P3100 & P3200 Series Hydraulic Deadweight Tester Users Manual PN 3952224 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 ...................
P3100 & P3200 Series Users Manual 5 Calibration in Different Pressure Units ............................................. 5-1 Calibration in Different Pressure Units.............................................................. 5-1 Conversion Weights ...................................................................................... 5-1 Software......................................................................................................... 5-1 6 Maintenance and Servicing ....................
Contents (continued) Pointer Remover/Punch, P5551.....................................................................
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List of Tables Table 1-1. 1-2. 2-1. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. Title Symbols.................................................................................................................. Operation and Storage Specifications .................................................................... Test Port Insert Parts List ....................................................................................... PCU Assembly - 10 mm Parts List .........................................................
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List of Figures Figure 1-1. 1-2. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 4-1. 4-2. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 9-1. 9-2. 9-3. Title Hydraulic Circuit Schematic .................................................................................. Dual PCU Instrument ............................................................................................. Screw on Gauge Adapter........................................................................................ Making Pressure Connections.......................
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Chapter 1 General Information Introduction This manual covers the following pressure instruments: Oil Operated Instruments: P3111, P3112, P3113, P3114, P3115, P3116, P3123, P3124, and P3125. Distilled Water Operated Instruments: P3211, P3213, P3214, P3223, and P3224.
P3100 & P3200 Series Users Manual Safety Information Safety Summary The following are general safety precautions that are not related to any specific procedures and do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during equipment operation and maintenance to ensure safety and health and protection of property.
General Information Operating Principle 1 Operating Principle Deadweight Testers are the primary standard for pressure measurement. Utilizing the well-proven Piston-Gauge system, consisting of a vertically mounted, precision lapped Piston and Cylinder assembly, accurately calibrated weight masses (Force) are loaded on the piston (Area), which rises freely within its cylinder. These weights balance the upward force created by the pressure within the system.
P3100 & P3200 Series Users Manual HIGH PRESSURE PCU DEVICE UNDER TEST LOW PRESSURE PCU RESERVOIR SCREW PUMP PRIMING PUMP gjn001.eps Figure 1-1. Hydraulic Circuit Schematic Operating & Storage Specification are as follows: Temperature and relative humidity ranges for operation and storage of the deadweight tester. Table 1-2.
General Information Environmental Corrections 1 Environmental Corrections The deadweight tester has been calibrated to the Gravity, Temperature, and Air Density stated on the certificate. Equations and factors are given on the certificate to adjust for any variations in these environmental conditions. Gravity Gravity varies greatly with geographic location, and so will the deadweight tester reading. Due to the significant change in gravity throughout the world (0.
P3100 & P3200 Series Users Manual Head of Fluid The pressure measured is at the top of the test port seal. Vertical height difference between this datum point and the connection to the instrument under test should be corrected for. To correct for vertical heights above and below the datum line, either subtract or add respectively, the amount stated on the certificate. To ensure accuracy is maintained, the piston and weights must be kept clean and undamaged.
General Information Model Variations 1 Models: 3112, 3113, 3114, 3115, 3116, 3213, and 3214. Figure 1-3. Single High Pressure PCU Instrument gjn004.bmp Models: 3111 and 3211. Figure 1-4. Single Low Pressure PCU Instrument gjn005.
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Chapter 2 Preparation Introduction The deadweight tester must be set up on a level, stable workbench or similar surface. Remove spokes from tool roll and fit to capstan hub. Level the tester using the four adjustable feet to the bubble level attached to the top plate. Rotate reservoir dust cover through ¼ turn and fill reservoir approximately ¾ full with the appropriate fluid. Rotate dust cover back to cover hole.
P3100 & P3200 Series Users Manual Connections Fit the device under test (DUT) to the test port using the method described below: W Caution Ensure that all devices are internally clean and free from contamination before connecting to the tester. Particle contamination can damage the sensitive piston assemblies, valve seats and screw pump.
Preparation Connections 2 2. Screw assembly down COUNTER-CLOCKWISE on to test port. Note Hand-tight is sufficient; ensure that the bottom face contacts the O-ring on the test port. Figure 2-2. Making Pressure Connections Figure 2-3. Adjusting Pressure Connections 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.
P3100 & P3200 Series Users Manual Figure 2-4. Adjust Gauge Position gjn009.bmp 4. Hold the instrument steady, while turning the gauge adapter COUNTER-CLOCKWISE until it pulls down onto the O-ring. Figure 2-5. Tighten Gauge gjn010.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.
Preparation Connections 2 1 2 3 4 gjn012.eps Figure 2-6. Test Port Insert Table 2-1. Test Port Insert Parts List Item Description Part 1 O RING 3865142 2 TEST PORT INSERT 3919892 3 O RING 3883397 4 TEST PORT 3921414 To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle Adapter (Refer to Chapter 9, Ancillary Equipment).
