P3000 Series Pneumatic Deadweight Tester Users Manual PN 3952260 November 2010 © 2010 Fluke Corporation. All rights reserved. Printed in USA. Specifications are subject to change without notice. All product names are trademarks of their respective companies.
LIMITED WARRANTY AND LIMITATION OF LIABILITY Each Fluke product is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is one year and begins on the date of shipment. Parts, product repairs, and services are warranted for 90 days.
Table of Contents Chapter 1 Title General Information ............................................................................ 1-1 Introduction........................................................................................................ How to Contact Fluke ........................................................................................ Safety Information ............................................................................................. Safety Summary ...................
P3000 Series Users Manual 5 Maintenance & Servicing .................................................................... 5-1 Introduction........................................................................................................ PCU Assembly — 10 mm Nominal Diameter — Pressure ............................... Piston Disassembly........................................................................................ Piston Cleaning.................................................................
List of Tables Table 1-1. 1-2. 2-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. Title Symbols.................................................................................................................. Operation and Storage Specifications .................................................................... Test Port Inserts - Parts List ................................................................................... PCU Assembly - 10 mm - Pressure - Parts List .............................................
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List of Figures Figure 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 3-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 8-1. 8-2. 8-3. Title Single PCU Instrument .......................................................................................... Single PCU Instrument with Handpump................................................................ Dual PCU (Pressure & Vacuum) Instrument ......................................................... Dual PCU (Pressure & Vacuum) Instrument with Handpump .
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Chapter 1 General Information Introduction This User’s Manual covers the following pressure instruments: P3011, P3011P, P3012P, P3013P, P3014P, P3015, P3015P, P3022, P3022P, P3023, P3023P, P3025, and the P3025P.
P3000 Series Users Manual Compressed Gas Use of compressed gas can create an environment of propelled foreign matter. Pressure system safety precautions apply to all ranges of pressure. Care must be taken during testing to ensure that all connections are properly and tightly made prior to applying pressure. Personnel must wear eye protection to prevent injury. Heavy Weights Lifting and movement of heavy weights can create an environment of strain and impact hazards.
General Information Environmental Corrections 1 When the gas pressure within the system balances the combined downward force of the piston and weights, the piston and weights will float freely and the system is in equilibrium. The design of a Piston/Cylinder Unit (PCU) fitted to a deadweight tester allows for a very small clearance gap between the piston and cylinder. This is required to allow the gas to pass between the components, providing a lubricating film, and preventing metal-to-metal contact.
P3000 Series Users Manual Temperature and Air Density variations are less significant than gravity. Variations should be corrected for when maximum accuracy is required. Temperature variation example: Deadweight Tester calibrated temperature 20 °C Operating temperature 24 °C Percentage change per °C 0.002% Indicated Pressure 250 psi TRUE PRESSURE = 250 + (20 − 24) x 0.002 x 250 100 TRUE PRESSURE = 249.
General Information Model Variations 1 Model 3012P, 3013P, 3014P and 3015P Figure 1-2. Single PCU Instrument with Handpump gjn025.bmp Model 3022, 3023 and 3025 Figure 1-3. Dual PCU (Pressure & Vacuum) Instrument gjn026.
P3000 Series Users Manual Model 3022P, 3023P and 3025P Figure 1-4. Dual PCU (Pressure & Vacuum) Instrument with Handpump gjn027.bmp Model 3011 Figure 1-5. Vacuum Instrument 1-6 gjn028.
General Information Model Variations 1 Model 3011P Figure 1-6. Vacuum Instrument with Handpump gjn029.
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Chapter 2 Preparation Introduction The deadweight tester must be set up on a level, stable workbench or similar surface. If instrument has fitted handpump, remove pump handle form tool roll and fit to pump arm. Level the tester using the four adjustable feet to the bubble level attached to the top plate. Connection to External Pressure/Vacuum Supplies Connection ports in the rear panel of the instrument are 1/4 NPT.
P3000 Series Users Manual Connections Fit the device under test (DUT) to the test port using the method described below: W Warning DO NOT use Teflon/PTFE tape on these connections, as this will prevent correct sealing. The Gauge Adapter sealing system is designed for hand-tight sealing up to 20,000 psi / 1,400 bar-wrenches or similar tools are not required — over tightening can cause damage to threads or sealing faces. Before connection, ensure that there is an O-ring fitted to the test port.
Preparation Connections Figure 2-2. Connect Assembly to Test Port Figure 2-3. Hand-Tighten Only 2 gjn007.bmp gjn008.bmp 3. To adjust the position to face forward, hold the gauge adapter and turn the instrument COUNTER-CLOCKWISE, so that it faces forward.
P3000 Series Users Manual Figure 2-4. Adjust Gauge Position gjn009.bmp 4. Hold the instrument steady, whilst turning the gauge adapter COUNTER-CLOCKWISE until it pulls down onto the O-ring. Figure 2-5. Tighten Gauge 2-4 gjn010.
