Fluke P5510 User manual

PN 3952297
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.
P5510
Pneumatic Comparison Test Pump
Users Manual
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
TestEquipmentDepot.com

i
Table of Contents
Title Page
Introduction........................................................................................................ 1
Operating Ranges............................................................................................... 1
How to Contact Fluke ........................................................................................ 2
Safety Information ............................................................................................. 2
Safety Summary ............................................................................................ 2
Compressed Gas ............................................................................................ 2
Personal Protective Equipment...................................................................... 2
Symbols Used in this Manual........................................................................ 2
Connections ....................................................................................................... 3
Test Port Insert................................................................................................... 6
Operation ........................................................................................................... 6
Vacuum ......................................................................................................... 6
Pressure ......................................................................................................... 7
Maintenance and Servicing................................................................................ 7
Contamination ............................................................................................... 7
Pump Removal .............................................................................................. 8
Pump Disassembly ........................................................................................ 8
Cleaning & Inspection................................................................................... 8
Pump Reassembly ......................................................................................... 8
Ancillary Equipment.......................................................................................... 10
Dirt/Moisture Trap, P5531 ............................................................................ 10
Angle Adapter, P5543 ................................................................................... 10
Pointer Remover/Punch, P5551..................................................................... 11

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Users Manual
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iii
List of Tables
Table Title Page
1. Mode and Maximum Working Pressure ................................................................ 1
2. Symbols.................................................................................................................. 3
3. Test Port Insert - Parts List..................................................................................... 6
4. Handpump Assembly - Parts List........................................................................... 9

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v
List of Figures
Figure Title Page
1. Fitting Gauge Adapter............................................................................................ 4
2. Connect Assembly to Test Port.............................................................................. 4
3. Hand Tighten Only................................................................................................. 4
4. Adjust Gauge Position............................................................................................ 5
5. Tighten Gauge Adapter .......................................................................................... 5
6. Hand Tighten Only................................................................................................. 5
8. Handpump Assembly ............................................................................................. 9
9. Dirt/Moisture Trap ................................................................................................. 10
10. Angle Adapter ........................................................................................................ 10
11. Pointer Remover/Punch.......................................................................................... 11

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Users Manual
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1
Introduction
This manual applies to Model P5510.
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.
The comparison test pump should be mounted securely to a stable workbench or similar
surface. Four mounting holes are provided in the pump stand for this purpose.
Operating Ranges
Model P5510 combines the function of both pressure and vacuum pump with a selector
valve that reverses the operating mode of the handpump.
The table below details the mode and maximum working pressure of these instruments.
Table 1. Mode and Maximum Working Pressure
Model Mode Max. Working Pressure
P5510 Pressure & Vacuum 300 psi / 20 bar & 90% Vacuum

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Users Manual
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Safety Information
WWarning
Read before Pneumatic Comparison Test Pump use.
To prevent possible equipment damage or personal injury,
follow these guidelines.
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.
Compressed Gas
Use of compressed gasses 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 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 Pneumatic
Comparison Test Pump.

Pneumatic Comparison Test Pump
Connections
3
Symbols used on the Pneumatic Comparison Test Pump and in this manual are explained
in Table 2.
Table 2. 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.
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 contamination from moisture, and protect the system
from particulates, we recommend the use of a
P5531 Dirt/Moisture Trap. (Refer section 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:

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1. Screw the appropriate gauge adapter fully on to the instrument to be tested.
gla01.bmp
Figure 1. Fitting Gauge Adapter
2. Screw assembly down COUNTER-CLOCKWISE on to test port.
gla02.bmp
Figure 2. Connect Assembly to Test Port
gla03.bmp
Figure 3. Hand Tighten Only

Pneumatic Comparison Test Pump
Connections
5
Note
Hand-tight is sufficient; ensure that the bottom face contacts the O-ring on
the test port.
3. To adjust the position to face forward, hold the gauge adapter and turn the instrument
COUNTER-CLOCKWISE, so that it faces forward.
gla04.bmp
Figure 4. Adjust Gauge Position
4. Hold the instrument steady, while turning the gauge adapter
COUNTER-CLOCKWISE until it pulls down onto the O-ring.
gla05.bmp
Figure 5. Tighten Gauge Adapter
gla06.bmp
Figure 6. Hand Tighten Only

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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.
3
2
1
gla012.eps
Figure 7. Test Port Insert
Table 3. Test Port Insert - Parts List
Item Description Part
1 O Ring 3865142
2 Test Port Insert 3919892
3 O Ring 3883397
To calibrate panel-mounted gauges with pressure connections in the rear, use a P5543
Angle Adapter (refer to section Ancillary Equipment).
Operation
Vacuum
Turn the selector valve on the front panel to either “Vacuum” or “Pressure” and then
operate as described in sections Vacuum, and Pressure, as applicable.
WCaution
Ensure that the selector valve is positioned correctly before
operation of the handpump, to avoid potential damage that may
be caused by pressurization of sensitive vacuum devices.

