WIKA Wally Box III CPH7600 User manual

Operating instructions
Betriebsanleitung
GB
D
Wally Box III model CPH7600
Wally Box III Typ CPH7600
Portable pressure calibrator, Wally Box III, model CPH7600

2
14051628.01 11/2012 GB/D
WIKA operating instructions, model CPH7600
GB
D
Operating instructions model CPH7600 Page 3 - 46
Betriebsanleitung Typ CPH7600 Seite 47 - 89
© 2012 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!

3WIKA operating instructions, model CPH7600
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1. General information 4
2. Safety 5
2.1 Intended use 5
2.2 Personnel qualication 6
2.3 Special hazards 7
2.4 Labelling, safety marks 9
3. Specications 10
4. Design and function 13
4.1 Description 13
4.2 Scope of delivery 13
4.3 Voltage supply 13
4.4 Pressure connection 14
4.5 Keypad 15
5. Transport, packaging and storage 16
6. Commissioning, operation 17
6.1 Calibrator display 17
6.2 Using the backlighting 20
6.3 Using of the "ZERO" function 20
6.4 Other menu controlled functions 20
6.5 Menu structure 25
6.6 First usage and various operating modes 27
6.7 Measuring pressure 28
6.8 Measuring and transmitting current (4 ... 20 mA) 29
6.9 Measuring voltage 31
6.10 Performing a pressure switch test 32
6.11 Calibrating transmitters 34
6.12 MIN/MAX value capture 40
7. Maintenance, cleaning and recalibration 41
8. Faults 42
9. Dismounting, return and disposal 43
10. Accessories 44
Appendix: EC Declaration of Conformity for model CPH7600 45
Declarations of conformity can be found online at www.wika.com.
Contents
Contents

4 WIKA operating instructions, model CPH7600
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1. General information
1. General information
■
The hand-held 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 certied 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 insuciently qualied skilled personnel or unauthorised
modications to the instrument.
■
The general terms and conditions contained in the sales documentation shall apply.
■
Subject to technical modications.
■
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 17.01
- Application consultant: Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]

5WIKA operating instructions, model CPH7600
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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 equipment or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for ecient
and trouble-free operation.
DANGER!
...identies hazards caused by electric 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 specic 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.
2.1 Intended use
This hand-held pressure calibrator is used as a calibration instrument for various
pressure measuring instruments.

6 WIKA operating instructions, model CPH7600
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2. Safety
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The technical specications contained in these operating instructions must be
observed. Improper handling or operation of the instrument outside of its technical
specications 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 elds, 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.
2.2 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
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 qualications 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-specic regulations, current standards and directives, are capable
of carrying out the work described and independently recognising potential hazards.

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2. Safety
2.3 Special hazards
WARNING!
■
Do not apply a voltage greater than the specied voltage to the
instrument. See chapter 3 "Specications".
■
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 or missing plastic parts on
the case. Pay particular attention to the insulation of the connectors.
■
Select the proper function and correct measuring range for the
measurement.
■
Observe the working conditions in accordance with chapter
3 "Specications".
■
Always operate the pressure calibrator within its overload limits.
■
To ensure problem-free operation, only operate the instrument
on battery power. Only use the mains connection for charging the
instrument's batteries.
■
Inspect the test cables for damaged insulation or exposed metal.
Check the continuity of the test leads. Damaged test leads should be
replaced before using the instrument.
■
When using test probes keep ngers away from the test probe
contacts. Keep your ngers behind the test probes' nger guards.
■
First connect the common lead, and then the live lead. When
disconnecting, remove the live test lead rst.
■
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 process pressure
line is shut o and depressurised before it is connected to or
disconnected from the pressure module.
■
Disconnect test leads before changing to another measurement or
generation function.
■
To avoid false readings, which could lead to possible electric shock
or personal injury, replace the 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.
■
When screwing an adapter onto the NPT thread of the calibrator, a
sealing material must also be used (e.g. PTFE tape).

8 WIKA operating instructions, model CPH7600
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2. Safety
DANGER!
Danger of death caused by electric current
Upon contact with live parts, there is a direct danger of death.
■
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 mains connector permitted by WIKA for the model
CPH7600 hand-held 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 not working as specied.
■
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.

9WIKA operating instructions, model CPH7600
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2. Safety
2.4 Labelling, safety marks
Product label
Explanation of symbols
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
CE, Communauté Européenne
Instruments bearing this mark comply with the relevant European
directives.
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 (see
directive 2002/96/EC).
Pressure range
Accuracy
Input signal
Serial no.
Output signal
Power supply
Date of Manufacture
For an explanation
of Symbol, see
below.
For an explanation
of Symbol, see
below.

