Instruction

for Hand-Held Field-Service Instrument

Model 909.40.500
Pressure Calibrators
Model PCS-L
Model PCS-H
Contents

01.00 General
01.01 Attendance and maintenance of digital instruments and sensors
01.02 Maintenance of test pumps
01.10 Power supply
01.11 Inbuilt rechargeable battery
01.12 External power supply

02.00 Sensor inputs

02.10 Pressure transmitters
02.20 Temperature sensors
02.30 mA measurement
02.40 V measurement
02.50 Flow measurement

03.00 Signal output

03.10 Analog signal
03.20 Serial data port RS 232 (optional extra)
03.21 Communciation software for RS 232

04.00 LCD display

04.10 Measurement
04.20 LoBat indicator
04.30 Error messages

05.00 Operation
05.10 ON / OFF
05.20 PORT 1 (channel 1)/PORT 2 (channel 2)
05.21 REAL display
05.22 MIN display
05.23 MAX display
05.24 RESET
05.25 HOLD
05.30 DIFF 1-2 (differential of channels 1 – 2)

06.00 Wiring
06.10 Wiring of cable links
06.20 Wiring of pressure transmitter
06.30 Wiring of thermometer
06.40 Wiring of flow meter

07.00 Units of measurement

07.10 UNITS A (bar; mbar; mmH2O; mmHg; kg/cm³, kPa)
07.20 UNITS B (psi; psi x 10; inH2O; inHg; l/min; gpm)
07.30 UNITS C (V; mA; °C; °F; K; 1/s)

08.00 Technical data / dimensions

08.10 Digital instrument model 909.40.500
08.20 Pressure transmitter model 891.X3.59X
08.21 Calibration of zero and span

09.00 Test pumps

09.10 Description
09.11 Technical data hand pump for Model PCS-L
09.12 Technical data spindle pump for Model PCS-H
09.13 Accessories (not included in basic equipment)
09.20 Handling
09.21 Hand pump (pneumatic system)
09.22 Spindle pump Model H 250 (hydraulic system)
09.23 Spindle pump Model H 1000 (hydraulic system)
09.24 Spindle pump Model H 250 / H 1000 (hydraulic) with reservoir

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 2

01.00 General

The versatile hand-held field service instrument model 909.40.500 answers almost any requirement for measurement.
It is just as suitable for use in the rough day-to-day business and in service and commissioning departments as for
the occasional use in laboratories.
Due to the fact that the instrument is absolutely user-friendly despite its variety of functions, it is as indispensable as
a multi-purpose measuring instrument for current, voltage and frequency.
The self-explanatory keypad and display as well as the logic structure of the functions allow even less experienced
users to handle all performance features before very long.
The shockproof plastic case is fully protected against dust and spraying water and allows outdoor use even without
additional precautions.

01.01 Attendance and maintenance of digital instruments and sensors

Neither digital instrument nor sensors contain any parts which are subject to wear and tear so that it is not necessary
to open the cases of the instruments. To maintain the warranty claims, it is imperative to abstain from opening the
cases.
For cleaning the case surfaces of digital instrument, pressure transmitters and temperature sensors we recommend
to use a soft damp cloth with soapy water. We advise against using caustic cleansing agents.
As generally applicable for precision measuring equipment, all sensors should always be treated with care. Moreover,
the compliance with the specifications should be examined frequently (about once a year – refer to item 08.21).

01.02 Maintenance of test pumps

The test pumps need no maintenance but it is important that they do not come into contact with aggressive media.
Loss of media can occur with the hydraulic pumps, Model H 250 or Model 1000, respectively, should the connected
periphery measuring instrumentation leak. In this case the hydraulic pump must be topped up again with the
appropriate medium to ensure perfect operation, i.e. the reservoir available as accessory must be used.

01.10 Power supply

Regular power supply for digital readout and connected sensors is by means of inbuilt rechargeable batteries. The
batteries are located in a separate compartment inside the case of the digital instrument. Due to the low consumption
of pressure transmitters and digital instrument, the capacity of the rechargeable battery covers about 10 hours of
normal operation.

01.11 Inbuilt rechargeable battery

The instrument is supplied with NC batteries (Mignon 1.2 V/0.6 Ah). To provide long-term service it is recommended
to use this type only.

F WARNING
Never use regular non-rechargeable batteries. These will disintegrate and seriously damage
the instrument should the external power supply and battery charger be accidentally plugged
in!

