LR-Cal LDW-HK User manual

Operang instrucons
Betriebsanleitung
GB
D
Pressure balance in compact design, model LDW-HKLR-Cal
Kolbenmanometer in Kompaktausführung, Modell LDW-HKLR-Cal
Deadweight Tester / LDW-HKPressure balance in compact design LR-Cal
Anleitung - Manual Rel. 20150206

GB
D
2Manual M LDW-HKodel LR-Cal
Operang instrucons model LDW-HKLR-Cal Page 3 - 46
Betriebsanleitung Modell LDW-HKLR-Cal Seite
All rights reserved. / Alle Rechte vorbehalten.
LR-Cal is a trademark .of DRUCK & TEMPERATUR Leitenberger GmbH
LR-Cal ist ein Markenzeichen der DRUCK & TEMPERATUR Leitenberger GmbH
Prior to starng any work, read the operang instrucons!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch au ewahren!
Copyright © DRUCK & TEMPERATUR Leitenberger GmbH, 2015.
Alle Rechte vorbehalten. All rights reserved.

3
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1. General informaon 4
2. Safety 6
2.1 Intended use 6
2.2 Personnel quali icaonf7
2.3 Personal protecve equipment 7
2.4 Special hazards 8
2.5 Labelling, safety marks 10
3. Speciicaons 11
4. Design and funcon 20
4.1 Descripon 20
4.2 Scope of delivery 20
4.3 Base unit 20
4.4 Piston unit 22
4.5 Funcon 23
5. Transport, packaging and storage 24
6. Commissioning, operaon 25
6.1 Unpacking the pressure balance 25
6.2 Environmental requirement 25
6.3 Assembly of base units 25
6.4 Assembly of piston unit 26
6.5 Assembly of the pressure balance 27
6.6 Procedure 28
6.7 Compleon 31
6.8 MS Excel sheet for calculaon of correcons 31
6.9 Temperature measurement of piston units 32
6.10 Cleaning gauges 32
7. Maintenance, cleaning and recalibraon 34
7.1 Periodic maintenance 34
7.2 Correcve maintenance 34
7.3 Cleaning 38
7.4 Recalibraon 38
8. Faults 41
9. Return and disposal 43
10. Accessories 44
Appendix: EC Declaraon of conformity for model LDW-HKLR-Cal 45
Contents
Contents
Manual M LDW-HKodel LR-Cal

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1. General informaon
1. General informaon
■
The model pressure balance in compact design described in the operangLDW-HKLR-Cal
instrucons has been designed and manufactured using state-of-the-art technology.
All components are subject to stringent quality and environmental criteria during
producon. Our management systems cer ied to ISO 9001.is f
■
These operang instrucons contain important informaon on handling the
instrument.Working safely requires that all safety instrucons and work instrucons
are observed.
■
Observe the relevant local accident prevenon regulaons and general safety
regulaons for the instrument's range of use.
■
The operang instrucons are part of the product and must be kept in the immediate
vicinity of the instrument and readily accessible to skilled personnel at any me.
■
Skilled personnel must have carefully read and understood the operang instrucons
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 operang
instrucons, assignment of insu ciently quali ied skilled personnel or unauthorizedffif
modiicaons to the instrument.
■
The general terms and condions contained in the sales documentaon shall apply.
■
DRUCK & TEMPERATUR Leitenberger GmbH reserve the right to change the contents
or form of these operang instrucons at any me without prior noce having been given.
■
Subject to technical modiicaons.
■
Factory calibraons or calibraons (pressure calibraon with a mass set) areDKD/DAkkS
carried out in accordance with internaonal standards.
Manual M LDW-HKodel LR-Cal

