Protect eyes from flying 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 first-aid equipment is available and aid is provided whenever required.
■■ that the operating personnel are regularly instructed in all topics regarding work safety, first 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 sufficient 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 |
2. Safety
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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
effective barrier cream and/or protective gloves will greatly reduce this EN possibility.
Description
Closed flash 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 |
CO2/dry chemical foam or water fog |
Spillage |
Soak with absorbent clay or proprietary absorbent |
Waste disposal |
Burn or dump in approved area |
Emergency treatment of acute effects
Ingestion |
Do not induce vomiting. |
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Administer 250 ml milk or olive oil. |
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The main hazard following accidental ingestion is aspiration |
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of liquid into lungs. |
Aspiration |
Send to hospital immediately |
Inhalation |
Remove to fresh air, if nausea persists seek medical |
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attention. |
Eye contact |
Wash with copious amounts of water for at least 10 minutes. |
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If irritation results or persists, obtain medical advice. |
Skin contact |
Where skin rashes or other abnormalities occur as a result |
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of prolonged or repeated contact, medical advice should be |
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obtained as soon as possible. |
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.
WIKA operating instructions model CPB3800 |
9 |
2. Safety
2.4.3 Lifting of masses
WARNING!
EN 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 off the dead-weight tester.
2.5 Labelling, safety marks Product label
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.
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WIKA operating instructions model CPB3800 |
14062232.04 03/2015 EN/DE
3.Specifications |
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3.Specifications |
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Piston-cylinder systems (standard) |
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Measuring range 1) |
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bar |
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1 … 120 |
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2.5 ... 300 |
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5 ... 700 |
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10 ... 1,200 |
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Required masses |
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kg |
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41 |
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50 |
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58 |
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50 |
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Smallest step 2) |
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bar |
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1 |
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2.5 |
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5 |
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10 |
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(Standard mass set) |
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Nominal effective area of the |
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in² |
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1/16 |
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1/40 |
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1/80 |
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1/160 |
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piston |
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Measuring range 1) |
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lb/in² |
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10 … 1,600 |
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25 ... 4,000 |
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50 ... 10,000 |
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100 ... 16,000 |
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Required masses |
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kg |
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47 |
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47 |
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58 |
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47 |
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Smallest step 2) |
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lb/in² |
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10 |
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25 |
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50 |
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100 |
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(Standard mass set) |
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Nominal effective area of the |
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in² |
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1/16 |
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1/40 |
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1/80 |
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1/160 |
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piston |
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Accuracies |
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Standard 3) 4) |
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0.05 % of reading |
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Option 3) 4) |
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0.025 % of reading |
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Pressure transmission medium |
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Hydraulic fluid based onVG22 mineral oil (0.5 l included in scope |
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of delivery) |
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Material |
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Piston |
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Tungsten carbide |
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Cylinder |
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Tungsten carbide |
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Mass set |
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Stainless steel, non-magnetic |
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Weight |
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Piston-cylinder system |
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kg |
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2.4 |
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BAR mass set incl. mass carrier |
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kg |
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41.5 |
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50.5 |
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58.5 |
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50.5 |
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lb/in² mass set incl. mass carrier |
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kg |
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47.5 |
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47.5 |
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58.5 |
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47.5 |
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Storage case for mass set |
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kg |
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5.8 |
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(optional, 2 pieces required) |
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Dimensions |
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Storage case for mass set |
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400 x 310 x 310 mm (W x H x D) and |
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(optional) |
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215 x 310 x 310 mm (W x H x D) |
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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 fine 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 fixed 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.
