WIKA CPB3500 User manual

Operating instructions
Betriebsanleitung
EN
DE
Pneumatic dead-weight tester, model CPB3500
Pneumatische Druckwaage, Typ CPB3500
Pneumatic dead-weight tester, model CPB3500

2WIKA operating instructions, model CPB3500
14147066.01 06/2023 EN/DE
EN
DE
© 06/2023 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!
Operating instructions model CPB3500 Page 3 - 42
Betriebsanleitung Typ CPB3500 Seite 43 - 82
Further languages can be found at www.wika.com.

3WIKA operating instructions, model CPB3500
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Contents
1. General information 5
1.1 Abbreviations, definitions. . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Short overview 6
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Safety 8
3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Transport, packaging and storage 10
4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Design and function 11
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3 The piston-cylinder system model CPS3500 . . . . . . . . . . . . . . . . . . . 12
5.4 Piston range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.1 Range 0.015 ... 1 bar (pure gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.2 Range 0.1 ... 7 bar (pure gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.3 Range 0.2 ... 25 bar (pure gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.4 Range 1 ... 70 and 1 ... 120 bar (oil-lubricated, gas-operated) . . . . . . . . . . . . . . . . . 14
5.5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Commissioning, operation 15
6.1 Unpacking the dead-weight tester. . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Ambient conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Installing the base . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Assembly of the dead-weight tester . . . . . . . . . . . . . . . . . . . . . . 16
6.5 Connecting the pneumatic pressure supply . . . . . . . . . . . . . . . . . . . 16
6.6 Connection of the test item . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.7 Post-assembly test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.8 Pressure calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.8.1 Procedure all positive pressure units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.8.2 Procedure vacuum calibration -1 ... -0.015 bar . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.8.3 Inlet and vent valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.8.4 During calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.8.5 Pressure range 1 ... 70 bar and 1 ... 120 bar only! . . . . . . . . . . . . . . . . . . . . . . . . 20
6.9 Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.10 Temperature measurement of piston . . . . . . . . . . . . . . . . . . . . . . 20
6.11 Cleaning the measuring instruments . . . . . . . . . . . . . . . . . . . . . . 21
Contents

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Contents
7. Faults 22
8. Maintenance, corrective maintenance, cleaning and calibration 23
8.1 Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2 Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2.1 Removing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2.2 Replacing seals on inlet valve and vent valve . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2.3 Inlet valve and vent valve testing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2.4 Volume adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2.5 Replacing the seal of pressure measuring instrument . . . . . . . . . . . . . . . . . . . . . 26
8.2.6 Piston-cylinder system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.2.7 Spare seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3.1 Cleaning the unit and checking the liquid levels . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.3.2 Cleaning of the piston-cylinder system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.4 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.4.1 Overhaul and calibration of dead-weight testers, maintenance of accuracy . . . . . . . . . 30
8.4.2 Need for overhaul and calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.4.3 Identification of masses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.4.4 Overhaul and calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
9. Return and disposal 32
9.1 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10. Specifications 33
10.1 Piston-cylinder system . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.2 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.3 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.4 Tables of masses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5 Transport dimensions for complete instrument . . . . . . . . . . . . . . . . . . 37
10.6 Dimensions in mm [in]. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.6.1 Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.6.2 Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.6.3 Standard connection piston-cylinder system . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11. Accessories 41

