Fluke Calibration P3000 Series User 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.
P3000 Series
Pneumatic Deadweight Tester
Users Manual

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. This warranty extends only to the original buyer or end-user customer of
a Fluke authorized reseller, and does not apply to fuses, disposable batteries, or to any product which, in
Fluke's opinion, has been misused, altered, neglected, contaminated, or damaged by accident or abnormal
conditions of operation or handling. Fluke warrants that software will operate substantially in accordance
with its functional specifications for 90 days and that it has been properly recorded on non-defective media.
Fluke does not warrant that software will be error free or operate without interruption.
Fluke authorized resellers shall extend this warranty on new and unused products to end-user customers
only but have no authority to extend a greater or different warranty on behalf of Fluke. Warranty support is
available only if product is purchased through a Fluke authorized sales outlet or Buyer has paid the
applicable international price. Fluke reserves the right to invoice Buyer for importation costs of
repair/replacement parts when product purchased in one country is submitted for repair in another country.
Fluke's warranty obligation is limited, at Fluke's option, to refund of the purchase price, free of charge repair,
or replacement of a defective product which is returned to a Fluke authorized service center within the
warranty period.
To obtain warranty service, contact your nearest Fluke authorized service center to obtain return
authorization information, then send the product to that service center, with a description of the difficulty,
postage and insurance prepaid (FOB Destination). Fluke assumes no risk for damage in transit. Following
warranty repair, the product will be returned to Buyer, transportation prepaid (FOB Destination). If Fluke
determines that failure was caused by neglect, misuse, contamination, alteration, accident, or abnormal
condition of operation or handling, including overvoltage failures caused by use outside the product’s
specified rating, or normal wear and tear of mechanical components, Fluke will provide an estimate of repair
costs and obtain authorization before commencing the work. Following repair, the product will be returned to
the Buyer transportation prepaid and the Buyer will be billed for the repair and return transportation charges
(FOB Shipping Point).
THIS WARRANTY IS BUYER'S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FLUKE SHALL NOT BE LIABLE
FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSSES,
INCLUDING LOSS OF DATA, ARISING FROM ANY CAUSE OR THEORY.
Since some countries or states do not allow limitation of the term of an implied warranty, or exclusion or
limitation of incidental or consequential damages, the limitations and exclusions of this warranty may not
apply to every buyer. If any provision of this Warranty is held invalid or unenforceable by a court or other
decision-maker of competent jurisdiction, such holding will not affect the validity or enforceability of any other
provision.
Fluke Corporation
P.O. Box 9090
Everett, WA 98206-9090
U.S.A.
Fluke Europe B.V.
P.O. Box 1186
5602 BD Eindhoven
The Netherlands
11/99
To register your product online, visit register.fluke.com

i
Table of Contents
Chapter Title Page
1 General Information ............................................................................ 1-1
Introduction........................................................................................................ 1-1
How to Contact Fluke ........................................................................................ 1-1
Safety Information ............................................................................................. 1-1
Safety Summary ............................................................................................ 1-1
Compressed Gas ............................................................................................ 1-2
Heavy Weights .............................................................................................. 1-2
Personal Protective Equipment...................................................................... 1-2
Symbols Used in this Manual ............................................................................ 1-2
Operating Principle ............................................................................................ 1-2
Operating & Storage Specification................................................................ 1-3
Environmental Corrections ................................................................................ 1-3
Gravity........................................................................................................... 1-3
Temperature................................................................................................... 1-4
Model Variations ............................................................................................... 1-4
2 Preparation .......................................................................................... 2-1
Introduction........................................................................................................ 2-1
Connection to External Pressure/Vacuum Supplies........................................... 2-1
Connections ....................................................................................................... 2-2
Test Port Insert .............................................................................................. 2-5
3 Operation ............................................................................................. 3-1
Introduction........................................................................................................ 3-1
Single PCU Models — Pressure ........................................................................ 3-1
Single PCU Models — Vacuum ........................................................................ 3-2
Dual PCU (Pressure & Vacuum) Models .......................................................... 3-2
4 Calibration in Different Pressure Units ............................................. 4-1
Introduction........................................................................................................ 4-1
Conversion Weights........................................................................................... 4-1
Software............................................................................................................. 4-1

