Fluke P5515-V User manual

PN 3952251
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.
P5515, P5515-V, &
P5515-EP
Hydraulic Comparison Test Pump
Users Manual

To register your product online, visit register.fluke.com

i
Table of Contents
Title Page
Introduction........................................................................................................ 1
How to Contact Fluke ........................................................................................ 2
Safety Information ............................................................................................. 2
Safety Summary ............................................................................................ 2
Compressed Liquid........................................................................................ 2
Personal Protective Equipment...................................................................... 2
Symbols Used in this Manual ............................................................................ 2
Preparation ......................................................................................................... 3
Operating Fluid Compatibility........................................................................... 3
Connections ....................................................................................................... 3
Test Port Insert................................................................................................... 7
Priming .............................................................................................................. 7
Operation ........................................................................................................... 8
Maintenance and Servicing................................................................................ 8
Top Plate Removal ........................................................................................ 8
Screw Pump Assembly.................................................................................. 9
Priming Pump Assembly............................................................................... 11
Disassembly .............................................................................................. 11
Reassembly ............................................................................................... 11
Check Valves................................................................................................. 13
Inlet Check Valve...................................................................................... 13
Outlet Check Valve ................................................................................... 13
Reservoir Assembly....................................................................................... 14
Fault Finding...................................................................................................... 16
System Will Not Prime.................................................................................. 16
System Will Not Pressurize........................................................................... 16
Priming Pump Malfunction ........................................................................... 17
Cannot Reach Maximum Pressure ................................................................ 17
Pressure Falls Away ...................................................................................... 17
Storage and Transportation ................................................................................ 17
Ancillary Equipment.......................................................................................... 18
Angle Adapter, P5543 ................................................................................... 18
Pointer Remover/Punch, P5551..................................................................... 18
Liquid Separator, P5521................................................................................ 19

P5515, P5515-V, & P5515-EP
Users Manual
ii

iii
List of Tables
Table Title Page
1. Symbols.................................................................................................................. 3
2. Increased Fluid Compatibility Models................................................................... 3
3. Test Port Insert - Parts............................................................................................ 7
4. Screw Pump Assembly - Parts List ........................................................................ 10
5. Priming Pump Assembly - Parts List ..................................................................... 13
6. Check Valve Assemblies - Parts List ..................................................................... 14
7. Reservoir Assembly - Parts List............................................................................. 16

P5515, P5515-V, & P5515-EP
Users Manual
iv

v
List of Figures
Figure Title Page
1. Hydraulic Circuit Schematic .................................................................................. 1
2. Screw on Gauge Adapter........................................................................................ 4
3. Mount Gauge.......................................................................................................... 5
4. Adjust Gauge Position............................................................................................ 5
5. Tighten Gauge........................................................................................................ 6
6. Do Not Over-Tighten ............................................................................................. 6
7. Test Port Insert ....................................................................................................... 7
8. Screw Pump Assembly .......................................................................................... 10
9. Priming Pump Assembly........................................................................................ 12
10. Check Valve Assemblies........................................................................................ 14
11. Reservoir Assembly ............................................................................................... 15
12. Angle Adapter ........................................................................................................ 18
13. Pointer Remover/Punch.......................................................................................... 18
14. Liquid Separator..................................................................................................... 19

P5515, P5515-V, & P5515-EP
Users Manual
vi

Introduction
This manual contains operation and routine and preventive maintenance instructions for
the Model P5515, P5515-V, and P5515-EP Hydraulic Comparison Test Pump. The
manual will refer to all model numbers of the instrument listed above generically as a
Model P5515, unless denoted as only applicable to a specific model number.
The Comparison Test Pump is used for checking pressure-measuring instruments against
Master Test Gauges.
Note
The terms Master Test Gauge and Gauge in this document refer to
any pressure-measuring instrument such as Transfer Standards, Digital
Calibrators, and Transducers.
This system is only as accurate as the Master Test Gauge used. The Master Test Gauge
must be regularly calibrated on a Primary Reference Standard (such as a Deadweight
Tester) to ensure accuracy is maintained.
gkx01.eps
Figure 1. Hydraulic Circuit Schematic

P5515, P5515-V, & P5515-EP
Users Manual
How to Contact Fluke
To order accessories, receive operating assistance, or get the location of the nearest Fluke
distributor or Service Center, call:
Technical Support USA: 1-800-99-FLUKE (1-800-993-5853)
Calibration/Repair USA: 1-888-99-FLUKE (1-888-993-5853)
Canada: 1-800-36-FLUKE (1-800-363-5853)
Europe: [phone]
China: [phone]
Japan: [phone]
Singapore: [phone]
Anywhere in the world: [phone]
Or, visit Fluke's website at www.fluke.com.
To register your product, visit http://register.fluke.com.
To view, print, or download the latest manual supplement, visit
http://us.fluke.com/usen/support/manuals.
Safety Information
Safety Summary
The following are general safety precautions that are not related to any specific
procedures and do not appear elsewhere in this publication. These are recommended
precautions that personnel must understand and apply during equipment operation and
maintenance to ensure safety and health and protection of property.
Warning
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.
Personal Protective Equipment
Wear eye protection 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
Comparison Test Pump.
Symbols used on the Hydraulic Comparison Test Pump and in this manual are explained
in 1.

