Operating instructions for the high pressure calibrator (HPX)
Contents
1. CE La pr sente d claration est valable pour les produits de cette s rie mar qu s avec le sigle CE et faisant partie int grante de la pr sente d claration La norme appliqu e pour valuer la compatibilit electromagnetique des dits instruments est la suivante EN 61326 2 3 2006 Diese Erkl rung wird verantwortlich f r den Hersteller This declaration is given for the manu facturer La pr sente d claration est fournie pour le fabricant KELLER AG f r Druckmesstechnik St Gallerstrasse 119 CH 8404 Winterthur abgegeben durch die in full responsibility by par KELLER GmbH Schwarzwaldstrasse 17 D 79798 Jestetten Jestetten 4 Oktober October Octobre 2012 ff C F f Hannes W Keller Gesch ftsf hrender Inhaber Managing Owner Pr sident Directeur G n ral mit rechtsg ltiger Unterschrift with legally effective signature d ment autoris a signer KELLER AG f r Druckmesstechnik St Gallerstrasse 119 CH 8404 Winterthur Tel 41 0 52 235 25 25 Fax 41 0 52 235 25 00 www keller druck com November November Novembre 20122. 700 bar relative The measurement technology incor porated into this device allows ac curate measurement and documen tation of the characteristic of a test object that is connected to it The measured pressure progression can be displayed evaluated and saved with a computer monitoring program CCS30 The calibrator is operated with the two function buttons SELECT and ENTER located directly below the display The calibrator itself is powered by a3 0 V battery but power can also be supplied externally via the K 114A interface converter Test ob jects transmitters or pressure switch es must be supplied from an external source Pressure range for the display High pressure calibrators are them selves calibrated with the ambient air pressure as the zero point reference The Zero function allows any desired pressure value to be set as the new zero point reference To take relative the high pressure calibrator is zeroed at ambient pressure SET ZERO To reset the pressure zero point to the factory setting use the RES ZERO function reset zero measurements 14 Commissioning A pressure resistant connection for the test object is required in order to use the high pressure calibrator The pressure connection for the test object is already screwed to the pressure distributor of the high pressure calibra tor so that it is pressure resistant when it leaves the factory and it must not be dismantled Recommended to
3. K DISP Leak measurement function Leak mode is used to determine the pressure change over a defined period which can be adjusted The unit to be tested must be connected to the high pressure calibrator on the pressure side Start leak measurement Activate the ANGO menu The display shows LEAK DISP Press the ENTER button and then the SELECT button Press ENTER to confirm LEAK START The leak measurement starts and the display alternates between the current leak time and the pressure change measured thus far Active leak measurement During leak measurement the lower part of the display alternates each sec ond between the measurement time that has now elapsed mm ss and the pressure change measured thus far ND Mano mode ENTER Leak d 5P ENTER Launch Leak mode by press ing the ENTER button Es I Start the leak r measurement with ENTER ENTER bar o Unit of pressure MMM Current Leak run LU measured value timein pain Min mm ss Li Dh LL Li Pressure change within leak runtime End leak measurement early To end a leak measurement early press the ENTER button and confirm the LEAK STOP display by pressing ENTER Leak measurement completed If the leak measurement time has elapsed or if the measurement was manually ended ahead of time the display alternates between the elapsed leak measurement time and the measured pressure
4. Operating instructions for the high pressure calibrator HPX Table of contents View 13 Notes on the operating instructions 14 1 Description of the device 14 2 General safety warnings 14 3 Operating the HPX calibrator 15 4 Description of the functions 15 5 Menu navigation for calibrators 16 6 Commissioning 16 7 Maintenance disposal 17 8 Software for calibrators 18 Technical data 19 Spare parts and accessories for KELLER pressure calibrators 20 Declaration of conformity 31 View oO ON DO OA P Go PD 11 Port for interface cable K 104A or K 114A PC connection RS485 Device base Display SELECT and ENTER buttons Oil chamber Recirculation pipe Screwed sealing plug Manual booster pump Pressure connection for test object without overpressure valve 700 bar Drain valve Screw compressor 13 Notes on the operating instructions The operating instructions are in tended for specialist workers and trained personnel Before each stage of work read the relevant notes and warnings care fully and keep to the sequence as stated Pay particular attention to the sec tion on General safety warnings If you have any problems or questions please contact your supplier or consult KELLER directly 1 Description of the device General description The high pressure calibrator enables pressure to be generated by means of the integrated pressure pump up to
