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.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 11
3.2 Operation .
The maximum permissible pressure for the CPP 3000-X is 3,000 bar, for the CPP
5000-X 5,000 bar and for the CPP 7000-X 7,000 bar. Higher pressures may
damage the pump. The reference instrument, test specimen and any connecting
tubes that are used must not be subjected to pressures above the maximum
permissible level.
3.2.1 Increasing the pressure .
We recommend unscrewing the spindle pump completely when you start to record
measurement values, (turning anticlockwise) to allow enough volume for
measurements. The low-pressure and high-pressure shut-off valve must be opened
during this process.
The system must first be filled with oil and pre-compressed.
For this the valves must be in the basic position:
Low-pressure shut-off valve closed
High-pressure shut-off valve opened
Then run the initial pressure pump for several strokes. The pressure increases to a maximum of
about 50 bar (depending on the volume of the connected instruments).
The high-pressure shut-off valve must be closed after pre-pressure generation.
After that, increase the pressure resp. make a fine adjustment by turning the built-in spindle pump
clockwise to approach the calibration points.
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.
Now you can compare the indication of the test specimen with the reference instrument at each
calibration point.
If small amounts of air are compressed in the system together with medium, the test
pressure that has been generated first drops off slightly. After this it must be
readjusted.
A longer waiting time before stable operating conditions are reached should be
expected at higher pressures than at lower pressures.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 12
3.2.2 Reducing the pressure .
Turn the spindle pump anticlockwise to release pressure in the system.
If the pressure is close to the next test level, make the fine adjustment with the spindle wheel.
Once the spindle pump is turned back completely counter-clockwise, only the initial pressure
remains in the system.
Now the high-pressure shut-off valve can be opened.
Open the high-pressure shut-off valve only if the pressure in the system has
been relieved to initial pressure. For this purpose, always first turn the spindle
pump back completely counter-clockwise.
The initial pressure can be further relieved by carefully opening the low-pressure shut-off valve.
By completely opening the low-pressure shut-off valve, the initial pressure will completely escape
back into the tank.
The system is now completely relieved
Even if you wish to relieve the system from a high pressure completely down to
zero immediately, the spindle pump must first be completely turned back
counter-clockwise. Then open the high-pressure shut-off valve, and
subsequently open the low-pressure shut-off valve. The initial pressure then
escapes completely into the tank. The system is now completely relieved.
3.3 Disassembly .
After all pressure points have been recorded, ensure that the system is depressurised (see section
3.2.2).
Now the test specimen and the reference instrument can be removed from the test connection.
Do not disconnect the test specimen or the reference instrument until the
pressure in the comparison test pump has been completely released.
The handle bars of the star handle can now be unscrewed from the spindle pump.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 13
4. Troubleshooting measures .
If faults cannot be repaired, the system must be put out of operation
immediately and this information is to be given to the manufacturer.
Repairs must only be carried out by the manufacturer. Interventions and
changes on the appliance are not allowed.
In case of faults caused by defects of the hydraulic equipment the operators must inform their
superiors immediately and call in the qualified and authorised technical staff for maintenance.
Table: Fault description and measures .
Type of fault Measures
I. Unable to build up pressure during pre-
pressure generation
Close low-pressure shut-off valve
correctly
Attention: Do not tighten the shut-off
valve more than finger tight. Otherwise
the valve seat could be damaged.
Check whether there is enough operating
fluid in the tank.
II. Unable to build up further pressure at high-
pressure generation with the spindle pump
Close high-pressure shut-off valve
correctly
Please note: In case of an opened, or not
properly closed high-pressure shut-off
valve, the safety overflow valve is not
activated until approximately 100 bar are
reached, and the oil will flow back into the
tank. Therefore, no pressure > 100 bar
can be built up.
III. Unable to build up pressure / oil discharge at
the test connections
Tighten the test specimen and the
reference instrument with the connecting
adapter and knurled nut (see section
3.1.2)
In case of wear or damage to the sealing
cone, proceed as described in section 5.1.
IV. Unable to build up pressure, or range cannot
be reached
After the clamping of the test specimen
and the reference instrument, air may be
trapped in the system.
Please note: The system should be
vented before beginning with calibration.
For this purpose, proceed according to
section 3.1.3.
Afterwards, build the pressure back up.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 14
V. Slow lowering of the pressure Leak in the system, see fault III.
If small amounts of air are compressed in
the system together with medium, the test
pressure that has been generated first
drops off slightly. After this it must be
readjusted.
If the system is pressurised quickly, it
takes a certain time (< 1 minute) until it
can stabilise thermally. The pressure
should then be adjusted accordingly.
After the clamping of the test specimen
and the reference instrument, air may be
trapped in the system, see point VI.
Afterwards, build the pressure back up.
Further help can be found through WIKA's Test & Calibration Technology Department.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 15
5. Maintenance .
5.1 Wear parts .
Sealing in the test connections is purely metallic using a sealing cone. The individual components are
made of wear-proof materials. Should the seal faces show signs of wear or damage on the interior or
exterior cone, the components must be replaced. In this case, please contact the manufacturer.
5.2 Changing the hydraulic oil .
The hydraulic oil should be changed whenever visible contamination is present.
5.2.1 Removing hydraulic oil .
Open the locking screw with the oil filling symbol on top of the basement
Siphon the oil out of the tank, for example, by using a suitable nozzle
Small amounts of oil residue additionally may be siphoned off the test connections opened. For
this purpose, the spindle pump must be slowly turned in clockwise with the low-pressure and high-
pressure shut-off valves open.
Minute amounts of oil residue may remain in the piping
In case of severe contamination of the hydraulic oil, the complete cleaning of the
piping and of all media-contacted individual components of the basement in a
dismantled state may be advisable. This procedure may be performed by the
manufacturer only.
Waste oil must be disposed of according to legal requirements.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 16
5.2.2 Filling in of hydraulic oil .
Open the high-pressure shut-off valve
Open the low-pressure shut-off valve
Turn in the spindle pump clockwise until it reaches the initial stop
Open the locking screw with the oil filling symbol on top of the basement
Fill in special oil (0.5 litre supplied, or available as accessory) via the tank opening, until the fill
level reaches the thread of the tank opening (approximately 250ml). The fill level must always be
observed.
Twist out the spindle pump counter-clockwise until it reaches the rear stop. The filling medium is
suctioned out of the tank into the system.
Close the tank opening with the locking screw
5.2.3 Venting of the system (after complete filling only) .
After initial filling, or after a complete oil change, air may be trapped in the system. The system should
be vented using the following procedure:
Open the high-pressure shut-off valve
Open the low-pressure shut-off valve
The test connections must be open
Twist out the spindle pump counter-clockwise until it reaches the rear stop.
Carefully pump using the initial pressure pump, while continuously observing the filling medium in
the open test connections. At this point, trapped air escapes toward the exterior by means of the
formation of bubbles. The initial pressure pump must be actuated until air bubbles no longer
appear.
Any oil escaping in the open test connections should be siphoned off, for example, with a nozzle.

