WIKA CPH7650 User manual

Operating instructions
Betriebsanleitung
EN
DE
Portable pressure calibrator, model CPH7650
Tragbarer Druckkalibrator, Typ CPH7650
Portable pressure calibrator, model CPH7650

2
14261987.01 03/2018 EN/DE
WIKA operating instructions, model CPH7650
EN
DE
Operating instructions model CPH7650 Page 3 - 58
Betriebsanleitung Typ CPH7650 Seite 59 - 113
Further languages can be found at www.wika.com.
© 03/2018 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!

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Contents
Contents
1. General information 5
2. Safety 6
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Personnel qualification . . . . . . . . . . . . . . . . . . . 8
2.3 Special hazards . . . . . . . . . . . . . . . . . . . . . 8
2.4 Use of Lithium-Ion rechargeable batteries . . . . . . . . . . . . 10
2.5 Labelling, safety marks . . . . . . . . . . . . . . . . . . .12
3. Specifications 13
4. Design and function 15
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Front . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . .17
4.4 Voltage supply . . . . . . . . . . . . . . . . . . . . . .17
4.5 User interface . . . . . . . . . . . . . . . . . . . . . . 18
4.5.1 Requirements for test assemblies with the CPH7650 . . . . . . . 19
4.5.2 Important instrument settings for calibration using calibration mode . . 19
4.5.3 Zero point setting and offset correction . . . . . . . . . . . . 20
4.5.4 Reference pressure sensor CPT6000 . . . . . . . . . . . . 20
5. Transport, packaging and storage 22
5.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . 22
6. Commissioning, operation 23
6.1 Menu structure (operating modes) . . . . . . . . . . . . . . . 24
6.2 Explanation of the display . . . . . . . . . . . . . . . . . . 25
6.2.1 Instrument status messages shortly after switching on the CPH7650 . .25
6.2.2 Switching the pressure calibrator off . . . . . . . . . . . . .26
6.2.3 Display contents of the operating modes . . . . . . . . . . . 26
6.2.4 Content of the SETUP menu . . . . . . . . . . . . . . . 29
6.3 Operating modes . . . . . . . . . . . . . . . . . . . . .32
6.3.1 MEASURING mode . . . . . . . . . . . . . . . . . . 32
6.3.2 MEASURING mode (with test item) . . . . . . . . . . . . . 34
6.3.3 Mode CALIBRATION . . . . . . . . . . . . . . . . . . 36
6.3.4 CALIBRATION mode (preparing the test points of a calibration). . . . 38
6.3.5 CALIBRATION mode (calibration of a pressure transmitter) . . . . . 41
6.3.6 CALIBRATION mode (calibration of a pressure gauge) . . . . . . 42
6.3.7 SWITCH TEST mode . . . . . . . . . . . . . . . . . . 43
6.4 SETUP additional menu items . . . . . . . . . . . . . . . . 45

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Contents
Declarations of conformity can be found online at www.wika.com.
6.4.1 SETUP additional menu items: Functions . . . . . . . . . . . 45
6.4.2 SETUP additional menu items: CPH info . . . . . . . . . . . 46
6.4.3 SETUP additional menu items: Reference sensor . . . . . . . . 47
6.4.4 SETUP additional menu items: Reference sensor list . . . . . . . 48
6.4.5 SETUP additional menu items: CPH configuration . . . . . . . . 49
6.4.6 SETUP additional menu items: Interface . . . . . . . . . . . 50
6.4.7 SETUP additional menu items: CLEAR CalProg . . . . . . . . .50
6.5 Connection of the model CPT6000 reference pressure sensor . . . . . 51
6.6 Voltage supply . . . . . . . . . . . . . . . . . . . . . .51
6.7 Charging/discharging the Lithium-Ion rechargeable batteries . . . . . . 52
6.8 Pressure measurement . . . . . . . . . . . . . . . . . . .53
6.9 Measuring and sourcing current (4 ... 20 mA) . . . . . . . . . . . 53
7. Maintenance, cleaning and recalibration 54
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . 54
7.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . .54
7.3 Recalibration . . . . . . . . . . . . . . . . . . . . . . 54
8. Faults 55
9. Dismounting, return and disposal 56
9.1 Dismounting . . . . . . . . . . . . . . . . . . . . . . 56
9.2 Return. . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . .56
10. Accessories 57