01.12 External power supply

WIKA offers a power pack and battery charger especially customised for the digital instrument to recharge the
batteries and to provide continuous line operation. The power pack and battery charger shuts down automatically
after 14 hours so that the service life of the batteries will not be minimised by overcharging.
The power pack and battery charger is suitable for 100/110 or 230/240 V, 50 ... Hz mains voltage.
The jack to accept the power cable is located at the right hand bottom side of the instrument near the inscription
UNITS C.

F WARNING
Never use any other than the original power pack and battery charger approved by WIKA!
Make sure the mains voltage is as stated on the label of the power pack and battery charger!
Other power packs and higher mains voltage may damage the electronic system!

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 3

02.00 Sensor inputs

The digital instrument accepts only WIKA pressure transmitters Model 891.13.591 and 891.23.590 and WIKA
temperature sensors Model TR-590.
Other sensors or transmitters may be connected using the mA or voltage input channel, but the instrument will not
indicate units of pressure or temperature.
Two sensors of optionally pressure or temperature or both may be connected simultaneously.
Connection is made by means of the 8-pin DIN socket identified P1 (for channel 1) or P2 (for channel 2).
Turbine-type flow meters are connected by means of a special adaptor that facilitates calibration based on the signal
output of the flow meter. An inbuilt EEPROM processor converts the signal to provide direct readout of l/min (litres
per minute) or gpm (US gallons per minute). Available are also adaptors to directly indicate pulses per second (1/s).

02.10 Pressure transmitters

Suitable pressure transmitters for direct connection to the digital instrument of the hand-held field-service instrument
Model 909.40.500 are WIKA Model 891.13.590 (measuring ranges 0 ... 100 mbar to 0 ... 16 bar relative and absolute
pressure), Model 891.13.591 (measuring ranges 0 ... 25 mbar to 0 ... 60 mbar relative pressure) and Model
891.23.590 (measuring ranges 0 ... 25 bar to 0 ... 4000 bar relative pressure). Moreover, pressure transmitters with
flush diaphragm are available for ranges 0 ... 100 mbar to 0 ... 600 bar.
All transmitter models have an automatic area code, i.e. an inbuilt serial interface communicates to the connected
digital readout and the microprocessor provides for correct display of the pressure value in any pressure value
selected. This ensures that the measuring values are correctly displayed in terms of figures and size when the mode
is changed to other units.
The hand-held field-service instrument Model 909.40.500 will not accept pressure transmitters for the previous model
999.01.1905.

02.20 Thermometers
Only resistance thermometers of WIKA Model TR-590 may be directly connected to the hand-held field-service
instrument Model 909.40.500.
The measuring element of these thermometers is a Pt 100 with Q grade DIN EN 60751 class B.
The linearisation is fully digitalised and within DIN specifications for the temperature range
–50°C to +400°C.
Resolution of the readout is 0.1°C, 1°F or 0.1K.
Due to the response time of the temperature sensor, changes in temperature are alternately displayed in 0.2 and
0.3°C steps.

02.30 mA measurement
mA measurement is provided by using the jacks +l-in and –l-in (next to P1). Maximum
50 mA DC can be measured with an accuracy of +/-0.06 % +/- 1 digit and 0.01 mA resolution.
The inbuilt fuse of 125 mA may be replaced after opening the case.
Input impedance is approximately 10 Ohms.

02.40 V (voltage) measurement

V measurement is provided by using the jacks identified + U-in and U-in. Maximum 50 V DC can be measured with
an accuracy of +/- 0.06% +/- 1 digit and 0.01 mA resolution. Input impedance is approximately 1 Mohm.

F WARNING
The voltage input is not fused.
Voltage higher than 50 V DC may cause severe damage of the instrument!

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 4

02.50 Flow measurement
Turbine-type flow meters are accepted by PORT 2 only. The flow meter requires a signal conditioning adaptor that
incorporates an EEPROM to linearise and convert the signal as required. When selecting the turbine-type flow meter
you have to pay attention to the fact that the values required for the adaptor are complied with:

- max. volume flow 0 ... 10999 l/min

- max. frequency 1 ... 2000 Hz
- max. voltage level 0 ... 50 mV

The adaptor enables the user to specify up to 12 paired values reflecting the ratio of flow and pulses per second. The
processor interpolates linear across the values specified. Measurement may start at any point of the flow meter‘s
output signal which makes it possible to zoom the readout within a particular range.

It is recommended to dedicate one adaptor to a particular flow meter in order to handle inconsistencies of the K-
factor of individual flow meters.