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1. General information
1. General information
■The model CPB3500 pneumatic dead-weight tester described in the operating instructions has been manufactured using
state-of-the-art technology. All components are subject to stringent quality and environmental criteria during production. Our
management systems are certified to ISO 9001 and ISO 14001.
■These operating instructions contain important information on handling the instrument.Working safely requires that all
safety instructions and work instructions are observed.
■Observe the relevant local accident prevention regulations and general safety regulations 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. Pass the operating instructions onto the next operator or owner of the
instrument.
■Skilled personnel must have carefully read and understood the operating instructions prior to beginning any work.
■In case of a different interpretation of the translated and the English operation instruction, the English wording shall prevail.
■The general terms and conditions contained in the sales documentation shall apply.
■Subject to technical modifications.
■Factory calibrations/UKAS calibrations are carried out in accordance with international standards.
■Further information:
DH-Budenberg
A division of WIKA Instruments Ltd.
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 31.22
- Contact: Tel: [phone]
[email protected].uk
■Importer for EU
WIKA Alexander Wiegand SE & Co. KG
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: CT 31.22
- Contact: Tel.: [phone]
[e-mail]
1.1 Abbreviations, definitions
■Bullet
▶Handling instructions
1. ... x. Follow the instruction step by step
⇒Result of an instruction
→See ... cross-references

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1. General information / 2. Short overview
1.2 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 property or the
environment, if not avoided.
DANGER!
... indicates a potentially dangerous situation that can result in serious injury or death, if not avoided.
Information
... points out useful tips, recommendations and information for efficient and trouble-free operation.
2. Short overview
2.1 Overview
1Test connection with G ½, female thread, loose union connection
2Connection block G 1, female thread
3Inlet valve
4Levelling feet
5Volume adjuster with star handle
6Vent valve
7Pressure generation control schematic
8Pressure measuring instrument
9Inlet manifold (rear side)
1
2
6
4
1
2
5
8
3
4
9
7

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2. Short overview
2.2 Description
Pressure balances (dead-weight testers) are instruments for the calibration of electronic or mechanical pressure measuring
instruments. By direct measurement of the pressure as the quotient of force and area (p = F/A), pressure balances
(dead-weight testers) are approved as primary standards.
The model CPB3500 dead-weight tester is a pneumatic dead-weight tester for the provision of pneumatic pressure range from
-1 ... 120 bar [-14.5 ... 1,600 lb/in²]. It is technically identical to the base instrument of the model CPP120-X comparison test
pump.
The individual test points can be easily controlled with the two integrated fine metering valves for pressure inlet and pressure
outlet.
For the precise setting for accurate comparative testing, the CPB3500 features a precisely adjustable volume adjuster.
The connection for the necessary external pressure or vacuum supply is located on the rear side of the instrument.
By connecting the test item and a sufficiently accurate reference pressure measuring instrument to the test pump, the same
pressure will act on both measuring instruments. By comparison of the two measured values at any given pressure value, a
check of the accuracy and/or adjustment of the pressure measuring instrument under test can be carried out.
The two test connections are equipped with G ½ female loose union connections. Corresponding thread adapters are
available for the calibration of instruments with different connection threads.
The core component of the CPB3500 is therefore a very precisely manufactured piston-cylinder system, onto which mass
sets are applied in order to generate the individual test points.The mass set is proportional to the target pressure and this is
achieved through optimally graduated masses. A maximum pressure of 120 bar [1,600 lb/in²] must not be exceeded.
The pressure is set via an integrated, finely adjustable, precision dual-area spindle pump. As soon as the measuring system
reaches equilibrium, there is a balance of forces between the pressure and the mass load applied.The test item can thus be
calibrated or adjusted.
2.3 Scope of delivery
■Instrument base with ABS cover
■Piston-cylinder system
■Masses, manufactured to standard gravity (standard value: 9.80665 m/s²)
■VG22 mineral oil (0.5 litre), for 70 and 120 bar [1,000 and 1,600 lb/in²] only
■Standard tool set with:
1 x 2 mm Allen key
1 x 3 mm Allen key
2 x open-ended spanner SW 30
1 x level
4 x plates for levelling feet
1 x bag with seals
1 x G ½ connection for test item
1 x pointer punch
1 x pointer remover
1 x adapter for inlet connection
1 x set of connections consisting of 1 x (BSP) G ⅛, G ¼, G ⅜ and G ½
■Operating instructions
■Calibration certificate(s)
Cross-check scope of delivery with delivery note.

