WIKA CPB 5000 User manual

Operating Instructions
Betriebsanleitung
CPB 5000
Pressure Balance GB
Pressure Balance CPB 5000
Kolbenmanometer D

Pressure Balance GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 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 Page 4 - 39GB
Betriebsanleitung Kolbenmanometer Seite 40 - 77D

Pressure Balance GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 3
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1. General.................................................................................................... 5
1.1 General Instructions.................................................................................................................... 5
1.2 Safety Instructions...................................................................................................................... 6
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............................................................................................ 10
2.4.1 Pneumatic low-pressure base............................................................................................... 11
2.4.2 Pneumatic high-pressure / vacuum base. ........................................................................... 12
2.4.3 Hydraulic base........................................................................................................................ 13
3. Commissioning and Operation.................................................................................................. 14
3.1 Preparation................................................................................................................................. 14
3.1.1 Setting up the Device............................................................................................................. 14
3.1.1.1 Instructions for pneumatic high-pressure / vacuum version......................................... 14
3.1.1.2 Instructions for pneumatic version with integrated gas to oil separator...................... 14
3.1.1.3 Instructions for hydraulic version..................................................................................... 15
3.1.2 Installing the ConTect System.............................................................................................. 16
3.1.2.1 Connection for piston/cylinder system with M30 x 2 female thread.............................. 16
3.1.2.2 Connection for piston/cylinder system with ConTect quick connector........................ 17
3.1.2.3 Vacuum piston/cylinder system. ....................................................................................... 18
3.1.2.4 Connection for piston/cylinder system with integrated separator, M30 x 2 female thread........19
3.1.3 Connecting the test specimen.............................................................................................. 20
3.1.4 Venting the System (Hydraulic Design only)....................................................................... 20
3.2 Operation.................................................................................................................................. 21
3.2.1 Weight Pieces......................................................................................................................... 21
3.2.2.1 Approaching the pressure value – hydraulic base.......................................................... 22
3.2.2.2 Approaching the pressure value – pneumatic low-pressure base. ............................... 22
3.2.2.3 Approaching the pressure value – pneumatic high-pressure / vacuum base.............. 23
3.2.2.4 Approaching the pressure value – pneumatic version with separator.......................... 23
3.2.3 Pressure stable....................................................................................................................... 23
3.2.4 Next pressure level................................................................................................................. 24
3.2.5 Vacuum operation.................................................................................................................. 24
3.2.5.1 Weight pieces for vacuum.................................................................................................. 24
3.2.5.2 Approaching the vacuum values....................................................................................... 25
3.2.5.3 Vacuum stable..................................................................................................................... 25
3.2.5.4 Next vacuum level............................................................................................................... 25
3.2.6 Releasing pressure – hydraulic , pneumatic and vacuum................................................. 25
3.3 Disassembly............................................................................................................................... 26
4. Troubleshooting measures.................................................................................................. 27
5. Maintenance and Care.................................................................................................. 28

Pressure Balance GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 4
5.1 Cleaning. .................................................................................................................................... 28
5.1.1 Piston/Cylinder system.......................................................................................................... 28
5.1.1.1 Hydraulic piston/cylinder system...................................................................................... 28
5.1.1.2 Pneumatic piston/cylinder system.................................................................................... 30
5.1.2 Weight Set............................................................................................................................... 31
5.2 Wear Parts.................................................................................................................................. 31
5.3 Changing the Hydraulic Oil (Hydraulic Design only)............................................................. 32
5.3.1 Removing Hydraulic Oil......................................................................................................... 32
5.3.2 Filling in of Hydraulic Oil....................................................................................................... 32
5.3.3 Venting of the System (after Complete Filling only)........................................................... 32
5.4 Recalibration..............................................................................................................................33
6. Specifications.................................................................................................. 34
7. Tables of masses.................................................................................................. 37
7.1 Hydraulic models....................................................................................................................... 37
7.2 Pneumatic models..................................................................................................................... 38
8. Accessories.................................................................................................. 39

Pressure Balance GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 5
1. General .
1.1 General Instructions .
In the following chapters detailed information on the CPB 5000 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: [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
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 GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 6
1.2 Safety Instructions .
Read these operating instructions carefully prior to operating
the pressure balance CPB 5000. 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 always has to be handled with the care required for an 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.
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.

