Operating Instructions
Betriebsanleitung
Pressure Balance GB
Kolbenmanometer D
CPB 5000
Pressure Balance CPB 5000
Pressure Balance GB
CPB 5000
Operating Instructions Pressure Balance Page 4 - 39 GB
Betriebsanleitung Kolbenmanometer Seite 40 - 77 D
Information
This symbol provides you with information, notes and tips.
Warning!
This symbol warns you against actions that can cause injury to people or
damage to the instrument.
WIKA Operating Instructions Pressure Balance Version 3.1
2
Pressure Balance GB
CPB 5000
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1. General . ................................................................................................... 5
1.1 General Instructions . ................................................................................................................... 5
1.2 Safety Instructions . ..................................................................................................................... 6
2. Product Description . ................................................................................................... 7
2.1 General Product Information . ..................................................................................................... 7
2.2 Basic principle of the Pressure Balance . .................................................................................. 8
2.3 Factors at work . ........................................................................................................................... 8
2.3.1 Local fluctuations in the gravity-value . .................................................................................. 8
2.3.2 Temperature (Piston/Cylinder) . ............................................................................................... 9
2.3.3 Ambient conditions . ................................................................................................................. 9
2.3.4 How the cross-sectional surface responds to pressure . ................................................... 10
2.4 Arrangement of control elements . ........................................................................................... 10
2.4.1 Pneumatic low-pressure base . .............................................................................................. 11
2.4.2 Pneumatic high-pressure / vacuum base . ........................................................................... 12
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2.4.3 Hydraulic base . ....................................................................................................................... 13
3. Commissioning and Operation . ................................................................................................. 14
3.1 Preparation . ................................................................................................................................ 14
3.1.1 Setting up the Device . ............................................................................................................ 14
3.1.1.1 Instructions for pneumatic high-pressure / vacuum version . ........................................ 14
3.1.1.2 Instructions for pneumatic version with integrated gas to oil separator . ..................... 14
3.1.1.3 Instructions for hydraulic version . .................................................................................... 15
3.1.2 Installing the ConTect System . ............................................................................................. 16
3.1.2.1 Connection for piston/cylinder system with M30 x 2 female thread . ............................. 16
3.1.2.2 Connection for piston/cylinder system with ConTect quick conne ctor . ....................... 17
3.1.2.3 Vacuum piston/cylinder system . ....................................................................................... 18
3.1.2.4 Connection for piston/cylinder system with integrated separator, M30 x 2 female thread........19
3.1.3 Connecting the test specimen . ............................................................................................. 20
3.1.4 Venting the System (Hydraulic Design only) . ...................................................................... 20
3.2 Operation . ................................................................................................................................. 21
3.2.1 Weight Pieces . ........................................................................................................................ 21
3.2.2.1 Approaching the pressure value – hydraulic base . ......................................................... 22
3.2.2.2 Approaching the pressure value – pneumatic low-pressure base . ............................... 22
3.2.2.3 Approaching the pressure value – pneumatic high-pressure / vacuum base . ............. 23
3.2.2.4 Approaching the pressure value – pneumatic version with separator . ......................... 23
3.2.3 Pressure stable . ...................................................................................................................... 23
3.2.4 Next pressure level . ................................................................................................................ 24
3.2.5 Vacuum operation . ................................................................................................................. 24
3.2.5.1 Weight pieces for vacuum . ................................................................................................. 24
3.2.5.2 Approaching the vacuum values . ...................................................................................... 25
3.2.5.3 Vacuum stable . .................................................................................................................... 25
3.2.5.4 Next vacuum level . .............................................................................................................. 25
3.2.6 Releasing pressure – hydraulic , pneumatic and vacuum . ................................................ 25
3.3 Disassembly . .............................................................................................................................. 26
4. Troubleshooting measures . ................................................................................................. 27
5. Maintenance and Care . ................................................................................................. 28
WIKA Operating Instructions Pressure Balance Version 3.1
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Pressure Balance GB
CPB 5000
5.1 Cleaning
5.1.1 Piston/Cylinder system . ......................................................................................................... 28
5.1.1.1 Hydraulic piston/cylinder system . ..................................................................................... 28
5.1.1.2 Pneumatic piston/cylinder system . ................................................................................... 30
5.1.2 Weight Set . .............................................................................................................................. 31
5.2 Wear Parts . ................................................................................................................................. 31
5.3 Changing the Hydraulic Oil (Hydraulic Design only) . ............................................................ 32
5.3.1 Removing Hydraulic Oil . ........................................................................................................ 32
5.3.2 Filling in of Hydraulic Oil . ...................................................................................................... 32
5.3.3 Venting of the System (after Complete Filling only) . .......................................................... 32
5.4 Recalibration . ............................................................................................................................. 33
6. Specifications . ................................................................................................. 34
7. Tables of masses . ................................................................................................. 37
7.1 Hydraulic models . ...................................................................................................................... 37
7.2 Pneumatic models . .................................................................................................................... 38
8. Accessories . ................................................................................................. 39
. .................................................................................................................................... 28