Preparation Connections 2 Test Port Insert For devices with 1/8 BSP or NPT mounting threads, the diameter of the thread is very close to the effective sealing diameter of the O-ring fitted to the test port. This can make it difficult to achieve a good seal. When mounting these devices, use the test port insert (stored in the spare seals container) as shown in Figure 2-6. 1 2 3 4 gjn012.eps Figure 2-6. Test Port Insert Table 2-1.
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Chapter 3 Operation Introduction All P3000 Series pneumatic deadweight testers have a monitor gauge fitted to the instrument top plate, to serve as a guide to the operator by indicating the approximate pressure in the system. Single PCU Models — Pressure 1. Ensure that both Inlet and Exhaust valves are closed. 2. Select the required weights and stack them on the piston assembly. The pressure measured is the sum of the weights plus the piston/weight carrier. 3.
P3000 Series Users Manual 8. Depressurize the system by SLOWLY opening the Exhaust valve, as sudden depressurization will cause the weight stack to fall quickly, which may damage the piston assembly. 9. Remove the weights from the piston. Single PCU Models — Vacuum 1. Ensure that both Inlet and Exhaust valves are closed. 2. Select the required weights and stack them on the piston assembly. The vacuum measured is the sum of the weights plus the piston/weight carrier.
Operation Dual PCU (Pressure & Vacuum) Models 3 3. If either the system or handpump selector valve is set for vacuum, when pressure is applied to the system, the safety valve fitted to the front of the PCU mounting assembly will be ejected, venting the system. (The safety valve is retained by the assembly, and will not “fly-out” of the instrument). This is to limit the possible damage caused by pressurizing a vacuum instrument under test.
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Chapter 4 Calibration in Different Pressure Units Introduction The deadweight tester can be used to calibrate in different pressure units in either of two methods. Conversion Weights A set of Conversion Weights can be supplied, marked in the required pressure unit, and adjusted to the correct mass for use with the existing piston(s). The set includes (where applicable) a replacement low-pressure weight carrier table, and a replacement high-pressure weight carrier ring.
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Chapter 5 Maintenance & Servicing Introduction Note The piston/cylinder assembly is the most critical and sensitive part of the deadweight tester. To maintain accuracy, the piston must always slide freely in the cylinder, and the gas supply must remain clean and dry. The Figures on the following pages detail the components of each assembly, together with the relevant part numbers.
P3000 Series Users Manual W Caution Never touch the working surface of a clean piston with bare fingers — the natural oil in your skin can cause the piston and cylinder to stick. 8. Wipe any dirt or moisture from the outside surfaces of the cylinder (2). 9. Roll a NEW tissue into a tapered rod of appropriate size. Force the tissue through the cylinder bore while rotating. Ensure that the tissue is a tight fit inside the bore so that dirt and contamination is removed. 10.
Maintenance & Servicing PCU Assembly — 10 mm Nominal Diameter — Vacuum 5 1 2 3 4 gjn31.eps Figure 5-1. PCU Assembly - 10mm - Pressure Table 5-1. PCU Assembly - 10 mm - Pressure - Parts List Item Description Part Item Description Part 1 Weight Carrier Spec 3 Piston Spec 2 Cylinder Spec 4 O Ring 3864954 PCU Assembly — 10 mm Nominal Diameter — Vacuum Piston Disassembly 1. Unscrew the PCU assembly from the instrument; use the dowel hole if the cylinder is tight. 2.
P3000 Series Users Manual 5. After removal from the solvent, using a NEW tissue, repeat the cleaning procedure in step 3, taking great care to ensure that all traces of solvent are removed from the inside of the tubular piston and weight carrier. 6. Place piston carefully on a NEW tissue where it will not be damaged while the cylinder is cleaned. W Caution Never touch the working surface of a clean piston with bare fingers — the natural oil in your skin can cause the piston and cylinder to stick. 7.
Maintenance & Servicing PCU Assembly — 16 mm Nominal Diameter 5 3 2 1 gjn32.eps Figure 5-2. PCU Assembly - 10mm - Vacuum Table 5-2. PCU Assembly - 10 mm - Vacuum - Parts List Item Description Part 1 Piston Spec 2 Cylinder Spec Item 3 Description Bonded Seal Part 3918392 PCU Assembly — 16 mm Nominal Diameter Piston Disassembly 1. Unscrew the PCU assembly from the instrument; use the dowel hole if the cylinder is tight. 2. Unscrew piston stop (5). 3.
P3000 Series Users Manual 6. After removal from the solvent, using a NEW tissue, repeat the cleaning procedure in step 4, take great care to ensure that all traces of solvent are removed from inside the tubular piston. 7. Place piston carefully on a NEW tissue where it will not be damaged while the cylinder is cleaned. W Caution Never touch the working surface of a clean piston with bare fingers — the natural oil in your skin can cause the piston and cylinder to stick. 8.
Maintenance & Servicing PCU Assembly — 22 mm Nominal Diameter 5 1 2 3 4 5 6 gjn33.eps Figure 5-3. PCU Assembly - 16 mm Table 5-3. PCU Assembly - 16 mm - Parts List Item Description Part Item Description Part 1 Piston Spec 4 O Ring 3864766 2 Bearing 3918063 5 Piston Stop Spec 3 Cylinder Spec 6 O Ring 3864954 PCU Assembly — 22 mm Nominal Diameter 1. The weight carrier is permanently attached to the piston; hold the weight carrier and gently lift the piston (1). 2.