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3. Specications
3. Specications
Measuring ranges
Pressure
Relative pressure -0.8 ... +20 bar
Overpressure limit 40 bar 1)
Burst pressure 135 bar 1)
Accuracy 0.025 % of reading ±0.01 % FS
Resolution 5-digit
Temperature compensation 15 … 35 °C
Temperature coecient 0.002 % of the span/°C beyond the 15 ... 35 °C
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) Maximum pressure for the integrated lines: 40 bar
Base instrument
Pressure supply maximum pressure for the integrated pressure generation: 20 bar
maximum pressure via external pressure supply: 7 bar
Pressure connection 1/8 NPT (female)
Permissible media clean, dry, non-corrosive gases, compatible with silicon, Pyrex,
RTV, gold, ceramic, nickel and aluminium
Output
Voltage supply DC 24 V
Power supply
Battery type DC 16 V, NiMH rechargeable battery
Battery life (fully-charged) approx. 50 hours (only measurement or with external pressure
supply)
125 pump cycles to 20 bar
300 pump cycles to 10 bar
1,000 pump cycles to 2 bar
Permissible ambient conditions
Operating temperature -10 … +50 °C
Storage temperature -20 … +60 °C
Relative humidity 35 ... 85 % r. h. (no condensation)

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3. Specications
Case
Material
Case NK-7TM Resin
Front panel Aluminium
Ingress protection IP 67 (case closed)
IP 40 (case opened)
Dimensions 387.4 x 304.8 x 177.8 mm (15.25 x 12 x 7")
Weight approx. 7 kg (15.5 lbs.)
Approvals and certicates
CE conformity
EMC directive 2004/108/EC, EN 61326 emission (group 1, class B) and inter-
ference immunity (portable equipment)
Certicate
Calibration 3.1 calibration certicate per DIN EN 10204
Option: DKD/DAkkS calibration certicate
For further approvals and certicates, see website.
Available pressure range and resolution
Pressure range and factors
Relative pressure -0.8 ... +20 bar
Overpressure limit 40 bar
Burst pressure 135 bar
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
For further specications see WIKA data sheet CT 17.01 and the order documentation.

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3. Specications
Dimensions in mm (inch)
368,5 mm (14,51")
253,4 mm (9,98")
390 mm (15,36")172 mm (6,76")
308 mm (12,13")
104 mm
(4,11")
158 mm (6,22")

13WIKA operating instructions, model CPH7600
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4. Design and function
4. Design and function
4.1 Description
With the Model CPH7600, Wally Box III, WIKA oers a further development of the
well-known Wally Box I and Wally Box II. The Wally Box III is a compact, portable
pressure calibrator, which has been designed for mobile use as well as for stationary
workshop and laboratory testing. A special feature of this test instrument is that it is tted
with two independently-operating pressure systems.
One pneumatic system is designed to be supplied from an external pressure supply,
while the supply pressure of the second system is generated by the integrated electrical
pressure generation. This enables the user to perform dierent measurement tasks or
calibrations, regardless of external pressure and power supplies.
4.2 Scope of delivery
■
Wally Box III model CPH7600
■
Operating instructions
■
Test cables
■
Calibration hose with ⅛ NPT male thread connections
■
Adapter set consist of:
- ⅛ NPT female to ¼ NPT female
- ⅛ NPT female to ¼ BSP female
- ⅛ NPT female to G ½ female
■
PTFE thread seal tape
■
Battery charger
■
3.1 calibration certicate per DIN EN 10204
Cross-check scope of delivery with delivery note.
4.3 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
o automatically.
Exclusively use the mains connector permitted by WIKA for the model
CPH7600 hand-held pressure calibrator.

14 WIKA operating instructions, model CPH7600
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4. Design and function
4.4 Pressure connection
(Figure: Pressure supply via external compressed air)
0 ... 8,3 bar
Compressed air supply
Test item
-0.8 ... +20 bar
(Figure: Pressure supply via integrated electric pump )
(Figure: Pressure measurement)
Test item

15WIKA operating instructions, model CPH7600
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4. Design and function
4.5 Keypad
1) Function keys
Conguration of the instruments
2) HOME key
Return to main menu
3) Arrow keys
Control of the current source/current simulation and adjustment of the pump limit
and the %-error limit
4) ZERO key
Zeroing of the pressure measurement
5) Pump key
Start-up of the pump operation
6) ON/OFF key
Turning the instrument on and o
1
3
2
46
5

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5. Transport, packaging and storage
5. Transport, packaging and storage
5.1 Transport
Check hand-held pressure calibrator for any damage that may have been caused by
transport. Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before use.
Keep the packaging as it will provide optimum protection during transport (e.g. change
in installation site, sending for repair).
5.3 Storage
Permissible conditions at the place of storage:
■
Storage temperature: -20 ... +60 °C
■
Humidity: 35 ... 85 % relative humidity (no condensation)
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
■
Potentially explosive environments, ammable atmospheres
Store the hand-held pressure calibrator in its original packaging in a location that fulls
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 lm.
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.