WIKA Operating Instructions Pressure Balance Version 3.1
4
Pressure Balance GB
CPB 5000
1. General .
1.1 General Instructions .
In the following chapters detailed information on the CPB 5000 pressure balance and its proper use
can be found.
Should you require further information, or should there be problems which are not dealt within detail in
the operating instructions, please contact the address below:
WIKA Alexander Wiegand SE & Co. KG
Alex
ander Wiegand Strasse
D-63911 Klingenberg
Tel: +49-(0)9372/132-0
Fax: +49-(0)9372/132-406
E-Mail: calibration@wika.de
If nothing to the contrary is agreed, the pressure balance is calibrated in compliance with the currently
valid body of international regulations and can be referred directly to a national standard.
The warranty period for the pressure balance is 24 months according to the general term s of supply of
ZVEI.
The guarantee is void if the appliance is put to improper use or if the operating instructions are not
observed or if an attempt is made to open the appliance or to release attachment parts or the tubing.
We also point out that the content of these operating instructions neither forms part of an earlier or
existing agreement, assurance or legal relationship nor is meant to change these. All obligations of
WIKA Alexander Wiegand SE & Co. KG result from the respective sales contract and the general
business terms of WIKA Alexander Wiegand SE & Co. KG.
WIKA is a registered trade mark of WIKA Alexander Wiegand SE & Co. KG.
Names of companies or products mentioned in this handbook are registered trade
marks of the manufacturer.
The devices described in this manual represent the latest state of the art in terms of their design,
dimension and materials. We reserve the right to make changes to or replace materials without any
obligation to give immediate notification.
Duplication of this manual in whole or in part is prohibited.
© 2010 Copyright WIKA Alexander Wiegand SE & Co. KG. All rights reserved.
WIKA Operating Instructions Pressure Balance Version 3.1
5
Pressure Balance GB
CPB 5000
1.2 Safety Instructions .
Read these operating instructions carefully prior to operating
the pressure balance CPB 5000. Its trouble-free operation and reliability cannot
be guaranteed unless the safety advise given in this manual is followed when
using the device.
1. The system must only be operated by trained and authorised personnel who know the manual and
can work according to them.
2. Trouble-free operation and reliability of the device can only be guaranteed so long as the
conditions stated under "Setting up the device" are taken into consideration.
3. The CPB 5000 always has to be handled with the care required for an precision instrument (protect
from humidity, impacts and extreme temperatures). The device, the piston-cylinder-system and the
mass-set must be handled with care (don't throw, hit, etc.) and protect them from contamination. By
no means apply any force to the operating elements of the CPB 5000.
4. If the device is moved from a cold to a warm environment, you should therefore ensure the device
temperature has adjusted to the ambient temperature before trying to put it into operation.
5. If the equipment is damaged and might no longer operate safely, then it should be taken out of use
and securely marked in such a way so that isn't used again.
Operator safety may be at risk if:
There is visible damage to the device
The device is not working as specified
The device has been stored under unsuitable conditions for an extended period of time.
If there is any doubt, please return the device to the manufacturer for repair or maintenance.
6. Customers must not attempt to alter or repair the device themselves. If the instrument is opened or
attachment parts or the tubing are released, its trouble-free operation and reliability is impaired and
endangers the operator. Please return the device to the manufacturer for any repair or
maintenance.
7. There must be used only the original sealings in the device.
8. Any operation not included in the following instructions or outside the specifications must not be
attempted.
WIKA Operating Instructions Pressure Balance Version 3.1
6
Pressure Balance GB
CPB 5000
2. Product Description .
2.1 General Product Information .
Application
Pressure balances are the most accurate instruments for the calibration of electronic or mechanical
pressure measuring instruments. The direct measurement of pressure, according to its definition as a
quotient of force and area, and the use of high-quality materials result in small uncertainties of
measurement and an excellent long-term stability of five years.
