WIKA DH Budenberg CPP4000-X Operating Instructions Manual Download | Manualshive

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7. Maintenance, cleaning and servicing

WIKA Operating Instruction, CPP4000-X

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Summary of Contents for DH Budenberg CPP4000-X

Page 1: ...Hydraulic comparison test pump model CPP4000 X EN Hydraulic comparison test pump model CPP4000 X Operating instructions ...

Page 2: ...ction model CPP4000 X Page 2 31 Further languages can be found at www wika com 2016 WIKA Alexander Wiegand SE Co KG All rights reserved WIKA is a registered trademark in various countries Prior to starting any work read the operating instructions Keep for later use ...

Page 3: ...tion 11 3 2 Scope of delivery 11 3 3 Base unit 11 3 3 1 Spindle pump 13 3 3 2 Reservoir 13 3 3 3 Control valves 13 3 3 4 Connection blocks 13 3 4 Function 13 4 Transport packaging and storage 15 4 1 Transport 15 4 2 Packaging and storage 15 5 Commissioning operation 16 5 1 Unpacking the hydraulic comparison test pump 16 5 2 Environmental requirement 16 5 3 Assembly of base units Fastening base to ...

Page 4: ...2 Corrective maintenance 24 7 2 1 General 24 7 2 2 Removing the cover 26 7 2 3 Reservoir seals 26 7 2 4 Valve seals 26 7 2 5 Spindle pump 26 7 2 6 Hub assembly 27 7 3 Cleaning 27 7 3 1 Cleaning the unit and checking the liquid levels 27 8 Dismounting return and disposal 28 8 1 Return 28 8 2 Disposal 28 9 Specifications 29 10 Accessories 31 Declarations of conformity can be found online at www wika...

Page 5: ...ydraulic comparison test pump The operating instructions are part of the instrument and must be kept in the immediate vicinity of the model CPP4000 X hydraulic comparison test pump 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 general terms and conditions contained in the ...

Page 6: ...nd reference measuring instrument which can be used in any order If one connects the test item and a sufficiently accurate reference measuring instrument to the test pump on actuating the pump the same pressure will act on both instruments By comparison of the two measured values at any given pressure value a check of the accuracy and or adjustment of the pressure measuring instrument under test c...

Page 7: ...ring instruments with the required care protect from humidity impacts strong magnetic fields static electricity and extreme temperatures do not insert any objects into the instrument or its openings 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 tem...

Page 8: ...azards that could impair their safety or health during work When carrying out the various tasks on and with the instrument the skilled personnel must wear personal protective equipment Follow the instructions displayed in the work area regarding personal protective equipment The requisite personal protective equipment must be provided by the operating company Wear safety goggles Protect eyes from ...

Page 9: ... m Fire extinguishing media CO2 dry chemical foam or water fog Spillage Soak with absorbent clay or proprietary absorbent Waste disposal Burn or dump in approved area Emergency treatment of acute effects Ingestion Do not induce vomiting Administer 250 ml milk or olive oil The main hazard following accidental ingestion is aspiration of liquid into lungs Aspiration Send to hospital immediately Inhal...

Page 10: ...roduct label 1 Model 2 Serial number 3 Pressure 4 Date of manufacturing 5 Permissible pressure medium 2 7 2 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 2 3 4 5 1 ...

Page 11: ...e sealing face VG22 mineral oil 0 5 litre Tool and maintenance set consisting of 1 hexagon wrench key 3 mm A F o 1x 30 mm A F open ended spanners o 2x G1 2 differential nut connections o 1x G3 8 differential nut connection o 1x Sealing coned joint o 2x Sealing coned joint 1 end recessed o 1x spirit level o 4x level plates 1 bag of seals o 1x pointer punch o 1x pointer remover Operating instruction...

Page 12: ...4 Design and Function 12 WIKA Operating Instruction model CPP4000 X EN 14155460 00 08 2016 GB Sectioned view of spindle pump ...

Page 13: ... 3 3 Control valves Two control valves are provided on the top of reservoir high pressure cylinder block The valve mechanisms are built into the reservoir high pressure cylinder block and they control the flow of liquid through internal drillings in the reservoir high pressure cylinder block The rear valve is referred to as valve A and is used to control the output from the high pressure ram of th...

Page 14: ...essure part of the spindle pump and valve B is opened to allow the liquid in the low pressure part of the spindle pump to return to the reservoir as the pump is operated This ensures that the pump can be operated without having to put large forces on the spindle pump handwheel To release the test pressure the spindle pump is wound out and valve A is opened ...

Page 15: ...ovide optimum protection during transport e g change in installation site sending for repair Permissible conditions at the place of storage Storage temperature 10 50 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 Pot...

Page 16: ...fficient space to operate is required 5 3 Assembly of base units Fastening base to bench The base is to be mounted on a firm level table or bench about 0 9 m high The centre line of the front adjustable feet of the unit should be about 40 mm from the front edge of the bench to allow adequate clearance for the handwheel 1 Mark the position of the adjustable feet of the unit on the top of the bench ...

