WIKA CPB5000HP User manual

Operating Instructions
Betriebsanleitung
CPB5000HP
Pressure Balance High-Pressure
Pressure Balance High-Pressure CPB5000HP
GB
Höchstdruck Kolbenmanometer
D

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
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 - 30
GB
Betriebsanleitung Höchstdruck Kolbenmanometer Seite 31 - 59
D

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
3
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1. General ........................................................................................................................................... 4
1.1 General Instructions .................................................................................................................... 4
1.2 Safety Instructions .................................................................................................................... 5
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 ................................................................................................... .11
3. Commissioning and Operation .................................................................................................. 12
3.1 Preparation .................................................................................................................. 12
3.1.1 Setting up the Device ............................................................................................................. 12
3.1.2 Installing the piston cylinder system ................................................................................... 13
3.1.3 Connecting the test specimen .............................................................................................. 14
3.1.4 Venting the System ................................................................................................................ 15
3.2 Operation .................................................................................................................. 16
3.2.1 Weight Pieces ......................................................................................................................... 17
3.2.2 Approaching the pressure value (increasing pressure) ..................................................... 18
3.2.3 Pressure stable ....................................................................................................................... 19
3.2.4 Next pressure level ................................................................................................................. 19
3.2.5 Approaching the pressure value (decreasing pressure) .................................................... 20
3.3 Disassembly .................................................................................................................. 21
3.4 Transport .................................................................................................................. 21
4. Troubleshooting measures ........................................................................................................ 22
5. Maintenance and Care ................................................................................................................ 24
5.1 Cleaning .................................................................................................................. 24
5.1.1 Piston/Cylinder system .......................................................................................................... 24
5.1.2 Weight Set ............................................................................................................................... 24
5.2 Wear Parts .................................................................................................................. 24
5.3 Changing the Hydraulic Oil............................................................................................................. .25
5.3.1 Removing Hydraulic Oil ......................................................................................................... 25
5.3.2 Filling in of Hydraulic Oil ....................................................................................................... 25
5.3.3 Venting of the System (after Complete Filling only) ........................................................... 25
5.4 Recalibration .................................................................................................................. 26
6. Specifications .............................................................................................................................. 27
7. Tables of masses ......................................................................................................................... 29
8. Accessories ................................................................................................................................. 30

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
4
1. General .
1.1 General Instructions .
In the following chapters detailed information on the CPB5000HP 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
Alexander Wiegand Strasse
D-63911 Klingenberg
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
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
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.

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
5
1.2 Safety Instructions .
Read these operating instructions carefully prior to operating the pressure
balance high-pressure CPB5000HP. 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 it.
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 CPB5000HP 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 CPB5000HP.
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. Any operation not included in the following instructions or outside the specifications must not be
attempted.
When the specified nominal pressure of the unit is exceeded, the accuracy and
durability of the piston-cylinder system can be reduced.

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
6
Wear safety glasses to protect against leaking oil.
Use only those accessories such as thread adapter, which is suitable for the
pressure range and the medium used.
See Safety Data Sheet of the medium used under the product page CPB5000HP
at www.wika.de

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
7
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 CPB5000HP 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 2,500 bar,
4,000 bar and 5,000 bar respectively 40,000 psi, 60,000 psi and 70,000 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.

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
8
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 bemade automaticallywith the CalibratorUnit CPU6000
(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
gg
pp
dardS
Local 0449.100
80665.9 81105.9
100
tan
Nominal 
Without the correction, measurements would all be "off" by 0.05 %.

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
9
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
11
valueNominal
Example:
Reference temperature: 20 °C
Temperature during use: 23 °C
TK: 0.0022 %
 
 
barbarpressureTrue 99340.99
2.2202311
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 7,900 kg/m3
A fluctuation of 5 % in the relative humidity causes an additional uncertainty in the measurement of
about 0.001 %.

Pressure Balance High-Pressure GB
CPB5000HP
WIKA Operating Instructions Pressure Balance High-Pressure Version 2.5
10
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 ().
pressureNominal1 pressureNominal 


pressureTrue
Example:
Measuring point: 1,000 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 %.