P3031 & P3032 Pneumatic Deadweight Tester Users Manual PN 3963385 November © 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 ...................
P3031 & P3032 Users Manual Introduction........................................................................................................ PCU Assembly................................................................................................... Piston Disassembly........................................................................................ Piston Cleaning.............................................................................................. Piston Reassembly.....................
List of Tables Table 1-1. 1-2. 2-1. 5-1. 5-2. 5-3. Title Symbols.................................................................................................................. Temperature and Humidity Ranges for the DWT .................................................. Test Port Insert - Parts List..................................................................................... PCU Assembly - Parts List.....................................................................................
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List of Figures Figure 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 3-1. 3-2. 5-1. 5-2. 5-3. 8-1. 8-2. 8-3. Title Screw on Gauge Adapter........................................................................................ Making Pressure Connections................................................................................ Do Not Over-Tighten ............................................................................................. Adjust Gauge Position...............................................
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Chapter 1 General Information Introduction This manual covers the operation and maintenance of the P3031 and P3032 Pneumatic Deadweight Testers (DWT).
P3031 & P3032 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 hydraulic 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 Operating & Storage Specification 1 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. Operating & Storage Specification Temperature and relative humidity ranges for operation and storage of the deadweight tester are listed in Table 1-2. Table 1-2.
P3031 & P3032 Users Manual Temperature and Air Density 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.
Chapter 2 Preparation Preparation The deadweight tester must be set up on a level, stable workbench or similar surface. Level the tester using the four adjustable feet to the bubble level attached to the top plate. Connection to External Pressure Supply The connection port in the rear panel of the instrument is ¼ NPT. Pressure supply must be both clean and dry — a compressed gas bottle (instrument quality nitrogen or air) fitted with a pressure regulator is recommended.
P3031 & P3032 Users Manual 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. Making Pressure Connections Figure 2-3. Do Not Over-Tighten 2 gmg02.bmp gmg03.bmp 3. To adjust the position to face forward, hold the gauge adapter and turn the instrument COUNTER-CLOCKWISE, so that it faces forward. Figure 2-4. Adjust Gauge Position gmg04.bmp 4. Hold the instrument steady, while turning the gauge adapter COUNTER-CLOCKWISE until it pulls down onto the O-ring.
P3031 & P3032 Users Manual Figure 2-5. Tighten Gauge Figure 2-6. Do Not Over-Tighten gmg05.bmp gmg06.bmp 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 2-7. 1 2 3 Figure 2-7. Test Port Insert 2-4 gmg07.
Preparation PCU Priming 2 Table 2-1. Test Port Insert - Parts List Item Description Part 1 O Ring 3865142 2 Test Port Insert 3919892 3 O Ring 3883397 To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle Adapter P5543, (see Chapter 8, Ancillary Equipment). PCU Priming If the instrument is to be primed for the first time after drainage for storage/transportation, the following points apply: 1. Remove PCU assembly — see Chapter 5, PCU Assembly. 2.
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Chapter 3 Operation Introduction There is 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. 1. Ensure that both Inlet and Exhaust valves are closed. 2. Turn screw press out (counter-clockwise) to approximately half its travel. 3. 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. 4.
P3031 & P3032 Users Manual Note At low pressures, the piston may require lifting manually to overcome the ‘stick’ due to surface tension of the film of fluid that will develop between the top of the cylinder and the underside of the weight carrier. 6. Gently rotate the weight stack clockwise, such that it is turning between approximately 10 and 60 rpm.
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 W Caution 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.
P3031 & P3032 Users Manual 9. Roll a NEW tissue into a tapered rod of appropriate size. Force the tissue through the cylinder bore whilst rotating. Ensure that the tissue is a tight fit inside the bore so that dirt and contamination is removed. 10. Repeat step 9, using a NEW tissue, but from the opposite end of the cylinder. 11. Immerse the cylinder in a suitable, clean solvent. 12. After removal from the solvent, using a NEW tissue, repeat the cleaning procedure in step 9 & 10. Piston Reassembly 13.
Maintenance & Servicing Draining PCU Fluid 5 1 2 5 3 4 gmg11.eps Figure 5-1. PCU Assembly Table 5-1.
P3031 & P3032 Users Manual 6. To ensure all fluid is removed, unscrew cylinder retainer, and remove PCU assembly. 7. Unscrew 6 screws, and remove cylinder holder. 8. Carefully wipe all traces of fluid from inside the PCU housing. 9. Ensure that there is no particulate contamination inside the housing, then replace cylinder holder and screws, ensuring that the o-ring is correctly re-fitted. 10. Carefully re-fit PCU assembly, and secure with cylinder retainer. 1 2 3 4 8 5 6 8 7 8 Figure 5-2.
Maintenance & Servicing Top Plate Removal 5 Table 5-2. PCU Housing Assembly - Parts List Item Description Part 1 O-ring 3867582 2 Screw 3910035 3 Cylinder Holder 3919202 4 O-ring 3867594 5 PCU Housing 3867582 6 Filler Plug 3919233 7 Drain Plug 3919233 8 O-ring 3867575 Top Plate Removal Note In order to perform maintenance procedures on the pneumatic system, the Top Plate Assembly must first be removed from the instrument case. 1.
P3031 & P3032 Users Manual Screw Press 1. Unscrew the large union nut (just behind the inner hub) of the screw press assembly. 2. Withdraw the lead screw assembly from the barrel (5), taking care not to drop the rambler assembly (9). 3. The white, anti-extrusion ring (8) is a PTFE spiral, and can be removed by “unwinding” it from the rambler. 4.
Maintenance & Servicing Screw Press 5 2 1 4 3 7 8 9 10 6 5 11 gmg13.eps Figure 5-3. Screw Press Assembly Table 5-3.
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Chapter 6 Fault Finding Poor PCU Spin/Sensitivity General If the piston is not free, do not rotate, as damage may occur — dismantle and clean the assembly as described in Chapter 5, PCU Assembly. To check the freedom of the PCU, open the Exhaust valve and hold the weight carrier. Lift the piston vertically, gently up and down. It should slide freely within the cylinder, if any resistance is detected, it must be cleaned immediately.
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Chapter 7 Storage & Transportation Instrument — Storage 1. Shut-off external gas supply, and depressurize system by slowly opening both Inlet and Exhaust valves. 2. Disconnect external gas supply. 3. Refit instrument lid, ensuring that the hinges are correctly engaged, and secure with toggle clips at the sides. 4. The instrument should be kept horizontal at all times.
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Chapter 8 Ancillary Equipment Dirt/Moisture Trap, P5532 If there is any doubt that the instrument to be tested is not internally clean, then the addition of the P5532 Dirt/Moisture Trap will protect the deadweight tester from contamination and possible damage. Any particles or moisture present within the DUT will fall and be trapped in the aluminum chamber, which can be periodically inspected by the operator.
P3031 & P3032 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 gmg15.bmp Pointer Remover/Punch, P5551 To remove and refit the pointer of a pressure gauge, use this tool.