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6. Commissioning, operation
6. Commissioning, operation
As soon as the hand-held pressure calibrator is turned on, by pressing the ON/OFF
key, it will go through a short self-test routine. During that routine, the display shows the
current rmware version, auto-shutdown status and the range of the internal pressure
sensor. The calibrator requires a maximum of 5 minutes warm-up to reach its specied
accuracy. Large changes in ambient temperature may make a longer warm-up period
necessary. The pressure indication of the calibrator should be zeroed before starting the
pressure calibration.
6.1 Calibrator display
The calibrator's display consists of two sectors: The menu bar (located along the
bottom of the screen) is used to access the menu system. The main display (the rest of
the display) consists of up to three sub-sectors for the measurement activities. These
sub-sectors will be referred to as the UPPER, MIDDLE and LOWER displays in this
document.
Figure 1 shows the location of the dierent display elds, while are described in the
following table.
1) Pressure units
Indication of the pressure unit (selectable from 13 pressure units)
2) Display of the span
Indication of the 4 ... 20 mA span (only for the functions mA and mA current loop)
3) Primary parameter
Indication of the current measured parameters
Figure 1: Display
1
2
3

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6. Commissioning, operation
6.1.1 Main display functionality
There are three options for this menu: "MENU", {active display}, and "LIGHT".
6.1.1.1 Using the "MENU" option
The "MENU" option is entry to the rest of the menu system.
6.1.1.2 Using the {active display} option
The {active display} is displayed via the middle option in the menu in the main display.
It is used to select which display on the screen, for example, the ZERO key will be used
for.
6.1.1.3 Using the "LIGHT" option
The backlight can be toggled on and o using this key.
6.1.2 Main menu Functionality
There are three options on the menu, "CONFIG", {active display} and "MORE". The
main menu is the 'home' for the menu display.
6.1.2.1 Setting the {active display}
The {active display} is displayed via the middle option in the menu in the main display.
Pressing the F2 key switches between the {active display}.
6.1.2.2 Setting the {active display} parameters
In order to set the {active display} parameters, select the "CONFIG" option and open
the conguration menu.

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6. Commissioning, operation
Here the "SELECT" option will switch between the available choices for each
parameter. The rst parameter is "MODE". Since voltage, current and switch test
modes all use the same leads, two of these functions cannot be used concurrently.
The ability to select certain functions is limited and dependent upon what is already
selected in the other display sector. The "NEXT" option is used to change to the second
parameter. Only the pressure modes have a second parameter.
Within any single display sector, the following modes are available:
P[1] = integrated pressure sensor
[EXT] = pressure with external pressure module
P[1] ST = switch test with integrated sensor
[EXT] ST = switch test with external pressure module
Current functions are only available on the lower display:
mA measurement = current measurement without voltage supply
mA w/24V = current measurement with voltage supply
mA Source = current source
mA sim = mA simulation using an external supply from the instrument under test
VOLT = voltage measurement
The following table shows which functions are available concurrently.
An "--" in a column indicates that the mode in the active display will not be available for
selection if the mode in that row is in use in any other display sector.
Active display
Other displays
P[1] [EXT] P[1]
ST
[EXT]
ST mA mA-loop Volt RTD
P[1]   
[EXT]   
P[1] ST   -- -- -- -- -- 
[EXT] ST   -- -- -- -- -- 
mA   -- -- -- -- 
mA-loop   -- -- -- -- 
Volt   -- -- -- --  
6.1.2.3 Accessing other menus
In order to access further menus, select the "MORE" option in the main menu.

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6. Commissioning, operation
6.2 Using the backlighting
The backlight is controlled by the "LIGHT" option on the main menu. The light is toggled
on and o when the F3 key is pressed.
6.3 Using the "ZERO" function
When the ZERO key is pressed, the calibrator will zero the {active display}, as long as
a pressure mode is selected and the pressure is within the zero limit. The zero limits are
within 5 % of the full scale range of the selected sensor. If the display indicates "OL" the
zero function will not operate.
The ZERO key is only used for pressure.
6.3.1 External pressure module (not absolute)
When a pressure module is selected in the {active display} and the ZERO key is
pressed, the calibrator subtracts the current displayed reading from the output value.
The zero limits are within 10 % of the full scale range of the selected sensor. If the
display indicates "OL" the zero function will not operate.
6.3.2 External pressure module (absolute)
When an external absolute pressure module is selected in the {active display} and the
ZERO key is pressed, the calibrator prompts the user to enter the barometric reference
pressure. For this the arrow keys can be used. The sensor port should be opened
(vented) to atmosphere while performing this procedure.
6.4 Other menu controlled functions
There are 10 sub-menus that can be accessed through the "MORE" option of the main
menu. A sub-menu contains three options. The rst option is unique to this function. The
second and third options of a sub-menu are always the same. The "NEXT" option leads
to the next sub-menu and the "DONE" option returns to home.