Example:

Frequency [Hz] Flow capacity [l/min]

st
1 pair of values: 20 40
nd
2 pair of values: 900 60
rd
3 pair of values: 1500 80
th
4 pair of values: 1800 90

At least 2 pairs of values are required for programming the EEPROM.

03.00 Signal output

The analog auxiliary output is serial standard. A serial port interface RS 232 is optional.

03.10 Analog signal

The jacks identified +A-out and –A-out (located between mA and V jacks) provide an output signal equalling 0.1 mV
per digit indicated. The measurement interval on the analog output for instruments with interface is approx. 250 ms;
for instruments without interface approx. 30 ms. The output corresponds to the mode selected, i.e. true value, MIN,
MAX, HOLD or tare-function (see RESET). An error message displayed automatically interrupts the output signal.
Equipment interfaced should maintain a minimum impedence of 100 kOhms.

03.20 Serial data port RS 232 (optional extra)

Connection of the serial RS-232 interface is made by means of a 3.5 mm earphone jack located at the right hand
side, about level with HOLD key.

Wiring of the jack is given below:

Tip RX (receive data)

Middle TX (transmit data)
Body GND (ground / earth)

The transmitting rate is normally set to 4800 Baud and not adjustable.
The data string consists of subsequent ASCII strings of 33 Byte length followed by CRLF (carriage return DEC 13
plus line feed DEC 10).

Each third string is followed by an EOF signal (^ Z, DEC 26).

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 5

String code:
Byte 1 – 2 Px (channel no., x = 1, 2 or 3)
Byte 3 Space (DEC 32)
Byte 4 – 10 REAL value incl. sign and decimal point
Byte 11 Space (DEC 32)
Byte 12 – 18 MIN value incl. sign and decimal point
Byte 19 Space (DEC 32)
Byte 20 – 26 MAX value incl. sign and decimal point
Byte 27 Space (DEC 32)
Byte 28 – 33 Unit of measurement, e.g. kg/cm²
(Space will be sent for not used characters)

Examples of string sequences (both channels pressure):

P1 +09.456 -00.789 +09.678 bar (channel 1)
P2 +01.234 –00.345 + 10.045 kg/cm2 (channel 2)
P3 +0119.6 –0002.6 +0136.1 psi (diff. channels 1-2)

Examples of string sequences (both channels temperature):

P1 +00174. –00080. +00257. F (channel 1)
P2 +0023.4 –0019.1 +0251.9 C (channel 2)
P3 +0055.5 –0041.2 +0135.8 K (diff. channels 1 – 2)

Examples of string sequences (1 ea. pressure and temperature)

P1 +09.456 –00.789 +09.678 bar (channel 1)
P2 +0023.4 –0019.1 +0251.9 C (channel 2)
P3 +0055.5 –0041.2 +0135.8 K (diff. channels 1 – 2)
(Bytes 1 and 2 plus 31 spaces will be sent for P3 if differential is
incompatible)

03.22 Communication software for RS 232

A communication software is included in the standard scope of delivery for versions with a serial interface RS 232.
The detailed description is enclosed to every software provided.

04.00 LCD display

04.10 Measurement read-out

The LCD displays +/- 10999 digits of 10.2 mm height plus decimal point.

04.20 LoBat indicator

LoBat appearing at the left upper corner indicates low battery to be recharged. After LoBat indication instrument can
be used approx. 1 hour.

04.30 Error messages

The following error messages may appear to indicate incorrect operation or malfunction:
-00- Sensor not connected
-01- Overflow of A/D converter
-02- Overflow of range or unit of measure
-03- Mode not feasible

Error -00- indicates no sensor as well as interrupted data transmission between sensor and instrument.

Error -01- occurs if connected sensor signal is too high (for example because of defect or overload)
Error -02- indicates either an attempt to measure a pressure or temperature that exceeds the range of the sensor by
more than 10 % of if the unit selected is too small in consideration of the sensor connected, e.g. to obtain readout in
mmH2O from a 100 bar sensor.

Error -03- indicates either an attempt to attach pressure unit to a temperature sensor and vice versa or an attempt to
indicate the difference between a pressure and temperature sensor or to change unit of measurement from pressure
to temperature with activated HOLD-function.

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 6

05.00 Operation

05.10 ON / OFF
By depressing the key ON/OFF, the digital instrument is switched on. Depressing this key once more, it is switched
off.
When switched on the instrument carries out a self-test cycles and automatically zeroes input amplifier, A/D-
converter and D/A-converter. The display and all LED’s will be tested subsequently during this cycle.
Default mode (channel 1, REAL, bar) will be automatically selected.
The complete test takes about 8 seconds.

