Fluke P3100 Series User 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.
P3100 & P3200 Series
Hydraulic 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............................................................................................. 1-2
Safety Summary ............................................................................................ 1-2
Compressed Liquid........................................................................................ 1-2
Heavy Weights .............................................................................................. 1-2
Personal Protective Equipment...................................................................... 1-2
Symbols Used in this Manual............................................................................ 1-2
Operating Principle............................................................................................ 1-3
Environmental Corrections................................................................................ 1-5
Gravity........................................................................................................... 1-5
Temperature................................................................................................... 1-5
Head of Fluid................................................................................................. 1-6
Model Variations ............................................................................................... 1-6
2 Preparation .......................................................................................... 2-1
Introduction........................................................................................................ 2-1
Operating Fluid.................................................................................................. 2-1
Connections ....................................................................................................... 2-2
Test Port Insert .............................................................................................. 2-4
3 Priming................................................................................................. 3-1
Priming .............................................................................................................. 3-1
4 Operation ............................................................................................. 4-1
Operation ........................................................................................................... 4-1

P3100 & P3200 Series
Users Manual
ii
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................................................................ 6-1
Maintenance and Servicing................................................................................ 6-1
PCU Assembly - 10 mm Nominal Diameter................................................. 6-1
Piston Disassembly ................................................................................... 6-1
Piston Cleaning ......................................................................................... 6-1
Piston Re-Assembly.................................................................................. 6-2
Replacement PCU Assembly.................................................................... 6-3
PCU Assembly - 2 & 3 mm Nominal Diameters .......................................... 6-4
Piston Disassembly ................................................................................... 6-4
Piston Cleaning ......................................................................................... 6-4
Piston Re-Assembly.................................................................................. 6-5
Replacement PCU Assembly.................................................................... 6-5
PCU Assembly - 5 mm Nominal Diameter................................................... 6-7
Piston Disassembly ................................................................................... 6-7
Piston Cleaning ......................................................................................... 6-7
Piston Re-Assembly.................................................................................. 6-7
Replacement PCU Assembly.................................................................... 6-8
Top Plate Removal........................................................................................ 6-10
Screw Pump Assembly.................................................................................. 6-10
Priming Pump Assembly............................................................................... 6-12
Disassembly .............................................................................................. 6-12
Re-Assembly............................................................................................. 6-12
Check Valves................................................................................................. 6-14
Inlet Check Valve...................................................................................... 6-14
Outlet Check Valve................................................................................... 6-14
Reservoir Assembly....................................................................................... 6-15
7 Fault Finding........................................................................................ 7-1
Poor PCU Spin/Sensitivity................................................................................. 7-1
General .......................................................................................................... 7-1
PCU Assembly - 10 mm................................................................................ 7-1
PCU Assembly - 2 and 3 mm........................................................................ 7-1
PCU Assembly - 5 mm.................................................................................. 7-2
High PCU Fall-Rate........................................................................................... 7-2
System Will Not Prime...................................................................................... 7-2
System Will Not Pressurize............................................................................... 7-3
Priming Pump Malfunction ............................................................................... 7-3
Cannot Reach Maximum Pressure..................................................................... 7-3
8 Storage and Transportation ............................................................... 8-1
Storage and Transportation................................................................................ 8-1
Instrument...................................................................................................... 8-1
Weights.......................................................................................................... 8-1
9 Ancillary Equipment............................................................................ 9-1
Ancillary Equipment.......................................................................................... 9-1
Liquid Separator, P5521 or P5522 ................................................................ 9-1
Angle Adapter, P5543................................................................................... 9-2

Contents (continued)
iii
Pointer Remover/Punch, P5551..................................................................... 9-2

P3100 & P3200 Series
Users Manual
iv

v
List of Tables
Table Title Page
1-1. Symbols.................................................................................................................. 1-2
1-2. Operation and Storage Specifications.................................................................... 1-4
2-1. Test Port Insert Parts List....................................................................................... 2-5
6-1. PCU Assembly - 10 mm Parts List ........................................................................ 6-4
6-2. PCU Assembly - 2 and 3 mm Parts List................................................................. 6-6
6-3. PCU Assembly - 5 mm Parts List .......................................................................... 6-9
6-4. Screw Pump Assembly Parts List .......................................................................... 6-12
6-5. Priming Pump Assembly - Parts List..................................................................... 6-14
6-6. Check Valves Assemblies Parts List...................................................................... 6-15
6-7. Reservoir Assembly Parts List............................................................................... 6-18

P3100 & P3200 Series
Users Manual
vi

vii
List of Figures
Figure Title Page
1-1. Hydraulic Circuit Schematic.................................................................................. 1-4
1-2. Dual PCU Instrument............................................................................................. 1-7
2-1. Screw on Gauge Adapter........................................................................................ 2-2
2-2. Making Pressure Connections................................................................................ 2-3
2-3. Making Pressure Connections................................................................................ 2-3
2-4. Adjust Gauge Position............................................................................................ 2-4
2-5. Tighten Gauge........................................................................................................ 2-4
2-6. Test Port Insert....................................................................................................... 2-5
4-1. Float-Height Indicator Post.................................................................................... 4-1
4-2. Weight Rotation..................................................................................................... 4-2
6-1. PCU Assembly - 10 mm ........................................................................................ 6-3
6-2. PCU Assembly - 2 and 3 mm................................................................................. 6-6
6-3. PCU Assembly - 5 mm .......................................................................................... 6-9
6-4. Screw Pump Assembly .......................................................................................... 6-11
6-5. Priming Pump Assembly........................................................................................ 6-13
6-6. Check Valves Assemblies...................................................................................... 6-15
9-1. Liquid Separator..................................................................................................... 9-1
9-2. Angle Adapter........................................................................................................ 9-2
9-3. Pointer/Remover Punch.......................................................................................... 9-2

P3100 & P3200 Series
Users Manual
viii

1-1
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.
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.