P3000 Series Users Manual 6. After removal from the solvent, using a NEW tissue, repeat the cleaning procedure in step 4, take great care to ensure that all traces of solvent are removed from inside the tubular piston. 7. Place piston carefully on a NEW tissue where it will not be damaged while the cylinder is cleaned. W Caution Never touch the working surface of a clean piston with bare fingers — the natural oil in your skin can cause the piston and cylinder to stick. 8.
Maintenance & Servicing Top Plate Removal 5 1 3 2 4 gjn34.eps Figure 5-4. PCU Assembly - 22 mm Table 5-4. PCU Assembly - 22 mm - Parts List Item Description Part Item Description Part 1 Piston Spec 3 Bearing Cap 3918182 2 Cylinder Spec 4 O Ring 3867509 Top Plate Removal Note In order to perform maintenance procedures on the hydraulic system, the Top Plate Assembly must first be removed from the instrument case. 1. Depressurize the system by slowly opening the Exhaust valve. 2.
P3000 Series Users Manual W Caution When handling the top plate assembly, it is good practice to remove the piston assemblies to avoid accidental damage. Note Replacement is simply the reverse of the above procedure. Handpump Assembly Disassembly 1. Disconnect tubing from check valve (19) and/or (23). 2. On the upper side of the top plate, unscrew locknut (3) 1/2 turn, and remove spring clip (1) from clevis (2). 3. The pump arm assembly can be swung out of the way. 4. Remove locknut (3) and clevis (2). 5.
Maintenance & Servicing Handpump Assembly 2 1 9 10 4 3 5 11 5 12 6 13 20 7 21 8 14 15 16 17 18 22 23 19 gjn35.eps Figure 5-5. Handpump Assembly Table 5-5. Handpump Assembly - Parts List Item Description Part Item Description Part 1 Spring Clip 3920224 13 Cylinder Spec 2 Clevis 3920236 14 Bonded Seal 3918879 3 Locknut 3918713 15 O Ring 3865075 4 Set Screw 3918822 16 Bullet 3918846 5 Pump Lock Spec. 17 Spring 3918854 6 Guide Spec.
P3000 Series Users Manual System Selector Valve Before commencing disassembly of the selector valve, make a note of the tubing connections to avoid problems during reassembly. Disassembly 1. Disconnect nylon tubing from connectors (11). 2. Loosen set screws (1), and remove knob (2) from valve shaft (3). 3. Remove screws (13), and withdraw valve assembly from support bracket (12). 4. Remove screw (9), and lift off valve rotor (8), taking care not to lose O rings (7). 5.
Maintenance & Servicing Safety Valve 5 14 2 12 13 1 4 6 4 5 8 9 3 5 11 10 7 gjn36.eps Figure 5-6. System Selector Valve Table 5-6.
P3000 Series Users Manual 1 2 3 4 5 6 7 gjn37.eps Figure 5-7. Safety Valve Table 5-7.
Chapter 6 Fault Finding Poor PCU Spin/Sensitivity The clean pneumatic piston/weight carrier assembly will rotate freely, without additional weights, slowing down gradually to a complete stop. If the rotation stops quickly, then the PCU may be dirty and require cleaning. If the piston “squeaks” when rotated, it must be cleaned immediately, see Chapter 5, Maintenance & Servicing. To check the freedom of the PCU, open the Exhaust valve and hold the weight carrier.
P3000 Series Users Manual High PCU Fall-Rate The piston will always fall slowly as the gas passes between the piston and cylinder. However, this fall rate will never be so fast that a stable reading cannot be made. 1. The system may be leaking. Check that exhaust valve is fully closed, and test port connections are correctly made. 2. The DUT may be leaking.
Chapter 7 Storage & Transportation Instrument 1. Shut-off any external supplies, and depressurize system by slowly opening both Inlet and Exhaust valves. 2. Disconnect external supplies. 3. Remove screw-in handle from handpump arm (if fitted) and store in tool roll. 4. Refit instrument lid, ensuring that the hinges are correctly engaged, and secure with toggle clips at the sides. Weights 1. Starting with the largest increments first, stack all appropriate weights in the wooden weight case. 2.
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Chapter 8 Ancillary Equipment Dirt/Moisture Trap, P5531 If there is any doubt that the instrument to be tested is not internally clean, then the addition of the P5531 Dirt/Moisture Trap will protect the deadweight tester from contamination and possible damage. Any particles or moisture present within the DUT will fall into the clear, acrylic chamber, where they can be seen by the operator.
P3000 Series Users Manual Angle Adapter, P5543 To calibrate gauges with the pressure connection on the rear (e.g. panel-mount gauges) in their correct position, an angle adapter should be used. The angle adapter fits directly onto the test station, converting it through 90 degrees, allowing the standard adapters to be used. Figure 8-2. Angle Adapter gjn022.bmp Pointer Remover/Punch, P5551 To remove and refit the pointer of a pressure gauge, a pointer remover/punch should be used.