05.20 PORT 1 (channel 1) / PORT 2 (channel 2)

Channel 1 will be automatically selected when the instrument is switched on. It is possible to switch from PORT 1 or
DIFF 1 – 2 to channel 2 by depressing the key PORT 2.

05.21 REAL
Channel 1, mode REAL (current measuring value) will be automatically selected when the instrument is switched on.

05.22 MIN
Depressing the PORT or DIFF key actuates MIN mode. The lowest value of channel 1 will be indicated, measured
since RESET was depressed last.

05.23 MAX
Depressing the PORT of DIFF key once more actuates MAX mode. The highest value of channel 1 will be indicated,
measured since RESET was depressed last.

05.24 RESET
This key operates two functions:
a) Short depressing: Reset of the peak memories
By depressing the RESET 1 / RESET 2 key briefly, the MIN or MAX memory for channel 1 / channel 2 or both will be
erased, depending on which mode was selected.
MIN only is erased if MIN only was selected.
MAX only is erased if MAX only was selected.
Both memories will be erased if the REAL mode is actuated.
The MIN / MAX memory cannot be completely reset to zero by the RESET key, as the amplifier vibrations of the
pressure transmitter will be immediately displayed again due to the fast sampling rate of the memory (1,000
measurements/sec.). The values indicated in this display, however, are within the accuracy class.

F NOTE
Always depress the RESET key prior to new measurement or when changing a sensor.
Changing a sensor may generate voltage spikes causing storage of erratic data in either
memory. With activated HOLD the RESET is not effective.

b) Long depressing (min. 3 sec): Zeroing of the displayed value (tare function)
By depressing the RESET key for a minimum of 3 seconds the displayed value will be zeroed. Blinking of RESET LED
indicates activated tare function.

This function allows the manual zeroing of the measurement system, consisting of sensor and digital readout, if A/D
converter shwos small zero deviations and in addition the measurement with respect to a reference pressure. This
tare mode only displays positive and negative deviations from the stored reference pressure.
Reset of tare mode is by depressing the RESET key for a minimum of 3 seconds.

F NOTE
Always depress the RESET key prior to new measurement or when changing a sensor.
Changing a sensor may generate voltage spikes causing storage of erratic data in either
memory. With activated HOLD the RESET is not effective.

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 7

05.25 HOLD
Depressing the HOLD key will freeze the readout of the display regardless of mode REAL, MIN or MAX selected.
The MIN and MAX memories will continue to store data entered while the display is on hold.
However, depressing HOLD while channel 2 is active will freeze the true value of channel 1 as well as MIN and MAX
memory.
When changing back to channel 1, then HOLD 1 must be depressed once more to continue measurement of
channel 1.

05.30 DIFF 1 – 2 (differential channel 1 – channel 2)

This mode enables the user to display the differential by subtracting the value of PORT 2 (REAL, MIN or MAX) from
the corresponding value of PORT 1. The unit(s) of measurement displayed will always be as selected for PORT 1 – 2,
regardless of the unit(s) selected for PORT 1 or PORT 2 individually. Correct conversion is made automatically.
To permit differential measurement sensors interfaced must be of a like configuration, i.e. pressure or temperature.
Otherwise the display will show „error message“ (-03-).

06.00 Wiring

The 8-pin DIN sockets are identified P1 and P2. Suitable pressure and temperature sensors can be immediately
connected by means of the cables supplied. Flow meters or other pulse generators will require an adaptor which is
optionally available.

06.10 Wiring of cable links

Pin Colour
1 black
3 red
5 yellow
7 blue
Pin Colour
2 brown
4 orange
6 green
8 purple

06.20 Wiring of pressure transmitter

Pin Function Pin Function
1 Data I/O 2 Serial clock
3 low 4 Chip select
5 + supply (U) 6 + signal
7 - supply (U) 8 - signal

06.30 Wiring of thermometer

Pin Function Pin Function
1 low 2 unused
3 low 4 unused
5 + supply (U) 6 + signal
7 - supply (U) 8 - signal

Note: Non-dedicated Pt 100 resistance thermometers of the quadripole type may be connected
following above scheme. In addition, jump pins 1, 3 and 4 of the plug. When using 3-wire
thermometer jump also pins 7 and 8, furthermore 5 and 6 with 2-wire thermometers,
respectively.