For these reasons pressure balances have already been used in calibration laboratories of industry,
national institutes and research labs for many years. Due to the integrated pressure generation and
the purely mechanical measuring principle the CPB 5000 is also ideally suited for on-site use as well
as service and maintenance purposes.
Piston/cylinder measuring system
Pressure is defined as a quotient of force and area. Correspondingly, the core of the CPB 5000 is a
very precisely manufactured piston/cylinder system. Both the piston and cylinder are manufactured
from Tungsten Carbide and are very well protected in a solid stainless steel housing against touching,
impacts or contamination from outside.
As a standard the connection of the piston/cylinder system is a M30 x 2 male thread. The patented
ConTect quick connector is available as an option. It allows a quick and safe change of the measuring
range without the need for tools. Thus it is possible to set up a compact complete system at a
favourable price, consisting of an universal instrument base and up to 3 ConTect piston/cylinder
systems with different measuring ranges with only one weight set.
The pneumatic piston/cylinder systems are available for vacuum and pres sure ranges from 2 bar up to
100 bar resp. 30 psi up to 1500 psi and the hydraulic systems are available for pre ssure ran ges from
60 bar up to 1000 bar resp. 1000 psi up to 14500 psi. The accuracy is 0.015 % (optional also 0.008 %)
of reading.
The entire construction design of the piston/cylinder unit and the very precise manufacturing of the
piston and the cylinder stand for excellent operating characteristics with a long free rotation time and
low fall rates and for a very high long term stability. Therefore the recommended re-calibration interval
is 5 years.
Functioning
Depending on the measuring range of the device under test you can fit the instrument basement with
the corresponding system. In order to generate the individual test points, the piston cylinder system is
weighted with mass-loads. The weight applied is proportional to the desired pressure and provided by
using optimally graduated weights. These weights are manufactured to standard gravity (9.80665
m/s²) although for fixed location usage they can be adjusted to a customer specified local gravity.
Depending on the instrument version the pressure is set either via an integrated pump or via external
pressure supply by the use of control valves. For fine adjustment an adjustable volume with precision
spindle is available. As soon as the measuring system reaches equilibrium, there is a balance of
forces between pressure and wheel weights.
Due to the high-grade quality of the system this pressure remains stable over several minutes, so that
for instance adjustments of your device under test can be carried out without any problems.
WIKA Operating Instructions Pressure Balance Version 3.1
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Pressure Balance GB
CPB 5000
2.2 Basic principle of the Pressure Balance .
Their operating principle is based on the physical definition of pressure, the quotient of force and
surface.
essure =Pr
Force
Area
The key element of the pressure balance is a precision-manufactured piston/cylinder system with a
precisely measured cross-sectional surface.
To apply a pressure charge to the system, the piston is placed under a load with (calibrated) weight
pieces.
Each holding disk from the set of weights is identified by a nominal weight, which generates a
pressure value in the system (assuming standard reference conditions). Each weight has a number
and in the calibration certificate there is described the mass value to each weight with its resultant
pressure value. The weights are chosen according to the desired pressure value.
After that, the integrated spindle pump increases the pressure until the weights are in a floating state.
2.3 Factors at work .
The piston pressure gauge is calibrated to standard reference conditions when it leaves the factory
(depending on customer specifications).
If there are significant deviations between the application conditions and the defined referenc e
conditions, appropriate corrections must be made.
Following are the main factors that enter into play and must be considered.
These corrections can be made automatically with the CalibratorUnit CPU 5000
(see accessories point 8)!
2.3.1 Local fluctuations in the gravity-value .
The local force of gravitation is subject to major fluctuations caused by geographical variation.
The value may differ from one place on earth to another by as much as 0.5 %. Since this value has a
direct effect on the measurement, it is essential that it be taken into consideration.
The weight pieces can even be adjusted during manufacturing to match the location where they will be
used. Another option, especially if the device will be used at multiple locations, is to perform a
calibration to the standard gravity,
"Standard-g = 9.80665 m/s
Then a correction must be performed for each measurement according to the formula below:
pressureTrue
Example:
Local gravity set during manufacturing: 9.806650 m/s
Locale gravity at application site: 9.811053 m/s
Nominal pressure: 100 bar
True pressure:
Without the correction, measurements would all be "off" by 0.05 %.
pp
Nominal
2
".