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 17
6. Specifications .
CPP 3000-X CPP 5000-X
CPP 7000-X
Pressure range bar 0 ... 3,000 0 … 5,000 resp. 0 … 7,000
Medium Hydraulic oil Sebacate-oil
Pressure connections 2 x M16 x 1.5 male thread, 2 x M16 x 1.5 male thread,
rotating, changeable, rotating, changeable,
with sealing cone with sealing cone
Distance of the test connections mm 346 346
Liquid reservoir cm³ 250 250
Piston diameter mm 8.0 7.5
Swept volume per revolution cm³ approx. 0.15 approx. 0.08
Overall swept volume cm³ approx. 3.0 approx. 2.5
Required moment at
- 250 bar Nm 2.0 1.5
- 500 bar Nm 4.0 3.0
- 1,000 bar Nm 8.0 6.0
- 3,000 bar Nm 24 18
- 5,000 bar Nm - 30
- 7,000 bar Nm - 42
Material
- Cylinder Stainless steel Stainless steel
- Piston Hardened stainless steel Hardened steel
- Tubing Stainless steel 1.4404, 6 x 2 mm Stainless steel 1.4404, 6 x 2 mm
- Sealing gaskets PTFE NBR
Dimensions mm 460 (W) x 445 (D) x 265 (H) 460 (W) x 445 (D) x 265 (H)
Weight kg 33.5 32.5
CE-conformity 97/23/EC Pressure equipment 97/23/EC Pressure equipment
directive (Module A) directive (Module A)

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 18
Dimensions CPP 3000-X / CPP 5000-X and CPP 7000-X

Comparison Test Pump GB
CPP 3000-X / CPP 5000-X / CPP 7000-X
WIKA Operating Instructions Comparison Test Pump Version 2.1 19
7. Accessories .
Description / Features Order no.
Operating fluid for CPP1000 / CPP1600 and CPP3000 test pump series in plastic bottle,
content 1 litre 2099882
Operating fluid for CPP5000 & CPP7000 test pump series in plastic bottle, content 0.5 litre 11123150
Threaded adapter M16 x 1.5 male thread with sealing cone,
mat.: hardened stainless steel 11093740
Threaded adapter M20 x 1.5 male thread with sealing cone,
mat.: hardened stainless steel 11093901
Threaded adapter 9/16-18UNF male thread with sealing cone,
mat.: hardened stainless steel 11093871
Threaded adapter G 1/2 female thread with O-ring, max. 1,600 bar, mat.: 1.4571 11095912
Recommended reference instruments:
Hand-Held Pressure Indicator Model CPH 6200
Measuring range:up to 1,000 bar
Accuracy: 0.2 % of span
Specifications according data sheet CT 11.01
ProcessCalibrator Model CPH 6000
Measuring range:up to 8,000 bar
Accuracy: 0.025 % of span (< 1,000 bar)
0.1 % of span (> 1,000 bar)
Specifications according data sheet CT 15.01
Precision Hand-Held Pressure Indicator Model CPH 6400
Measuring range:up to 8,000 bar
Accuracy: 0.025 % of span (< 1,000 bar)
0.1 % of span (> 1,000 bar)
Specifications according data sheet CT 14.01
Calibration software:
Calibration software EasyCal
For inspection equipment monitoring incl. generation
of calibration reports and archiving of calibration data
Specifications according data sheet CT 95.01

Vergleichsprüfpumpe D
CPP 3000-X / CPP 5000-X und CPP 7000-X
WIKA Betriebsanleitung Vergleichsprüfpumpe Version 2.1 20
Information
Dieses Zeichen gibt Ihnen Informationen, Hinweise oder Tipps.
Warnung!
Dieses Symbol warnt Sie vor Handlungen, die Schäden an Personen oder
am Gerät verursachen können.
D