06.40 Wiring of flow meter

1. Wiring of digital instrument and adaptor:
Pin Function
1 Data I/O
3 low
5 + supply (U)
7 - supply (U)
Pin Function
2 Serial clock
4 Frequency input
6 unused
8 unused

2. Wiring of flow meter and adaptor

Pin Function Pin Function
1 Output signal 2 Output signal

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 8

07.00 Units of measurement
Units other than the SI units bar or °C, respectively, will be calculated by the inbuilt microprocessor using
internationally agreed conversion factors.

Once powered up the instrument will display values in bar. Depressing the keys UNITS A, UNITS B or UNITS C once
or several times respectively will change the display to read other units of measurement.

07.10 UNITS A
Unit Conversion factor Unit Conversion factor
bar Base unit mmHg 750
mbar 1000 kg/cm² 1.02
mmH2O 10200 kPa 100

07.20 UNITS B
Unit Conversion factor Unit Conversion factor
psi 14.5 inHg 29.5
psi x 10 1.45 l/min dedicated to sensor used
inH2O 401.6 gpm l/min x 0.2641728

07.30 UNITS C
Unit Conversion factor Unit Conversion factor
V independent unit °F (°C x 9/5) + 32
mA independent unit K °C + 273.16
°C Base unit 1/s independent unit

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 9

08.00 Technical data / dimensions

Specifications Model 909.40.500

Display
principle 7-segment liquid crystal display, 10. mm high
range ± 10999
accuracy ± 0.6% of span ± 1 Digit (Max./min. memory: ± 0.% of span)
units can be selected from the following: bar, mbar, mm H2O, mm Hg, kg/cm², kPa, psi,
psi x 10, in H2O, in Hg, °C, °F, K, l/min, gpm, 1/s
Error messages -00- sensor not connected
-01- A/D converter overrun
-02- measurement range or physical unit exceeded
-03- mode not possible
Status indication LoBat (for low battery)
Sign automatic change to “--“ for negative values
Decimal point set automatically depending on range
Pick up rate 1000 per second, display renewal 4 per second
Zero adjustment automatic adjustment when power turned on
Zeroing of displayed pressing the appropriate RESET key for 3 seconds zeros port 1 or port 2 or diff. 1-2,
value then only positive or negative deviations are indicated
(tara function)
Differntial measurement measurement of pressure or temperature differential through connection of two
sensors. The sensors may have different measure ranges; the resolution is determined
by the higher range. Any of the available physical units may be used.
1
Tempeature Pt 100 resistance thermometer, 4-wire, accuracy /3 DIN
measurement Range –50 ...+400 °C. Resolution 0.3%
Flow measurement max. 0 ... 10000 l/min {with special plug-in adapter only}; max. 1 ... 2000 Hz;
max. 0 ... 50 mV
Voltage measurement max. DC 50 V; resolution 0.01 V
Current measurement max. DC 50 mA; resolution 0.01 mA
Frequency measurement 0 ... 2000/s {with special plug-in adapter only}
Analog output 0.1 mV/digit (minimum output impedance 50 kΩ, effect of load 0.7 mV/10 kΩ);
polarity changes with negative values;
also effective for display of MIN and MAX values and differential measurement
Digital output {serial interface RS 232}; {cable and communications-software for RS 232}
CE-conformity interference emission per EN 50 081-2 (march 94) and EN 50 011, class A, group 1
interference immunity per EN 50 081-2 (march 95), declaration of conformity on
request
Hold memory digital, no data loss as long as power on (life of battery); seperate memory for each
Max./min. supply port
digital, no data loss as long as power on (life of battery); seperate sign for each port;
individual RESET keys
Power Supply Built-in storage battery, 6 VDC, for appox.12 hours continuous operation, or using
separate line and charging unit with European plug, 230 VAC, 50 Hz (U.S. plug: 110
VAC, 60 Hz, or UK plug: 240 VA, 50 Hz). Charging unit turns iteslf off after about 14
hours of continuous charging to extend the life of the storage battery
Degree of protection
EN 60529/IEC 529 IP 65
Dimenstions see drawings
Weight approx. 0.4 kg incl. batteries
Items in curved brackets { } are optional extras for additional price

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 10

Dimensions in mm Explanations

A ON/OFF ON / OFF key

B PORT 1 Select channel 1; b
C PORT 2 Select channel 2, c
D Diff 1 – 2 Differential across 1-2
E RESET 1 Erase memory 1 and activate tara
function
F RESET 2 Erase memory 2 and activate tara
function
G RESET 1-2 Erase differential memory and
activate tara function differential
measurement
H HOLD 1 Hold value channel 1
I HOLD 2 Hold value channel 2
J HOLD 1-2 Hold differential value
K UNITS A Select bar, mbar, mmH2O, kg/cm²,
kPa
L UNITS B Select psi, psi x 10, in H2O, inHg,
l/min, gpm
M UNITS C Select °C, °F, K, V, mA, 1/s
N U-in V measurement
O I-in mA measurement
P A-out Analog signal
Q DC-in Socket for line adapter and
charging unit