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3. Safety
3. Safety
3.1 Intended use
The model CPB3500 dead-weight tester is a pneumatic dead-weight tester for the provision of pneumatic pressure range from
-1 ... 120 bar [-14.5 ... 1,600 lb/in²].
The pneumatic dead-weight tester is intended for calibration of clean dry instruments.
The pneumatic dead-weight tester requires a regulated supply of clean dry gas to operate.We recommend using a Nitrogen
Cylinder as the gas from this is normally dry and clean. Alternatively use compressed air, filtered and dried to remove oil and
moisture which could cause that the piston-cylinder system or the moveable parts of the base unit become sticky.
This instrument is not permitted to be used in hazardous areas!
The instrument has been designed and built solely for the intended use described here, and may only be used accordingly.
The technical specifications contained in these operating instructions must be observed, see chapter 10 “Specifications”.
Improper handling or operation of the instrument outside of its technical specifications 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.
3.2 Improper use
Dirt and excessive moisture in the base will significantly affect the performance of the unit, and can cause damage, particularly
if a piston unit is used for a prolonged period when dirty.
Additionally, the following must be observed:
■Refrain from unauthorised modifications to the instrument.
■Do not use the instrument within hazardous areas.
■Do not use the instrument with liquid media.
■Do not use the instrument to calibrate oxygen gauges.
■Do not use oxygen as pressure supply.
Not for oxygen use!
DH-Budenberg/WIKA do not produce a dead-weight tester that is suitable for use on oxygen, non-standard manufacturing
procedures can be employed to produce an OIL-FREE version, but this should be made clear of its intended use at the
earliest.
If the user is not sure of the condition of the dead-weight tester with regards as to how it has been used in the past, it is
DH-Budenberg/WIKA recommendation that the base should not be used for calibrating instruments for use on oxygen.
▶Failure to comply with this procedure would render any liabilites against DH-Budenberg/WIKA null and void.
DANGER!
Danger to life from explosion!
If the dead-weight tester is used to calibrate oxygen instruments it is imperative that no oil/hydrocarbons are
present, as this would result in an explosion when it came into contact with oxygen.
▶Calibrate only oil-free gauges to avoid contamination of the dead-weight tester.
Any use beyond or different to the intended use is considered as improper use.

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3. Safety
3.3 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient
Improper handling can result in considerable injury and damage to property.
▶The activities described in these operating instructions may only be carried out by skilled personnel who
have the qualifications described below.
Skilled personnel
Skilled personnel, authorised by the operator, 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-specific regulations,
current standards and directives, are capable of carrying out the work described and independently recognising potential
hazards.
DH-Budenberg/WIKA can provide dedicated training courses on the correct use of these products. Please
contact your local office for further details.
3.4 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 flying particles and liquid splashes.
During the operation, cleaning or maintenance at the comparison test pump it is necessary to wear safety
goggles.
Please observe also the additional notes in the individual chapters of this operating instruction.

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4. Transport, packaging and storage
4. Transport, packaging and storage
4.1 Transport
Check the model CPB3500 pneumatic dead-weight tester for any damage that may have been caused by transport.
In case of obvious damage, contact DH-Budenberg/WIKA immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can occur.
▶When unloading packed goods upon delivery as well as during internal transport, proceed carefully and
observe the symbols on the packaging.
▶With internal transport, observe the instructions in chapter 4.2 “Packaging and storage”.
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.
4.2 Packaging and storage
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).
Masses are shipped in cardboard and not in their respective wooden cases, if ordered.
Wooden cases are not suitable for use as shipping cases.
Permissible conditions at the place of storage:
■Storage temperature: -10 ... +50 °C [14 ... 122 °F]
■Humidity: 35 ... 85 % relative humidity for instrument base and mass set (non-condensing)
■Humidity: 35 ... 65 % relative humidity for piston-cylinder system (non-condensing)
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, flammable atmospheres
Store the CPB3500 in its original packaging in a location that fulfils the conditions listed above. If the original packaging is not
available, pack and store the instrument as described below:
1. Wrap the instrument in an antistatic plastic film.
2. Place the instrument along with 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.