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1. General information
1. General information
■The portable pressure calibrator 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.
■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 instructions,
assignment of insufficiently qualified skilled personnel or unauthorised modifications to
the instrument.
■The general terms and conditions contained in the sales documentation shall apply.
■Subject to technical modifications.
■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: CT 17.02
- Application consultant: Tel.: [phone]
Fax: [phone]
[e-mail]

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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 property or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for efficient and
trouble-free operation.
DANGER!
... identifies hazards caused by electrical power. Should the safety
instructions not be observed, there is a risk of serious or fatal injury.
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the
appropriate reference pressure sensor has been selected in terms of
measuring range, design and specific measuring conditions.
Non-observance can result in serious injury and/or damage to the
equipment.
Further important safety instructions can be found in the individual chapters
of these operating instructions.

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2. Safety
2.1 Intended use
This portable pressure calibrator serves as a calibration instrument for the widest variety
of pressure measuring instruments and has been designed for mobile use as well as for
stationary workshop and laboratory testing. Through the combination of the integrated
electrical pump and the electrical modules, in addition to the traditional measurement of
current and voltage signals it also enables you to supply transmitters or sensors with a
max. of 30 mA (voltage (idling) = DC 24 V).The pressure calibrator can be used to carry
out and document a complete calibration process.
WARNING!
■Only use model CPT6000 reference pressure sensors!
■Using other sensors could damage both the pressure calibrator and the
reference pressure sensor.
■To change the sensor, switch off the pressure calibrator and make sure
the system is vented. Before switching the instrument on, connect the
sensor, otherwise it may not be correctly identified by the instrument.
■When the CPH7650 is switched on, the CPT6000 reference pressure
sensor must not be under pressure, but rather should be at atmospheric
pressure. For overpressure or gauge pressure sensors, there is a
pressure compensation vent in the top of the sensor under the plastic
fitting.This vent (with integrated diaphragm) must always remain clear!
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.
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.
Handle electronic precision measuring instruments with the required care (protect from
humidity, impacts, strong magnetic fields, static electricity and extreme temperatures,
do not insert any objects into the instrument or its openings). Plugs and sockets must be
protected from contamination.
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.

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2. Safety
2.2 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient!
Improper handling can result in considerable injury and damage to
equipment.
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 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.
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
2.3 Special hazards
WARNING!
■Do not apply a voltage greater than the specified voltage to the
instrument (see chapter 3 „Specifications“).
■Do not apply any external pressure to the CPH7650.
■Make sure that the test probes never contact a voltage source while the
test cables are connected to the current terminals.
■Do not use the calibrator if it is damaged. Before using the instrument,
check that there are no cracks on the case or any missing plastic parts.
Pay particular attention to the insulation of the connectors.
■Select the proper function and correct measuring range for the
measurement.
■Observe the operating parameters in accordance with chapter
3 “Specifications”.
■Always operate the pressure calibrator within the defined pressure range.
■To ensure problem-free operation, only operate the instrument on battery
power. Only use the power supply unit for charging the instrument's
batteries.
■Inspect the test cables for damaged insulation or exposed metal. Check
the continuity of the leads. Damaged test leads should be replaced before
using the instrument.
■When using test probes, keep fingers away from the test probe contacts.
Keep your fingers behind the test probes' finger guards.
■First connect the common lead, and then the live lead.When
disconnecting, remove the live test lead first.

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2. Safety
■Do not use the instrument if it is not working properly.The instrument
protection might be compromised. If in doubt, have the instrument
checked.
■Do not operate the instrument in areas with explosive gases, vapours or
dust.
■When measuring pressure, make sure that the pressure calibrator has
been switched to a depressurised state before the reference sensor or
the test item is connected or disconnected.
■Disconnect test leads before changing to another measurement or source
function.
■The switching valve (+/- pressure) should only ever be actuated when in a
depressurised state.
WARNING!
■To avoid false indications, which could lead to possible electric shock or
injuries, charge the rechargeable battery as soon as the battery indicator
appears.
■In order to avoid any possible damage to the instrument or the test
equipment, use the correct leads, the correct function and the correct
range for the measuring application.
DANGER!
Danger to life caused by electric current
Upon contact with live parts, there is a direct danger to life.
■Charging using a defective power supply unit (e.g. short circuit from the
mains voltage to the output voltage) can result in life-threatening voltages
at the instrument!
■Only use the power supply unit permitted by WIKA for the model
CPH7650 portable pressure calibrator.
■Only use a charger that is fully functional or undamaged.
The safety of the operator may be endangered if, for example
■there is visible damage to the instrument.
■the instrument is no longer working as specified.
■the instrument has been stored under unsuitable conditions for an extended period of
time.
If there is any doubt, please return the instrument to the manufacturer for repair or
maintenance.

