WIKA CPP 3000-X User manual

Operating Instructions
Betriebsanleitung
CPP 3000-X
CPP 5000-X
CPP 7000-X
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Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 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 Comparison Test Pump Page 4 - 19GB
Betriebsanleitung Vergleichsprüfpumpe Seite 20 - 40
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Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 3
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1. General........................................................................................................................................... 4
1.1 General instructions.................................................................................................................... 4
1.2 Safety instructions...................................................................................................................... 5
2. Product description....................................................................................................................... 6
2.1 General product information...................................................................................................... 6
2.2 Arrangement of control elements CPP 3000-X / CPP 5000-X and CPP 7000-X..................... 7
3. Commissioning and operation..................................................................................................... 8
3.1 Preparation................................................................................................................................... 8
3.1.1 Setting up the device............................................................................................................... 8
3.1.2 Connecting the test specimen and the reference instrument............................................. 9
3.1.3 Venting the system................................................................................................................. 10
3.2 Operation.................................................................................................................................. 11
3.2.1 Increasing the pressure......................................................................................................... 11
3.2.2 Reducing the pressure.......................................................................................................... 12
3.3 Disassembly...............................................................................................................................12
4. Troubleshooting measures........................................................................................................ 13
5. Maintenance................................................................................................................................. 15
5.1 Wear parts.................................................................................................................................. 15
5.2 Changing the hydraulic oil....................................................................................................... 15
5.2.1 Removing hydraulic oil.......................................................................................................... 15
5.2.2 Filling in of hydraulic oil........................................................................................................ 16
5.2.3 Venting of the system (after complete filling only)............................................................. 16
6. Specifications.............................................................................................................................. 17
7. Accessories................................................................................................................................. 19

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 4
1. General .
1.1 General instructions .
In the following chapters detailed information on the CPP 3000-X / CPP 5000-X and CPP 7000-X
comparison test pump 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]
The warranty period for the comparison test pump 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.
© 2009 Copyright WIKA Alexander Wiegand SE & Co. KG. All rights reserved.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 5
1.2 Safety instructions .
Read these operating instructions carefully prior to operating
the comparison test pumps CPP 3000-X / CPP 5000-X and CPP 7000-X. 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 CPP 3000-X / CPP 5000-X or CPP 7000-X always has to be handled with the care required for
an precision instrument (protect from humidity, impacts and extreme temperatures). The device
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 pumps.
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.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 6
2. Product description .
2.1 General product information .
Application
Test pumps are used to generate pressures for checking, adjusting and calibrating mechanical and
electronic pressure measuring instruments by comparative measurements. These pressure tests may
be carried out in laboratories, workshops or on site at the measuring point.
Functioning
The comparison test pump is equipped with two connections for the test specimen and the reference
instrument which can be used in any order. If the instrument to be tested and a sufficiently accurate
reference measuring instrument are connected to the test pump, the same pressure is applied to the
two measuring instruments when the pump is operated. By comparing the two measured values at
random pressure values, the accuracy can be verified or the instrument under test can be adjusted.
First the pressure is set via an integrated initial pressure pump. For fine adjustment by approaching
the measuring points precisely an adjustable volume with precision spindle is available. Another
important feature of the pumps is the rotating spindle that only runs inside the body of the pump. This
eliminates the negative effect of a bending torque on a spindle turning outside the body and offers the
advantage, especially for use in the field, that the dimensions of these pumps do not change during
operation due to the spindle turning.
The term ”reference instrument” in this manual relates to each kind of pressure
measuring instrument like: spring manometer, electrical pressure measuring
instrument and pressure transmitters with electrical outlet. The comparison test pump
is only as precise as the used reference instrument. The reference instrument should
be recalibrated in regular intervals to guarantee the specifications of the manufacturer.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 7
2.2 Arrangement of control elements CPP 3000-X / CPP 5000-X and CPP 7000-X .
View from above
Rear view
Front view
Connection for test
specimen or
reference instrument
Initial pressure
p
um
p
Water
level
Spindle pump
Screwed drain plug for
tank
High-pressure
shut-off valve (HP)
Low-pressure
shut-off valve (LP)
Connection for test
specimen or
reference instrument
Rotating base

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 8
3. Commissioning and operation .
3.1 Preparation .
3.1.1 Setting up the device .
Set up the comparison test pump on a solid surface. If it is not resting on a solid foundation or is
subject to vibrations, measurements could be affected. This should be avoided.
The water level should be used to align the device. Using the rotating feed, position the device so
that it is horizontal.
The oil container may need to be filled, or refilled (volume 250 ml). For this purpose, the locking
screw with the oil filling symbol on top of the basement must be opened. Special oil must be used
for refilling (0,5 litre supplied, or available as accessory). The system must be vented before initial
filling, or after a complete oil change. For this purpose, please proceed according to section 5.2.3.
Place the star handle with knobs onto the spindle pump. Ensure that the spring-loaded thrust pad
engages into the star handle bushing.
We recommend unscrewing the spindle pump completely when you start to record measurement
values, (turning anticlockwise) to allow enough volume for measurements. The outlet valve must be
opened during this process.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 9
3.1.2 Connecting the test specimen and the reference instrument .
Before releasing the closure plugs in the test connections, ensure that the
system (spindle pump turned back completely counter-clockwise, open high-
pressure shut-off valve, open low-pressure shut-off valve) is depressurised.
Note: The closure plugs serve to seal off the test connections from oil leaks, or
from any penetrating contamination. It may not be pressurised under any
circumstances.
The test connections have a knurled nut with a G ¾ female thread, in which various threaded
connecting adapters may be screwed into. 2 threaded adapters with M16 x 1.5 male thread are
included in the scope of supply as standard equipment:
Connecting adapters with M20 x 1.5 male thread and 9/16-18UNF male thread with
sealing cone and a connecting adapter with G ½ female thread with an O-ring seal are
available as accessories. The maximum pressure permitted with the use of this
adapter is limited to 1600 bar.
First, install the matching threaded adapters on your test specimen and reference instrument.
Then connect the test specimen and the reference instrument, including the installed threaded
adapters, to the knurled nut of the test connections at the test pump. The free-running knurled nut
enables the orientation of the instruments. Firmly tighten the knurled nut and the threaded adapter
with a flat wrench in the desired clamping position. The wrench width for the knurled nut and the
threaded adapter is SW 36.
Additional sealing elements are not required. Sealing is performed purely metallic using a sealing
cone.
Threaded adapter
Knurled nut

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 10
3.1.3 Venting the system .
After the clamping of the test specimen and the reference instrument, air may be trapped in the
system. The system may be vented before beginning with calibration using the following procedure:
The test specimen and the reference instrument must be clamped
Close the low-pressure shut-off valve
Open the high-pressure shut-off valve
Generate a pressure of approximately 50 bar using the initial pressure pump
Close the high-pressure shut-off valve
Increase the pressure with the spindle pump until just below the final value of the measuring range
of the test specimen or of the reference instrument (the smaller pressure range is the decisive
factor).
Carefully open the high-pressure shut-off valve, any trapped air will escape into the tank
Open the low-pressure shut-off valve
This procedure may need to be repeated several times in order to remove all trapped air.
Opening the high-pressure shut-off valve without first turning out the spindle pump in counter-
clockwise direction in order to relieve the system on initial pressure is permitted only with the venting
procedure described herein.
After generating initial pressure, the high-pressure shut-off valve must always
be closed before pressure is increased using the spindle pump. An integrated
safety overflow valve (adjusted to approximately 100 bar) additionally protects
the low-pressure circulation from any errors on the operator’s part.
The device is now ready to use.