5. cannot build up in the oil reservoir Use the manual booster pump 8 to set the pressure to about 10 bar You can use the screw compressor 11 to increase or reduce the pressure Release pressure 1 Open the screw compressor 11 completely 2 Open the drain valve 10 IMPORTANT Do not open if there is high pressure in the system If you can no longer reach the desired pressure please consult the section on Maintenance to find out how to vent the system Zeroing the device Open the drain valve 10 to release any pressure that may have built up If the pressure display does not show zero perform a zeroing procedure SET ZERO and then close the drain valve Information about the display If no pressure can be shown on the dis play it will show GFL overflow or UFL underflow If pressure outside the device s measuring range is applied the Min max display w doP Leak measurement Zero the display Reset display Automatic Cont last valid pressure value that was measured will flash on the display overload warning Reset hPa kMPa PSI mbar kp cm inftH20 cmH20 mmHg inHgkN HDD Cont E 2 Leak z HAABA L 4 Description of the functions Menu navigation If the selected function or unit is not ac tivated by pressing the ENTER button within 5 seconds the display will return to measuring mode without changing a setting Shows the peak and trou
6. change Set leak measurement time The leak measurement time is preset to 10 minutes in the factory and it can only be changed with the Mano Con fig software Software for calibrators MANO Continuous function Automatic switch off function the de vice switches off automatically 15 mi nutes after a button was last pressed Leak measurements are canceled by the automatic switch off function if the measurement time is more than the switch off time CONT GN Disables the automatic switch off function TEE CONT GFF Enables the automatic switch off function If the Continuous function is en abled LONT flashes on the display Leak ok oP br o Unit of pressure MU Current Leak run LU measured value timein gt pa hum gt mm ss 13 06 LL Li Pressure change within leak runtime Cont on Cont ott 7 Maintenance disposal Venting the pressure system Release the pressure completely and then open the drain valve 10 and the screwed sealing plug 7 Screw the screw compressor 11 in completely Pump steadily with the manual boos ter pump 8 to clear the system of air When no more bubbles come out of the recirculation pipe 6 close the drain valve 10 Changing the oil We recommend have that you KELLER change the oil The entire system is cleaned at the same time Only use type HLP 22 BP hydraulic oil Battery The
7. equest 840 bar lt 0 05 FS lt 0 1 FS 700 bar 2 bar 10 min 1 mbar 5 digits 0 5 seconds RS485 the Fischer cable socket on the side fits the K 104A K 114A interface converter 0 50 C 0 50 C 10 60 C 5 95 relative humidity Button cell battery type CR2430 gt 2000 h in continuous operation HLP 22 BP 315 337 x 155 x 148 mm IP 65 bar mbar hPa kPa MPa PSI kp cm cmH20 mH2O inH2O ftH2O mmHg inHg including accuracy temperature coefficients zero point and range tolerance Physical effects caused by a pressure change lead at first to a clear difference in pressure Advice To minimise the influence of these physical effects increase steadily the last 5 of the target pressure and regulate towards the target pressure for the first minutes The stated leakage rate is at a thermal balanced condition when temperature of pressure media and of the environment is equable 19 Spare parts and accessories for KELLER pressure calibrators suitable for Description Article number Attclenumber a mpx mer Vera nn Kas 2 KA Battery type CR2430 557005 0001 Hr Connecting nipple G 1 4 508832 0004 X X including sealing ring 9 8 Test object adapter 506810 0028 G 1 4 M G 3 8 F Test object adapter 506810 0013 G 1 4 M G 1 2 F Sealing ring G 1 8 mmm 0001 Sealing ring G 1 4 508635 0002 CrNi filter 307025201 u Fine tuning valve 309030 0006 B
