Fluke RUSKA 2482 User manual

PN 3966525
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.
RUSKA 2482
Differential Pressure Piston Gauge
Users Manual
Via Acquanera, 29 22100 Como
tel. 031.526.566 (r.a.) fax 031.507.984
[e-mail] www.calpower.it

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
Title Page
Introduction........................................................................................................ 1
How to Contact Fluke ........................................................................................ 1
Safety Information ............................................................................................. 1
Compressed Gas ............................................................................................ 1
Heavy Weights .............................................................................................. 1
Personal Protective Equipment...................................................................... 2
Symbols Used in this Manual ............................................................................ 2
General Information........................................................................................... 2
NVLAP Accredited Calibrations ....................................................................... 3
Theory of Operation........................................................................................... 3
Installation ......................................................................................................... 5
Minimum Requirements................................................................................ 5
Unpacking...................................................................................................... 5
Mechanical Setup .......................................................................................... 6
Gas Mode Setup ........................................................................................ 8
Electrical Setup .................................................................................................. 9
Software Setup................................................................................................... 10
Installation ..................................................................................................... 10
Troubleshooting Communication Setup........................................................ 11
WinPrompt® Software ................................................................................... 11
RUSKA 2482 Software ................................................................................. 12
Menu Commands........................................................................................... 13
Menu: File | Exit........................................................................................ 13
Menu: Communications | Port................................................................... 14
Menu: Communications | Disconnect | Connect ...................................... 14
Menu: Set-up | Display Resolution ........................................................... 14
Menu: Set-up | Line Pressure Units........................................................... 15
Menu: Set-up | Balance Filter.................................................................... 15
Menu: Set-up | Calibrate | Line ................................................................. 16
Menu: Set-up | Calibrate | Balance............................................................ 18
Menu: Set-up | Coefficient File | Save ...................................................... 18
Menu: Set-up | Clear Tare ......................................................................... 19
Menu: Windows | PID Values................................................................... 19
Menu: Windows | Control + Filter ............................................................ 20
Menu: Windows | Chart ............................................................................ 20
Menu: Windows | RS-232 Viewer ............................................................ 21

RUSKA 2482
Users Manual
ii
Operation ........................................................................................................... 22
Power On Sequence....................................................................................... 22
Differential Measurements Using Dioctyl Sebacate (DOS) Oil.................... 23
PID Selection ............................................................................................ 23
Connecting the Device Under Test (DUT) ............................................... 23
Generate Differential Pressures — Hydraulic........................................... 23
Techniques for Extended Calibrations ...................................................... 25
Differential Measurements Using Compressed Gas...................................... 25
PID selection ............................................................................................. 25
Verify Gas Supply Connection ................................................................. 25
Using the Oil/Gas Interfaces ..................................................................... 25
Connecting the Device Under Test (DUT) ............................................... 26
Generate Differential Pressures — Gas .................................................... 27
Techniques for Extended Calibrations ...................................................... 28
Head Height .............................................................................................. 29
Maintenance....................................................................................................... 30
Pump.............................................................................................................. 30
Screw Press Seals...................................................................................... 32
Complete Disassembly.............................................................................. 33
Full System Purge of Air............................................................................... 33
Major Purge Process ................................................................................. 34
Minor Purge Process ................................................................................. 34
Balance Removal/Installation........................................................................ 35
Leveling the Balance................................................................................. 35
Masses....................................................................................................... 35
Specifications..................................................................................................... 36
Differential Pressure Range........................................................................... 36
Line Pressure Range ...................................................................................... 36
Accuracy........................................................................................................ 36
Differential Pressure Reproducibility............................................................ 36
Piston and Cylinder ....................................................................................... 36
Electrical Power Requirements ..................................................................... 36
Operating Conditions..................................................................................... 36
Storage Conditions ........................................................................................ 36
Instrument Conditions ................................................................................... 36
Instrument Weight ......................................................................................... 36
Operating Medium......................................................................................... 36
Packaging........................................................................................................... 37
Disconnecting the System ............................................................................. 37
Installation of Clamps.................................................................................... 37
Cleaning......................................................................................................... 37
Packaging for Shipment ................................................................................ 37
Optional Shipping Method ............................................................................ 38
Final Instructions........................................................................................... 38

iii
List of Tables
Table Title Page
1. Symbols.................................................................................................................. 2
2. Oil and Gas Isolation Valves - States..................................................................... 26
3. Reservoir/Test Port Assemblies and Screw Press Assembly - Parts List............... 31