Hydraulic Comparison Test Pump
Preparation
Table 1. Symbols
Symbol Description
AC (Alternating Current)
Earth Ground
Important Information: refer to manual
Do not dispose of this product as unsorted
municipal waste. Go to Flukes website for
recycling information.
Preparation
The comparison test pump 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 prevent rocking.
Rotate reservoir dust cover through ¼ turn and fill reservoir approximately ¾ full with
the appropriate fluid. Rotate dust cover back to cover hole.
Caution
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.
Operating Fluid Compatibility
Caution
The standard system is designed for use with a wide range of fluids,
however, the reservoir tube is Acrylic, and the O-ring seals are Nitrile; use
of solvents, fuel oils, brake fluids or other, similar aggressive fluids can
damage the seals and the reservoir tube.
The table below details the two alternative versions of this instrument, which offer
increased compatibility with other fluids.
Table 2. Increased Fluid Compatibility Models
Model O Rings Reservoir Tube
P5515 Nitrile Acrylic
P5515-V Viton Anodized Aluminum
P5515-EP Ethylene Propylene Anodized Aluminum
Connections
Fit the device under test (DUT) to the test port using the method described below:
Caution
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.

P5515, P5515-V, & P5515-EP
Users Manual
To avoid cross-contamination from other fluids, and protect the
system from particulates, we recommend the use of a Liquid
Separator, (refer to section Ancillary Equipment).
Warning
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.
gkx02.bmp
Figure 2. 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.

Hydraulic Comparison Test Pump
Connections
gkx03.bmp
Figure 3. Mount Gauge
gkx05.bmp
Figure 4. Adjust Gauge Position
3. To adjust the position to face forward, hold the gauge adapter and turn the instrument
COUNTER-CLOCKWISE, so that it faces forward.

P5515, P5515-V, & P5515-EP
Users Manual
gkx06.bmp
Figure 5. Tighten Gauge
4. Hold the instrument steady, while turning the gauge adapter
COUNTER-CLOCKWISE until it pulls down onto the O-ring.
gkx07.bmp
Figure 6. Do Not Over-Tighten

Hydraulic Comparison Test Pump
Test Port Insert
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 7.
gjn012.eps
Figure 7. Test Port Insert
Table 3. Test Port Insert - Parts
Part
Item Description
P5515 P5515-V P5515-EP
1 O Ring 3865142 3865163 3867888
2 Test Port Insert 3919892
3 O Ring 3883397 3883521 3867895
4 Test Port 3921414
To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle
Adapter (see Chapter 8, Ancillary Equipment).
Priming
1. Open reservoir valve one turn counter-clockwise and turn capstan fully in.
2. Pump the priming pump two times.
3. Close valve (see caution below) and turn capstan fully out.
4. Open valve and turn capstan fully in.

P5515, P5515-V, & P5515-EP
Users Manual
Note
During this operation, bubbles may appear in the reservoir, as trapped air
is expelled. For large volumes, repeat steps 3 &.4 until no further bubbles
appear.
5. With valve open, turn capstan fully out and close valve. The tester is now ready for
use.
Warning
Turning the capstan out with the reservoir valve closed will
generate approximately 15 inHg / 0.5 bar vacuum. If the DUT is
vacuum sensitive, leave valve open during priming operation.
Operation
1. Turn the screw press in (clockwise) to generate pressure.
Note
The priming pump is intended for system priming only, and cannot be used
to generate high pressures.
2. Allow a few moments for the system to stabilize before taking any readings,
especially after large changes in system pressure.
Note
Large, sudden changes in pressure will cause the system temperature to
rise or fall, which can cause instrument readings to change as the fluid in
the system expands or contracts, thus increasing or decreasing the
pressure.
3. Compare the reading of the gauge under test with that of the master gauge.
4. For the next, higher calibration point, repeat from step 1 above.
5. To measure reducing pressures, turn the screw press out (counter-clockwise).
6. Depressurize the system by turning the screw press FULLY OUT, then open the
reservoir valve
Caution
Never release the system pressure by using the reservoir valve
alone, as sudden depressurization will shock the system,
which may cause damage to sensitive instruments attached
to it.
Maintenance and Servicing
The figures on the following pages detail the components of each assembly, together with
the relevant part numbers. Where SPEC appears as a part number, this indicates that
this particular component varies with the specification of the comparison test pump, and
is usually associated with other components in an assembly for replacement purposes.
The part number for the seal kit for the P5515, P5515-V, and P5515-EP is P5515SK,
P5515SK-V, and P5515SK-EP, respectively.
Top Plate Removal
1. Depressurize the system, open the reservoir valve, and turn the screw press fully in.
2. Disconnect any DUT from the test ports, and drain the fluid from the system; the
reservoir is fitted with a drain plug, which can be accessed from the underside of the
instrument, see Chapter 5, Reserve Assembly.