WIKA operating instructions model CPB3800 |
11 |
3.Specifications
Base
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Connections |
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Connection for piston-cylinder |
G ¾ B (male) |
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system |
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Test item connection |
G ½ female thread, loose union connection |
Material |
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Wetted parts |
Austenitic stainless steel, high tensile brass, nitrile rubber |
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Pressure transmission |
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Hydraulic fluid based onVG22 mineral oil (0.5 l included in scope of |
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delivery) 5) |
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Reservoir |
170 cm³ |
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Weight |
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Base |
13.5 kg |
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Storage case for the base |
8.5 kg |
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(optional) |
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Permissible ambient conditions |
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Operating temperature |
18 ... 28 °C |
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Dimensions |
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Base |
401 x 397 x 155 mm ) (W x D x H), for details, see technical drawings |
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5)Other pressure transmission media on request.
CE conformity and certificates
CE conformity |
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Pressure equipment directive |
97/23/EC (Module A) |
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Certificate |
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Calibration |
Calibration certificate |
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Option:UKAS calibration certificate (pressure calibration with a mass |
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set) for CPB3800 standard models |
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Option:UKAS calibration certificate (area and mass calibration) for |
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CPS/CPM5800 only |
Approvals and certificates, see website
For further specifications seeWIKA data sheet CT 31.06 and the order documentation.
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12 |
WIKA operating instructions model CPB3800 |
3.Specifications
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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.
EN
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
Measuring range |
1 ... 120 |
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2,5 ... 300 |
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[bar] |
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Quantity |
Nominal |
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Quantity |
Nominal |
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pressure per |
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pressure per |
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piece |
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piece |
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[bar] |
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[bar] |
Piston and make-up weight |
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1 |
1 |
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1 |
2.5 |
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Piston, mass carrier and mass carrier |
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1 |
20 |
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1 |
50 |
make-up weight |
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Masses (stackable on mass carrier ) |
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3 |
20 |
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3 |
50 |
Masses (stackable on piston) |
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1 |
20 |
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1 |
50 |
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1 |
10 |
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1 |
25 |
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2 |
4 |
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2 |
10 |
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1 |
2 |
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1 |
5 |
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1 |
1 |
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1 |
2.5 |
Measuring range |
5 ... 700 |
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10 ... 1.200 |
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[bar] |
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Quantity |
Nominal |
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Quantity |
Nominal |
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pressure per |
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pressure per |
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piece |
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piece |
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[bar] |
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[bar] |
Piston and make-up weight |
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1 |
5 |
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1 |
10 |
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Piston, mass carrier and mass carrier |
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1 |
100 |
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1 |
200 |
make-up weight |
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Masses (stackable on mass carrier) |
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4 |
100 |
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3 |
200 |
Masses (stackable on piston) |
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1 |
100 |
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1 |
200 |
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1 |
50 |
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1 |
100 |
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2 |
20 |
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2 |
40 |
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1 |
10 |
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1 |
20 |
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1 |
5 |
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1 |
10 |
WIKA operating instructions model CPB3800 |
13 |
3.Specifications
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Measuring range |
10 ... 1,600 |
25 ... 4,000 |
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[lb/in²] |
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Quantity |
Nominal |
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Quantity |
Nominal |
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pressure per |
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pressure per |
EN |
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piece |
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piece |
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[lb/in²] |
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[lb/in²] |
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Piston |
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1 |
10 |
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1 |
25 |
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Mass carrier and mass carrier make- |
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1 |
190 |
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1 |
475 |
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up weight |
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Masses (stackable on mass carrier) |
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5 |
200 |
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5 |
500 |
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Masses (stackable on piston) |
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1 |
200 |
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1 |
500 |
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1 |
100 |
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1 |
250 |
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2 |
40 |
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2 |
100 |
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1 |
20 |
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1 |
50 |
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1 |
10 |
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1 |
25 |
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Measuring range |
50 ... 10,000 |
100 ... 16,000 |
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[lb/in²] |
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Quantity |
Nominal |
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Quantity |
Nominal |
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pressure per |
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pressure per |
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piece |
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piece |
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[lb/in²] |
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[lb/in²] |
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Piston |
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1 |
50 |
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1 |
100 |
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mass carrier and mass carrier make- |
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1 |
950 |
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1 |
1,900 |
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up weight |
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Masses (stackable on mass carrier) |
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7 |
1,000 |
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5 |
2,000 |
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Masses (stackable on piston) |
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1 |
1,000 |
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1 |
2,000 |
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1 |
500 |
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1 |
1,000 |
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2 |
200 |
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2 |
400 |
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1 |
100 |
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1 |
200 |
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1 |
50 |
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1 |
100 |
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14 |
WIKA operating instructions model CPB3800 |
3.Specifications
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.