−
valueNominal
⋅=
tan
g
Local
g
tan
100
dardS
sitenApplicatiog
gdardS
−
2
2
81105.9
===
barbar
0449.100
80665.9
WIKA Operating Instructions Pressure Balance Version 3.1
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Pressure Balance GB
CPB 5000
2.3.2 Temperature (Piston/Cylinder) .
The effective cross-sectional surface of the piston/cylinder system depends on the temperature.
The effect depends on the material used and is described by the temperature coefficient (TK).
In the event of deviations from standard reference conditions (typically 20°C), the following formula
must be used to make a correction:
pressureTrue
Example:
Reference temperature: 20°C
Temperature during use: 23°C
TK: 0.0022%
100
Without the correction, measurements would all be "off" by 0.007 %.
valueNominal
⋅=
⋅=
()()
1
1
()
()
1
ferenceAppl
Re
=
5
−
2.220231
⋅−+
TKtt
⋅−+
barbarpressureTrue 99340.99
2.3.3 Ambient conditions .
The effects of ambient conditions
air pressure
room temperature
relative humidity
should always be taken into consideration if the highest level of accuracy is required.
Fluctuations in ambient conditions change air density.
The air density affects the pressure through the buoyancy of the weights:
⎛
⎜
Weight 1 weightNominal
The air density is typically 1.2 kg/m
The density of the weights (non-magnetic steel) is 7900 kg/m3
A fluctuation of 5% in the relative humidity causes an additional uncertainty in the measurement of
about 0.001%.
−⋅=
⎜
⎝
densityAir
densityWeight
3
⎞
⎟
⎟
⎠
WIKA Operating Instructions Pressure Balance Version 3.1
9
Pressure Balance GB
⋅
CPB 5000
2.3.4 How the cross-sectional surface responds to pressure .
At higher pressures, the effective cross-sectional surface changes due to the pressure load.
The ratio of the cross-section and prevailing pressure is linear within an initial approximation. It is
represented by the coefficient of expansion caused by pressure distortion (λ).
pressureTrue
Example:
Measuring point: 1000 bar
System with distortion coefficient: 10
=
⋅+
λ
=
1000
+
Without the correction, measurements would all be "off" by 0.01 %.
2.4 Arrangement of control elements .
The CPB 5000 instrument bases are available in the 4 following versions, which
of the control elements:
Pneumatic low-pressure base
- up to max 10 bar / 150 psi
- with integrated pressure generation via initial pressure pump and spindle pump
- tubing made of flexible hose (polyurethane), 6 x 1 mm
Pneumatic high-pressure / vacuum base
- up to max 100 bar / 1,500 psi
- for external pressure or vacuum connection
- tubing made of stainless steel (1.4571), 3 x 1 mm
Pneumatic base with integrated gas to oil separator
- up to max. 400 bar / 5000 psi
- for external pressure connection
- for the use with hydraulic piston cylinder systems with M30 x 2 connection
- test item can be calibrated easily, dryly and cleanly with air
- tubing made of stainless steel (1.4571), 3 x 1 mm
Hydraulic base
- up to max 1,000 bar / 14,500 psi
- with integrated pressure generation via initial pressure pump and spindle pump
- tubing made of stainless steel (1.4404), 6 x 2 mm
- up to 1200 bar / 17400 psi available as special version
As a standard all instrument bases are equipped with a M30 x 2 female thread as connection for the
piston/cylinder system.
The patented ConTect quick connector can be installed as an opti on allowing a quick and safe change
of the measuring range without the need for tools (not available for the version wit h integrated gas to
oil separator).
pressure Nominal
pressure Nominal1
–7
1/bar:
7
−
10001011
⋅
=
barbarpressureTrue 90.999
vary in the arrangement
WIKA Operating Instructions Pressure Balance Version 3.1
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Pressure Balance GB
CPB 5000
2.4.1 Pneumatic low-pressure base .
View from above
Fixture for
piston/cylinder
system
Connection for
test specimen
Water
level
Initial pressure pump
Spindle pump
Front view
Test pressure
gauge
Outlet
valve
Rear view
Interface to CPU 5000
(in combination with CPU 5000 only)
WIKA Operating Instructions Pressure Balance Version 3.1
Interface to the
external piston
temperature sensor
(optional and in
combination with
CPU 5000 only)
Rotating base
11
Pressure Balance GB
CPB 5000
2.4.2 Pneumatic high-pressure / vacuum base .
(also valid for version with integrated gas to oil separator)
View from above
Fixture for
piston/cylinder
system resp.