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2. Safety
2.4 Use of Lithium-Ion rechargeable batteries
WARNING!
Misusing Lithium-Ion batteries can lead to heating, explosion or ignition and
result in serious injury. Follow the safety instructions listed below:
■Do not solder directly to the Lithium-Ion batteries.
■Do not incinerate or heat the Lithium-Ion batteries.
■The Lithium-Ion batteries must only ever be connected with the correct
polarity.
■Never connect the positive terminal and the negative terminal of the
Lithium-Ion batteries to each other with any metallic object (such as wire).
■Never carry or store the Lithium-Ion batteries together with necklaces,
hairpins, or other metal objects.
WARNING!
■Lithium-Ion batteries should never be punctured with nails nor hit with a
hammer. In addition, Lithium-Ion batteries must never be trodden on or
exposed to other strong shocks or vibrations.
■Lithium-Ion batteries must never come into contact with water or salt
water. Moreover, they must never get wet.
WARNING!
Never take the Lithium-Ion battery apart nor alter it in any way. It contains
safety and protection devices which, if damaged, may cause it to generate
heat, explode or ignite.
WARNING!
Never place the Lithium-Ion batteries close to fires, ovens or other
high-temperature locations. Never leave the Lithium-Ion batteries in direct
sunshine or use or store them inside cars in hot weather. Doing so may
cause the Lithium-Ion batteries to generate heat, explode or ignite. Using the
Lithium-Ion batteries in this manner may also result in a loss of performance
and a shortened service life.
Never fit the Lithium-Ion batteries into equipment designed to be
hermetically sealed. In some cases hydrogen or oxygen may be discharged
from the Lithium-Ion batteries, which may result in rupture, fire or explosion.

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2. Safety
WARNING!
The Lithium-Ion batteries must, without fail, no longer be used if, during
operation, charging or storing they give off an unusual smell, feel hot,
change colour, change shape, or appear abnormal in any other way. Contact
your sales partner if any of these problems are observed.
Never put the Lithium-Ion batteries in microwave ovens, high-pressure
containers nor on induction cookers.
Should the Lithium-Ion batteries ever leak and the fluid come into contact
with the eyes, do not under any circumstances rub the eyes. Rinse the eyes
thoroughly with water and seek immediate medical attention. If the eyes are
left untreated, damage to the eyes could occur.
CAUTION!
When the Lithium-Ion batteries wear out, insulate the terminals with
adhesive tape or similar materials before disposal.
WARNING!
Follow the instructions listed below for charging the Lithium-Ion batteries.
Failure to do so may cause the Lithium-Ion batteries to become hot, explode
or ignite and result in serious injury.
■To charge the Lithium-Ion batteries, only ever use the specified WIKA
battery charger.
■Never connect the Lithium-Ion batteries directly to a mains plug or to a
car's cigarette lighter.
■Never leave the Lithium-Ion batteries in or near fire, nor in direct sunlight.
If the Lithium-Ion batteries become hot, the built-in safety device is
activated and overcharging prevented. Heating the Lithium-Ion batteries
can damage the safety device and can thus lead them to heat up further,
to cease to work or to ignite.
WARNING!
Never continue to charge the Lithium-Ion batteries if they do not fully
recharge within the specified time. Doing so may cause the Lithium-Ion
batteries to become hot, explode or ignite.

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2. Safety
2.5 Labelling, safety marks
Product label
1Product name
2Date of manufacture (month/year)
3Serial number
4Output signal, power supply
5Input signal
6Pressure range
Symbols
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
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 manufacturer
or by the corresponding municipal authorities.
3
4
2
1
5
6

