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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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
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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
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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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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 11
3.2 Operation .
The maximum permissible pressure for the CPP 1000-X is 1,000 bar resp. for the
CPP 1600-X is 1,600 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 .
The outlet valve must be closed.
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).
After that, increase the pressure resp. make a fine adjustment by turning the built-in spindle pump
clockwise to approach the calibration points.
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.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 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.
To release pressure more quickly or for venting, the fine adjustment valve can also be carefully
opened.
3.3 Disassembly .
After all pressure points have been recorded, open the outlet valve.
Now the test specimen and the reference instrument can be removed from the quick clamp.
Do not disconnect the test specimen or the reference instrument until the
pressure in the comparison test pump has been completely released.
In order to remove the star handle from the spindle pump, the spring-loaded thrust pad must be
pressed downward with the aid of a small screwdriver, or a ball-point pen. The star handle may
now be pulled off toward the front.
Spring-loaded
thrust pad
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 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 / leak in the system Close outlet valve correctly
Attention: Do not tighten the fine
adjustment valve more than finger tight.
Otherwise the valve seat could be
damaged.
Check whether the seals have been
placed in the quick clamp for the test
specimen and the reference instrument
and whether they are properly positioned.
Check whether there is enough operating
fluid in the tank.
II. 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.
III. Slow lowering of the pressure Leak in the system, see fault I.
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 (hydraulic design
only), see point II.
Afterwards, build the pressure back up.
Further help can be found through WIKA's Test & Calibration Technology Department.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 14
5. Maintenance .
5.1 Wear parts .
The O-rings in the test connections are subjected to wear. Both O-rings must be checked for proper
seat and any wear before any calibrating is performed. If necessary, the O-rings must be replaced in
regular intervals, or whenever necessary (see Accessories, section 7).
Important: Use original seals only. Seals having deviant measurements, or
materials, or material grades, may cause damage to the device and test
specimen, and pose a danger for the operator.
5.2 Changing the operating fluid .
The operating fluid should be changed whenever visible contamination is present.
5.2.1 Removing operating fluid .
Open the locking screw with the filling symbol on top of the basement
Siphon the medium out of the tank, for example, by using a suitable nozzle
Small amounts of medium residue additionally may be siphoned off the test connections opened
and with the outlet valve closed, by means of slowly turning in of the spindle pump
Minute amounts of medium residue may remain in the piping
In case of severe contamination of the operating fluid, 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.
For operating fluid hydraulic oil:
Waste oil must be disposed of according to legal requirements.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 15
5.2.2 Filling in of operating fluid .
Turn in the spindle pump clockwise until it reaches the initial stop
Close the outlet valve
Open the locking screw with the filling symbol on top of the basement
Fill in special oil (1 litre supplied, or available as accessory) or clean water, free of calcium-
carbonate / scale 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 medium change, air may be trapped in the system. The system
should be vented using the following procedure:
The test connections must be open
Close the outlet valve
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 medium escaping in the open test connections should be siphoned off, for example, with a
nozzle.
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 16
6. Specifications .
CPP 1000-X CPP 1600-X
Pressure range bar 0 ... 1,000 0 … 1,600
Medium Mineral oil based hydraulic fluid / Mineral oil based hydraulic fluid /
clean water, free of calcium- clean water, free of calcium-
carbonate / scale 1) carbonate / scale 1)
Pressure connections 2 x quick connector G ½“ 2 x quick connector G ½“
female thread, rotating, female thread, rotating,
changeable, with O-ring changeable, with O-ring
Distance of the test connections mm 300 300
Liquid reservoir cm³ 250 250
Piston diameter mm 8 8
Swept volume per revolution cm³ approx. 0.1 approx. 0.1
Overall swept volume cm³ approx. 3.9 approx. 3.9
Required moment at
- 250 bar Nm 2.0 2.0
- 500 bar Nm 4.0 4.0
- 1000 bar Nm 8.0 8.0
Material
- Cylinder Brass Brass
- Piston Stainless steel Stainless steel
- Tubing Stainless steel 1.4404, 6 x 2 mm Stainless steel 1.4404, 6 x 2 mm
- Rear flange Aluminium Aluminium
- Sealing gaskets FKM and NBR (standard) FKM and NBR (standard)
optional EPDM optional EPDM
Dimensions mm 400 (W) x 375 (D) x 265 (H) 400 (W) x 375 (D) x 265 (H)
Weight kg 20 20
CE-conformity - 97/23/EC Pressure equipment
directive (Module A)
1) Other pressure transmitting media on request.
Version 1.1 05/2009

Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 17
Dimensions CPP 1000-X
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 18
Dimensions CPP 1600-X
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Comparison Test Pump GB
CPP 1000-X and CPP 1600-X
WIKA Operating Instructions Comparison Test Pump 19
7. Accessories .
Description / Features Order no.
Operating fluid for CPP1000 & CPP1600 test pump series in plastic bottle, content 1 litre 2099882
Set of O-rings consisting of: 5 pieces 8x2 and 5 pieces 4 x 2.2 12328562
Set of adapters for the quick-connector in a case with threaded inserts G1/4, G3/8, 1/2
NPT, 1/4 NPT and M20x1.5 for adaptation to the knurled nut 2036941
Angle connection 90° for test specimens with back mounting connection 1564838
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 1,000 bar
Accuracy: 0.025 % of span
Specifications according data sheet CT 15.01
Hand-Held Pressure Indicator Model CPH 6400
Measuring range:up to 4,000 bar
Accuracy: 0.025 % of span or 0.1 % of reading
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
Version 1.1 05/2009

Vergleichsprüfpumpe D
CPP 1000-X und CPP 1600-X
WIKA Betriebsanleitung Vergleichsprüfpumpe 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
Version 1.1 05/2009