RUSKA 2482
Users Manual
iv

v
List of Figures
Figure Title Page
1. Basic System Diagram ........................................................................................... 3
2. System Operation Overview .................................................................................. 4
3. Transit Clamp with Retaining Screw ..................................................................... 6
4. Transit Strap Removal............................................................................................ 6
5. Plumbing Connections ........................................................................................... 7
6. Hydraulic Pump ..................................................................................................... 8
7. Back of Hydraulic Pump........................................................................................ 9
8. Power Connection .................................................................................................. 9
9. RUSKA 2482 - Drivers Selection .......................................................................... 10
10. Software Window - Typical Setup ......................................................................... 10
11. RUSKA 2482 - WinPrompt® - Typical Setup....................................................... 12
12. RUSKA 2482 Deadweight Controller - Current Status Window........................... 12
13. File Menu ............................................................................................................... 13
14. Communications Menu .......................................................................................... 14
15. Comm Port Selection ............................................................................................. 14
16. Display Resolution Selection ................................................................................. 15
17. Line Pressure Units Selection ................................................................................ 15
18. Balance Filter Selection ......................................................................................... 16
19. Calibration Selection.............................................................................................. 16
20. Calibrate Line Pressure .......................................................................................... 17
21. Calibrate Internal Balance...................................................................................... 18
22. Saving/Loading Coefficient Files........................................................................... 18
23. PID Values with Control Coefficients ................................................................... 19
24. Control/Filter Status ............................................................................................... 20
25. Tared Reading Graph ............................................................................................. 20
26. RS-232 View.......................................................................................................... 21
27. System Piping Diagram.......................................................................................... 22
28. Activating the Pressure Control Bias ..................................................................... 24
29. Reservoir and Test Port Assemblies....................................................................... 30
30. Screw Press Assembly ........................................................................................... 31

RUSKA 2482
Users Manual
vi

1
Introduction
This manual covers the operation and maintenance of the RUSKA 2482 Differential
Pressure Piston Gauge.
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
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, health, and protection of property.
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 pneumatic connections are properly and tightly made prior to
applying pressure. Personnel must were eye protection to prevent injury.
Heavy Weights
Lifting and movement of heavy weights can create an environment of strain and impact
hazards. Are 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.

RUSKA 2482
Users Manual
2
Personal Protective Equipment
Wear eye protection and reinforced safety shoes approved for the materials and tools
being used.
WWarning
If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
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 Differential Pressure
Piston Gauge or the equipment under test.
Symbols used on the Differential Pressure Piston Gauge and in this manual are explained
in Table 1.
Table 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.
P
This equipment meets the requirements of
all relevant European safety directives. The
equipment carries the CE mark.
General Information
The RUSKA 2482 Differential Pressure Piston Gauge is a precision standard that
provides unsurpassed performance in the field of differential pressure metrology at high
static line pressures. This instrument can calibrate virtually any differential pressure
device used at high static line pressures. A single piston design eliminates many of the
difficulties associated with dual piston differential systems.
The RUSKA 2482 is a hydraulic gauge that allows for gas calibrations through the gas/oil
interface chambers. The pressure control system uses feedback from a sensitive load cell
to maintain the system null condition. The RUSKA 2482 software is incorporated into
WinPrompt®to provide the full range of corrections and calculations required to get the
highest performance from a precision piston gauge standard. For a basic system diagram,
see Figure 1.

