Operating instructions
Betriebsanleitung
Hydraulic comparison test pump, model CPP1200-X
Hydraulische Vergleichsprüfpumpe, Typ CPP1200-X
EN
DE
Hydraulic comparison test pump, model CPP1200-X
EN
Operating instructions model CPP1200-X Page 3 - 36
Betriebsanleitung Typ CPP1200-X Seite 37 - 70
DE
© 2013 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
®
WIKA
is a registered trademark in various countries.
®
WIKA
ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
2
WIKA operating instructions model CPP1200-X
14076968.02 02/2015 EN/DE
Contents
Contents
1. General information 4
2. Safety 5
2.1 Intended use 6
2.2 Personnel qualication 7
2.3 Personal protective equipment (P.P.E.) 7
2.4 Special hazards 8
2.5 Labelling, safety marks 10
3. Specications 11
4. Design and function 17
4.1 Description 17
4.2 Scope of delivery 17
4.3 Base unit 17
4.4 Function 20
5. Transport, packaging and storage 21
6. Commissioning, operation 22
6.1 Unpacking the hydraulic comparison test pump 22
6.2 Environmental requirement 22
6.3 Assembly of base units 22
6.4 Assembly 23
6.5 Procedure 24
6.6 Completion 25
6.7 Cleaning gauges 26
7. Maintenance, cleaning and recalibration 27
7.1 Periodic maintenance 27
7.2 Corrective maintenance 27
7.3 Cleaning 31
8. Faults 32
9. Return and disposal 34
10. Accessories 35
Appendix: EC Declaration of conformity for model CPP1200-X 36
EN
Declarations of conformity can be found online at www.wika.com.
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WIKA operating instructions model CPP1200-X
3
1. General information
1. General information
■
EN
The model CPP1200-X hydraulic comparison test pump described in the 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 certied to ISO 9001 and ISO 14001.
■
These operating instructions contain important information on handling the
instrument. Working safely requires that all safety instructions and work instructions
are observed.
■
Observe the relevant local accident prevention regulations and general safety
regulations for the instrument's range of use.
■
The operating instructions are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any time.
■
Skilled personnel must have carefully read and understood the operating instructions
prior to beginning any work.
■
The manufacturer's liability is void in the case of any damage caused by using
the product contrary to its intended use, non-compliance with these operating
instructions, assignment of insuciently qualied skilled personnel or unauthorised
modications to the instrument.
■
The general terms and conditions contained in the sales documentation shall apply.
■
Subject to technical modications.
■
Further information:
DH-Budenberg
A division of WIKA Instruments Ltd.
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 31.06
- Application consultant: Tel.: +44 844 4060086
Fax: +44 844 4060087
sales@dh-budenberg.co.uk
4
WIKA operating instructions model CPP1200-X
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1. General information / 2. Safety
WIKA Alexander Wiegand SE & Co. KG
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 31.06
- Application consultant: Tel.: +49 9372 132-0
Fax: +49 9372 132-406
info@wika.com
Explanation of symbols
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.
EN
Information
... points out useful tips, recommendations and information for ecient
and trouble-free operation.
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the
appropriate hydraulic comparison test pump has been selected in terms
of pressure range, design and specic measuring conditions.
Non-observance can result in serious injury and/or damage to the
equipment.
Further important safety instructions can be found in the individual
chapters of these operating instructions.
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5
2. Safety
2.1 Intended use
Comparison test pumps serve as pressure generators for the testing, adjustment and
calibration of mechanical and electronic pressure measuring instruments through
comparative measurements. These pressure tests can take place in the laboratory or
EN
workshop, or on site at the measuring point.
The hydraulic comparison test pump features two connections, for test item and
reference measuring instrument, which can be used in any order. If one connects the
test item and a suciently accurate reference measuring instrument to the test pump,
on actuating the pump, the same pressure will act on both instruments. By comparison
of the two measured values at any given pressure value, a check of the accuracy and/or
adjustment of the pressure measuring instrument under test can be carried out.
The integrated dual-area spindle pump enables rapid lling of the test system and
smooth pressure generation up to 1,200 bar. At the same time, the precise, adjustable
spindle pump also enables ne pressure adjustment.
A control schematic for pressure generation on the instrument base facilitates quick
and easy operation. The pump is further characterised by the spindle which runs
solely within the pump body. This eliminates any harmful bending moment from an
externally running spindle and, especially for eld operation, there is the advantage that
dimensions of this pump do not alter during operation through the rotation of the spindle.
The term “reference measuring instrument” in these operating
instructions refers to any pressure measuring instrument, such as:
pressure gauge, electrical pressure measuring instrument and pressure
transmitter with electrical output. The hydraulic comparison test pump
system is only as accurate as the reference measuring instrument used.
The reference measuring instrument should be regularly calibrated in
order to ensure that its accuracy is maintained.
