Fluke P3800 Series User manual

PN 3952319
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.
P3800 Series
High Pressure Hydraulic Deadweight Tester
Users Manual
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
TestEquipmentDepot.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
Symbols Used in this Manual ............................................................................ 1-2
Hydraulic Circuit Schematic.............................................................................. 1-3
2 Preparation .......................................................................................... 2-1
Location ............................................................................................................. 2-1
Fluid Filling ....................................................................................................... 2-1
3 Operation ............................................................................................. 3-1
Connections ....................................................................................................... 3-1
Procedure for Removing Trapped Air from System.......................................... 3-2
Procedure for Priming the Pressure Intensifier.................................................. 3-4
Procedure for Generating System Pressure........................................................ 3-5
Generating Calibration Pressure ........................................................................ 3-6
4 Maintenance......................................................................................... 4-1
Introduction........................................................................................................ 4-1
PCU Removal .................................................................................................... 4-1
Cleaning............................................................................................................. 4-2
Replacement....................................................................................................... 4-3
5 Recalibration........................................................................................ 5-1
Introduction........................................................................................................ 5-1
Do's and Don'ts .................................................................................................. 5-1
Don'ts............................................................................................................. 5-1
Do's................................................................................................................ 5-1
6 Pressure Corrections.......................................................................... 6-1
Introduction........................................................................................................ 6-1

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Users Manual
ii
Temperature and Gravity Corrections ............................................................... 6-2

iii
List of Tables
Table Title Page
1-1. Symbols.................................................................................................................. 1-2

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Users Manual
iv

v
List of Figures
Figure Title Page
1-1. Hydraulic Circuit Schematic .................................................................................. 1-3
3-1. Pressure Connection - Method 1 ............................................................................ 3-1
3-2. Pressure Connection - Method 2 ............................................................................ 3-2
3-3. Remove Trapped Air.............................................................................................. 3-2
3-4. Turn Capstan Fully Clockwise............................................................................... 3-3
3-5. Prime the Pressure Intensifier ................................................................................ 3-4
3-6. Generate System Pressure ...................................................................................... 3-5
3-7. Close Reserve Valve .............................................................................................. 3-6
3-8. 5 Correct Float Position ......................................................................................... 3-7
4-1. Piston/Cylinder Removal ....................................................................................... 4-2
6-1. Pressure Corrections............................................................................................... 6-2
6-2. Nomogram for Finding the Value of...................................................................... 6-3

P3800 Series
Users Manual
vi

1-1
Chapter 1
General Information
Introduction
This manual contains operation and routine and preventive maintenance instructions for
the Model P3830, P3840, and P3860 High Pressure Hydraulic Deadweight Tester (DWT)
manufactured by Fluke. This section of the manual provides general information about
the DWT.
The P3800 Series of Deadweight Testers (DWT) provides a convenient means of testing
high pressure instruments for calibration accuracy.
The design incorporates the “Piston Gauge” principle, in which an applied pressure
within the system, balances a known mass applied to a piston of known effective area. i.e.
pistonofareaEffective
pistontoappliedmassTotal
PRESSURE =
The unit comprises a base plate onto which is mounted a high pressure manifold, a
piston/cylinder unit (PCU), a test station (to mount the equipment under test), a fluid
reservoir, a ram screw pressure generating system, a pressure intensifier (which increases
the pressure generated by a factor of 7:1), and a safety relief valve (which protects both
the low and high pressure systems from accidental overpressure). The whole assembly is
contained within a strong GRP housing.
The unit is equipped with four adjustable feet to enable correct leveling. This ensures that
the PCU is in the vertical plane, which is essential for both accurate and reliable
performance.
The hydraulic fluid supplied with the unit has been specially formulated to remain fluid at
high pressures and to ensure no corrosion of internal parts. In addition the fluid will not
oxidize in contact with air or emulsify or mix with water.

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Users Manual
1-2
Safety Information
WWarning
Pressurized vessels and associated equipment are potentially
dangerous. The apparatus described in this manual should be
operated by personnel trained in procedures that will assure
safety to themselves, to others, and to the equipment.
WWarning
Please read these instructions carefully prior to installing and
using the Tester. The pressure built up internally during use
can be extremely high. Ensure that all connections are made
correctly.
DO NOT CONNECT DWT TO EXTERNAL PRESSURE SOURCE
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 Deadweight
Tester (DWT).
Symbols used on the Deadweight Tester (DWT) and in this manual are explained in
Table 1-1.
Table 1-1. Symbols
Symbol Description
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.