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 11

Specifications Models 891.13.591/891.13.590/891.23.590
Pressure range (see table to right) Pressure range •, Overpressure safety ‚, Burst pressure ƒ • ‚ ƒ
Pressure datum rel. {absolute pressure: only 891.13.590 from 0.25 bar} Model 891.13.591
Pressure connection
standard G ½ A per DIN 16288; 25 250 250
M 16 x 1.5 female for ranges over 1600 bar mbar 40 250 250
flush diaphragm G 1 A with O-ring 0 ... 0.25 bar to 0 ... 2.5 bar 60 250 250
G ¾ A with O-ring 0 ... 1 bar to 0 ... 6 bar
G ½ A with O-ring 0 ... 4 bar to 0 ... 600 bar Model 891.13.590
Material wetted parts
model 892.13.591 stainless steel 1.4571, silicon, aluminium, gold 0.1 1 2
model 892.13.590 stainless steel 1.4571 0.16 1.5 2
model 892.23.590 stainless steel 1.4571 and 1.4542 0.25 2 2
Case stainless steel 1.4301 0.4 2 2
Internal transmitting silicon oil; only necessary for pressure ranges 0.6 4 4
liquid 16 bar or with flush diaphragm
? bar 1 5 5
{halocarbon oil for oxygen service} 1.6 10 10
Power supply rechargeable batteries in digital instrument 2.5 10 10
Response time (10 ... 90%) ms <1 4 17 17
Linearity % of span < 0.5 {0.25}1) (limit point calibration) 6 35 35
Hysteresis % of span < 0.1 10 35 35
Repeatability % of span < 0.05 16 80 80
1-year stability % of span < 0.2 (with reference conditions)
Permissible temperature of Model 891.23.590
pressure mesdium °C -30 ... +100
ambient °C -10 ... + 80 25 50 100
storage °C -40 ... +100 40 80 150
Compensated range °C 0 ... + 80 60 120 200
Temperature coefficients in 100 200 300
compensated temp. range: 160 320 500
mean TC of zero signal % of span/10 K =0.2 (< 0.4 for ranges 0 ... 0.1 bar and 0 ... 0.16 bar) bar 250 500 800
mean TC of span % of span/10 K =0.2 400 800 1500
Electrical connection 8-pin DIN plug 600 1000 2000
Weather protection 1000 1500 3000
EN 60529 / IEC 529 IP 65 1600 2000 4000
Dimensions see drawings 2500 3000 5000
Weight kg approx. 0.15 4000 4400 7000
Items in curved brackets { } are optional for additional price.
1)
only possible for measuring ranges > 0 ... 0.16 bar
Dimensions in mm Pressure connections G ½ A G ½ A (Model 891.23.590)

Typ 891.13.591 Model 891.23.590 may

Typ 891.13.590 either be screwed in sing a
Typ 891.13.590 threaded socket acc. to
DIN 16 288 or, for sealing
through the sealing ring,
using a special G ½ A +
threaded socket (for design,
please refer to the drawing
on the right) 1605194

Threaded sockets 1605186

1537164
1605321
1605216 G 1 A flush diaphragm with
Pressure connection O-ring (Model 891.23.590)
M 16 x 1.5 female Pressure connections G ½ A
(Model 891.23.590) flush diaphragm with O-ring
Sealing Ring
29.7 x 35.7 x 2.0

Sealing Ring O-Ring 26 x 2

18.5 x 23.9 x 1.5

O-Ring 15 x 2

1605234
1605216
Threaded sockets or weld-on adaptors
Chamfer after
160520 tapping
Chamfer after
tapping

Finless
1605234
Finless
1524283
08.21 Calibration of zero and span
Depending on the operating conditions in which the instruments are used, the pressure transmitters should be
examined about once a year on the fact whether they still comply with the required specifications. If required, they
should be readjusted. The calibration may be made as follows:

- Remove threaded ring, which is used to fix the plug or the screwed cable gland
- Adjust zero (Z) by means of potentiometer
Zero (Z)
- Adjust span (S) by means of potentiometer
- Check both adjustments once again Span (S)
- Attach threaded ring again
Screen

The examination and adjustment of the zero is to be made in unpressurised condition. A sufficiently accurate
pressure standard will be required as reference in order to examine and adjust the measuring span properly.
WIKA is a member of the DKD (German Calibration Service) and will be pleased to carry out such examinations and
adjustment upon your request.