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specications contained in these operating instructions must be
observed. Improper handling or operation of the instrument outside of its technical
specications requires the instrument to be taken out of service immediately and
inspected by an authorised DH-Budenberg/WIKA service engineer.
Handle mechanical precision measuring instruments with the required care (protect
from humidity, impacts, strong magnetic elds, static electricity and extreme
temperatures, do not insert any objects into the instrument or its openings).
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WIKA operating instructions model CPP1200-X
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2. Safety
If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in instrument malfunction. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
The manufacturer shall not be liable for claims of any type based on operation contrary
to the intended use.
2.2 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to
equipment.
■
The activities described in these operating instructions may only be
carried out by skilled personnel who have the qualications described
below.
■
Keep unqualied personnel away from hazardous areas.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and
knowledge of country-specic regulations, current standards and directives, are capable
of carrying out the work described and independently recognising potential hazards.
EN
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
DH-Budenberg/WIKA can provide dedicated training courses on the correct use of our
products. Please contact your local oce for further details.
2.3 Personal protective equipment (P.P.E.)
The personal protective equipment is designed to protect the skilled personnel from
hazards that could impair their safety or health during work. When carrying out the
various tasks on and with the instrument, the skilled personnel must wear personal
protective equipment.
Follow the instructions, displayed in the work area, regarding personal
protective equipment!
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7
2. Safety
The required personal protective equipment must be provided by the operating
company.
EN
Wear safety goggles!
Protect eyes from ying particles and liquid splashes.
2.4 Special hazards
WARNING!
To ensure safe working on the instrument, the operating company must
ensure
■
that suitable rst-aid equipment is available and aid is provided
whenever required.
■
that the operating personnel are regularly instructed in all topics
regarding work safety, rst aid and environmental protection and
knows the operating instructions and, in particular, the safety
instructions contained therein.
WARNING!
Residual media on the hydraulic comparison test pump can result in
a risk to persons, the environment and the equipment. Take sucient
precautionary measures.
2.4.1 Mineral oils health and safety information
DH-Budenberg/WIKA provide hydraulic mineral oil in containers up to 500 ml, labelled
“ISO VG 22”, for use up to 4,000 bar in test pumps. It is no more hazardous than other
common lubricating oils.
It is the nature of the way in which this equipment is used, that there
could be frequent and/or prolonged skin contact; in a few individuals this
could give rise to skin irritation (Keratosis or Dermatitis). The use of an
eective barrier cream and/or protective gloves will greatly reduce this
possibility.
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WIKA operating instructions model CPP1200-X
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2. Safety
Description
Closed ash point greater than 120 °C
Storage not above 30 °C
Oral LD 50 15 g per kg body weight
Threshold limit value 5 mg/m³
Fire extinguishing media CO
Spillage Soak with absorbent clay or proprietary absorbent
Waste disposal Burn or dump in approved area
Emergency treatment of acute eects
Ingestion Do not induce vomiting.
Aspiration Send to hospital immediately
Inhalation Remove to fresh air, if nausea persists seek medical
Eye contact Wash with copious amounts of water for at least 10 minutes.
Skin contact Where skin rashes or other abnormalities occur as a result
/dry chemical foam or water fog
2
Administer 250 ml milk or olive oil.
The main hazard following accidental ingestion is aspiration
of liquid into lungs.
attention.
If irritation results or persists, obtain medical advice.
of prolonged or repeated contact, medical advice should be
obtained as soon as possible.
EN
2.4.2 Other liquids
For some very particular applications we supply specially constructed liquids. Copies of
manufacturer’s data can be sent on request.
If the hydraulic comparison test pump is used with water as the pressure
medium, for pressures greater than 700 bar, it is recommended that a
mixture of 90 % water and 10 % glycerine (by volume) is used.
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9
2. Safety
2.5 Labelling, safety marks
Product label
EN
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.
For an explanation of
symbols, see below.
Serial No.
Pressure range
Date of manufacture
Pressure medium
10
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WIKA operating instructions model CPP1200-X
3. Specications
3. Specications
Specications Model CPP1200-X
Pressure range 0 ... 1,200 bar
Pressure transmission
medium
Reservoir 170 cm³
Pressure connections
Test item connection 2 x G ½ female thread, loose union connection
Distance between test
connections
Piston of spindle pump
Piston diameter, low-pressure
piston
Piston diameter, high-pressure
piston
Displacement approx. 10 cm³
Material
Wetted parts Austenitic stainless steel, high tensile brass, nitrile rubber
Permissible ambient conditions
Operating temperature 0 ... 40 °C
Instrument base
Dimensions 401 x 397 x 155 mm (W x D x H), for details, see technical
Weight 13.5 kg
1) Other pressure transmission media available on request.