Hydraulic Comparison Test Pump
Maintenance and Servicing
3. Remove the spokes from the hub on the front of the instrument.
4. Remove the 4 screws from the instrument top plate, (1 at the mid-point of each edge).
5. Hold the top plate assembly by the test port, and tilt the plate so that the rear edge is
lifted, but the front edge remains in contact with the instrument case.
6. Slide the top plate towards the rear until the capstan hub is clear of the front lip of the
instrument case.
7. Lift out the top plate assembly.
Screw Pump Assembly
1. Unscrew the large union nut (just behind the inner hub) of the screw press assembly.
2. Withdraw the lead screw assembly from the barrel (4), taking care not to drop the
rambler assembly (8).
3. The white, anti-extrusion ring (7) is a PTFE spiral, and can be removed by
unwinding it from the rambler.
4. When removing the rambler seal (6), take care not to use any tool that may have a
sharp edge that will scratch the surfaces of the rambler, otherwise it may leak when
reassembled.
5. The replacement rambler seal can be eased over the front of the rambler, and into the
groove.
6. Similarly, the new anti-extrusion ring can be wound into the groove in the rambler,
behind the rambler seal.
7. If it is necessary to remove the barrel (4), the locknut (3) must be loosened
approximately ½ turn. The barrel can then be unscrewed from the test station (1).
Note
It is often easier to remove the barrel support bracket (5) to allow greater
movement, (remove the 2 screws from the upper side of the top plate).
8. Before re-fitting the barrel, ensure that the barrel seal (2) is correctly located in the
counter-bore in the front of the barrel. Screw the barrel fully in to the test station, and
secure with the locknut.
9. Re-align the barrel support bracket (if removed), and secure through the top plate
with the 2 screws.
10. Ensure that the rambler assembly is correctly located on the end of the lead screw
assembly. Carefully introduce the rambler into the open end of the barrel; making
sure that it does not tilt when entering the barrel.
11. Push the lead screw assembly fully in to the barrel, ensuring that the key in the nut
locates correctly in the slot in the barrel.
12. Re-tighten the barrel union nut.
Caution
If the lead screw assembly shows signs of excessive wear, then
it is very likely that the associated components have worn also;
therefore, the screw press assembly is available as a spare
part  see diagrams for part numbers.

P5515, P5515-V, & P5515-EP
Users Manual
gkx09.eps
Figure 8. Screw Pump Assembly
Table 4. Screw Pump Assembly - Parts List
Part
Item Description
P5515 P5515-V P5515-EP
1 Test Port 3921414
2 O Ring 3864922 3865332 3865565
3 Barrel Locknut 3921438
4 Barrel 3921450
5 Barrel Support 3821492
6 O Ring 3867566 3867920 3867901
7 Back-Up Ring 3919118
8 Rambler 3919129
9 Ball 3917855
10 Lead Screw Assembly 3885994

Hydraulic Comparison Test Pump
Maintenance and Servicing
Priming Pump Assembly
Disassembly
1. On the underside of the top plate, disconnect the hydraulic tubing from the pump
block assembly (14).
2. On the upper side of the top plate, unscrew locknut (3) ½ turn, and remove clip pin
from clevis (2).
3. The pump arm assembly can be swung out of the way.
4. Remove locknut (3) and clevis (2).
5. Unscrew union nut (4), and withdraw pump assembly from below the top plate.
6. Withdraw pump shaft (6), taking care not to drop shaft bearing (5) or rambler
assembly (8).
7. The white, anti-extrusion ring (9) is a PTFE spiral, and can be removed by
unwinding it from the rambler.
8. When removing the rambler seal (10), take care not to use any tool that may have a
sharp edge that will scratch the surfaces of the groove in the rambler, otherwise it
may leak when reassembled.
9. The replacement rambler seal can be eased over the front of the rambler, and into the
groove.
10. Similarly, the new anti-extrusion ring can be wound into the groove in the rambler,
behind the rambler seal.
11. If it is necessary to remove the barrel (12), the locknut (11) must be loosened
approximately ½ turn. The barrel can then be unscrewed from the pump block
assembly (14).
Reassembly
1. Before re-fitting the barrel, ensure that the O-ring (13) is correctly located in the
counter-bore in the front of the barrel. Screw the barrel fully in to the test station, and
secure with the locknut.
2. Ensure that the rambler assembly is correctly located on the end of the pump shaft.
Carefully introduce the rambler into the open end of the barrel; making sure that it
does not tilt when entering the barrel.
3. Slide the pump bearing (5) over the shaft, and locate it inside the barrel.
4. Re-introduce the pump assembly from the underside of the top plate, and secure with
the union nut (4).
5. Replace locknut (3) and clevis (2), reconnect pump arm assembly, and secure with
pin clip.
6. Reconnect hydraulic tubing.

P5515, P5515-V, & P5515-EP
Users Manual
gkx10.eps
Figure 9. Priming Pump Assembly