EN
Standard CPB3800 units |
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Weight in kg |
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Weight in kg |
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Version in bar |
net |
gross |
Version in lb/in² |
net |
gross |
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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 |
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Optional CPS/CPM5800 units with CPB3800 base
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Weight in kg |
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Version in bar |
net |
gross |
Single-piston measuring ranges |
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1 … 120 bar |
77 |
95.5 |
2 … 300 bar |
77 |
95.5 |
|
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Dual-piston measuring ranges |
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1 … 60 bar / |
85.5 |
104 |
10 … 700 bar |
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1 … 60 bar / |
77.5 |
96 |
20 … 1,200 bar |
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1 … 60 bar / |
85.5 |
104 |
20 … 1,400 bar |
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Weight in kg |
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Version in psi |
net |
gross |
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Single-piston measuring ranges |
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10 |
… 1,600 psi |
73 |
91.5 |
30 |
… 4,000 psi |
72.5 |
91 |
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||
Dual-piston measuring ranges |
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10 |
… 800 psi / |
84.5 |
103 |
100 … 10,000 psi |
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|
10 |
… 800 psi / |
73 |
91.5 |
200 … 16,000 psi |
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|
10 … 800 psi / |
84.5 |
103 |
|
200 … 20,000 psi |
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|
WIKA operating instructions model CPB3800 |
15 |
3.Specifications
Dimensions in mm
(without disc weigths)
EN Front view
Side view
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WIKA operating instructions model CPB3800 |
3.Specifications
Top view
2
6
7
3
5
8
1
4
(1)Test item connection
(2)High-pressure shut-off valve
(3)Low-pressure shut-off 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
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EN
WIKA operating instructions model CPB3800 |
17 |
3.Specifications
|
Standard connection piston-cylinder system |
EN |
O-ring 8.9 x 1.9 |
|
Oil collecting tray |
Test connection
Adapter, see scope of delivery
Sealing ring
USIT 10.7 x 18 x 1.5
Oil collecting tray
When using thread adapters, the thread adapter has to be connected pressure tight to the test item first.
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.Specifications
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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 EN 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.
ISO 3448 |
Approx. SAE |
Shell |
Esso |
Mobil |
viscosity |
viscosity clas- |
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grade |
sification |
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|
VG22 |
-- |
Tellus 22 |
Nuto H22 |
DTE 22 |
VG32 |
10W |
Tellus R22 |
Nuto H32 |
DTE Oil Light |
Tellus V32 |
||||
VG37 |
-- |
DTE 24 |
-- |
-- |
Tellus 37 |
||||
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Tellus R37 |
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Tellus T37
Tellus V37
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 fluid, it is the end user responsibility to ensure that the fluid is compatible with high tensile brass, stainless steel, mild steel, and nitrile rubber, which are the materials that will come into contact with the fluid.
Fluids, which attack ABS, should be used with caution. Continual immersion of the cover in such fluids will cause deterioration.Spillages should be wiped off immediately.
Wear safety goggles!
Protect eyes from flying particles and liquid splashes.
Wear protective gloves!
Protect hands from contact with aggressive media.
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 filling, pressure generation and fine 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 different 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 certificate
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
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WIKA operating instructions model CPB3800 |
4. Design and function
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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 |
EN |
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 filled
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 flow 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 flow of liquid to and from the reservoir.