Hydraulic uid from mineral oil/clean water, free of calcium-
carbonate
290 mm
31.2 mm
12.7 mm
drawings
1)
EN
Storage case (option)
Material Wood
Dimensions 664 x 614 x 380 mm (W x D x H)
Weight 8.5 kg
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11
3. Specications
CE conformity
Pressure equipment directive 97/23/EC (PS > 1,000 bar; Module A, pressure accessory)
EN
Approvals and certicates, see website
For further specications see WIKA data sheet CT 91.08 and the order documentation.
Transport dimensions
The hydraulic comparison test pump in the standard version and standard scope of
supply will be delivered in a single package with dimensions 590 x 490 x 380 mm. The
weight is 18 kg net / 22 kg gross.
12
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WIKA operating instructions model CPP1200-X
3. Specications
Dimensions in mm
Front view
EN
Side view
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13
3. Specications
Top view
EN
5
1
2
6
3
7
1
4
(1) Test connection
(2) High-pressure shut-o valve
(3) Low-pressure shut-o valve
(4) Dual-area spindle pump with star handle
(5) Rotatable feet
(6) Reservoir with sealing plug
(7) Pressure generation control schematic
14
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WIKA operating instructions model CPP1200-X
3. Specications
Test connection
Oil collecting tray
EN
Adapter, see scope
of delivery
Sealing ring
USIT 10.7 x 18 x 1.5
When using thread adapters, the thread adapter has to be connected
pressure tight to the test item rst.
After that the test item with mounted adapter can be inserted into the test
connection and can be oriented.
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15
3. Specications
Liquids used
A hydraulic mineral oil with viscosity 20 ... 37 cSt at 40 °C and viscosity grade VG20 to
VG37 to ISO 3448 (BS 4231) is used for the model CPP1200-X hydraulic comparison
test pump. Most users will be able to obtain locally suitable oil (see below) as used in
EN
hydraulic machinery. However, for the convenience of users we can supply a 500 ml
bottle of oil, viscosity grade VG22.
Oils suitable for test pumps
The following oils are the commercially available oils suitable for use in test pumps.
ISO 3448
viscosity
grade
VG22 -- Tellus 22
VG32 10W Tellus V32
VG37 -- Tellus 37
Other liquids
The model CPP1200-X hydraulic comparison test pump is designed for use with mineral
oils. If an end user wishes to use it on another uid, it is the end user responsibility to
ensure that the uid is compatible with high tensile brass, stainless steel, mild steel, and
nitrile rubber, which are the materials that will come into contact with the uid.
Approx. SAE
Shell Esso Mobil
viscosity clas-
sication
Nuto H22 DTE 22
Tellus R22
Nuto H32 DTE Oil Light
DTE 24
-- -Tellus R37
Tellus T37
Tellus V37
Fluids, which attack ABS, should be used with caution. Continual
immersion of the cover in such uids will cause deterioration. Spillages
should be wiped o immediately.
16
Wear safety goggles!
Protect eyes from ying particles and liquid splashes.
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WIKA operating instructions model CPP1200-X
4. Design and function
4. Design and function
4.1 Description
The model CPP1200-X hydraulic comparison test pump features optimal characteristics
for use in the laboratory, as well as the ruggedness needed for industrial applications. It
is suitable for pressure generation up to 1,200 bar.
Test item and reference measuring instrument are connected to the two test
connections.
4.2 Scope of delivery
■
Instrument base
■
Dual-area spindle pump for lling, pressure generation and ne pressure adjustment
■
2 test connections with G ½ female thread, loose union connection
■
Adapter set for test item connection selectable from 3 dierent sets:
- Set of adapters “BSP” G ½ male on G ⅛, G ¼, G ⅜ and G ½ female
- Set of adapters “NPT” G ½ male on ⅛ NPT, ¼ NPT, ⅜ NPT and ½ NPT female
- Set of adapters “metric” G ½ male on M12 x 1.5 and M20 x 1.5 female
■
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 pointer punch
1 pointer remover
1 test item connection
■
Operating instructions in German and English language
EN
Cross-check scope of delivery with delivery note.
4.3 Base unit
The model CPP1200-X base unit consists of a solid aluminium base plate mounted
on four adjustable levelling feet, a spindle pump, reservoir, control valves, pipework to
two stainless steel pressure connection blocks. The pipework and above mentioned
assemblies are covered by an easy to clean ABS cover.
The component identication numbers in brackets in each procedure refer to the
following gure.
