WIKA BCS10 User manual

Operating instructions
Betriebsanleitung
Mode d'emploi
Manual de instrucciones
EN
DE
FR
ES
Kalibriersystem für SF6-Gasdichtemessgeräte,
Typ BCS10
Calibration system for SF6gas density measuring instruments
model BCS10
Calibration system for SF6 gas density measuring
instruments, model BCS10
Sistema de calibración para instrumentos de
medición de densidad del gas SF6, modelo BCS10
Système d'étalonnage pour instruments de
mesure de la densité de gaz SF6, type BCS10

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WIKA operating instructions calibration system, model BCS10
EN
DE
FR
ES
© 2012 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!
Lire le mode d'emploi avant de commencer toute opération !
A conserver pour une utilisation ultérieure !
¡Leer el manual de instrucciones antes de comenzar cualquier trabajo!
¡Guardar el manual para una eventual consulta!
Operating instructions model BCS10 Page 3 - 20
Betriebsanleitung Typ BCS10 Seite 21 - 38
Mode d‘emploi type BCS10 Page 39 - 56
Manual de instrucciones modelo BCS10 Página 57 - 74

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Contents
Contents
Declarations of conformity can be found online at www.wika.com.
1. General information 4
2. Safety 5
3. Specifications 9
4. Design and function 11
5. Transport, packaging and storage 13
6. Commissioning, operation 14
7. Maintenance and cleaning 18
8. Faults 18
9. Dismounting, return and disposal 20

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1. General information
1. General information
■
The calibration system 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 certied to ISO 9001 and ISO 14001.
■
These operating instructions contain important information on handling the instru-
ment. Working safely requires that all safety instructions and work instructions are
observed.
■
Observe the relevant local accident prevention regulations and general safety regula-
tions 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 instruc-
tions, assignment of insuciently qualied skilled personnel or unauthorised modi-
cations to the instrument.
■
The general terms and conditions contained in the sales documentation shall apply.
■
Subject to technical modications.
■
Factory calibrations / DKD/DAkkS calibrations are carried out in accordance with
international standards.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: SP 60.08
- Application consultant: Tel.: [phone]
Fax: [phone]
E-mail: [email protected]

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1. General information / 2. Safety
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.
Information
... points out useful tips, recommendations and information for ecient
and trouble-free operation.
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the appro-
priate calibration system has been selected in terms of measuring range,
design and specic measuring conditions.
Non-observance can result in serious injury and/or damage to the equip-
ment.
Further important safety instructions can be found in the individual
chapters of these operating instructions.
2.1 Intended use
The calibration system model BCS10 serves for the inspection of SF ₆ gas density
measuring instruments and pressure measuring instruments.
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specications contained in these operating instructions must be obser-
ved. Improper handling or operation of the instrument outside of its technical specica-
tions requires the instrument to be taken out of service immediately and inspected by an
authorised WIKA service engineer.
The manufacturer shall not be liable for claims of any type based on operation contrary
to the intended use.
Handle electronic 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). Plugs and sockets must be
protected from contamination.

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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 qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to equip-
ment.
■
The activities described in these operating instructions may only be
carried out by skilled personnel who have the qualications described
below.
■
Keep unqualied 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-specic regulations, current standards and directives, are capab-
le of carrying out the work described and independently recognising potential hazards.
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
2.3 Additional safety instructions for SF₆ gas in switchgear
The plant operator must ensure that the handling of SF₆ gas is only carried out by
a qualied company or by qualied persons which have been specially trained in
accordance with IEC 61634, section 4.3.1 or IEC 60480, section 10.3.1.
Valid standards and directives for SF₆ gas
Installation, assembly, commissioning:
■
IEC 61634 (Handling of SF₆ gas)
■
IEC 60376 (New SF₆ gas, technical grade SF₆ gas)
■
IEC 60480 (Used SF₆ gas)
■
CIGRE report 276, 2005 (Practical SF₆ gas handling instructions)
Leaks during operation:
■
IEC 60376 (New SF₆ gas, technical grade SF₆ gas)
■
IEC 60480 (Used SF₆ gas)
■
CIGRE 2002 (“SF₆ gas in the electrical industry”)

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2. Safety
Repair work and maintenance:
■
IEC 61634 (Use and handling of SF₆ gas in high-voltage switchgear and controlgear)
■
CIGRE 1991 (Handling of SF₆ gas)
■
CIGRE report 276, 2005 (Practical SF₆ gas handling instructions)
■
CIGRE report 163, 2000 (Guide for SF₆ gas mixtures)
SF₆ is a colourless and odourless, chemically neutral, inert and
non-ammable gas which is approx. ve times heavier than air, non-toxic
and not harmful to the ozone layer.
Detailed information is given in IEC 60376 and IEC 61634.
2.4 Personal protective equipment
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!
The requisite personal protective equipment must be provided by the operating company.
Wear safety goggles!
Protect eyes from ying particles and liquid splashes.
Wear protective gloves!
Protect hands from friction, abrasion, cuts or deep injuries and also from
contact with hot surfaces.