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 fitted 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 fitted to the unit cover around the threaded bosses of the connection blocks to catch any oil drips from the gauge stand during gauge fitting and removal.
WIKA operating instructions model CPB3800 |
21 |
4. Design and function
Sectioned view of spindle pump
EN
K
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H |
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J |
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E |
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D |
G |
EN/DE |
|
F |
03/2015 |
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C |
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WIKA operating instructions model CPB3800 |
4.Design and function
4.4Piston 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 EN coloured band indicates when the piston is floating.
For higher pressure points, a mass carrier is fitted 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 floating.
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 fill 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 off 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.
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Valve A
Reservoir
Valve B
Hand pump
WIKA operating instructions model CPB3800 |
23 |
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5. Transport, packaging and storage |
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5. Transport, packaging and storage |
|
|
|
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5.1 Transport |
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EN |
|
|
||
|
Check the model CPB3800 dead-weight tester for any damage that may have been |
|
||
|
|
caused by transport. Obvious damage must be reported immediately. |
|
|
|
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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 |
|
|
|
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in installation site, sending for repair or recalibration). |
|
|
|
|
Disc weights are shipped in cardboard and not in their respective |
|
|
|
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wooden cases, if ordered. |
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|
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Wooden cases are not suitable for use as shipping cases. |
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|
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5.3 Storage |
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|
|
Permissible conditions at the place of storage: |
|
|
|
|
■■ Storage temperature: -10 ... +50 °C |
|
|
|
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■■ Humidity: 35 ... 85 % relative humidity for instrument base and mass set |
|
|
|
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35 ... 65 % relative humidity for piston-cylinder system (no condensation) |
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|
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Avoid exposure to the following factors: |
|
||
|
|
■■ Direct sunlight or proximity to hot objects |
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|
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■■ Mechanical vibration, mechanical shock (putting it down hard) |
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■■ Soot, vapour, dust and corrosive gases |
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■■ Potentially explosive environments, flammable atmospheres |
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|
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■■ Corrosive liquids |
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|
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Store the model CPB3800 dead-weight tester in its original packaging in a location that |
|
||
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fulfils the conditions listed above.If the original packaging is not available, pack and |
|
||
|
store the instrument as described below: |
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||
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1.Wrap the instrument in an antistatic plastic film. |
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||
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2. Place the instrument, along with shock-absorbent material, in the packaging. |
EN/DE |
||
|
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 |
6. Commissioning, operation
6. Commissioning, operation
|
6.1 Unpacking the dead-weight tester |
|
|
EN |
|
|
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 satisfies 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 sufficient space to operate is required. |
|
|
6.3 Assembly of base units |
|
|
Fastening base to bench |
|
|
The base is to be mounted on a firm, 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. |
|
|
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. |
|
EN/DE |
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 |
|
|
03/201514062232.04 |
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piston-cylinder system. |
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WIKA operating instructions model CPB3800 |
25 |
6.Commissioning, operation
6.4Assembly 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
EN back for recalibration. The following details show how the piston is to be assembled/ disassembled to the main body.
1.Unscrew the knurled retaining cap from the main body.
2.Place the piston head on a flat 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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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 |
EN |
to achieve an effective 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, fit additional loose union connection (order number 14031251) to port that piston unit would be fitted 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 first.
After that the test item with mounted adapter can be inserted into the test connection and can be oriented.
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6.5.1 Filling the base unit with liquid
1.Remove filler 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 fitted 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 flying particles and liquid splashes.
WIKA operating instructions model CPB3800 |
27 |
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 filled 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 fitted with a relief valve, which will release at a set pressure, should the valve operation be incorrect.
Alternatively, we can supply a modified 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 insufficient to reach the pressure required.In this case, the equipment should be filled 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 fitted as they contaminate the system unless they are first cleaned.
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WIKA operating instructions model CPB3800 |
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