General Information
Hydraulic Circuit Schematic 1
1-3
Hydraulic Circuit Schematic
CAPSTAN
RAM SCREW ASSEMBLY
RELIEF VALVE
RESERVOIR VALVE
RESERVOIR
FLUID
LP VALVEHP VALVE
7:1 INTENSIFIER
TEST STATION
TO TAKE
ITEM UNDER TEST
PISTON/CYLINDER
ASSEMBLY
glf01.eps
Figure 1-1. Hydraulic Circuit Schematic

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Users Manual
1-4

2-1
Chapter 2
Preparation
Location
Note
Item number references in the following text, (1), (2), etc, relate to the
hydraulic system schematic, shown in the figures below.
Place the unit onto a clean, flat surface of a strong and rigid workbench.
Ensure that the front of the unit is approximately ¾” / 20 mm from the front edge of the
bench to allow the ram screw capstan to overhang and freely rotate.
Level the DWT by placing the spirit level on top of the weight carrier tube and adjusting
the 4 leveling feet accordingly.
Fluid Filling
Fill the fluid reservoir as follows:
Fully unscrew (counter-clockwise) the reservoir valve screw (3) and remove it together
with the spring and reservoir cover. Place to one side. Fill with the correct fluid to the top
of the brass nut visible on the inside of the reservoir. Fully wind out (counter-clockwise)
the capstan so that fluid is drawn into the DWT. Refill the reservoir to the top of the brass
nut and replace the cover, spring and reservoir valve screw. Fully screw in (clockwise)
the reservoir valve screw and then unscrew (counter-clockwise) again 4 full turns.
The deadweight tester is now ready to receive the Equipment Under Test (EUT).

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Users Manual
2-2

3-1
Chapter 3
Operation
Connections
Connect the EUT to the test station using a gauge adapter and lens ring from the selection
provided.
WCaution
This unit can generate very high pressures and, as a
consequence, only metal-to-metal sealing is acceptable, i.e. no
sealing washers of any description should be used (see Figure
3.1 and 3.2 for methods of sealing).
glf02.eps
Figure 3-1. Pressure Connection - Method 1

P3800 Series
Users Manual
3-2
glf03.eps
Figure 3-2. Pressure Connection - Method 2
Procedure for Removing Trapped Air from System
glf04.bmp
Figure 3-3. Remove Trapped Air

Operation
Procedure for Removing Trapped Air from System 3
3-3
1. Open HP valve (1) and LP valve (2) fully, (counter-clockwise).
2. Open reservoir valve (3), (approximately 4 turns counter-clockwise).
3. Turn capstan fully out (counter-clockwise), and wait for approximately 60 seconds.
glf05.bmp
Figure 3-4. Turn Capstan Fully Clockwise
4. Turn capstan fully in (clockwise), and wait for approximately 15 seconds.
5. Trapped air from the system will appear as bubbles in the reservoir.
6. Repeat the procedure until no more air appears in the reservoir.

P3800 Series
Users Manual
3-4
Procedure for Priming the Pressure Intensifier
glf06.bmp
Figure 3-5. Prime the Pressure Intensifier
1. Close LP valve (2) by turning fully clockwise.
2. Turn capstan in (clockwise) until resistance is felt. This is a result of the pressure
required to move the intensifier piston backward in its cylinder, and to lift the
measuring piston and weight carrier.
3. Some additional bubbles may appear in the reservoir.

Operation
Procedure for Generating System Pressure 3
3-5
Procedure for Generating System Pressure
TEST PORT
INTENSIFIER
RESERVOIR
VALVE (3)
LP VALVE (2)
HP VALVE (1)
CAPSTAN
PCU
glf07.eps
Figure 3-6. Generate System Pressure
1. Close HP valve (1).
2. Open LP valve (2).
3. Turn capstan fully out to prime it with fluid from the reservoir.

P3800 Series
Users Manual
3-6
glf08.bmp
Figure 3-7. Close Reserve Valve
4. Close reservoir valve (3).
5. Turn capstan in to generate system pressure. The displaced fluid from the ram screw
moves the intensifier piston, generating system pressure to lift the measuring piston
and weights.
Generating Calibration Pressure
To generate any required pressure select weights so that the sum of all the weights (their
pressure equivalents are marked on the top of each weight) PLUS the pressure marked on
the carrier is equal to the pressure required. Load the weights onto the carrier one at a
time, ensuring correct location.
Generate pressure by winding the capstan in (clockwise) until the weight stack starts to
rise. Spin the weight stack in a clockwise direction at approximately 40 rpm by using the
palms of the hands on opposite side of the stack.
Adjust the height of the weight stack winding the capstan in or out until the underside of
the bottom weight lines up with the mid-float position marked on the indicator rod (see
Figure 3-8). The areas above and below the mid-float position indicate the upper and
lower travel limits of the piston assembly.
Before adding or removing weights, it is essential that the weight stack is no longer
spinning.