Differential Pressure Piston Gauge
NVLAP Accredited Calibrations
3
gms02.bmp
Figure 1. Basic System Diagram
NVLAP Accredited Calibrations
Fluke is recognized by the United States Department of Commerce National Institute of
Standards and Technology’s National Voluntary Accreditation Program (NVLAP) for
conformance with criteria set forth in NIST Handbook 150:2001 and all requirements of
ISO/IEC 17025:1999.
A NVLAP accredited calibration certificate is provided standard with the RUSKA 2482.
Theory of Operation
An overview of the RUSKA 2482 system is shown in Figure 2. During the initial
configuration of the system, the Balance is internally aligned and zeroed. With only the
weight of the piston and associated hardware acting on the Balance, the Balance is zeroed.

RUSKA 2482
Users Manual
4
Thermal
Adjust
Device
Under
Test
Line Pressure
Sensor
SetPoint
-nudge-
PID
Line
Pressure
Display
Thermal
Adust
Software
0.04g = 0.005mbar = 1ppm
Fine Tare
Error
Balance Rd
Oil
Isolation
Valve
-
+
Piston
Mass Carrier
Balance
-Coarse Tare-
gms03.eps
Figure 2. System Operation Overview
With the Oil Isolation Valve open, there is zero differential across the Piston. Using the
hand pump a line pressure can be applied. This pressure is generated equally across the
Piston when the Oil Isolation Valve is open. Changes in the line pressure may result in a
small offset on the Balance. This effect is nulled by using the control program to tare the
offset and establish a zero datum at the given line pressure.
If the Oil Isolation Valve is closed and the thermal compensation enabled, the control
program will adjust the power to the temperature compensators to maintain a zero
reading from the Balance.
When a weight is added to the Mass Carrier, a force will be transferred to the Balance.
The resulting non-zero reading of the Balance will drive the controller to adjust the power
of the thermal compensators. The PID controller drives a change in the differential
pressure until the Balance is returned to the zero datum.

Differential Pressure Piston Gauge
Installation
5
Once at the zero datum the differential pressure is determined by the weight applied and
the piston area, thus giving a primary standard for differential pressure. WinPrompt®
software manages the calculations for these conversions and can also be used to
compensate for other environmental factors.
If a small incremental pressure change is desired, the program can thermally control the
pressure to leave a small residual weight on the Balance. This residual weight is added to
the applied weight. For small increments, the induced errors on the Balance will have
negligible effect on the overall accuracy.
Installation
Minimum Requirements
To install the RUSKA 2482, the following are required:
•A sturdy workbench able to safely support the additional weight of the
RUSKA 2482 with accessories, approximately 45 kg (100 lbs)
•PC computer with Microsoft®Windows®2000 or XP, 400 MHz, 1.6 MB hard
disk space available, 256 kb RAM available, RS-232 serial port
(USB to RS-232 adapter is acceptable)
•Refer to Specifications for additional environmental, power, media, and supply
gas requirements.
Unpacking
1. Carefully remove all packaged items from the shipping box and place the
RUSKA 2482 on the workbench.
The following items will be included with the package:
•RUSKA 2482 main chassis
•RUSKA 2482 User’s Manual
•WinPrompt®software Version 2R20 or later
•Hand pump assembly and pump spindle handles
•Two flexible hoses
•Accessories kit
•Power supply and power cord
2. Inspect the instrument for any shipping damage. If any damage is discovered, notify
the shipping company immediately.
3. Save specialized packaging for future shipping and/or storage requirements.

RUSKA 2482
Users Manual
6
Mechanical Setup
1. Remove the transit clamp and the retaining screw (see Figure 3).
Retaining screw
gms04.eps
Figure 3. Transit Clamp with Retaining Screw
2. Remove the balance transit strap as follows (see Figure 4):
a. Remove the three screws that secure the left panel door — two from the rear
panel and one from the bottom side panel.
b. Open the panel door.
c. Loosen and remove the balance transit strap.
d. Close the side panel door.
e. Replace the three panel screws.
f. Store the transit strap for future use.
Transit strap
gms05.eps
Figure 4. Transit Strap Removal
3. Adjust the leveling screws so the level vial on top of the instrument indicates the
instrument is level. All four leveling screws must be in contact with the workbench.