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Chapter 3 Priming Priming 1. 2. 3. 4. Open reservoir valve one turn counter-clockwise and turn capstan fully in. Pump the priming pump two times. Close valve and turn capstan fully out. Open valve and turn capstan fully in. Note During this operation, bubbles may appear in the reservoir, as trapped air is expelled. For large volumes, repeat steps 3 and 4 until no further bubbles appear. 5. With valve open, turn capstan fully out and close valve. The tester is now ready for use.
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Chapter 4 Operation Operation 1. Select the required weights and stack them on the appropriate piston assembly. The pressure measured is the sum of the weights plus the piston/weight carrier. Dual PCU models: The PCU’s are matched in a ratio of effective areas, 20:1 or 10:1, depending upon model, and the weights will be marked accordingly with both high and low pressure values. Note The priming pump is intended for system priming only, and cannot be used to generate high pressures. 2.
P3100 & P3200 Series Users Manual 3. Gently rotate the weight stack clockwise, such that it is turning between approximately 10 and 60 rpm. Avoid side-loads when turning the weights by placing the palms of the hands on either side and “rolling” the stack by pulling in opposite directions, see Figure 4-2. DO NOT rotate weights when the piston is against the top or bottom limits of travel. Figure 4-2. Weight Rotation gjn013.bmp 4.
Operation Operation 4 Note 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 working fluid to pass between the components, providing a lubricating film, and preventing metal-to-metal contact. Therefore, during the normal operation of a deadweight tester, the working fluid in the system will be slowly passed through this clearance gap.
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Chapter 5 Calibration in Different Pressure Units Calibration in Different Pressure Units 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 6 Maintenance and Servicing Maintenance and Servicing 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 hydraulic fluid must remain clean. The Figures on the following pages detail the components of each assembly, together with the relevant part numbers.
P3100 & P3200 Series Users Manual 8. 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. 9. Wipe excess fluid from the outside surfaces of the cylinder (2). 10. Roll a NEW tissue into a tapered rod of appropriate size. Force the tissue through the cylinder bore while rotating.
Maintenance and Servicing Maintenance and Servicing 6 Replacement PCU Assembly W Caution The piston and cylinder assembly is a matched pair, which is calibrated and adjusted to a calculated mass figure. If, for any reason, the piston or cylinder becomes damaged, then the entire assembly must be replaced. The replacement assembly consists of the following components: Item numbers 1 through 5. 1 2 3 4 5 6 7 Figure 6-1. PCU Assembly - 10 mm 8 gjn014.
P3100 & P3200 Series Users Manual Table 6-1. PCU Assembly - 10 mm Parts List Item Description Part Item Description Part 1 Weight Carrier Spec 5 Piston Spec 2 Cylinder Spec 6 O Ring 3864802 3 O Ring 3867553 7 LP PCU Body 3921406 4 Support Ring 3918481 8 Sump Ring 3921391 PCU Assembly - 2 & 3 mm Nominal Diameters Piston Disassembly 1. Lift off the weight carrier assembly (1 & 2), and unscrew the piston nut (5). Use the dowel hole if the nut is tight.
Maintenance and Servicing Maintenance and Servicing 6 Piston Re-Assembly 13. Replace O-ring (7) in the counter-bore in the underside of the cylinder (F), ensuring that it is located correctly and evenly. 14. Holding the piston by the larger “head” end, dip the other end into a container of clean operating fluid, and transfer to the bore in the underside of the cylinder. Allow the fluid to run through the bore.
P3100 & P3200 Series Users Manual 1 6 2 7 8 3 9 4 10 5 11 12 gjn015.eps Figure 6-2. PCU Assembly - 2 and 3 mm Table 6-2.
Maintenance and Servicing Maintenance and Servicing 6 PCU Assembly - 5 mm Nominal Diameter Piston Disassembly 1. Lift off the weight carrier assembly (1 & 2), and unscrew the piston nut (5). Use the dowel hole if the nut is tight. Remove the piston/cylinder assembly. 2. Loosen set screw (3) in piston cap (4), and gently pull the piston cap from the piston. DO NOT PULL IN SUCH A WAY THAT THE PISTON CAN BEND. The piston and cylinder assembly (6 & 7) can now be removed from the piston nut. 3.
P3100 & P3200 Series Users Manual 16. Insert piston/cylinder assembly into piston nut (5) through the threaded end, such that the shoulder on the cylinder is located within the central bore of the nut. 17. Replace piston cap (4), and secure with set screw (3), DO NOT OVER-TIGHTEN. 18. Carefully screw the assembly into the instrument, ensuring that the o-ring (9) is clean and undamaged, and correctly fitted to the piston post (10). 19.
Maintenance and Servicing Maintenance and Servicing 6 1 6 2 7 3 8 4 9 5 10 11 gjn016.eps Figure 6-3. PCU Assembly - 5 mm Table 6-3.
P3100 & P3200 Series Users Manual 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, open the reservoir valve, and turn the capstan fully in. 2. Disconnect any DUT from the test station, and remove the fluid from the reservoir*. 3. Remove the spokes from the capstan hub of the screw pump. 4.