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1. General informaon
■
Further informaon:
DRUCK & TEMPERATUR Leitenberger GmbH
- Internet address: www. .LR-Cal net
- Relevant data sheet: LDW-HK
- Applicaon consultant: Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Explanaon of symbols
DANGER!
... indicates a directly dangerous situaon resulng in serious injury or
death, if not avoided.
WARNING!
... indicates a potenally dangerous situaon that can result in serious
injury or death, if not avoided.
CAUTION!
... indicates a potenally dangerous situaon that can result in light
injuries or damage to equipment or the environment, if not avoided.
Informaon
... points out useful ps, recommendaons and informaon for e cientffi
and trouble-free operaon.
Manual M LDW-HKodel LR-Cal

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2. Safety
2. Safety
WARNING!
Before installaon, commissioning and operaon, ensure that the
appropriate pressure balance has been selected in terms of measuring
range, design and speciic measuring condions.
Non-observance can result in serious injury and/or damage to the
equipment.
Further important safety instrucons can be found in the individual
chapters of these operang instrucons.
2.1 Intended use
Pressure balances are the most accurate instruments available on the market for the
calibraon of electronic or mechanical pressure measuring instruments. By direct
measurement of the pressure as the quoent of force and area (p = F/A), pressure
balances are approved as primary standards.
The core component of the is therefore a very precisely-manufacturedLDW-HKLR-Cal
piston-cylinder system, which is loaded with masses in order to generate the individual
test points.The masses applied are proporonal to the target pressure and this is achieved
through graduated masses. A maximum pressure of 1,200 bar must not be exceeded.
The pressure is set via an integrated, inely-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 operaon (integrated pressure generaon and the pure
mechanical measuring principle), the model is ideal for on-site useLDW-HKLR-Cal
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 speciicaons contained in these operang instrucons must be
observed. Improper handling or operaon of the instrument outside of its technical
speciicaons requires the instrument to be taken out of service immediately and
inspected by an authorised service engineer.LEITENBERGER
Manual M LDW-HKodel LR-Cal

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2. Safety
Handle mechanical precision measuring instruments with the required care (protect
from humidity, impacts, strong magnec ields, stac electricity and extreme
temperatures, do not insert any objects into the instrument or its openings).
If the instrument is transported from a cold into a warm environment, the formaon of
condensaon may result in instrument malfuncon. Before pu ng it back into operaon,
wait for the instrument temperature and the room temperature to equalise.
The manufacturer shall not be liable for claims of any type based on operaon contrary
to the intended use.
2.2 Personnel qualificaon
WARNING!
Risk of injury should qualiicaon be insu cient!ffi
Improper handling can result in considerable injury and damage to
equipment.
■
The acvies described in these operang instrucons may only be
carried out by skilled personnel who have the qualiicaons described
below.
■
Keep unqualiied 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-speciic regulaons, current standards and direcves, are capable
of carrying out the work described and independently recognising potenal hazards.
Special operang condions require further appropriate knowledge, e.g. of aggressive
media.
DRUCK & TEMPERATUR Leitenberger GmbH can provide dedicated training courses on the
correct use of our products. Please contact your for further details.supplier
2.3 Personal protecve equipment (P.P.E.)
The personal protecve 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
protecve equipment.
Manual M LDW-HKodel LR-Cal

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2. Safety
Follow the instrucons, displayed in the work area, regarding personal
protecve equipment!
The required personal protecve equipment must be provided by the operang
company.
Wear safety goggles!
Protect eyes from lying parcles and liquid splashes.
2.4 Special hazards
WARNING!
To ensure safe working on the instrument, the operang company must
ensure
■
that suitable irst-aid equipment is available and aid is provided
whenever required.
■
that the operang personnel are regularly instructed in all topics
regarding work safety, irst aid and environmental protecon and
knows the operang instrucons and, in parcular, the safety
instrucons contained therein.
WARNING!
Residual media at the pressure balance can result in a risk to persons,
the environment and the equipment.Take su cient precauonary
measures.
2.4.1 Mineral oils health and safety informaon
DRUCK & TEMPERATUR Leitenberger GmbH provide hydraulic mineral oil in 500 ml
containers labelled "ISO VG 22" for use up to 4,000 bar in pressure balances. It is no
more hazardous than other common lubricang 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 irritaon (Keratosis or Dermas). The use of an
efecve barrier cream and/or protecve gloves will greatly reduce this
possibility.
Manual M LDW-HKodel LR-Cal