8. gh pressure values measured thus far Display is shown with reduced resolution Leak mode is used to determine the pressure change over a defined period which can be changed Leak measurement 10 minutes period factory setting Permanently sets the applied pressure as the new pressure zero point Resets the pressure zero point to the factory set ting Continuous The device switches off switch off function Select units hPa kMPa PSI mbar kp cm inftH20 cmH20 mmHg inHgkN automatically after a defined period which can be changed starting from the last time a button was pressed Switch off period factory setting 15 minutes mbar bar hPa kPa MPa cemH20O mH2O inH2O ftH20O PSI kp cm mmHg inHg SELECT button The SELECT button positioned on the front is used to switch the device on to select a function and to select the various pressure units ENTER button The ENTER button positioned on the front is used to activate the se lected function or pressure unit on the device You can also press the ENTER button to switch between the minimum and maximum pressure values measured thus far SELECT button Min max display am HZzm Leak measurement Set zero point permanently oe999986 Select units gt IO foe SS O 6 Commissioning Switch the device on Press the SELECT button to switch the device
9. ntion and workplace Scope of delivery High pressure calibrator e Operating instructi ions for the high pressure calibrator HPX safety must be followed whenever work is carried out Internal regula tions issued by the operator must be followed even if they are not mentioned in these instructions Never use the high pressure calibra tor together with an external pressure source Do not remove any connected compo nents e g test objects when the high pressure calibrator is under pressure Open the screwed sealing plug before removing parts Do not use Teflon tape to seal the pressure connection Residues of Teflon tape could penetrate the high pressure calibrator and damage it Only use the adapters and seals that are available as accessories Do not store the calibrator under pres sure only store the high pressure cali brator with the drain valve open Avoid the action of force of any kind on the high pressure calibrator and its operating controls Do not use high pressure calibrators if they are damaged or faulty 3 Operating the HPX calibrator Operating the high pressure calibrator is described starting on page 16 Connect the test object You can connect your test object to the high pressure calibrator via the pres sure connection 9 Pressure generation When using the calibrator the screwed sealing plug 7 must be opened 2 turns so that overpressure
10. on Initially the device shows the pressure range calibrated in the factory top and the software version year week Switch the device off Keep the SELECT button pressed down until the display shows GFF 16 Resetting peak and trough pressure hPa kMPa PSI mbar kp cm inftH20 cmH20 mmHg inHgkN nnn matt Current measured value Pressure change within leak runtime T Leak runtime in mm ss Reset zero point to factory setting Activate deactivate switch off function Press the ENTER button to execute the shutdown The settings made previously are retained when you switch the device on and off Display mode Display mode is the calibrator s basic mode The upper part of the display shows the pressure unit and the pres sure that is currently measured The lower part of the display shows the last function that was used either the min max display or the Leak function Using the functions Written descriptions of the individual functions are given below in addition to the diagram above Selecting functions The individual sub functions are called up from the MANO menu Keep the SELECT button pressed until MANG is shown and press ENTER to activate You can now use SELECT to choose the function you want and ENTER to execute the function Depending on the current setting the first function to be shown is either MIN MAX DISP or LEA
11. oth graphic and tabular form Measured data can be saved or exported for further pro cessing You will find more informa tion about the software in the CCS30 manual Step by step software installation Install from the CD or from www keller druck com 1 K 104 K 114 driver 2 CCS30 Control Center Series 30 3 ManoConfig if desired 18 Jl ManoConfiguration Configuration COM For COM1 COMe2 COM COM4 COMS COME COM COME coms CDMID COM11 COM12 COM13 COM14 20 0 0 ee eee ee ee toe LEX Leak done Fresca San K tantra Center series att ll Pakt Seed ut MEN p HELLER Dnzchmsestechoe 4 General Unis Dez adjust Leak settings iard Mear ah Yersion 3 9 2011 05 17 Control Center CCS30 ll x re REER Device nformal Device 106 State 1 Firmware mas SM L 20 Penge 7 01 30bar Tob 244 we j arine ManoConfig Technical data Pressure range FS Overpressure Accuracy error band 10 40 C Accuracy error band 0 50 C Leak rate Display resolution Number of digits on display Measurement interval Interface Compensated temperature range Operating temperature Storage temperature Air humidity Power supply Battery lifetime Hydraulic oil Dimensions L x W x H Degree of protection Selectable pressure units 0 700 bar others on r