integrated separator
Connection for
test specimen
Water
level
Spindle pump
Front view
Test pressure
gauge
Outlet
valve
Inlet
valve
Rear view
Interface to CPU 5000
(in combination with CPU 5000 only)
Connection for
external pressure
supply or vacuum
source
WIKA Operating Instructions Pressure Balance Version 3.1
Interface to the
external piston
temperature sensor
(optional and in
combination with
CPU 5000 only)
Rotating base
12
Pressure Balance GB
CPB 5000
2.4.3 Hydraulic base .
View from above
Screwed drain plug
for tank
Fixture for
piston/cylinder
system
Connection for
test specimen
Water
level
Initial pressure pump
Spindle pump
Front view
Test pressure gauge
(not for special version
1200 bar)
Outlet
valve
Rear view
Interface to CPU 5000
(in combination with CPU 5000 only)
WIKA Operating Instructions Pressure Balance Version 3.1
Interface to the
external piston
temperature sensor
(optional and in
combination with
CPU 5000 only)
Rotating base
13
Pressure Balance GB
CPB 5000
3. Commissioning and Operation .
3.1 Preparation .
3.1.1 Setting up the Device .
Set up the pressure balance on a solid surface. If it is not resting on a solid foundation or is
subject to vibrations, measurements could be affected. This should be avoided.
If no temperature control system is present, the device should at least not be placed near a heat
element or window. This will reduce drafts and warm air flows as much as possi ble.
The water level should be used to align the device. At this time, rough alignment can already be
performed without the piston/cylinder system. Using the rotating feed, position the device so that it
is horizontal.
Place the star handle with knobs onto the spindle pump. Ensure that the spring-loaded thrust pad
engages into the star handle bushing.
We recommend unscrewing the spindle pump completely when you start to record measurement
values, (turning anticlockwise) to allow enough volume for measurements. The outlet valve must be
opened during this process.
3.1.1.1 Instructions for pneumatic high-pressure / vacuum version .
In the pneumatic high-pressure / vacuum version, an external compressed air supply or a
vacuum source has to be connected.
The pressure connection is specified as SWAGELOK
®
pipe connection with an outside pipe
diameter of 6 mm at the back of the instrument base.
Attention: The maximum supply pressure must not exceed 110% of the range of
the device to be tested or piston/cylinder system in use. The maximum
permissible pressure is 110 bar!
The tubing is to be carried out by a fitter trained in SWAGELOK
according to SWAGELOK
®
-tubing instructions.
®
-connections
Only dry, cleaned and particle-free gases (for example nitrogen 4.0 or synthetic air) may be used.
3.1.1.2 Instructions for pneumatic version with integrated gas to oil separator .
In the pneumatic version with integrated gas to oil separator, an external compressed air
supply has to be connected.
The pressure connection is specified as SWAGELOK
®
pipe connection with an outside pipe
diameter of 6 mm at the back of the instrument base.
WIKA Operating Instructions Pressure Balance Version 3.1
14
Pressure Balance GB
(
)
CPB 5000
Attention: The maximum supply pressure must not exceed 110% of the range of
the device to be tested or piston/cylinder system in use. The maximum
permissible pressure is 440 bar!
The tubing is to be carried out by a fitter trained in SWAGELOK
according to SWAGELOK
®
-tubing instructions.
Only dry, cleaned and particle-free gases (for example nitrogen 4.0 or synthetic air) may be used.
The integrated separator at the fixture for the piston/ cylinder system may need to be filled, or
refilled with oil. For this purpose the removable cover of the piston fixture must be opened. First of
all the lateral safety screw must be unscrewed by the help of a hexagon socket wrench size 2.5
mm. Afterwards the removable cover has to be opened using a flat wrench size 41. Special oil
must be used for refilling (0.25 litre supplied, or available as accessory). During filling look to it, that
no oil gets into the upwards facing tubing. The oil level must not exceed the marking line.
Removable cover
41
Marking line max.
oil level
Bottom part
Safety screw
hexagon socket 2.5 mm
After filling screw the removable cover of the separator carefully and slowly into the bottom part.
Tighten the cover firmly with the flat wrench and screw the lateral safety screw in again. After this
the piston/cylinder system can be installed. For this purpose, please proceed according to section
3.1.2.4.