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2. Safety
Descripon
Closed lash 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 exnguishing media CO /dry chemical foam or water fog
2
Spillage Soak with absorbent clay or proprietary absorbent
Waste disposal Burn or dump in approved area
Emergency treatment of acute efects
Ingeson Do not induce voming.
Administer 250 ml milk or olive oil.
The main hazard following accidental ingeson is aspiraon
of liquid into lungs.
Aspiraon Send to hospital immediately
Inhalaon Remove to fresh air, if nausea persists seek medical a en -
on.
Eye contact Wash with copious amounts of water for at least 10 minutes.
If irritaon results or persists, obtain medical advice.
Skin contact Where skin rashes or other abnormalies occur as a result
of prolonged or repeated contact, medical advice should be
obtained as soon as possible.
2.4.2 Other liquids
For some very parcular applicaons we supply specially constructed liquids. Copies of
manufacturer’s data can be sent on request.
2.4.3 Liing of weights
WARNING!
Care must be taken when liing the weights onto the pressure balance.
Each weight must be lied individually and never a empt to li stack of
weights on or of the pressure balance.
Manual M LDW-HKodel LR-Cal

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2. Safety
Date of manufacture
Pressure range
Serial No.
2.5 Labelling, safety marks
Product label
Before mounng and commissioning the instrument, ensure you read the
operang instrucons!
CE, Communauté Européenne
Instruments bearing this mark comply with the relevant European
direcves.
Manual M LDW-HKodel LR-Cal
LDW-HK
Druckwaage / Kolbenmanometer
Deadweight Tester / Pressure Balance
Serien-Nr. / :Serial No. 31200
Max. Druck / :max. Pressure 0...1200 bar
Hergestellt / :Manufactured 06/2012
DRUCK & TEMPERATUR Leitenberger GmbH • GERMANY
www.LR-Cal.de • [e-mail] • Tel. [phone]

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3. Speci icaonsf
3. Speci icaonsf
Piston-cylinder systems
Measuring range 1) bar 1 … 120 2.5 ... 300 5 ... 700 10 ... 1,200
Required masses kg 41 50 58 50
Smallest step
(Standard mass set)
2) bar 1 2.5 5 10
Nominal cross-seconal area of
the piston
in² 1/16 1/40 1/80 1/160
Measuring range 1) psi 10 … 1,600 25 ... 4,000 50 ... 10,000 100 ... 16,000
Required masses kg 38 47 58 47
Smallest step
(Standard mass set)
2) psi 10 25 50 100
Nominal cross-seconal area of
the piston
in² 1/16 1/40 1/80 1/160
Accuracies
Standard 0.05 % of reading
3) 4)
Opon 0.025 % of reading
3) 4)
Pressure transmission
medium
Hydraulic luid based on VG22 mineral oil (0.5 lf
included in scope of delivery)
Material
Piston Tungsten carbide
Cylinder Tungsten carbide
Mass set Stainless steel, non-magnec
Weight
Piston-cylinder system kg 2.4
BAR mass set incl. overhang
(bell jar)
kg 41.5 50.5 58.5 50.5
PSI mass set incl. overhang
(bell jar)
kg 47.5 47.5 58.5 47.5
Carrying case for mass set
(oponal, 2 pieces required)
kg 5.8
Dimensions
Carrying case for mass set
(oponal)
Theorecal starng value; corresponds to the pressure value generated by the piston or the piston and its make-up weights (by
their own weight).To opmise the operang characteriscs more weights should be loaded.
2) The smallest pressure change value that can be achieved based on the standard weight set.To reduce this, a set of trim
masses is also available.
3) The accuracy from 10 % of the measuring range is based on the measured value. In the lower range, a ixed error based on 10
% of the range applies.
4) Measurement uncertainty assuming reference condions (ambient temperature 20 °C, air pressure 1,013 mbar, relave humid-
ity 40 %). orrecons must be made if required.C
Manual M LDW-HKodel LR-Cal
W 430 x H 310 x D 310 mm and
W 215 x H 310 x D 310 mm