09.00 Test pumps

09.10 Description
The test pumps are used to generate the pressure to calibrate and test pressure gauges. The reference pressure
measurement transmitter and the instruments to be tested are to be connected up to the test pumps by means of
quickly releasable connectors. Pressures up to 16 bar (with hand pump, pneumatic system) or up to 250 bar (single-
piston spindle pump, Model H 250, hydraulic system) and 1000 bar (double-piston spindle pump, Model H 1000,
hydraulic system) can be generated by these pumps.
All pumps are provided as standard with a variable volume for fine adjustment of the preset pressure (upwards and
downwards).
Further connection sets for adaptation to different connection threads can be ordered from the manufacturer.

09.11 Technical data, handpump for Model PCS-L

Technical data
Output pressure Bar 0 ... 16
Setting through hand lever
Fine setting through variable volume
Connections G ½ female thread acc. to DIN 16 288
Testing medium air
Material metal parts: chromium-plated brass, anodized aluminium
plastic parts: PTFE, Delrin
sealing parts: Nitril NBR 394
Weight Kg 0.4

09.12 Technical data, spindle pump for Model PCS-H

Technical data Model H 250 Model H 1000
Output pressure Bar 0 ... 250 0 ... 1000
Setting through hand spindle
Fine setting through variable volume
Connections G ½ female thread acc. to DIN 16288
Testing medium hydraulic oil
Working temperature °C 20 ... +80
Dimensions (L x W x H) Mm 405 x 220 x 96
Weight kg approx. 3.7 approx. 7.8

09.13 Accessories (not included in the basic equipment)

- various connection adapters
- „Minimess“ snap-fit couplings
- WIKA quick union G ½ A
- Reservoir up to max. 400 bar (E-No. 8391356) for spindle pump Model H 250 or Model H 1000 respectively,
incl. pressure gauge in-line filter and pressure gauge cock for the test specimen, refilling tank 0.3 l with
hydraulic oil ESSO J 13 as well as corresponding washers (please refer to 09.24)

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 13

09.20 Handling

09.21 Hand pump (pneumatic system)

F WARNING
The maximum permissible pressure is 20 bar. Higher pressures can damage the pump.
Pressure transmitter, test specimen and any used connection hoses must not be overloaded
with an inadmissably high pressure.

Œ Connect the appropriate pressure transmitter ‚ to the manifold ƒ of the pump ˆ (note pressure ranges!)
• Connect the Hand-Held Field-Service Instrument ‡ with the supplied connection cable • to the
pressure transmitter ‚.
Ž Connect the test specimen „ also to the manifold ƒ of the pump.
• Open air-bleed valve † (large knurled screw), if necessary correct zero point with tare function on Hand-
Held Field-Service Instrument ‡
• Bring the variable volume with set screw … to the middle setting to optimally exploit the fine setting of the
preset pressure (increasing and decreasing pressure).
‘ After this close the air-bleed valve †.
’ Pump up to the approximately required pressure.
“ Set the pressure precisely with the variable volume ….
” Read-off the reference pressure from the digital display of the Hand-Held Field-Service Instrument ‡.

Note: Since the air heats up when being compressed the pressure will slowly drop after pumping
has been stopped due to the air cooling down to ambient temperature.
Should the pressure not stop to drop then the measuring circuit must be checked for leaks.

ƒ
•
†
‚
…

‡ ˆ

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 14

09.22 Spindle pump, Model H 250 (hydraulic system)
F WARNING
The maximum permissible pressure is 350 bar. Higher pressures can damage the pump.
Pressure transmitter, test specimen and any used connection hoses must not be overloaded
with an inadmissably high pressure.

Œ Fit handcross … on spindle.

• Turn the spindle anticlockwise back to the stop with the handcross … without applying any great force to
be able to use the full stroke.
Ž Connect the appropriate pressure transmitter ‚ to the manifold ƒ of the pump (note pressure ranges!)
• Connect the Hand-Held Field-Service Instrument ‡ with the supplied connection cable • to the
pressure transmitter ‚.
• Connect the test specimen „ also to the manifold ƒ of the pump.
‘ Bring the variable volume with set screw † to the middle setting to optimally exploit the fine setting of the
preset pressure (increasing and decreasing pressure).
’ By turning the handcross … clockwise pump to the approximately required pressure (maximum 350 bar).
“ Set the pressure precisely with the variable volume †.
” Read-off the reference pressure from the digital display of the Hand-Held Field-Service Instrument ‡.