®
-connections
3.1.1.3 Instructions for hydraulic version .
The oil container may need to be filled, or refilled in the hydraulic design (volume 250 ml). For this
purpose, the locking screw with the oil filling symbol on top of the basement must be opened.
Special oil must be used for refilling (1 litre supplied, or available as accessory). The system must
be vented before initial filling, or after a complete oil change. For this purpose, please proceed
according to section 5.3.3.
The protection film on the screwed drain plug of the oil container need to be removed before
operating in the hydraulic design (coverage of the ventilation hole during transportation).
WIKA Operating Instructions Pressure Balance Version 3.1
15
Pressure Balance GB
CPB 5000
3.1.2 Installing the ConTect System .
The ConTect system that is used depends on the device to be tested. You should select a system
with a comparable or higher range.
Example:
Calibration of a 600-bar pressure gauge Î 600 bar ConTect system
Calibration of a 160-bar pressure gauge Î 250 bar ConTect system
The connection for the piston/cylinder system in the instrument base is available in 2 different
versions:
- Connection for piston/cylinder system with M30 x 2 female thread (see section 3.1.2.1)
- Connection for piston/cylinder system with ConTect quick connector (see section 3.1.2.2)
For vacuum operation a special piston/ cylinder system and a special set of masses is required. The
installation of the vacuum piston/cylinder system is described in section 3.1.2.3.
3.1.2.1 Connection for piston/cylinder system with M30 x 2 female thread .
Before releasing the closure plug on the bottom of the device, make sure the
system is not under pressure (open the outlet valve).
The piston/cylinder system is inse rted vertically into the thread of the piston receptacle, and firmly
tightened using a flat wrench with SW 32. An O-ring seal is already fitted, so no additional sealing
material is required.
For an exact alignment of the device, the water level may be removed from the basement plate and
placed on the top of the clamped piston/cylinder system. This will ensure the most accurate
referencing of the piston/cylinder system.
Note: Do not mix up the air and oil systems
Check the O-ring seal in the receptacle for the piston/cylinder system for proper
seat and for any wear. Replace, if necessary.
Here put on
water level
3.
O-ring
(see accessories section 8.)
2.
1.
32
2.
WIKA Operating Instructions Pressure Balance Version 3.1
16
Pressure Balance GB
CPB 5000
3.1.2.2 Connection for piston/cylinder system with ConTect quick connector .
Before releasing the closure plug on the bottom of the device, make sure the
system is not under pressure (open the outlet valve).
Place the ConTect system vertically in the quick connector.
Turning the butterfly screw about one and a half turn clockwise (as far as it will go) is enough to
screw the in place with an automatic seal (finger-tight).
For an exact alignment of the device, the water level may be removed from the basement plate and
placed on the top of the clamped piston/cylinder system. This will ensure the most accurate
referencing of the piston/cylinder system.
Note: Do not mix up the air and oil systems
Check the O-ring seal in the receptacle for the ConTect system for proper seat
and for any wear. Replace, if necessary.
1.
O-ring 4 x 2.2
(see accessories section 8.)
4.
Here put on
water level
3. 2.
WIKA Operating Instructions Pressure Balance Version 3.1
17
Pressure Balance GB
CPB 5000
3.1.2.3 Vacuum piston/cylinder system .
The vacuum piston/cylinder system can only be installed into a connection for
piston/cylinder systems with ConTect quick connector.
Screw the piston/cylinder system into the holding traverse. Hand-tightening will suffice for safe
sealing.
(step 1 and 2)
Place the holding traverse with piston/cylinder system vertically in the quick connector.
(step 3)
Turning the butterfly screw about one and a half turn clockwise (as far as it will go) is enough to
screw the system in place with an automatic seal (finger-tight).
(step 4)
For an exact alignment of the device, the water level may be removed from the basement plate and
placed on the top of the clamped piston/cylinder system. This will ensure the most accurate
referencing of the piston/cylinder system.
(step 5)
Here put on
water level
5.
2.
3.
4.
1.
WIKA Operating Instructions Pressure Balance Version 3.1
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Pressure Balance GB
CPB 5000
3.1.2.4 Connection for piston/cylinder system with integrated separator, M30 x 2 female thread .
Before releasing the closure plug on the fixture for piston/cylinder system,
make sure the system is not under pressure (open the outlet valv e).
Before installing the piston/cylinder system the separator must be vented. For this purpose the
external pressure supply is admitted by opening and closing the integrated fine adjustment valve
(inlet valve) carefully. Pressure is admitted as long as the oil reaches the O-ring sealing inside the
opened piston fixture. For this the outlet valve must be closed and a blind plug must be mounted
into the connection for test specimen.