Page 17: ...voir if necessary Wear safety goggles Protect eyes from flying particles and liquid splashes 5 4 3 Post assembly test 1 Carry out a test calibration of a known instrument see chapter 5 5 Procedure to ensure that the unit is working correctly 2 Release the pressure and remove the test instrument Information To remove the instrument from the system use the appropriate size of spanners on the top sec...

Page 18: ...generate pressure up to approximately 4 000 bar or 60 000 lb in 5 5 2 During calibration Increase the pressure via the spindle pump in the clockwise direction or use the fine adjustment to approach the individual calibration points The display of the pressure measuring instrument being tested can be compared with the reference measuring instrument at the individual calibration points Information I...

Page 19: ...r use with pressure gauges which are fitted with coiled Bourdon tubes nor any gauges which are to be used on oxygen as complete removal of oil is not assured Please contact DH Budenberg WIKA Equipment This consists of a syringe and a special needle with the point bent through 90 Instructions 1 Fill syringe with solvent suitable cold degreasing liquid 2 With gauge connection pointing upwards put ne...

Page 20: ...6 Commissioning operation 20 WIKA Operating Instruction model CPP4000 X EN 14155460 00 08 2016 GB ...

Page 21: ...r valve seat damaged Examine condition of valve B and valve seat Replace valve assembly or return test pump to DH Budenberg WIKA for overhaul as necessary If unable to locate a cause Return test pump to DH Budenberg WIKA for investigation Equipment provides pressure but pressure decays to zero Incorrect operating procedure being used Ensure that correct operating procedure is being followed see ch...

Page 22: ...l damage Return test pump to DH Budenberg WIKA for investigation Incorrect operating procedure being used Ensure that correct operating procedure is being followed see chapter 5 5 Procedure If unable to locate a cause Return test pump to DH Budenberg WIKA for investigation The spindle pump of the test pump becomes very stiff to operate when the test pump is being used in the range below 140 bar 2 ...

Page 23: ... by means of the measures listed above shut down the test pump immediately and ensure that pressure is no longer present and secure the instrument from being put back into operation inadvertently In this case contact the manufacturer If a return is needed please follow the instructions given in chapter 8 1 Return ...

Page 24: ... maintenance should be necessary If required the system can be returned to the manufacturer for re conditioning Fluids which attack ABS should be used with caution Continual immersion of the cover in such fluids will cause deterioration Spillage s should be wiped off immediately 7 2 Corrective maintenance 7 2 1 General This section contains details on stripping the unit and replacing the spare par...

Page 25: ...7 Maintenance cleaning and servicing WIKA Operating Instruction CPP4000 X 25 EN 14155460 0 08 2016 GB ...

Page 26: ...7 2 5 Spindle pump 1 Using a 4 mm hexagon wrench key unscrew the six socket head cap screws secur ing the hub locating plate These are positioned inside the recess in the back of the aluminium hub 2 By carefully pulling the hub the complete ram assembly can now be withdrawn from the barrel During this operation a container is required beneath the barrel to catch any liquid 3 Unscrew the ram from t...

Page 27: ...p these items together to eliminate end play and re assemble spring pin If using new spindle drill through 6 3 mm diameter to fit spring pin 1 10 Lubricate the thread with molybdenum disulphide grease and screw into ram nut 7 3 Cleaning 7 3 1 Cleaning the unit and checking the liquid levels Oil operation Keep the system clean and free from spilt oil Wipe out the oil cups under the gauge stands as ...

Page 28: ...acids bases solutions etc When returning the instrument use the original packaging or a suitable transport packaging To avoid damage 1 Wrap the instrument in an antistatic plastic film 2 Place the instrument along with shock absorbent material in the packaging Place shock absorbent material evenly on all sides of the transport packaging 3 If possible place a bag containing a desiccant inside the p...

Page 29: ...ow pressure piston 31 2 mm Piston diameter high pressure piston 6 35 mm Displacement approx 5 cm Material Wetted parts Austenitic stainless steel high tensile brass nitrile rubber Permissible ambient conditions Operating temperature 0 40 C Instrument base Dimensions 401 x 397 x 155 mm W x D x H for details see technical drawings Weight 13 5 kg 1 Other pressure transmission media on request Storage...

Page 30: ...9 Specifications 30 WIKA Operating Instruction model CPP4000 X EN 14155460 00 08 2016 GB Dimensions in mm Test Connection ...

Page 31: ...cone material stainless steel hardened 46858410 Adapter for test item connection G B male on M16 x 1 5 male with sealing cone material stainless steel hardened 57340075 Adapter for test item connection G B male on 9 16 18 UNF male with sealing cone material stainless steel hardened 46858411 Adapter for test item connection G B male on G1 2 female O ring seal 46858412 Sealing and maintenance set fo...

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