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3. Specifications
3. Specifications
Measuring ranges
Pressure 1)
Gauge pressure -1 … +20 bar, -1 … +10 bar, 0 … 20 bar, 0 … 10 bar
Absolute pressure 0 … 10 bar abs., 0 … 20 bar abs.
Overpressure limit 2) 3 times
Accuracy 0.025 % FS
Resolution 5-digit
Temperature compensation 15 … 35 °C (59 ... 95 °F)
Temperature coefficient 0.002 % of span/°C outside of 15 ... 35 °C (59 ... 95 °F)
Current
Measuring range 0 … 24 mA (max. load 1,000 Ω)
Resolution 1 µA
Accuracy 0.015 % of reading ±2 µA (simulation and measurement)
Voltage
Measuring range DC 0 … 30 V
Resolution 1 mV
Accuracy 0.015 % of reading ±2 mV (measurement)
1) Via exchangeable model CPT6000 reference pressure sensors
2) The electrical pump can generate -0.85 … +20 bar (-12 … 290 psi).
Base instrument
Pressure supply -0.85 ... +20 bar (-12 ... +290 psi), via integrated electric pump
Pressure connection for test
item
G ½" female thread
Permissible media For dry, clean and non-aggressive gases
Output
Voltage supply DC 24 V
Power supply
Battery type Lithium-Ion rechargeable battery
Permissible ambient conditions
Operating temperature -10 … +50 °C (14 ... 122 °F)
Storage temperature -20 … +60 °C (-4 ... +140 °F)
Relative humidity 35 ... 85 % r. h. (non-condensing)
Communication
Interface USB via special interface cable

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3. Specifications
Base instrument
Case
Case NK-7TM resin
Front panel Aluminium
Ingress protection IP67 (case closed)
IP40 (case opened)
Dimensions 387.4 x 304.8 x 177.8 mm (15.25 x 12 x 7 in)
Weight approx. 7 kg (15.5 lbs.)
Certificates
Certificate
Calibration Standard: 3.1 calibration certificate per DIN EN 10204
Option: DKD/DAkkS calibration certificate
Recommended recalibration
interval
1 year (dependent on conditions of use)
Approvals and certificates, see website
Available pressure range and resolution
Pressure range and factors
Gauge pressure -1 ... +20 bar (-14.5 ... +290 psi)
Overpressure limit 40 bar (580 psi)
Unit Conversion factor
psi 1 300.00
bar 0.06894757 20.684
mbar 68.94757 20,684
kPa 6.894757 2,068.4
MPa 0.00689476 2.0684
kg/cm² 0.07030697 21.092
cmH2O (4 °C) 70.3089 21,093
cmH2O (20 °C) 70.4336 21,130
inH2O (4 °C) 27.68067 8,304.2
inH2O (20 °C) 27.72977 8,318.9
inH2O (60 °F) 27.70759 8,312.3
mmHg (0 °C) 51.71508 15,515
inHg (0 °C) 2.03602 610.81
3) Electrical pump: -0.85 … +20 bar (-12 … 290 psi)

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3. Specifications / 4. Design and function
Dimensions in mm (in)
104 (4,11)
158 (6,22)
390 (15,36)
308 (12,13)
172 (6,76)
4. Design and function
4.1 Description
The CPH7650 is a compact, portable pressure calibrator, which has been designed
for mobile use as well as for stationary workshop and laboratory testing. An integrated
electrical pump enables you to generate pressures up to 20 bar (300 psi) and an
integrated electrical module also enables you to supply transmitters or sensors with
a current of max. 30 mA (voltage (idling) = DC 24 V), in addition to the traditional
measurement of current and voltage signals.
The pressure calibrator can be used to carry out and document a complete calibration
process. In addition to the features of displaying or measuring and calibration, there
is also a switch test.The use of the WIKA-Cal software also allows a complete
documentation.

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4. Design and function
4.2 Front
1Test item
2Overview of the electrical connection
3Electrical connection to the model CPT6000 reference sensor
4Reference sensor CPT6000
5Connecion of the power supply unit
6WIKA-Cal connection
7Fine adjustment / drain valve
8Switch for pressure / vacuum
9Pump speed controller
10 Operation
11 Electrical module
12 Display
13 Numeric keypad
3 4
1
5
6
2
7
8
9
10111213

