LR-Cal CPB 5000-HP User manual

Operating Instructions
Betriebsanleitung
CPB 5000-HP
Deadwei
g
ht Tester / Pressure Balance Hi
g
h-Pressure
Deadweight Tester / Pressure Balance High-Pressure LR-Cal CPB 5000-HP
Druckwaage / Kolbenmanometer Höchstdruck LR-Cal CPB5000-HP
GB
Höchstdruck Druckwaa
g
e / Kolbenmanometer D

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 2
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.
Operating Instructions Pressure Balance High-Pressure Page 3 - 28
GB
Betriebsanleitung Höchstdruck Kolbenmanometer Seite 29 - 55
D

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 3
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1. General ........................................................................................................................................... 4
1.1 General Instructions .................................................................................................................... 4
1.2 Safety Instructions .................................................................................................................... 5
2. Product Description ...................................................................................................................... 6
2.1 General Product Information ............................................................................................................ .6
2.2 Basic principle of the Pressure Balance........................................................................................... .7
2.3 Factors at work .................................................................................................................... 7
2.3.1 Local fluctuations in the gravity-value ................................................................................... 7
2.3.2 Temperature (Piston/Cylinder) ................................................................................................ 8
2.3.3 Ambient conditions .................................................................................................................. 8
2.3.4 How the cross-sectional surface responds to pressure ...................................................... 9
2.4 Arrangement of control elements ................................................................................................... .10
3. Commissioning and Operation .................................................................................................. 11
3.1 Preparation .................................................................................................................. 11
3.1.1 Setting up the Device ............................................................................................................. 11
3.1.2 Installing the piston cylinder system ................................................................................... 12
3.1.3 Connecting the test specimen .............................................................................................. 13
3.1.4 Venting the System ................................................................................................................ 14
3.2 Operation .................................................................................................................. 15
3.2.1 Weight Pieces ......................................................................................................................... 15
3.2.2 Approaching the pressure value (increasing pressure) ..................................................... 16
3.2.3 Pressure stable ....................................................................................................................... 17
3.2.4 Next pressure level ................................................................................................................. 17
3.2.5 Approaching the pressure value (decreasing pressure) .................................................... 18
3.3 Disassembly .................................................................................................................. 19
3.4 Transport .................................................................................................................. 19
4. Troubleshooting measures ........................................................................................................ 20
5. Maintenance and Care ................................................................................................................ 22
5.1 Cleaning .................................................................................................................. 22
5.1.1 Piston/Cylinder system .......................................................................................................... 22
5.1.2 Weight Set ............................................................................................................................... 22
5.2 Wear Parts .................................................................................................................. 22
5.3 Changing the Hydraulic Oil............................................................................................................. .23
5.3.1 Removing Hydraulic Oil ......................................................................................................... 23
5.3.2 Filling in of Hydraulic Oil ....................................................................................................... 23
5.3.3 Venting of the System (after Complete Filling only) ........................................................... 23
5.4 Recalibration .................................................................................................................. 24
6. Specifications .............................................................................................................................. 25
7. Tables of masses ......................................................................................................................... 27
8. Accessories .................................................................................................................................28

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 4
1. General .
1.1 General Instructions .
In the following chapters detailed information on the CPB 5000-HP deadweight tester / 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:
DRUCK & TEMPERATUR Leitenberger GmbH
Bahnhofstr. 33
D-72138 Kirchentellinsfurt / GERMANY
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
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 terms 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
DRUCK & TEMPERATUR Leitenberger GmbH result from the respective sales contract and the
general business terms of DRUCK & TEMPERATUR Leitenberger GmbH.
LR-Cal is a trade mark of DRUCK & TEMPERATUR Leitenberger GmbH.
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 DRUCK & TEMPERATUR Leitenberger GmbH. All rights reserved.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 5
1.2 Safety Instructions .
Read these operating instructions carefully prior to operating the pressure
balance high-pressure CPB 5000-HP. 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-HP always has to be handled with the care required for a 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-HP.
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.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 6
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-HP is also ideally suited for on-site use as
well as service and maintenance purposes.
Piston cylinder system
The hydraulic high-pressure piston cylinder systems are available for pressure ranges 2500 bar, 4000
bar and 5000 bar respectively 40000 psi, 60000 psi and 70000 psi. The accuracy is 0.025 % (optional
also 0.02 %) of reading.
Functioning
In order to generate the individual test points, the piston cylinder system is weighted with mass-loads,
which are also calibrated and specially adapted to the respective application.
The pressure is set via an integrated pump. For fine adjustment an adjustable volume with precision
spindle is available. The weight applied is proportional to the desired pressure and provided by using
optimally graduated weights. 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.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 7
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.
Area
Force
essure =Pr
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 reference
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 Intelligent Calibration Module IKM
(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/s2".
Then a correction must be performed for each measurement according to the formula below:
gdardS
sitenApplicatiog
pressureTrue −
−
⋅= tan
valueNominal
Example:
Local gravity set during manufacturing: 9.806650 m/s2
Locale gravity at application site: 9.811053 m/s2
Nominal pressure: 100 bar
True pressure: barbar
g
g
pp
dardS
Local 0449.100
80665.9
81105.9
100
tan
Nominal ===
Without the correction, measurements would all be "off" by 0.05 %.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 8
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:
()()
TKtt
pressureTrue
ferenceAppl ⋅−+
⋅=
Re
1
1
valueNominal
Example:
Reference temperature: 20°C
Temperature during use: 23°C
TK: 0.0022%
()
()
barbarpressureTrue 99340.99
2.220231
1
100 5=
⋅−+
⋅= −
Without the correction, measurements would all be "off" by 0.007 %.
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:







−⋅= densityWeight
densityAir
Weight 1weightNominal
The air density is typically 1.2 kg/m3
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%.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 9
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).
pressureNominal1
pressureNominal
⋅+
=
λ
pressureTrue
Example:
Measuring point: 1000 bar
System with distortion coefficient: 10 –7 1/bar:
barbarpressureTrue 90.999
10001011
1000
7=
⋅
⋅
+
=−
Without the correction, measurements would all be "off" by 0.01 %.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 10
2.4 Arrangement of control elements .
View from above
Rear view
Connection for
test specimen
Initial pressure
p
um
p
Connection for
piston cylinder
system
Water
level
Spindle pump
Rotating base
Interface to IKM
(in combination with
IKM only)
Screwed drain plug for
tank
High-pressure
shut-off valve (HP)
Low-pressure
shut-off valve (LP)
Front view

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 11
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 possible.
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.
The oil container may need to be filled, or refilled (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 (coverage of the ventilation hole during transportation).
Screw the handle bars of the star handle onto the spindle pump.
We recommend unscrewing the spindle pump completely when you start to record measurement
values, (turning anticlockwise) to allow enough volume for measurements. The low-pressure and
high-pressure shut-off valve must be opened during this process.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 12
3.1.2 Installing the piston cylinder system .
Before releasing the closure plug in the piston receptacle, ensure that the
system (spindle pump turned back completely counter-clockwise, open high-
pressure shut-off valve, open low-pressure shut-off valve) is depressurised.
Note: The closure plug serves to seal off the piston receptacle from oil leaks, or
from any penetrating contamination. It may not be pressurised under any
circumstances.
Remove transportation lock; please keep this lock for transportations (e.g. for re-calibration) see
section 3.4)
Before installing the piston/cylinder system the piping must be vented. For this purpose oil from the
reservoir has to be pumped into the system by operating the initial pressure pump carefully.
Pressure is admitted as long as the oil reaches the sealing cone inside the opened piston fixture
and as long as no air bubbles escape.
For this the low-pressure shut-off valve (LP) must be closed, the high-pressure shut-off valve (HP)
must be opened and a blind plug must be mounted into the connection for test specimen.
The piston/cylinder system is inserted vertically into the thread of the piston receptacle, and firmly
tightened using a flat wrench with SW 46.
Additional sealing elements are not required. Sealing is performed purely metallic using a sealing
cone.
For an exact alignment of the device, the water level may be removed from the basement plate and
placed on the top of the screwed-in piston/cylinder system. This will ensure the most accurate
referencing of the piston/cylinder system.
Here put on
water level

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 13
3.1.3 Connecting the test specimen .
Before releasing the closure plug in the test specimen receptacle, ensure that
the system (spindle pump turned back completely counter-clockwise, open
high-pressure shut-off valve, open low-pressure shut-off valve) is
depressurised.
Note: The closure plug serves to seal off the test specimen receptacle from oil
leaks, or from any penetrating contamination. It may not be pressurised under
any circumstances.
The test specimen connection has a knurled nut with a G ¾ female thread, in which various
threaded connecting adapters may be screwed into. 3 threaded adapters with the following
connector threads are included in the scope of supply as standard equipment:
M16 x 1.5 male
M20 x 1.5 male
9/16-18UNF male
A connecting adapter with G ½ female thread with an O-ring seal is available as an
accessory. The maximum pressure permitted with the use of this adapter is limited to
1600 bar.
First, install the matching threaded adapter on your test specimen.
Before installing the test specimen the piping must be vented. For this purpose oil from the
reservoir has to be pumped into the system by operating the initial pressure pump carefully.
Pressure is admitted as long as the oil reaches the sealing cone inside the opened test specimen
connection and as long as no air bubbles escape.
For this the low-pressure shut-off valve (LP) must be closed, the high-pressure shut-off valve (HP)
must be opened and the piston/cylinder system must be mounted.
Then connect the test specimen, including the installed threaded adapter, to the knurled nut of the
test specimen connection at the pressure balance. The free-running knurled nut enables the
orientation of the test specimen. Firmly tighten the knurled nut and the threaded adapter with a flat
wrench in the desired clamping position. The wrench width for the knurled nut and the threaded
adapter is SW 36.
Additional sealing elements are not required. Sealing is performed purely metallic using a sealing
cone.
Threaded adapter
Knurled nut