P3100 & P3200 Series
Users Manual
1-2
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.
Compressed Liquid
Use of compressed liquids can create an environment of propelled foreign matter.
Pressure system safety precautions apply to all ranges of pressure. Care must be taken
during testing to ensure that all hydraulic connections are properly and tightly made prior
to applying pressure. Personnel must wear eye protection to prevent injury.
Heavy Weights
Lifting and movement of heavy weights can create an environment of strain and impact
hazards. 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 Hydraulic
Deadweight Tester
Symbols used on the Hydraulic 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
XShock Hazard
~Do not dispose of this product as unsorted
municipal waste. Go to Fluke’s website for
recycling information.

General Information
Operating Principle 1
1-3
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.
The schematic diagram below shows the basic hydraulic circuit for a dual-PCU (Piston
Cylinder Unit) instrument.
The system is primed with liquid from the Reservoir, and the system pressure is increased
by means of the Screw Pump. As liquids are considered incompressible, the displaced
liquid causes the pistons to rise within their cylinders to balance the downward force of
the weights.
Fluids at the same height in a system are at the same pressure, so when the system is in
equilibrium (i.e. the piston and weights are floating freely, rotating and falling at its
natural sink-rate), the pressure generated by the combined mass of the piston and weights
equals the pressure within the device under test.
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 slowly pass through this clearance gap. This is perfectly normal, and there are
Sump Rings around the piston bodies to collect the excess fluid.
Although calibration is carried out using one PCU at a time, there is a point during
normal operation of a dual-PCU instrument where both PCUs will rise. This is due to the
overlap in pressure range of the two PCUs. The PCU that is not in use will seal in the
fully extended position to avoid additional fluid loss.

P3100 & P3200 Series
Users Manual
1-4
HIGH
PRESSURE
PCU
LOW
PRESSURE
PCU
DEVICE
UNDER
TEST RESERVOIR
PRIMING PUMP
SCREW 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. Operation and Storage Specifications
Operation Storage
Temperature 18 to 28 °C
64 to 82 °F 10 to 50 °C 50 to 122 °F
Relative Humidity
(Non-Condensing)
20 to 75 % 0 to 90 %

General Information
Environmental Corrections 1
1-5
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
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=

P3100 & P3200 Series
Users Manual
1-6
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. The tester is accurate when the piston and weights are floating and rotating
freely.
Model Variations
This manual covers many pressure ranges and models within the P3100 and P3200 series
of instruments.
The following illustrations detail the physical appearance of the three basic models:
Models: 3123, 3124, 3125, 3223 and 3224.
gjn003.bmp
Figure 1-2. Dual PCU Instrument

General Information
Model Variations 1
1-7
Models: 3112, 3113, 3114, 3115, 3116, 3213, and 3214.
gjn004.bmp
Figure 1-3. Single High Pressure PCU Instrument
Models: 3111 and 3211.
gjn005.bmp
Figure 1-4. Single Low Pressure PCU Instrument

P3100 & P3200 Series
Users Manual
1-8

2-1
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.
Operating Fluid
Oil: The instrument is supplied with Shell Spindle Oil 22, our reference 55-655.
Water: Only Distilled or De-ionized Water should be used in the instrument. Great
care must be taken when operating any deadweight tester that uses water as its operating
fluid, as any contamination present within the system will result in degradation of
performance, and eventual irreparable damage to the PCUs. The impurities found in
ordinary water supplies are sufficient to affect the spin and sensitivity of the PCU
assemblies, and damage the PCUs.
WWarning
The system is designed for use with the fluids described above
only; use of other fluids can effect the operation and
performance of the instrument, and CAN CAUSE PERMANENT
DAMAGE.
To avoid damage to the instrument, the operator should check
the quality of the operating fluid during use. If the fluid
becomes discolored, cloudy or particles appear in the reservoir,
the system should be drained and flushed with clean fluid.
If the device under test (DUT) is from a system operating on
different fluid from that of the deadweight tester, the Liquid
Separator, P5521, can be mounted to the test port of the
deadweight tester. This will allow the calibration of the DUT in
its normal operating fluid, and prevent cross-contamination of
the system, (See Chapter 9, Ancillary Equipment, Liquid
Separator).

P3100 & P3200 Series
Users Manual
2-2
Connections
Fit the device under test (DUT) to the test port using the method described below:
WCaution
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.
To avoid cross-contamination from other fluids, and protect the
system from particulates, we recommend the use of a
Liquid-to-Liquid Separator (see Chapter 7, Ancillary
Equipment).
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