Pressure Balance GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 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 CPB 5000 is also ideally suited for on-site use as well
as service and maintenance purposes.
Piston/cylinder measuring system
Pressure is defined as a quotient of force and area. Correspondingly, the core of the CPB 5000 is a
very precisely manufactured piston/cylinder system. Both the piston and cylinder are manufactured
from Tungsten Carbide and are very well protected in a solid stainless steel housing against touching,
impacts or contamination from outside.
As a standard the connection of the piston/cylinder system is a M30 x 2 male thread. The patented
ConTect quick connector is available as an option. It allows a quick and safe change of the measuring
range without the need for tools. Thus it is possible to set up a compact complete system at a
favourable price, consisting of an universal instrument base and up to 3 ConTect piston/cylinder
systems with different measuring ranges with only one weight set.
The pneumatic piston/cylinder systems are available for vacuum and pressure ranges from 2 bar up to
100 bar resp. 30 psi up to 1500 psi and the hydraulic systems are available for pressure ranges from
60 bar up to 1000 bar resp. 1000 psi up to 14500 psi. The accuracy is 0.015 % (optional also 0.008 %)
of reading.
The entire construction design of the piston/cylinder unit and the very precise manufacturing of the
piston and the cylinder stand for excellent operating characteristics with a long free rotation time and
low fall rates and for a very high long term stability. Therefore the recommended re-calibration interval
is 5 years.
Functioning
Depending on the measuring range of the device under test you can fit the instrument basement with
the corresponding system. In order to generate the individual test points, the piston cylinder system is
weighted with mass-loads. The weight applied is proportional to the desired pressure and provided by
using optimally graduated weights. These weights are manufactured to standard gravity (9.80665
m/s²) although for fixed location usage they can be adjusted to a customer specified local gravity.
Depending on the instrument version the pressure is set either via an integrated pump or via external
pressure supply by the use of control valves. For fine adjustment an adjustable volume with precision
spindle is available. 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 GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 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 be made automatically with the CalibratorUnit CPU 5000
(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 GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 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
2.220231 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%.

Pressure Balance GB
CPB 5000
WIKA Operating Instructions Pressure Balance Version 3.1 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 (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 %.
2.4 Arrangement of control elements .
The CPB 5000 instrument bases are available in the 4 following versions, which vary in the arrangement
of the control elements:
Pneumatic low-pressure base
- up to max 10 bar / 150 psi
- with integrated pressure generation via initial pressure pump and spindle pump
- tubing made of flexible hose (polyurethane), 6 x 1 mm
Pneumatic high-pressure / vacuum base
- up to max 100 bar / 1,500 psi
- for external pressure or vacuum connection
- tubing made of stainless steel (1.4571), 3 x 1 mm
Pneumatic base with integrated gas to oil separator
- up to max. 400 bar / 5000 psi
- for external pressure connection
- for the use with hydraulic piston cylinder systems with M30 x 2 connection
- test item can be calibrated easily, dryly and cleanly with air
- tubing made of stainless steel (1.4571), 3 x 1 mm
Hydraulic base
- up to max 1,000 bar / 14,500 psi
- with integrated pressure generation via initial pressure pump and spindle pump
- tubing made of stainless steel (1.4404), 6 x 2 mm
- up to 1200 bar / 17400 psi available as special version
As a standard all instrument bases are equipped with a M30 x 2 female thread as connection for the
piston/cylinder system.
The patented ConTect quick connector can be installed as an option allowing a quick and safe change
of the measuring range without the need for tools (not available for the version with integrated gas to
oil separator).