WIKA CPP 1000-X User manual

Operating Instructions
Betriebsanleitung
CPP 1000-X
CPP 1600-X
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 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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Version 1.1 05/2009

Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 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 1000-X ........................................................................ 7
2.3 Arrangement of control elements CPP 1600-X ........................................................................ 8
3. Commissioning and operation .................................................................................................... 9
3.1 Preparation .................................................................................................................................. 9
3.1.1 Setting up the device ............................................................................................................... 9
3.1.2 Connecting the test specimen and the reference instrument ........................................... 10
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 ................................................................................................................................ 14
5.1 Wear parts .................................................................................................................................. 14
5.2 Changing the operating fluid ................................................................................................... 14
5.2.1 Removing operating fluid ...................................................................................................... 14
5.2.2 Filling in of operating fluid .................................................................................................... 15
5.2.3 Venting of the system (after complete filling only) ............................................................ 15
6. Specifications .............................................................................................................................. 16
7. Accessories ................................................................................................................................. 19
8. Declaration of the manufacturer ........................................................... 37
9. Declaration of conformity ................................................................ 38
Version 1.1 05/2009

Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 4
1. General .
1.1 General instructions .
In the following chapters detailed information on the CPP 1000-X and CPP 1600-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]
[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 GmbH & Co. KG result from the respective sales contract and the general
business terms of WIKA Alexander Wiegand GmbH & Co. KG.
WIKA is a registered trade mark of WIKA Alexander Wiegand GmbH & 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.
© 2006 Copyright WIKA Alexander Wiegand GmbH & Co. KG. All rights reserved.
Version 1.1 05/2009

Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 5
1.2 Safety instructions .
Read these operating instructions carefully prior to operating
the comparison test pumps CPP 1000-X and CPP 1600-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 1000-X or CPP 1600-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.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 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.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 7
2.2 Arrangement of control elements CPP 1000-X .
View from above
Front view
Rear view
Connection for test
specimen or
reference instrument
Initial pressure pump
Connection for test
specimen or
reference instrument
Water
level
Spindle pump
Outlet
valve
Test pressure
gauge
Rotating base
Screwed drain plug for
tank
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 8
2.3 Arrangement of control elements CPP 1600-X .
View from above
Front view
Rear view
Connection for test
specimen or
reference instrument
Initial pressure pump
Connection for test
specimen or
reference instrument
Water
level
Spindle pump
Outlet
valve
Rotating base
Screwed drain plug for
tank
Version 1.1 05/2009

Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 9
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 medium container may need to be filled, or refilled (volume 250 ml). For this purpose, the
locking screw with the filling symbol on top of the basement must be opened. Special oil must be
used for refilling (1 litre supplied, or available as accessory) or clean water, free of calcium-
carbonate / scale. The system must be vented before initial filling, or after a complete medium
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.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 10
3.1.2 Connecting the test specimen and the reference instrument .
Place the device to be checked and the reference instrument in the quick connector with the
knurled nut. They can be freely positioned. The order makes no difference. Hand-tightening will
suffice for safe sealing.
To calibrate instruments with back pressure entry there is an angle connection 90°available (see
accessories section 7).
Check the O-ring seals in the test connections for proper seat and for any wear.
Replace, if necessary.
Please see to it, that each instrument mounted to the test pump must be clean
inside.
The quick connectors come equipped with a G 1/2 threaded insert in the standard delivery
package.
When you are calibrating devices with different connection threads, the threaded
inserts can be changed as appropriate (see accessories "Adapter Set").
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
The outlet valve must be closed.
Generate a pressure of approximately 50 bar using the initial pressure pump (Pay attention to the
measuring range of the instruments!)
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).
Open the outlet valve, any trapped air will escape into the tank
This procedure may need to be repeated several times in order to remove all trapped air.
The device is now ready to use.
O-ring 8 x 2
(see accessories section 7.)
Knurled nut
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