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2. Safety
2.5 Special hazards
WARNING!
Residual media in the dismounted pressure measuring instrument can
result in a risk to persons, the environment and equipment.
Take sucient precautionary measures.
WARNING!
The wetted parts have been designed exclusively for SF₆ gas and SF₆/N₂
mixtures.
The pressure inside the test pump can be extremely high. Ensure therefo-
re that all connections of the calibration system are connected correctly.
2.6 Labelling, safety marks
Product label
Model
Serial number
Article number
Measuring range
Adapter
Explanation of symbols
Before mounting and commissioning the instrument, ensure
you read the operating instructions!

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3. Specications
3. Specications
Measuring range
■
Measuring range comp. pressure:
■
Measuring range density:
0 ... 8.87 bar @ 20 °C
0 ... 60 g/l
■
Overload safety of the sensor: 48 bar
■
Burst pressure: 140 bar
Accuracy specications
■
Accuracy of pressure measurement: 0.05 % FS
■
Accuracy of density measurement: 0.6 % FS
■
Compensated temperature range: -10 ... +50 °C
Digital display
■
Type of indication: 7-segment LCD
■
Digits: 5 ½-digit
■
Resolution: depending on the selected pressure unit
■
Bar graph display: 20-segment bar graph, 0 ... 100 %
■
Possible density units: g/litre, kg/m³
■
Possible pressure units
SF₆ at 20 °C: bar, psi, kg/cm2, kPa, MPa and 15 other units
Operating conditions
■
Ingress protection: IP65
■
Ambient temperature: -10 ... +50 °C
■
Medium temperature: 0 ... +50 °C
■
Storage temperature: -20 ... +70 °C
■
Relative humidity: < 95 % r. h. (non-condensing)
Communication
■
Digital interface: WIKA-Wireless
■
Data exchange “myWIKA device” app (available free-of-charge in Google
Play Store and Apple App Store)

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3. Specications
Functions
■
Overpressure protection: Adjustable overpressure valve
■
Fine pressure adjustment: By means of the ne adjustment valve
■
Measuring rate for pressure: up to 50/s
■
Measuring rate for density: up to 3/s
■
Memory: MIN/MAX values
Integrated data logger
■
Data logger: Cyclic logger: Automatic recording of up to 1,000,000
values
Cycle time: Selectable from 1 ... 3,600 s in steps of 1
second or by measuring rate in the following
increments:
Density measurement: 1/s, 3/s
Pressure measurement: 1/s, 3/s, 10/s and 50/s
“myWIKA device” app is recommended for using the
data logger function
Voltage supply
■
Power supply: 3 x 1.5 V AA alkaline batteries
■
Battery life: Typically 2,000 ... 2,500 h (without backlighting and WIKA-
Wireless not active)
■
Battery status display: Symbol display with 4 bars indicates the battery status in 25
% steps
EU declaration of conformity
■
EMC directive
■
Pressure equipment directive
■
RoHS directive
■
R&TTE directive
EN 300 328, harmonised frequency range 2,400 ... 2,500 MHz is used; Bluetooth®
Classic, max. transmission power 10 mW. The instrument may be used without limita-
tions in the EU and also CH, NO and LI
Plastic case
■
Dimensions in mm: 395 x 295 x 106
■
Weight: approx. 4 kg (with contents)
For further specications see WIKA data sheet SP 60.08 and the order documentation.