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3. Speci icaonsf
Base
Connecons
Connecon for piston-cylinder
system
G ¾ B (male)
Test item connecon G ½ female thread, loose union connecon, incl. adapter set to
G ¼ and G female threads⅜
Material
We ed parts Austenic stainless steel, high tensile brass, nitrile rubber
Pressure transmission
medium
Hydraulic luid based on VG22 mineral oil (0.5 l included inf
scope of delivery)
Reservoir 170 cm³
Weight
Base 13.5 kg
Storage case for the base
(oponal)
8.5 kg
Permissible ambient condions
Operang temperature 18 ... 28 °C
Dimensions
Base 401 x 397 x 155 mm (W x D x H), for details, see technical
drawings
Approvals and cer icatesf
CE conformity
Pressure equipment direcve 97/23/EC (Module A)
Cer icatef
Calibraon Calibraon cer icatef
Opon: calibraon cer icate (pressure calibraon with aDKD/DAkkS f
mass set)
For further speci icaons seef the order documentaon and datasheet. .
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
Tables of masses
The following tables show, for the respecve measuring range, the number of masses
within a mass set, with their resulng nominal pressures.
Should the instrument not be operated under reference condions (ambient temperature
20 °C, air pressure 1,013 mbar, relave humidity 40 %), relevant correcons must be
made.
The masses are manufactured, as standard, to standard gravity of 9.80665 m/s². As an
oponal extra, mass sets can be manufactured for customer local gravity value.
Measuring range
[bar]
1 ... 120 2,5 ... 300
Quan-
ty
Nominal
pressure per
piece
Quan-
ty
Nominal
pressure per
piece
[bar] [bar]
Piston and make-up weight 1 1 1 2.5
Piston, overhang (bell jar) and
overhang make-up weight
120 150
Masses (stackable on overhang
(bell jar))
320 350
Masses (stackable on piston) 1 20 1 50
110 125
24 210
12 15
11 12.5
Measuring range
[bar]
5 ... 700 10 ... 1.200
Quan-
ty
Nominal
pressure per
piece
Quan-
ty
Nominal
pressure per
piece
[bar] [bar]
Piston and make-up weight 1 5 1 10
Piston, overhang (bell jar) and
overhang make-up weight
1 100 1 200
Masses (stackable on overhang
(bell jar))
4 100 3 200
Masses (stackable on piston) 1100 1 200
1 50 1 100
220 240
110 120
15 110
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
Measuring range
[]psi
10 ... 1,600 25 ... 4,000
Quan-
ty
Nominal
pressure per
piece
Quan-
ty
Nominal
pressure per
piece
[]psi []psi
Piston 1 10 1 25
Overhang (bell jar) and overhang
make-up weight
1 190 1 475
Masses (stackable on overhang
(bell jar)) 5 200 5 500
Masses (stackable on piston) 1 200 1 500
1 100 1 250
2 40 2 100
120 150
110 125
Measuring range
[]psi
50 ... 10,000 100 ... 16,000
Quan-
ty
Nominal
pressure per
piece
Quan-
ty
Nominal
pressure per
piece
[]psi []psi
Piston 1 50 1 100
Overhang (bell jar) and overhang
make-up weight
1 950 1 1,900
Masses (stackable on overhang
(bell jar))
7 1,000 5 2,000
Masses (stackable on piston) 1 1,000 1 2,000
1 500 1 1,000
2 200 2 400
1 100 1 200
1 50 1 100
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
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.
Weight in kg
Version net gross
1 … 120 bar 71 89
2.5 … 300 bar 71 89
5 … 700 bar 71 89
10 … 1,200 bar 71 89
10 ... 1,600
psi 68 86
25 ... 4,000
psi 68 86
50 ... 10,000
psi 68 86
100 ... 16,000
psi 68 86
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
Side view
Dimensions in mm
(without masses)
Front view
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
4
5
1
6
3
8
2
7
Top view
(1) Test item connecon
(2) High-pressure shut-of valve
(3) Low-pressure shut-of valve
(4) Dual-area pump with star handlespindle
(5) Piston-cylinder system
(6) Rotatable feet
(7) Reservoir with screwed sealing plug
(8) Pressure generaon control schemac
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
Oil collecng tray
Oil collecng tray
Standard connecon piston-cylinder system
Test item connecon
Sealing ring
USIT 10.7 x 18 x 1.5
Adapter, see scope
of delivery
O-ring 8.9 x 1.9
Manual M LDW-HKodel LR-Cal