Differential Pressure Piston Gauge
Installation
7
Note
Leveling is a critical function and should be verified before each operation.
4. Position the hydraulic pump unit on the workbench approximately 25 cm (10 in) to
the left of the main instrument (see Figure 5).
Pump Isolation Valve
Do not
tighten to
purge air
– Step 5-
gms06.eps
Figure 5. Plumbing Connections
Note
Figure 5 shows the gas supply connection. This connection is used in gas
mode operations and does not need to be installed for initial setup and
demonstration of oil mode operations. Refer to the Gas Mode Setup section.
5. Connect a flexible hose between the Pump Isolation Valve and the High Side Oil Port
on the RUSKA 2482 rear panel. Do NOT tighten the rear panel fitting until air has
been purged from the line (see Figure 5).
6. Connect a flexible hose between the High Side Gas Port on the RUSKA 2482
rear panel and the tee fitting located on the rear of the hydraulic pump assembly
(see Figure 5).
7. Route the waste oil drain tube to a suitable container compatible with
Dioctyl Sebacate Oil (DOS oil).
8. Position the hydraulic pump unit and the RUSKA 2482 close to the front of the
workbench. The placement should assure that the tubing is not being stressed and the
pump handles will not hit the workbench through the entire pump stroke.
9. Install the four pump spindle handles.
10. Anchor the hydraulic pump unit to the bench.
Note
Steps 11 through 14 are intended to purge air from the pump assembly and
tubing. The system is shipped with DOS oil in the system. If the integrity of
this system has been compromised, refer to the Maintenance section for
instructions to purge air from the entire system.
11. Close the Pump Isolation Valve. Loosen the Oil Reservoir Valve and rotate the
reservoir cover to the side. Fill the reservoir with fresh DOS oil to approximately
two-thirds full, then rotate the cover back over the top of the reservoir
(see Figure 6).

RUSKA 2482
Users Manual
8
Pump Isolation Valve
Oil Reservoir Valve
gms07.eps
Figure 6. Hydraulic Pump
12. Rotate the pump spindle fully clockwise to purge any air from the pump housing,
then rotate the spindle fully counterclockwise. Close the Oil Reservoir Valve.
13. Open the Pump Isolation Valve and rotate the pump spindle clockwise. This will
force the DOS oil through the line connected to the rear of the main instrument.
Continue pumping until DOS oil comes out of the loose fitting at the High Side Oil
Port. Once DOS oil is coming out of this fitting then tighten the fitting.
Once the system is sealed by tightening all fittings, the Oil Isolation Valve must be in
Equalize position. While the Oil Isolation Valve is in Equalize mode, turning the
pump spindle generates line pressures. While the Oil Isolation Valve is in Isolation
mode, turning the pump spindle will generate Delta pressures.
Note
If the pump spindle runs out of travel before the DOS oil comes out of the
line, repeat steps 12, 13, and 14.
14. Once the air is purged from the high side oil line, close the Pump Isolation Valve and
open the Oil Reservoir Valve. This prevents pressure building in the pump assembly
when not in use.
Note
When the system is free of air and closed, and the Oil Isolation Valve is in
Equalize mode, a one-half turn of the pump handle will generate system
line pressure.
Gas Mode Setup
The setup for gas mode operation does require the entire oil mode setup to be completed
as detailed in the Mechanical Setup section. A regulated gas supply needs to be
connected as shown.

Differential Pressure Piston Gauge
Electrical Setup
9
Gas supply connection
¼inch Swagelok
compression type
gms08.eps
Figure 7. Back of Hydraulic Pump
Electrical Setup
1. Insert the power adapter plug into the power receptacle on the rear panel of the
instrument (see Figure 5).
gms09.bmp
Figure 8. Power Connection
2. Plug the power adapter cord into a suitable wall outlet. The power lamp on the
front panel of the RUSKA 2482 will turn on.
3. Connect the RS-232 communication cable between the instrument and the
PC computer. The cable provided is a straight through cable (Pin 1 to 1, 2 to 2, …
9 to 9). If a USB to RS-232 adapter is used, the associated drivers must be installed
on the PC.