For the venting procedure it makes sense to adjust the external pressure supply to a
very low pressure value. Hence with the inlet valve can be charged as carefully and
smoothly as possible.
Before venting the oil level inside the separator may need to be checked and filled up,
if necessary. For this purpose, please proceed according to section 3.1.1.2.
Afterwards the piston/cylinder system is inserted vertically into the thread of the piston receptacle,
and firmly tightened using a flat wrench with SW 32. An O-ring seal is already fitted, so no
additional sealing material is required.
Note: Only hydraulic piston/cylinder systems must be used.
Check the O-ring seal in the receptacle for the piston/cylinder system for proper
seat and for any wear. Replace, if necessary.
For an exact alignment of the device, the water level may be removed from the basement plate
and placed on the top of the clamped piston/cylinder system. This will ensure the most accurate
referencing of the piston/cylinder system.
2.
1.
3.
Here put on
water level
O-ring
(see accessories section 8.)
32
WIKA Operating Instructions Pressure Balance Version 3.1
2.
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Pressure Balance GB
CPB 5000
3.1.3 Connecting the test specimen .
Place the device to be checked in the quick connecto r with the knu rled nut. It ca n be freely
positioned. Hand-tightening will suffice for safe sealing.
To calibrate instruments with back pre s sure entry there is an a
accessories section 8).
Check the O-ring seal in the test specimen connection for proper seat and for
any wear. Replace, if necessary.
Please see to it, that each instrument mounted to the pressure balance must be
clean inside.
The quick connector come s equipped with a G 1/2 threaded insert in the standard delivery
package.
When you are calibrating devices with different connection threads, the threaded
inserts can be changed as appropriate (see accessories "Adapte r Set").
Knurled nut
ngle connection 90°available (see
O-ring 8 x 2
(see accessories section 8.)
3.1.4 Venting the System (Hydraulic Design only) .
After the clamping of the ConTect system and the test specimen, air may be trapped in the system.
The system may be vented before beginning with calibration using the following procedure:
The ConTect system and test specimen must be clamped, and the complete weight set must be
placed on the piston/cylinder system.
Generate a pressure of approximately 50 bar using the initial pressure pump
Increase the pressure with the spindle pump until just below the final value of the value range of
the ConTect system, or of the test specimen (the smaller pressure range is the decisive factor).
Important: The piston/cylinder system must remain in its lower position for this
operation, i.e. not yet moving into equilibrium.
Open the outlet valve, any trapped air will escape into the tank
This procedure may need to be repeated 1 to 2 times in order to remove all trapped air.
The device is now ready to use.
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Pressure Balance GB
CPB 5000
3.2 Operation .
3.2.1 Weight Pieces .
Stack the weight pieces onto the bell de pending on the pressure value that is required.
It is usually best to start with the heaviest weight so that the centre of gravity is as low as possible.
Each component is identified by a consecutive number. In the calibration certifica t e to each number
the resultant pressure assuming reference conditions is listed.
Example table from a calibration certificate page 2:
The pressure that will be achieved thus corresponds to the sum of the basic weight (piston), the
bell and the weight rings.
To reduce the starting value, the weight plate (No. 2) can be used as the basic holding surface
instead of the bell (No. 1).
Druckwerte der Gewichtsstücke / Pressure values of masses
Bezeichnung des
Gewichtsstückes
type of weight piece
Kolben / piston 1262 0.08160 0.4002
Glocke / bell 1 0.81560 3.9998
Teller / plate 2 0.05097 0.2499
Masse / weight piece 3 1.01954 5.0000
Masse / weight piece
Masse / weight piece
Masse / weight piece 6 1.01954 5.0000
Masse / weight piece 7 1.01954 5.0000
Masse / weight piece 8 1.01954 5.0000
Masse / weight piece 9 1.01954 5.0000
Masse / weight piece 10 1.01953 5.0000
Masse / weight piece 11 1.01952 4.9999
Masse / weight piece 12 0.50976 2.5000
Masse / weight piece 13 0.20391 1.0000
Masse / weight piece 14 0.20391 1.0000
Masse / weight piece 15 0.12234 0.6000
Masse / weight piece 16 0.10196 0.5000
Masse / weight piece 17 0.07137 0.3500
Masse / weight piece 18 0.05098 0.2500
Nr.
no.