12. ottle of oil 0 5 650505 0005 HLP 22 BP hydraulic oil K 114A 309010 0075 Hand pump 309005 0004 g Konformitatserklarung Fur das folgenden Erzeugnis Hochdruckkalibrator HPX wird hiermit best tigt dass es den wesentlichen Schutzan forderungen entspricht die in der Richtlinie des Rates zur Angleichung der Rechtsvorschriften der Mitglied staaten ber die elektromagne tische Vertr glichkeit 2004 108 EG festgelegt sind Diese Erkl rung gilt f r Produkte die ser Serie die mit dem CE Zeichen versehen und die Bestandteil dieser Erkl rung sind Zur Beurteilung der Erzeugnisse hin sichtlich elektromagnetischer Ver tr glichkeit wurden folgende Normen herangezogen Herewith we declare that the following product or product range High pressure calibrator HPX meet the basic requirements for the electromagnetic compatibility which are established in the directive of the European Community 2004 108 EC This declaration is valid for products of this Series marked with the CE sign and which are part of this declaration As criteria for the electromagnetic compatibility the following norm is applied Declaration of Conformity Declaration de Conformite Nous attestons que le produit ou gamme de produits Calibrateur haute pression HPX repondent aux exigences de base en mati re de compatibilit electromag netique pr vues par la directive de la Communaut Europ enne 2004 108
13. pressure calibrator is powered by a 3 V button cell battery behind the display If the battery is low the battery symbol on the display lights up Replacing the battery Please switch the device off Turn the display section ring beyond the limit stop until it is released from the hous ing section turn through about 180 Open the battery compartment and change the battery type CR 2430 Disposal This product must not be disposed of as normal household waste at the end of its useful lifetime To prevent pos sible damage to the environment or to health due to uncontrolled waste disposal this product must be separated from other waste and recycled correctly in order to ensure sus tainable use of the raw materials 8 Software for calibrators The USB interface converter K 114A enables communication between the calibrator and a computer Before you connect the interface converter to the computer install driver K 104 K 114 the software CD is included in the scope of delivery K 114A or can be downloaded free of charge at www keller druck com Settings on the high pressure calibrator with the ManoConfig software Device settings such as the leak measurement time or the switch off time for the pressure calibrator can be adjusted using the ManoConfig software Record measurements with the CCS30 software The CCS30 software records the data measured by the pressure calibra tor and shows them in b
14. rque for the test object pressure connection 30 Nm IMPORTANT Nothing must adhere to the surface of the test object no oil grease water etc Impurities could pass through the adapter to reach the high pressure calibrator and damage it Overpressure If the pressure exceeds the measuring range by more than 20 the measur ing cell or the mechanism of the high pressure calibrator may be destroyed Recalibration The recalibration cycle depends on the conditions of use Recommended recalibration cycle 1 year Scope of delivery 1 calibrator including oil filling 1 carrying case 1 test record 5 points 1 test object adapter G 1 4 G 1 8 1 test object adapter G 1 4 G 1 2 1 Allen key 1 spare battery type CR2430 3 0 V 1 set of operating instructions 1 USB interface converter K 114A 1 KELLER software CD Intended use The high pressure calibrator HPX may only be used to generate pres sure with the type HLP 22 BP hydrau lic oil that is supplied with the product Use of the calibrator with other media will damage it The operational safety of the device supplied is guaranteed only if it is used as intended The limit values as stated see page 19 Tech nical data must never be exceeded Before installing the high pressure calibrator check that it is suitable for your applications 2 General safety warnings The current national regulations on accident preve
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