Maintenance and Servicing Maintenance and Servicing 6 10. Ensure that the rambler assembly is correctly located on the end of the lead screw assembly. Carefully introduce the rambler into the open end of the barrel making sure that it does not tilt when entering the barrel. 11. Push the lead screw assembly fully in to the barrel, ensuring that the key in the nut locates correctly in the slot in the barrel. 12. Re-tighten the barrel union nut.
P3100 & P3200 Series Users Manual Table 6-4. Screw Pump Assembly Parts List Item Description Part Item Description Part 1 Test Port 3921414 6 O Ring 3867566 2 O Ring 3864922 7 Back-Up Ring 3919118 3 Barrel Locknut 3921438 8 Rambler 3919129 4 Barrel 3921450 9 Ball 3917855 5 Barrel Support 3921492 10 Lead Screw 3885994 Priming Pump Assembly Disassembly 1. On the underside of the top plate, disconnect the hydraulic tubing from the pump block assembly (1). 2.
Maintenance and Servicing Maintenance and Servicing 6 5. Replace locknut (12) and clevis (13), reconnect pump arm assembly, and secure with pin clip. 6. Reconnect hydraulic tubing. 1 2 3 4 5 11 6 12 7 13 8 11 9 10 14 Figure 6-5. Priming Pump Assembly gjn018.
P3100 & P3200 Series Users Manual Table 6-5.
Maintenance and Servicing Maintenance and Servicing 6 1 6 2 3 8 9 4 7 5 10 gjn019.eps Figure 6-6. Check Valves Assemblies Table 6-6. Check Valves Assemblies Parts List Item Description Part Item Description Part 1 Pump Block 3921530 6 Pump Check Flange 3921744 2 O Ring 3864766 7 Screw 3909261 3 O Ring 3865142 8 Elbow 3862616 4 Bullet 3920584 9 Check Valve 3867767 5 Spring 3920600 10 Connector 3923564 Reservoir Assembly 1.
P3100 & P3200 Series Users Manual 9. Remove three screws from reservoir spacers that hold the assembly to the top plate. The assembly can now be withdrawn from the underside of the top plate. 10. The reservoir body (11) and reservoir cap (5) are a close fit to the reservoir tube (7), and both rely on the O-ring seal (6) to hold them in place. These parts can be separated by gently pulling them apart. 11. The valve vent (9) is disassembled from the reservoir body by removing the three screws (8). 12.
Maintenance and Servicing Maintenance and Servicing 6 7 1 8 2 3 9 10 4 11 5 12 6 6 13 14 15 16 Figure 6-7. Reservoir Assembly gjn020.
P3100 & P3200 Series Users Manual Table 6-7.
Chapter 7 Fault Finding Poor PCU Spin/Sensitivity General The weights floating on a clean PCU assembly will rotate freely, slowing down gradually to a complete stop. If the rotation stops quickly, then the PCU may be dirty and require cleaning. W Caution Do not rotate the piston if it is dirty as permanent damage can occur. If the spin/sensitivity of a recently cleaned PCU deteriorates quickly, then it is likely that the hydraulic system has become contaminated.
P3100 & P3200 Series Users Manual PCU Assembly - 5 mm Plug the test station to prevent leakage, and open the reservoir valve. Remove the weight carrier assembly (1 & 2). Hold the piston cap (4), and lift gently up and down, the piston should slide freely within its cylinder. If any resistance greater than fluid drag or a “gritty” sensation is detected, then the PCU must be removed and cleaned. (See Chapter 6, PCU Assembly - 5 mm Nominal Diameter.
Fault Finding System Will Not Pressurize 7 System Will Not Pressurize 1. Ensure correct valve operation during priming process. 2. Check DUT is not leaking. 3. Clean system externally, check for fluid leak by continually trying to pressurize. Wherever fluid appears, replace the seal—check sealing faces are clean and undamaged before re-assembly. Priming Pump Malfunction 1. If pumping does not generate pressure, then the inlet check valve has probably failed, and requires replacement. 2.
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Chapter 8 Storage and Transportation Storage and Transportation Instrument 1. With the test station plugged, open the reservoir valve and turn capstan fully in, close reservoir valve. 2. Remove spokes from capstan hub, and store in tool-roll. 3. Remove screw-in handle from pump arm, and store in tool-roll. 4. If fluid is to remain in the reservoir, ensure that the tester is kept level at all times to avoid spills. If not, drain the reservoir as described in Chapter 6, Reservoir Assembly. 5.
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Chapter 9 Ancillary Equipment Ancillary Equipment Liquid Separator, P5521 or P5522 If there is any doubt that the instrument to be tested is not internally clean, then the addition of the P5521 Liquid Separator will protect the deadweight tester from contamination and possible damage. The P5521 is also particularly useful in applications where the instruments under test are used on systems that must not be contaminated by the operating fluid from the deadweight tester.
P3100 & P3200 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 9-2. 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.