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4. Design and function
4. Design and function
4.1 Short description
The modular calibration system model BCS10 serves for pressure generation and
inspection of mechanical and electronic SF₆ gas density measuring instruments by
means of comparative measurements. Due to the internal temperature compensation of
the GDI-100-D reference tester, the SF₆ gas pressure is referred to 20 °C. As a result,
gas density measuring instruments can be calibrated at an ambient temperature of
-10 ... +50 °C.
The test pump enables pressure generation from 0 ... 16 bar. Individual measuring
points can be approached with highest accuracy by means of the ne adjustment valve.
Via the mounted precision digital gas density indicator, the measurements can be
displayed in one of 10 SF₆ density units, in one of 26 pressure units or also in customer-
specic units
4.2 Scope of delivery
■
Precision digital gas density indicator model GDI-100-D with mounted pneumatic test
pump model CPP30
■
Test item adapter with quick coupling for G ½
■
Test item adapter with quick coupling for G ¾
■
Test item adapter with quick coupling for M 30 x 2
■
Test item adapter with quick coupling for M26 x 1.5 (special connection for the WIKA
GDM-100 with separate test port and shut-off valve, more information can be found
in data sheet AC 20.01)
■
Adjustable overpressure valve
■
Metal flexible hose for connecting the test item, length 2 m
■
Plastic case, incl. foam insert and operating instructions
Cross-check scope of delivery with delivery note.

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4. Design and function
4.3 Construction of the calibration system
1) Digital pressure gauge
2) Fine adjustment valve
3) Pressure relief valve
4) Switching between pressure or vacuum generation
5) Pump handles
6) Adjustable knurled nut for setting the pumping capacity (overpressure protection)
7) Metal protection hose for connecting the test item, with quick coupling on both sides,
length 2 m
8) Adjustable overpressure valve
4.4 Battery life
The battery life time typically amounts to 2,000 ... 2,500 operating hours (without
backlighting and WIKA-Wireless not active). In the upper right corner of the digital
display you will nd a symbol of the battery capacity
For instructions on batteries see chapter 3 “Specications”.
For battery replacement see chapter 6.8 “Battery replacement”.
4.5 Serial interface
The digital gas density indicator has one WIKA-Wireless interface as standard.The
wireless data transfer can be used for conguration, calibration and transmission of
measured values of the measuring instrument. For this purpose, the “myWIKA device”
app is required (available free-of-charge in Google Play Store and Apple App Store).









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5. Transport, packaging and storage
5. Transport, packaging and storage
5.1 Transport
Check the calibration system 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).
5.3 Storage
Permissible conditions at the place of storage:
see chapter 3 “Specications”
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
■
Hazardous environments, ammable atmospheres
Store the calibration system in its original packaging in a location that fulls the condi-
tions listed above. If the original packaging is not available, pack and store the instru-
ment as described below:
1. Wrap the instrument in an antistatic plastic lm.
2. Place the instrument, along with the 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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6. Commissioning, operation
6. Commissioning, operation
Commissioning must only be carried out by trained skilled personnel. The calibration
system was comprehensively checked ex works for leak tightness.
WARNING!
Only connect or disconnect test and calibration installations once the
system has been depressurised!
6.1 Switching on and o
To switch on the calibration system, press
the Power button (1) for 3 seconds. Press
the Power button again to switch o the
calibration system.
After switching on the version of the rmware
is indicated on the display for approx.
1 second.
The bar graph display at the bottom of the
display indicates the applied pressure relative
to the total measuring range.
6.2 Backlighting
The backlighting makes it easier to read the
values of the digital display. Press the Scroll-
Down button (5) to turn the backlighting on
and o.
6.3 Description of menu items
A detailed description of the menu items is available in the operating instructions of the
digital gas density indicator model GDI-100-D.
6.4 Measurement setup and adjustment
WARNING!
Only connect or disconnect test and calibration installations once the
system has been depressurised!



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6. Commissioning, operation
Select an appropriate adapter and screw it
together with the test item.
Connect the test item via the quick coupling to
the metal exible hose.
For instruments with calibration valve, also
observe the mounting instruction of the
respective operating instructions.
Connect the other side of the metal exible hose
via the quick coupling to the calibration system.
Check that the switching for pressure or vacuum
generation (arrow) is set to pressure.
ATTENTION!
The construction of the calibration system is not
designed for vacuum generation. Always leave
the switching valve set to pressure generation.
Never adjust the switching valve when the
system is under pressure. Switch only when the
drain valve is open.
Close the pressure relief valve.
Turn the pressure relief valve clockwise until the
valve is closed. No hard stop can be felt.

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6. Commissioning, operation
Switch on the calibration system.
The measurement setup shall be now as in the
gure.
Actuate the pump handles several times until the
desired pressure is slightly exceeded.
To achieve the maximum pumping capacity, the
spring above the knurled nut must be relaxed.
For test items with low measuring ranges,
the stroke path can be reduced by turning
the knurled nut.This will reduce the pressure
increase per stroke and minimise the risk of the
overpressure.
Set the desired pressure via the ne adjustment
valve (arrow).
Normally, the test is carried out when the
pressure falls because the gas density
instruments are generally specied and adjusted
in such a way.
To reduce the pressure, turn the ne adjustment
valve counterclockwise.
Further reduction of the pressure is possible by
means of the pressure relief valve.
To increase the pressure, turn the ne
adjustment valve clockwise.
Use the digital pressure gauge to read the set
pressure.