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4. Design and function
Sectioned view of spindle pump
EN
K
18
H
J
G
D
F E
C
WIKA operating instructions model CPP1200-X
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4. Design and function
4.3.1 Spindle pump
The spindle pump is bolted to the reservoir/high pressure cylinder block fastened to the
base unit. A sectioned view of the pump is shown. The rotating handwheel (C) which
is operated by the spokes (D) is attached to a threaded spindle (E). The spindle is
supported in a sintered bearing (F). As the spindle (E) is rotated, it drives a non-rotating
ram (E and K) forward, the thrust being taken by a needle thrust bearing (G). The large
diameter of the ram (H) in the barrel of the pump (J) primes the pressure system and
provides the low pressure up to approximately 140 bar (2,000 lb/in²). The small diameter
of the ram (K) in the reservoir/high pressure cylinder block provides the higher test
pressures up to 1,200 bar (16,000 lb/in²).
4.3.2 Reservoir
A liquid reservoir is provided on the top of reservoir/high pressure cylinder block.
The reservoir is provided with a translucent cover to enable the reservoir level to be
monitored. A plug in the middle of the reservoir cover enables the reservoir to be lled
or topped up (the plug is removed whilst the test pump is in use). The reservoir contains
enough liquid (approximately 150 cm³) to enable normal operation of the test pump to
be carried out.
Low pressure ram displacement = 60 cm³
High pressure ram displacement = 10 cm³
EN
4.3.3 Control valves
Two control valves are provided on the top of reservoir/high pressure cylinder block.
The valve mechanisms are built into the reservoir/high pressure cylinder block and they
control the ow of liquid through internal drillings in the reservoir/high pressure cylinder
block. The rear valve is referred to as valve A and is used to control the output from the
high-pressure ram of the spindle pump. The front valve is referred to as valve B and is
used to control the ow of liquid to and from the reservoir.
4.3.4 Connection blocks
Pressure supply pipes from the spindle pump are terminated at two pressure blocks
mounted on the base unit. The pressure blocks are tted with threaded bosses
projecting up through the cover plate of the base unit. These threaded bosses enable
the delivered test connections to be directly screwed on to them, and it is also possible,
using threaded adapters, to connect the various sizes of measuring instrument
connections. Oil cups are tted to the unit cover around the threaded bosses of the
connection blocks to catch any oil drips from the gauge stand during gauge tting and
removal.
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19
4. Design and function
4.4 Function
Operation of the hydraulic comparison test pump is controlled by the two valves A and
B on the top of the reservoir/high pressure cylinder block. When initially priming the
system valves A and B are opened to ll the system with oil from the reservoir. Valve B
EN
is then closed with valve A left open and the spindle pump operated to provide the lower
test pressures. To provide the higher pressures valve A is closed to seal o the test
circuit from the low pressure part of the spindle pump and valve B is opened to allow the
liquid in the low pressure part of the spindle pump to return to the reservoir as the pump
is operated. This ensures that the pump can be operated without having to put large
forces on the spindle pump handwheel. To release the test pressure the spindle pump is
wound out and valve A is opened.
20
Valve A
Reservoir
Valve B
Hand pump
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5. Transport, packaging and storage
5. Transport, packaging and storage
5.1 Transport
Check the model CPP1200-X hydraulic comparison test pump for any damage that may
have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change
in installation site, sending for repair or recalibration).
5.3 Storage
Permissible conditions at the place of storage:
■
Storage temperature: -10 ... +50 °C
■
Humidity: 35 ... 85 % relative humidity
Avoid exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
■
Potentially explosive environments, ammable atmospheres
■
Corrosive liquids
EN
Store the model CPP1200-X hydraulic comparison test pump in its original packaging in
a location that fulls the conditions listed above. If the original packaging is not available,
pack and store the instrument as described below:
1. Wrap the instrument in an antistatic plastic lm.
2. Place the instrument, along with shock-absorbent material, in the packaging.
3. If stored for a prolonged period of time (more than 30 days), place a bag, containing
a desiccant, inside the packaging.
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21
6. Commissioning, operation
6. Commissioning, operation
6.1 Unpacking the hydraulic comparison test pump
EN
As soon as possible after delivery open the packaging of the hydraulic comparison test
pump 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 hydraulic comparison test pump not in a temperature controlled
laboratory, look for an area that satises the following criteria as much as possible:
■
A constant temperature area free from draughts and sources of heat or cold
■
An area free from noise and vibration, constantly used pathways
■
A clean dry area free from corrosive liquids or vapours
A strong, stable, level table or workbench with the capability of supporting the system
with sucient space to operate is required.
6.3 Assembly of base units
Fastening base to bench
The base is to be mounted on a rm, level table or bench about 0.9 m high. The centre
line of the front adjustable feet of the unit should be about 40 mm from the front edge of
the bench to allow adequate clearance for the handwheel.
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 hydraulic comparison test pump is rigid.
3. Fit the base unit on the bench with the adjustable feet on the level plates and the
handwheel shaft projecting over the front of the bench.
4. Screw in the four handwheel spokes into the hub.
5. Using the spirit level provided, level the test pump by adjusting the four knurled feet.
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