4 1.01954 5.0000
5 1.01954 5.0000
wahre Masse
true mass
in kg
Druckwert
für System
pressure value
for system
in bar
Example: weight piece no. 5 generates a pressure value of 5.0000 bar
with its weight value of 1.01954 kg assuming reference
conditions (room temperature 20°C, air pressure1013 mbar,
relative humidity 40 %)
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Pressure Balance GB
p
p
CPB 5000
. Weight pieces with bell . . Weight pieces with plate ..
Weight
ieces
Bell (No. 1)
Plate (No. 2)
ConTect system
Marking line for
osition
float
3.2.2.1 Approaching the pressure value – hydraulic base .
In hydraulic systems, the system must first be filled with oil and pre-compressed.
For this the outlet valve must be closed.
Then run the initial pressure pump for several strokes. The pressure increases to a maximum of
about 50 bar (depending on the volume of the connected test specimen).
After that, increase the pressure by turning the built-in spindle pump clockwise.
3.2.2.2 Approaching the pressure value – pneumatic low-pressure base .
The built-in initial pressure pump is use d to generate pressures up to 10 bar (depending on the
volume of the connected test specimen).
For this the outlet valve must be closed.
The spindle pump can be used to make a fine adjustment close to the pressure value.
The maximum permissible pressure for the pneumatic low-pressure version is
10 bar. Higher pressures may damage the instrument. The piston/cylinder
system, test specimen and any connecting tubes that are used must not be
subjected to pressures above the maximum permissible level.
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Pressure Balance GB
CPB 5000
3.2.2.3 Approaching the pressure value – pneumatic high-pressure / vacuum base .
An external compressed air supply has to be connected in the back of the instrument.
The external pressure supply can be admitted by opening and closing the integrated fine
adjustment valve (inlet valve) slightly.
For this the outlet valve must be closed.
The spindle pump can be used to make a fine adjustment close to the pressure value.
For vacuum operation see section 3.2.5.
The maximum permissible pressure for the pneumatic high-pressure / vacuum
version is 100 bar. Higher pressures may damage the instrument. The
piston/cylinder system, test specimen and any connecting tubes that are used
must not be subjected to pressures above the maximum permissible level.
3.2.2.4 Approaching the pressure value – pneumatic version with separator .
An external compressed air supply has to be connected in the back of the instrument.
The external pressure supply can be admitted by opening and closing the integrated fine
adjustment valve (inlet valve) slightly.
For this the outlet valve must be closed.
The pressurization with air causes the displacement of the oil inside the separator upwards into the
piston/cylinder system.
The spindle pump can be used to make a fine adjustment close to the pressure value.
The maximum permissible pressure for the pneumatic version with separator is
400 bar. Higher pressures may damage the instrument. The piston/cylinder
system, test specimen and any connecting tubes that are used must not be
subjected to pressures above the maximum permissible level.
3.2.3 Pressure stable .
Continue admitting pressure until the system is in a state of equilibrium.
This state is easy to identify with the aid of the level indicator and mirror. In this case the lo wer
edge of the bell must stay at the position of the marking line of the piston/cylinder system.
Lower edge of the
bell
Marking line for float
position
Mirror
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Pressure Balance GB
CPB 5000
Just before the float position, the system increases quickly.
We therefore recommend turning the spindle slowly and evenly clock wise.
To minimise the effect of friction, move the system up against the weight pieces carefully and make
a turning movement.
The piston and thus the test pressure as well now remain stable for several minutes.
3.2.4 Next pressure level .
To adjust to the next highest pressure, repeat the previous steps from 3.2.1 to 3.2.3
3.2.5 Vacuum operation .
For generating vacuum the use of an external vacuum source is necessary. It must be connected to
the back of the instrument. The external vacuum can be admitted resp. deflated via the integrated fine
adjustment valves for inlet and outlet. The spindle pump can be used to make the fine adjustment.
3.2.5.1 Weight pieces for vacuum .
In each case weight piece no. 1 (closed disc) must be put on the weight carrier first. The centring
collar of the disc should face downwards.
Stack the further weight pieces onto no. 1 depending on the pressure value that is required. Please
see to it, that the weight pieces are stacked on top of each other in such a way, that the open
sections of the discs are always staggered around 180°, this means oppositely positioned.
Never move the system up and make a turning movement, if the piston is in the
lower or upper block position.
weight piece no. 1 (closed disc) further weight pieces (open discs) weight carrier
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