RUSKA 2482
Users Manual
10
Software Setup
This section covers the installation of software and the verification that communications
with the RUSKA 2482 is established. Refer to the Software section to learn more about
software function and application.
WinPrompt®, Revision 3R00 and later, has the RUSKA 2482 driver included.
Installation
Insert the WinPrompt®CD (Version 3R00 or later) into the computer. If Autorun does
not begin the installation then manually activate the setup.exe program on the CD.
Refer to the WinPrompt®manual for more details.
Since WinPrompt®supports many Piston Gauge products, the RUSKA 2482
Differential Pressure Piston Gauge Driver needs to be activated (Figure 9).
WinPrompt® MAIN: SETUP|DRIVER
gms32.bmp
Figure 9. RUSKA 2482 - Drivers Selection
Once the Driver is selected the RUSKA 2482 software window will activate (Figure 10).
gms11.bmp
Figure 10. Software Window - Typical Setup

Differential Pressure Piston Gauge
Software Setup
11
Note
If the LEM will be used with the RUSKA 2482, it is recommended that the
RUSKA 2482 Driver installation and verification be completed before
installing the LEM Driver. This will simplify the resolution of any
configuration issues that may arise.
Note
The RUSKA 2482 Window can function as a Stand-Alone program without
WinPrompt®. Simply close Winprompt®and activate the DP2482.exe
from the File Manager. The DP2482.exe program is installed in the same
directory structure created for WinPrompt®.
When communication is established between WinPrompt®and the RUSKA 2482,
the status bar in WinPrompt®will turn green and the grams reading in the RUSKA 2482
window will update. The status bar is located on the bottom and center of the
WinPrompt®window (see Figure 10).
Troubleshooting Communication Setup
1. Verify the following in the RUSKA 2482 communications window:
a. Port menu: select Com Port being used
b. Address: Type 41
2. Verify the serial cable is a straight through cable.
3. Verify that the power is applied to the RUSKA 2482 instrument. The LED on the
RUSKA 2482 instrument will turn on when power is applied.
WinPrompt® Software
WinPrompt®performs pressure-to-mass and mass-to-pressure calculations for the
RUSKA 2482 Differential Pressure Piston Gauge. It provides the operator with the
pressure being generated by a required mass load while correcting for environmental
influences.
The RUSKA 2482 can be used without WinPrompt®by selecting the DP2482.exe
directly from the directory in which WinPrompt®was installed.
Figure 11 shows a typical setup of WinPrompt®for a RUSKA 2482 calibration. The
Setup of WinPrompt®is described in the WinPrompt®manual. As an overview, the user
will set up several files and configure how WinPrompt®receives information. Most of
this setup is performed rather infrequently, and is typically required only when a
procedure is edited, a piston and mass set is being used for the first time, or when a piston
or mass set has been recalibrated. The environmental conditions for humidity, barometric
pressure, and ambient Temperature can be entered manually or the values can be acquired
from a RUSKA 2456-LEM Laboratory Environment Monitor.

RUSKA 2482
Users Manual
12
2482 Tared Reading is
transferred real time to the
active WinPrompt Calibration
Point. This Trim is used real
time to adjust the value of
the Actual Pressure.
gms12.eps
Figure 11. RUSKA 2482 - WinPrompt® - Typical Setup
A typical setup for the RUSKA 2482 is shown in Figure 11. Above left is the
WinPrompt®window; above right is the chart window, and below right is the
RUSKA 2482 deadweight controller window
RUSKA 2482 Software
The RUSKA 2482 Deadweight Controller window is the primary operation window of
the RUSKA 2482 software. It shows the current state and provides buttons for the major
operations of the RUSKA 2482. It also provides for setup, calibration, and opening of all
other windows available in the RUSKA 2482.
The Current Status window (see Figure 12) shows the following items:
Current tared reading from the internal balance.
This reading can be zeroed by clicking.
This value is transferred to WinPrompt and is
used as the Trim Value for thecurrent pressure
calculation.
Line pressure sensor reading.
Current Tare value. This value is set by clicking
to make the tared reading zero.
Setpoint is the targeted grams value for the
thermal controller.
Shows the power setting being applied to each
of the Temperature Controllers.
gms13.eps
Figure 12. RUSKA 2482 Deadweight Controller - Current Status Window