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4. Design and function
4.3 Scope of delivery
■Portable pressure calibrator model CPH7650
■Operating instructions
■Test cables
■Battery charger
■3.1 calibration certificate per DIN EN 10204
Cross-check scope of delivery with delivery note.
4.4 Voltage supply
Charging the battery
In order to avoid false measurements, charge the battery as soon as the battery indicator
is displayed. If the battery has run down too far, the instrument will switch itself off
automatically.
Only ever use the power supply unit permitted by WIKA for the model CPH7650 portable
pressure calibrator.
To avoid measurement uncertainties, only use the CPH7650 without the mains supply
connected.The full pump performance can only be guaranteed with the battery fully
charged and without the power supply unit connected.
The instrument should be fully charged before being put into operation.
The battery capacity status (charge state in %) is displayed shortly after the instrument is
switched on.When the power supply unit is connected, the rechargeable battery will be
charged, even if the CPH7650 is switched off.
The typical charging time of the rechargeable battery is < 5 hours.
WARNING!
■When the power supply unit is no longer being used, the mains plug
should be disconnected from the mains socket. Do not leave the
rechargeable battery connected to the power supply unit for longer than
one day, since overcharging can shorten its service life.
■Should the rechargeable battery still not be fully charged after 24 hours,
contact the manufacturer. When not being used, a fully charged battery
will lose its charge over time.
■Extreme temperatures have an adverse effect on battery charging. As
a result, the battery may first need to be either cooled or warmed, as
appropriate.
■When the battery is almost completely discharged, the message “low
BAT” appears in the display.To avoid a data loss, the instrument must be
charged immediately

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4. Design and function
4.5 User interface
1SETUP menu
2Selection and entry confirmation
3Return to previous level
4Clear entry
5Input confirmation
6Numeric keypad
Switch on via pressing any button
Switch off via menu item in main menu
1
2
3
4
5
6

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4. Design and function
4.5.1 Requirements for test assemblies with the CPH7650
■Before starting any task, the instrument should be switched on briefly to determine
that there is sufficient charge in the battery (rechargeable battery capacity in %). The
battery capacity is indicated briefly in an instrument status message after switching
on (see chapter 6.2.1 “Instrument status messages shortly after switching on the
CPH7650”).
■Initially, the test assembly must be physically assembled and, if necessary, connected
electrically (see chapter 4.5.4.1 “Connection of the model CPT6000 reference
pressure sensor”).
■Before switching the CPH7650 on, ensure that the test assembly is not pressurised
(system is vented to atmosphere) and that the equipment is correctly assembled and
in the correct mounting position.
■Only connect test and calibration installations once the system has been
depressurised!
Compensation for height differences
If a significant elevation difference exists between the CPT6000 reference pressure
sensor and the test item, then the pressure difference, based on a medium column, can
be compensated automatically via the menu (see chapter 6.4.5 “SETUP additional menu
items: CPH configuration”).
4.5.2 Important instrument settings for calibration using calibration mode
Calibration date
The instrument has an integral real-time clock with date.The current date of a calibration
is stated later in the calibration certificate. Before starting a calibration, you must ensure
that the internal date of the CPH7650 is correct (see
chapter 6.4.5 “SETUP additional menu items: CPH configuration”).
Unit and resolution
After selecting one of the main menu items (e.g.: MEASURING, CALIBRATION or
SWITCH TEST) from the SETUP menu (press SETUP key), using the menu item “Unit”,
and its associated submenu respectively (move the cursor to “Unit” and press the right
or left arrow), you can set the unit and adjust its resolution (see chapter 6.3 “Operating
modes”).

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4. Design and function
Available units, including their conversion factors in relation to the unit bar
bar 1.00000E+00
mbar 1.00000E-03
hPa 1.00000E-03
psi 6.89475E-02
inHg (0 °C) 3.37690E-02
cmHG (0 °C) 1.33322E-02
MPa 1.00000E+01
kPa 1.00000E-02
Pa 1.00000E-05
mH2O (4 °C) 9.80670E-02
cmH2O (4 °C) 9.80670E-04
mmH2O (4 °C) 9.80670E-05
kg/cm29.80665E-01
inH2O (60 °C) 2.48800E-03
mmH2O (0 °C) 1.33322E-03
4.5.3 Zero point setting and offset correction
Zero point setting for overpressure sensors
If the measured value shown on the CPH7650, with an overpressure sensor connected
and the test assembly vented to atmosphere, is not equal to zero, then by pressing the
CLEAR button twice (within five seconds), the zero point can be corrected (maximum
allowable correction value is twice the magnitude of the class accuracy).
Offset correction for absolute pressure sensors
For absolute pressure sensors, an offset correction can be made via the menu (see
chapter 6.4.3 “SETUP additional menu items: Reference sensor”).
4.5.4 Reference pressure sensor CPT6000
For the model CPH7650 pressure calibrator, there are many reference pressure sensors
to choose from, with accuracies of 0.025 % which can be interchanged quickly and
without tools.When the pressure calibrator is switched on, the reference pressure sensor
attached is recognised automatically, so that no further configuration of the sensor is
needed.