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6. Commissioning, operation
Compare and record the displayed value of the
test item with the displayed value of the digital
pressure gauge.
To improve the readability of the display, the
backlighting can be activated by means of the
Scroll-Down button.
Open the pressure relief valve after calibration to
depressurise the system.
The test item can be separated from the
calibration system.
The calibration system can now be dismounted
in reverse order.
WARNING!
Only disconnect once the system
has been depressurised!

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7. Maintenance and cleaning / 8. Faults
7. Maintenance and cleaning
7.1 Maintenance
Repairs must only be carried out by the manufacturer.
7.2 Cleaning
CAUTION!
■
Clean the instrument with a moist cloth.
■
Electrical connections must not come into contact with moisture.
■
Residual media on the calibration system can result in a risk to
persons, the environment and equipment.
Take sucient precautionary measures.
For information on returning the instrument see chapter 9.2 “Return”.
7.3 Recalibration
DKD/DAkkS certicate - ocial certicates:
We recommend that the calibration system is regularly recalibrated by the manufacturer,
with time intervals of approx. 12 months. In addition, every factory recalibration includes
an extensive free-of-charge check of all system parameters with respect to their compli-
ance with the specication. The basic settings will be corrected if necessary.
8. Faults
8.1 Digital pressure gauge fault
Display Causes Measures
Low battery voltage, functioning
is only guaranteed for a short
period of time
Insert new alkaline batteries
OL
-OL Reading is signicantly above or below the measuring range = >
10 % FS
Check: Is the pressure within the
permissible measuring range of
the sensor?
No display or instru-
ment is not responding
to button press
Battery is empty Insert new alkaline batteries
Batteries inserted incorrectly Ensure the correct polarity
System error Switch o the GDI-100-D, wait
for a short period of time, switch
on again
Defect in the GDI-100-D Send in for repair

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8. Faults
CAUTION!
If faults cannot be eliminated by means of the measures listed above,
shut down the calibration system immediately, and ensure that pressure
and/or signal are no longer present, and secure the instrument from being
put back into operation inadvertently.
In this case, contact the manufacturer.
If a return is needed, please follow the instructions given in chapter 9.2
“Return”.
8.2 Test pump fault
Fault Causes Measures
The test pump is leaking Pressure relief valve is open Close the pressure relief
valve
Change-over contact for pressu-
re and vacuum is not switched
correctly
(The change-over contact is in the
middle position)
Turn the shift lever to pressu-
re generation.
The pump handles are
sti to operate The pump has not been used for a long time Actuate the pump until it functions smoothly
CAUTION!
If faults cannot be eliminated by means of the measures listed above,
shut down the calibration system immediately, and ensure that pressure
and/or signal are no longer present, and secure the instrument from being
put back into operation inadvertently.
In this case, contact the manufacturer.
If a return is needed, please follow the instructions given in chapter 9.2
“Return”.

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9. Dismounting, return and disposal
9. Dismounting, return and disposal
WARNING!
Residual media on the calibration system can result in a risk to persons,
the environment and equipment.
Take sucient precautionary measures.
9.1 Dismounting
Only dismount measurement setups once the system has been depressurised!
9.2 Return
WARNING!
Strictly observe the following when shipping the instrument:
All instruments delivered to WIKA must be free from any kind of hazar-
dous substances (acids, bases, solutions etc.).
When returning the instrument, use the original packaging or a suitable transport
packaging.
To avoid damage:
1. Wrap the calibration system in an antistatic plastic lm.
2. Place the calibration system, along with shock-absorbent material, in the packaging.
Place shock-absorbent material evenly on all sides of the transport packaging.
3. If possible, place a bag containing a desiccant inside the packaging.
4. Label the shipment as carriage of a highly sensitive measuring instrument.
Information on returns can be found under the heading “Service” on our
local website.
9.3 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an environmentally
compatible way and in accordance with the country-specic waste disposal regulations.
This marking on the instruments indicates that they must not be disposed
of in domestic waste. The disposal is carried out by return to the manufac-
turer or by the corresponding municipal authorities (see EU directive
2002/96EC).