Note: To be taken into account is a longer waiting period for high pressures compared with lower pressures
until the holding point has been achieved.

‚
„

•
†

ƒ
‡

Refilling

Proceed as follows to refill and proceed in the given sequence.

Œ Open one of the pressure connections on the manifold ƒ of the pump.

• Turn the pump spindle clockwise until the pressure medium becomes visible in the opened pressure
connection.
Ž Now turn the pump spindle anticlockwise to the stop and observe the liquid level in the pressure connection.
The system must always be filled iwth as much liquid as to ensure a constant liquid level in the pressure
connection.

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 15

09.23 Spindle pump, Model H 1000 (hydraulic system)
F WARNING
The maximum permissible pressure is 1000 bar. Higher pressures can damage the pump.
Pressure transmitter, test specimen and any used connection hoses must not be overloaded
with an inadmissably high pressure.

Œ Turn both spindles anticlockwise back to the stop with the handcross … without applying any great force to be
able to use the full stroke.
• Connect the appropriate pressure transmitter ‚ to the manifold (3) of the pump (note pressure ranges!).
Ž Connect the Hand-Held Field-Service Instrument ‡ with the supplied connection cable • to the pressure
transmitter ‚.
• Connect the test specimen „ also to the manifold ƒ of the pump.
• Bring the variable volume with set screw † to the middle setting to optimally exploit the fine setting of the preset
pressure (increasing and decreasing pressure).
‘ Turn clockwise with the handcross … on the spindle of the low pressure piston ˆ until the pressure has been
built up (up to 250 bar).
’ After this in the case of pressures over 250 bar fit the handcross … on the spindle of the high pressure piston ‰
and set the pressure at the required end pressure which must not be higher than 1000 bar.
“ Set the pressure precisely with the variable volume †.
” Read-off the reference pressure from the digital display of the Hand-Held Field-Service Instrument ‡.

Note: To be taken into account is a longer waiting period for high pressures compared with lower pressures until
the holding point has been achieved.

ƒ
„
‚

• †
‰
‡
…

ˆ
Refilling

Proceed as follows to refill and proceed in the given sequence.

Œ Open one of the pressure connections on the manifold ƒ of the pump.

• First turn the spindle of the low pressure piston ˆ clockwise until the pressure medium becomes visible in the
opened pressure connection.
Ž Now turn the spindle of the low pressure piston ˆ anticlockwise to the stop and observe the liquid level in the
pressure connection. The system must always be filled with as much liquid as to ensure a constant liquid level in
the pressure connection.
• Now carry out the procedure as described under Ž with the high pressure piston ‰. The spindle of the low
pressure piston ˆ must be run out to the stop.

WIKA Hand-Held Field-Service Instrument Model 909.40.500 Page 16

09.24 Spindle pump, Model H 250/H 1000 (hydraulic system) with reservoir
F WARNING
The maximum permissible pressure is 400 bar. Higher pressures can damage the pump.
Pressure transmitter, test specimen and any used connection hoses must not be overloaded
with an inadmissably high pressure.

The reservoir is only used in connection with the spindle pump Model PCS-H (up to max. 400 bar). The reservoir is a
useful accessory for the calibration of big pressure gauges (e.g. NS 160, NS 250) as well for frequent calibration
processes. The hydraulic oil ESSO J 13 supplied in the refilling tank (0.3 l) should be used for refilling of the reservoir
as the spindle pumps are already filled with this medium. It is, however, also possible to use other hydraulic oils.

Œ Install reservoir A to manifold ƒ in unpressurised condition, remove valve B and open threaded ring C, fill
reservoir A with hydraulic oil afterwards.
• Install pressure gauge in-line filter D and pressure gauge cock E as well as test specimen „ to manifold ƒ.
Ž Open pressure gauge cock E at the test specimen „ and close valve B at reservoir A.
• Pump up to the approximately required pressure as described under item 09.22 and 09.23, maximum 400 bar.
• If the required pressure has not yet been obtained, close pressure gauge cock E at the test specimen „.
‘ Open valve B at the reservoir A and turn pump spindle(s) with the handcross … anticlockwise to the stop.
’ Close valve B at the reservoir A.
“ Open pressure gauge cock E at the test specimen „.
” Pump up pressure (max. 400 bar) as described under 09.22 and 09.23.

Technical alteration rights reserved

WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 63911 Klingenberg
Phone +49 (0)93 72/1 32-0 Fax +49 (0)93 72 / 132 – 4 06/4 14