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Users Manual
ii
5 Maintenance & Servicing.................................................................... 5-1
Introduction........................................................................................................ 5-1
PCU Assembly — 10 mm Nominal Diameter — Pressure ............................... 5-1
Piston Disassembly........................................................................................ 5-1
Piston Cleaning.............................................................................................. 5-1
Piston Re-Assembly ...................................................................................... 5-2
Replacement PCU Assembly ........................................................................ 5-2
PCU Assembly — 10 mm Nominal Diameter — Vacuum ............................... 5-3
Piston Disassembly........................................................................................ 5-3
Piston Cleaning.............................................................................................. 5-3
Piston Re-Assembly ...................................................................................... 5-4
Replacement PCU Assembly ........................................................................ 5-4
PCU Assembly — 16 mm Nominal Diameter................................................... 5-5
Piston Disassembly........................................................................................ 5-5
Piston Cleaning.............................................................................................. 5-5
Piston Re-Assembly ...................................................................................... 5-6
Replacement PCU Assembly ........................................................................ 5-6
PCU Assembly — 22 mm Nominal Diameter................................................... 5-7
Piston Cleaning.............................................................................................. 5-7
Piston Re-Assembly ...................................................................................... 5-8
Replacement PCU Assembly ........................................................................ 5-8
Top Plate Removal............................................................................................. 5-9
Handpump Assembly......................................................................................... 5-10
Disassembly................................................................................................... 5-10
Cleaning and Inspection ................................................................................ 5-10
Re-Assembly ................................................................................................. 5-10
System Selector Valve ....................................................................................... 5-12
Disassembly................................................................................................... 5-12
Cleaning & Inspection................................................................................... 5-12
Re-Assembly ................................................................................................. 5-12
Safety Valve....................................................................................................... 5-13
Disassembly................................................................................................... 5-13
Re-Assembly ................................................................................................. 5-13
6 Fault Finding........................................................................................ 6-1
Poor PCU Spin/Sensitivity................................................................................. 6-1
System Will Not Pressurize ............................................................................... 6-1
High PCU Fall-Rate ...................................................................................... 6-2
Handpump Malfunction................................................................................. 6-2
7 Storage & Transportation ................................................................... 7-1
Instrument .......................................................................................................... 7-1
Weights .............................................................................................................. 7-1
8 Ancillary Equipment............................................................................ 8-1
Dirt/Moisture Trap, P5531................................................................................. 8-1
Angle Adapter, P5543........................................................................................ 8-2
Pointer Remover/Punch, P5551......................................................................... 8-2

iii
List of Tables
Table Title Page
1-1. Symbols.................................................................................................................. 1-2
1-2. Operation and Storage Specifications .................................................................... 1-3
2-1. Test Port Inserts - Parts List ................................................................................... 2-5
5-1. PCU Assembly - 10 mm - Pressure - Parts List ..................................................... 5-3
5-2. PCU Assembly - 10 mm - Vacuum - Parts List ..................................................... 5-5
5-3. PCU Assembly - 16 mm - Parts List ...................................................................... 5-7
5-4. PCU Assembly - 22 mm - Parts List ...................................................................... 5-9
5-5. Handpump Assembly - Parts List........................................................................... 5-11
5-6. System Selector Valve - Parts List......................................................................... 5-13
5-7. Safety Valve - Parts List ........................................................................................ 5-14

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Users Manual
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v
List of Figures
Figure Title Page
1-1. Single PCU Instrument .......................................................................................... 1-4
1-2. Single PCU Instrument with Handpump................................................................ 1-5
1-3. Dual PCU (Pressure & Vacuum) Instrument ......................................................... 1-5
1-4. Dual PCU (Pressure & Vacuum) Instrument with Handpump .............................. 1-6
1-5. Vacuum Instrument................................................................................................ 1-6
1-6. Vacuum Instrument with Handpump ..................................................................... 1-7
2-1. Screw on Gauge Adapter........................................................................................ 2-2
2-2. Connect Assembly to Test Port.............................................................................. 2-3
2-3. Hand-Tighten Only ................................................................................................ 2-3
2-4. Adjust Gauge Position............................................................................................ 2-4
2-5. Tighten Gauge........................................................................................................ 2-4
2-6. Test Port Insert ....................................................................................................... 2-5
3-1. Weight Rotation ..................................................................................................... 3-3
5-1. PCU Assembly - 10mm - Pressure......................................................................... 5-3
5-2. PCU Assembly - 10mm - Vacuum......................................................................... 5-5
5-3. PCU Assembly - 16 mm ........................................................................................ 5-7
5-4. PCU Assembly - 22 mm ........................................................................................ 5-9
5-5. Handpump Assembly ............................................................................................. 5-11
5-6. System Selector Valve ........................................................................................... 5-13
5-7. Safety Valve ........................................................................................................... 5-14
8-1. Dirt/Moisture Trap ................................................................................................. 8-1
8-2. Angle Adapter ........................................................................................................ 8-2
8-3. Pointer/Remover Punch.......................................................................................... 8-2

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Users Manual
vi

1-1
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.
How to Contact Fluke
To order accessories, receive operating assistance, or get the location of the nearest Fluke
distributor or Service Center, call:
•Technical Support USA: 1-800-99-FLUKE (1-800-993-5853)
•Calibration/Repair USA: 1-888-99-FLUKE (1-888-993-5853)
•Canada: 1-800-36-FLUKE (1-800-363-5853)
•Europe: [phone]
•China: [phone]
•Japan: [phone]
•Singapore: [phone]
•Anywhere in the world: [phone]
Or, visit Fluke's website at www.fluke.com.
To register your product, visit http://register.fluke.com.
To view, print, or download the latest manual supplement, visit
http://us.fluke.com/usen/support/manuals.
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.
WWarning
If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.