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 14
3.1.4 Venting the System .
After the clamping of the piston/cylinder system and the test specimen, air may be trapped in the
system again. The system may be vented before beginning with calibration using the following
procedure:
The piston/cylinder system and test specimen must be clamped, and the complete weight set must
be placed on the piston/cylinder system.
Close the low-pressure shut-off valve
Open the high-pressure shut-off valve
Generate a pressure of approximately 50 bar using the initial pressure pump
Close the high-pressure shut-off valve
Increase the pressure with the spindle pump until just below the final value of the value range of
the piston/cylinder 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.
Carefully open the high-pressure shut-off valve, any trapped air will escape into the tank
Open the low-pressure shut-off valve
This procedure may need to be repeated several times in order to remove all trapped air.
Opening the high-pressure shut-off valve without first turning out the spindle pump in counter-
clockwise direction in order to relieve the system on initial pressure is permitted only with the venting
procedure described herein, since the piston is located in the lower position.
After generating initial pressure, the high-pressure shut-off valve must always
be closed before pressure is increased using the spindle pump. An integrated
safety overflow valve (adjusted to approximately 100 bar) additionally protects
the low-pressure circulation from any errors on the operator’s part.
The device is now ready to use.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 15
3.2 Operation .
3.2.1 Weight Pieces .
Stack the weight pieces onto the bell depending 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 certificate to each number
the resultant pressure assuming reference conditions is listed.
Example table from a calibration certificate page 2:
Druckwerte der Gewichtsstücke / Pressure values of masses
Bezeichnung des
Gewichtsstückes
type of weight piece
Nr.
no.
wahre Masse
true mass
in kg
Druckwert
für HD-System
pressure value
for HP-system
in bar
Kolben / piston 1207 0.51001 24.9972
Masse / weight piece 1 0.10231 5.0143
Masse / weight piece 2 4.09305 200.6150
Masse / weight piece 3 4.09305 200.6150
Masse / weight piece 4 4.09305 200.6150
Masse / weight piece 5 4.09305 200.6150
Masse / weight piece 6 4.09305 200.6150
Masse / weight piece 7 4.09305 200.6150
Masse / weight piece 8 4.09305 200.6150
Masse / weight piece 9 4.09305 200.6150
Masse / weight piece 10 2.04650 100.3065
Masse / weight piece 11 2.04650 100.3065
Masse / weight piece 12 2.04650 100.3065
Masse / weight piece 13 2.04650 100.3065
Masse / weight piece 14 2.04650 100.3065
Masse / weight piece 15 2.04650 100.3065
Masse / weight piece 16 2.04650 100.3065
Masse / weight piece 17 2.04650 100.3065
Masse / weight piece 18 2.04650 100.3065
Masse / weight piece 19 1.02526 50.2517
Masse / weight piece 20 0.51163 25.0768
Masse / weight piece 21 0.51163 25.0768
Masse / weight piece 22 0.20465 10.0307
Masse / weight piece 23 0.10232 5.0153
Masse / weight piece 24 0.05116 2.5077
Example: weight piece no. 5 generates a pressure value of 200.6150 bar
with its weight value of 4.09305 kg assuming reference
conditions (room temperature 20°C, air pressure 1013 mbar,
relative humidity 40 %)
The pressure that will be achieved thus corresponds to the sum of the basic weight (piston), the
bell and the weight rings.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 16
3.2.2 Approaching the pressure value (increasing pressure) .
We recommend unscrewing the spindle pump completely when you start to record
measurement values, (turning anticlockwise) to allow enough volume for
measurements. The low-pressure and high-pressure shut-off valve must be opened
during this process.
The system must first be filled with oil and pre-compressed.
For this the valves must be in the basic position:
Low-pressure shut-off valve closed
High-pressure shut-off valve opened
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).
The high-pressure shut-off valve must be closed after pre-pressure generation.
After that, increase the pressure by turning the built-in spindle pump clockwise.
After generating initial pressure, the high-pressure shut-off valve must always
be closed, before pressure is increased using the spindle pump. An integrated
safety overflow valve (adjusted to approximately 100 bar) additionally protects
the low-pressure circulation from any errors on the operator’s part.
Piston cylinder system
with bell
Weight pieces