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3. Speci icaonsf
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 base unit. Most users will be ableLDW-HKLR-Cal
to obtain locally suitable oil (see below) as used in hydraulic machinery. However, for the
convenience of users we can supply a 500 ml bo le of oil, viscosity grade VG22.
Oils suitable for pressure balances
The following oils are the commercially available oils suitable for use in the pressure
balance.
ISO 3448
viscosity
grade
Approx. SAE
viscosity
classiicaon
Shell Esso Mobil
VG22 Tellus 22
Tellus R22
Nuto H22 DTE 22
VG32 10W Tellus V32
DTE 24
Nuto H32 DTE Oil Light
VG37 Tellus 37
Tellus R37
Tellus T37
Tellus V37
Other liquids
The model is manufactured for use on mineral oil only. Ifdeadweight tester LDW-HKLR-Cal
an end user wishes to use it on another luid, it is the end user rf esponsibility to ensure
that the luid is compable with high tensile brass, stainless steel, mild steel, and nitrilef
rubber, which are the materials that will come into contact with the luid.f
Fluids, which a ack ABS, should be used with cauon. Connual
immersion of the cover in such luids will cause deterioraon. Spillagesf
should be wiped of immediately.
Wear safety goggles!
Protect eyes from lying parcles and liquid splashes.f
Manual M LDW-HKodel LR-Cal

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4. Design and funcon
4. Design and funcon
4.1 Descripon
The model in compact design provides opmum featuresLDW-HK deadweight testerLR-Cal
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 le 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
■
Instrument base
■
Dual-area spindle pump for illing, pressure generaon and ine adjustmentff
■
Piston connecon with G ¾ B male thread
■
Test item connecon with G ½ female thread, loose union connecon
■
Adapter set for test item connecon, G ½ B male to G ¼ and G female threads⅜
■
Piston-cylinder system with overhang (bell jar)
■
Mass set manufactured to standard gravity (9.80665 m/s²)
■
VG22 mineral oil (0.5 litre)
■
Tool and maintenance set
■
Operang instrucons in German and English language
■
Factory calibraon cericate
Cross-check scope of delivery with delivery note.
4.3 Base unit
The model series base unit consists of a solid aluminium base plate mountedLDW-HKLR-Cal
on four adjustable levelling feet, a screw pump, reservoir, control valves, pipework to
two stainless steel pressure connecon blocks.The pipework and above menoned
assemblies are covered by an easy to clean ABS cover.
4.3.1 Screw pump
The screw pump is bolted to the reservoir/high pressure cylinder block fastened to the
base unit. A seconed view of the pump is shown.The rotang handwheel (C) which
is operated by the spokes (D) is a ached to a threaded spindle (E).The spindle is
supported in a sintered bearing . As the spindle(F) (E) is rotated, it drives a non-rotang
ram and(E 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 ).The small diameterpsi
of the ram in the reservoir/ high pressure cylinder block provides the higher test(K)
pressures up to 1,200 bar (16,000 ).psi
Manual M LDW-HKodel LR-Cal
• 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
• 1/2" BSP angle connecon
• 1 pointer press-on tool
• 1 pointer remover
• 1 test item connecon