Fluke 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
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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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P3000 Series
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
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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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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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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.
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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P3000 Series
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.
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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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P3000 Series
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
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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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P3000 Series
Users Manual
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
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General Information
Model Variations 1
1-7
Model 3011P
gjn029.bmp
Figure 1-6. Vacuum Instrument with Handpump
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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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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.
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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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P3000 Series
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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
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Preparation
Connections 2
2-5
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. Test Port Inserts - Parts List
Item Description Part
1 O Ring 3865142
2 Test Port Insert 3919892
3 O Ring 3883397
4 Test Port 3921566
To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle
Adapter (see Chapter 8, Ancillary Equipment).
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3-1
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. Use the handpump (if fitted) to generate pressure until the piston floats (i.e. not
touching the top or bottom travel limits.
Note
Handpump use: Slow down-strokes will only partially contribute pressure,
for higher pressurization, a faster down-stroke is required. The handpump
will generate approximately 300 psi/20 bar — above this pressure, an
external supply will be required.
Alternatively, if connected to an external supply, SLOWLY open and close
Inlet valve until piston floats. If piston is over-pressurized (piston against
top travel limit) then reduce pressure by SLOWLY opening and closing
Exhaust valve until the piston floats.
4. 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 3-1. DO NOT rotate weights when the piston is
against the top or bottom limits of travel.
5. Allow a few moments for the system to stabilize before taking any readings,
especially after large changes in system pressure.
6. For the next, higher calibration point, repeat from step 2 above.
7. To measure reducing pressures, remove the necessary weights, and by opening and
closing the Exhaust valve, SLOWLY reduce the system pressure until the piston
floats, then rotate clockwise as above.
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P3000 Series
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3-2
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. (The weights can
be passed over the weight carrier if held at a slight angle).
3. Use the handpump (if fitted) to generate pressure until the piston floats i.e. not
touching the top or bottom travel limits.
Note
Handpump use: Slow down-strokes will only partially contribute vacuum,
for higher vacuum, a faster down-stroke is required. The handpump will
generate approximately 75% vacuum (depending upon local atmospheric
conditions), above this range, an external vacuum supply will be required.
Alternatively, if connected to an external supply, SLOWLY open and close
Inlet valve until piston floats. If piston is over-pressurized (piston against
top travel limit) then reduce pressure by SLOWLY opening and closing
Exhaust valve until the piston floats.
4. 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 3-1. DO NOT rotate weights when the piston is
against the top or bottom limits of travel.
5. Allow a few moments for the system to stabilize before taking any readings,
especially after large changes in system pressure.
6. For the next, higher calibration point, repeat from step 2 above.
7. To measure reducing vacuum, remove the necessary weights, and by opening and
closing the Exhaust valve, SLOWLY reduce the system pressure until the piston
floats, then rotate clockwise as above.
8. Release vacuum 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.
Dual PCU (Pressure & Vacuum) Models
1. Select Pressure or Vacuum Mode by turning the system selector valve on the front of
the instrument, 1/4 turn counter-clockwise for Pressure, 1/4 turn clockwise for
vacuum. The selector valve automatically vents the system as it changes from
pressure to vacuum mode to prevent damage to sensitive vacuum equipment. During
the changeover, the operator may hear gas venting harmlessly inside the instrument
case as this occurs.
2. If the instrument is fitted with the optional handpump, ensure that the handpump
selector valve is also turned to the appropriate mode, 1/4 turn clockwise for Pressure
(handle pointing backward towards the pressure PCU) or 1/4 turn counter-clockwise
for Vacuum (handle pointing frontward towards the vacuum PCU).
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Operation
Dual PCU (Pressure & Vacuum) Models 3
3-3
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. Simply set the
selector valve(s) to the correct position, and reset the safety valve by pushing the
safety plug back in.
4. Pressure Mode: Operate as per Single PCU Models - Pressure, above.
5. Vacuum Mode: Operate as per Single PCU Models - Vacuum, above.
gjn013.bmp
Figure 3-1. Weight Rotation
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