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 17
3.2.3 Pressure stable .
Continue admitting pressure until the system is in a state of equilibrium.
The piston is in the float position. In this case the lower edge of the bell must stay at the position of
the marking line of the piston/cylinder system.
Just before the float position, the system increases quickly.
We therefore recommend turning the spindle slowly and evenly clockwise.
To minimise the effect of friction, move the system up against the weight pieces carefully and make
a turning movement.
Never move the system up and make a turning movement, if the piston is in the
lower or upper block position.
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
Marking line for
float position
Lower edge of the
bell

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 18
3.2.5 Approaching the pressure value (decreasing pressure) .
Turn the spindle pump anticlockwise to release pressure in the system.
If the pressure is close to the next test level, make the fine adjustment with the spindle wheel.
Caution:
The piston is lowered very quickly just before equilibrium is achieved.
Caution:
Do not remove masses completely from the piston/cylinder system under
pressure.
Once the spindle pump is turned back completely counter-clockwise, only the initial pressure
remains in the system.
Now the high-pressure shut-off valve can be opened.
Open the high-pressure shut-off valve only if the pressure in the system has
been relieved to initial pressure. For this purpose, always first turn the spindle
pump back completely counter-clockwise.
The initial pressure can be further relieved by carefully opening the low-pressure shut-off valve.
By completely opening the low-pressure shut-off valve, the initial pressure will completely escape
back into the tank.
The system is now completely relieved
Even if you wish to relieve the system from a high pressure completely down to
zero immediately, the spindle pump must first be completely turned back
counter-clockwise. Then open the high-pressure shut-off valve, and
subsequently open the low-pressure shut-off valve. The initial pressure then
escapes completely into the tank. The system is now completely relieved.

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 19
3.3 Disassembly .
After all pressure points have been recorded, ensure that the system is depressurised (see section
3.2.5).
Now the test specimen can be unscrewed from the test specimen connection.
Do not disconnect the test specimen or the piston cylinder system until the
pressure in the pressure balance has been completely released.
The handle bars of the star handle can now be unscrewed from the spindle pump.
3.4 Transport .
To avoid the piston cylinder system getting damaged during transport (e.g. for
Re-Calibrations), you have to fix the transportation lock at the piston cylinder
system (see figure 1 - 5).
The transport of the instrument should only be carried out on a pallet!
The transportation lock consists of 2 plastic plugs and one metal holder (see figure 1)
Put both plugs in the opposite holes (see figure 2)
Check, if the plugs are in the correct position (see figure 3)
After that push the metal holder carefully over the two plugs (see figure 4). Now the piston cylinder
system is protected during the transport (see figure 5)
figure 1 figure 2 figure 3
figure 4 figure 5

Deadweight Tester / Pressure Balance High-Pressure GB
LR-Cal CPB 5000-HP
LR-Cal Manual Deadweight Tester / Pressure Balance High Pressure 20
4. Troubleshooting measures .
If faults cannot be repaired, the system must be put out of operation
immediately and this information is to be given to the manufacturer.
Repairs must only be carried out by the manufacturer. Interventions and
changes on the appliance are not allowed.
In case of faults caused by defects of the hydraulic equipment the operators must inform their
superiors immediately and call in the qualified and authorised technical staff for maintenance.
Table: Fault description and measures .
Type of fault Measures
I. Unable to build up pressure during pre-
pressure generation
Close low-pressure shut-off valve
correctly
Attention: Do not tighten the shut-off
valve more than finger tight. Otherwise
the valve seat could be damaged.
II. Unable to build up further pressure at high-
pressure generation with the spindle pump
Close high-pressure shut-off valve
correctly
Please note: In case of an opened, or not
properly closed high-pressure shut-off
valve, the safety overflow valve is not
activated until approximately 100 bar are
reached, and the oil will flow back into the
tank. Therefore, no pressure > 100 bar
can be built up.
III. Unable to build up pressure / oil discharge at
the piston/cylinder system receptacle, or the test
specimen connection
Tighten the piston/cylinder system in the
piston receptacle (see section 3.1.2)
Tighten the test specimen with the
connecting adapter and knurled nut (see
section 3.1.3)
In case of wear or damage to the sealing
cone, proceed as described in section 5.2.
IV. Unable to build up pressure, or range cannot
be reached
After the clamping of the piston/cylinder
system and the test specimen, air may be
trapped in the system.
Please note: The system should be
vented before beginning with calibration.
For this purpose, proceed according to
section 3.1.4.
Afterwards, build the pressure back up.