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Users Manual
1-2
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. Care must be taken during testing to ensure that weight masses are lifted in a
manner that avoids over-reaching or twisting, and that the masses are not dropped.
Personnel must wear reinforced safety shoes to prevent injury.
Personal Protective Equipment
Wear eye protection and reinforced safety shoes approved for the materials and tools
being used.
Symbols Used in this Manual
In this manual, a Warning identifies conditions and actions that pose a hazard to the user.
A Caution identifies conditions and actions that may damage the Pneumatic Deadweight
Tester.
Symbols used on the Pneumatic Deadweight Tester and in this manual are explained in
Table 1-1.
Table 1-1. Symbols
Symbol Description
BAC (Alternating Current)
JEarth Ground
WImportant Information: refer to manual
~Do not dispose of this product as unsorted
municipal waste. Go to Fluke’s website for
recycling information.
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.
AREA
FORCE
PRESSURE =
Each weight is marked with the tester serial number, and the pressure measured when
placed on a correctly spinning and floating piston. The total pressure measured is the
summation of the weights plus the piston weight carrier assembly.

General Information
Environmental Corrections 1
1-3
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.
Operating & Storage Specification
Temperature and relative humidity ranges for operation and storage of the deadweight
tester.
Table 1-2. Operation and Storage Specifications
Operation Storage
Temperature 18 °C to 28 °C
64 °F to 82 °F
10 °C to 50 °C
50 °F to 122 °F
Relative Humidity
(Non-Condensing)
20 % to 75 % 0 % to 90 %
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 (0.5%), ensure that the
tester has either been manufactured to your local gravity, or that you have applied the
correction from the calibrated gravity.
Example:
Deadweight Tester calibrated gravity 980.665 cm/s²
(980.665 cm/s² is the International Standard Gravity)
Gravity at site 981.235 cm/s²
Indicated Pressure 250 psi
250
665.980
235.981 xPRESSURETRUE =
psiPRESSURETRUE 1453.250=
The ability to determine the local gravity value will depend on the data available in the
country that the instrument is to be used in. Some countries have geographic/geological
survey/mapping organizations that have the data readily available. If not, the countries’
National Standards Laboratory may be able to recommend a source of suitable
information.
Temperature

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Users Manual
1-4
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
()
250
100
002.0
2420250 xxPRESSURETRUE −+=
psiPRESSURETRUE 98.249=
Model Variations
This manual covers many pressure ranges and models within the P3000 series of
instruments.
The following illustrations detail the physical appearance of the six basic models:
Model 3015
gjn024.bmp
Figure 1-1. Single PCU Instrument

General Information
Model Variations 1
1-5
Model 3012P, 3013P, 3014P and 3015P
gjn025.bmp
Figure 1-2. Single PCU Instrument with Handpump
Model 3022, 3023 and 3025
gjn026.bmp
Figure 1-3. Dual PCU (Pressure & Vacuum) Instrument

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1-6
Model 3022P, 3023P and 3025P
gjn027.bmp
Figure 1-4. Dual PCU (Pressure & Vacuum) Instrument with Handpump
Model 3011
gjn028.bmp
Figure 1-5. Vacuum Instrument

General Information
Model Variations 1
1-7
Model 3011P
gjn029.bmp
Figure 1-6. Vacuum Instrument with Handpump

P3000 Series
Users Manual

2-1
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. Pressure supply must be
both clean and dry — a compressed gas bottle (instrument quality nitrogen or air) fitted
with a pressure regulator is recommended. Factory (compressed) air lines should only be
used if a series of filters are fitted to ensure that the supply is clean and dry.
WWarning
Great care must be taken when operating any pneumatic
deadweight tester, as any contamination present within the
system will result in degradation of performance, and eventual
IRREPARABLE DAMAGE to the PCUs.
To avoid damage to the instrument, the operator should ensure
that any device under test (DUT) is clean and dry before
connecting it to the test port. If the DUT is of unknown
cleanliness, the Dirt/Moisture Trap, P5531, can be mounted to
the test port of the deadweight tester. This will prevent any dirt
particles or moisture droplets present within the DUT from
passing into the deadweight tester system, (see Chapter 8).

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Users Manual
2-2
Connections
Fit the device under test (DUT) to the test port using the method described below:
WWarning
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.
Check that the sealing face of the device to be fitted is clean
and undamaged, as scratches or dents can form leak-paths.
Note
The thread on the test port, and the lower part of the gauge adapters is
LEFT-HANDED. The following procedure details the correct method for
mounting devices using these adapters:
1. Screw the appropriate gauge adapter fully on to the instrument to be tested.
gjn006.bmp
Figure 2-1. Screw on Gauge Adapter
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.

Preparation
Connections 2
2-3
gjn007.bmp
Figure 2-2. Connect Assembly to Test Port
gjn008.bmp
Figure 2-3. Hand-Tighten Only
3. To adjust the position to face forward, hold the gauge adapter and turn the instrument
COUNTER-CLOCKWISE, so that it faces forward.

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Users Manual
2-4
gjn009.bmp
Figure 2-4. Adjust Gauge Position
4. Hold the instrument steady, whilst turning the gauge adapter
COUNTER-CLOCKWISE until it pulls down onto the O-ring.
gjn010.bmp
Figure 2-5. Tighten Gauge