Pneumatic Comparison Test Pump
Maintenance and Servicing
7
1. Ensure exhaust valve is closed — Do not over tighten, as damage to the valve seat
can occur.
2. To generate a vacuum in the system, use the handpump until the desired reading is
reached.
3. 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 gas in
the system expands or contracts, thus increasing or decreasing the pressure.
4. For the next, higher vacuum point; repeat from 2 above.
5. For lower points, slowly open and close exhaust valve, allowing air into the system.
6. After calibration, always equalize the system pressure by slowly opening the exhaust
valve.
Pressure
1. Ensure exhaust valve is closed — Do not over tighten, as damage to the valve seat
can occur.
2. To increase the system pressure, use the handpump until the desired pressure is
reached.
3. 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 gas in
the system expands or contracts, thus increasing or decreasing the pressure.
4. For the next, higher pressure point, repeat from 2 above.
5. To reduce system pressure, slowly open and close exhaust valve until the desired
pressure is reached.
6. Before taking any readings, allow a few moments for the system to stabilize as before.
7. After calibration, always vent system pressure by slowly opening the exhaust valve.
During operation, air is drawn into the pump assembly through the upper port in the
pump cylinder (13) when the piston is lifted, and expelled through the lower port when
the piston is pushed down.
Maintenance and Servicing
The part number for the replacement seal kit is P5510SK.
Contamination
WCaution
If the system becomes contaminated with dirt or moisture the
instrument must be disassembled and cleaned, otherwise the
pump may become damaged beyond repair.
Pump Removal
1. Remove unit from bench such that it can be turned over.

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2. Remove 4 screws from sides of the housing (2 each side), and lift out cover plate
from underside.
3. Disconnect nylon tubing from check valves (23) and (19).
4. Loosen locknut (3) approximately 1 turn.
5. Remove spring clip (1) from clevis (2), and swing the pump handle out of the way.
6. Unscrew clevis from piston shaft.
7. Loosen set screws (4) approximately 1 turn, and unscrew pump lock (5).
8. Pump assembly can be withdrawn from the instrument housing.
Pump Disassembly
1. Disassemble outlet check valve assembly, by unscrewing valve body (19). Take care
not to loose the small internal items that may spring out.
2. Disassemble inlet check valve assembly. If there is any doubt about the functionality
of the in-line check valve (23) it should be replaced, as it is difficult to clean
effectively.
3. Remove guide (6) from cylinder (13) — take care not to damage this, as it is a tight
fit within the cylinder.
4. Remove piston assembly from cylinder (13).
5. The piston head assembly (12) can be separated from the piston shaft (10) by
removing the snap ring (9).
Cleaning & Inspection
Note
The piston head assembly cannot be further disassembled without damage
to the components, so it must be wiped clean with a soft cloth to remove any
contamination.
Check all seals for signs of wear and/or damage.
Check the cylinder bore for signs of excessive wear, scratches/scoring, etc.
Replacement seals are available; however, if there is significant damage to the internal
components, the pump is available as a replacement assembly.
Pump Reassembly
1. Reassembly is the reverse of the above disassembly instructions.
2. Care should be taken whenever a seal comes in contact with metal components, to
avoid damage to the seal from sharp edges, etc.
Examples:
•When introducing the piston head assembly (12) into the cylinder (13).
•When introducing the piston shaft (10) through the central hole in the guide (6).
•When introducing the guide (6) into the cylinder (13).

Pneumatic Comparison Test Pump
Maintenance and Servicing
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2
4
9
10
11
12
13
14 15 16 17 18 19
20
21
22
23
1
3
5
6
7
8
gla08.eps
Figure 8. Handpump Assembly
Table 4. Handpump Assembly - Parts List
Item Description Part Item Description Part
1 Spring Clip 3920224 13 Cylinder SPEC.
2 Clevis 3920236 14 Bonded Seal 3918879
3 Locknut 3918713 15 O Ring 3865075
4 Set Screw 3918822 16 Bullet 3918846
5 Pump Lock Spec. 17 Spring 3918854
6 Guide Spec. 18 Spring Guide 3918868
7 O Ring 3867548 19 Check Valve Body SPEC.
8 O Ring 3918984 20 Coupling 3918991
9 Snap Ring 3918797 21 Flexible Tubing 3922387
10 Piston Shaft Spec. 22 Coupling 3923564
11 O Ring 3865142 23 Check Valve Assy. 3920249
12 Piston Head Assy. 3967747

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Ancillary Equipment
Dirt/Moisture Trap, P5531
Dirt/Moisture Traps provide an effective barrier against the transfer of moisture and dirt
from an instrument under test to the clean pneumatic system of the comparison test pump
and the master test gauge connected to it. Unexpected particle contamination or fluid
inside the device under test will be prevented from entering the test system, avoiding
downtime for maintenance and repair.
5531 lp trap.jpg
Figure 9. Dirt/Moisture Trap
Angle Adapter, P5543
To calibrate gauges with the pressure connection on the rear (e.g. panel-mount gauges) in
their correct position, an angle adapter should be used. The angle adapter fits directly
onto the test station, converting it through 90 degrees, allowing the standard adapters to
be used.
gla09.bmp
Figure 10. Angle Adapter

Pneumatic Comparison Test Pump
Ancillary Equipment
11
Pointer Remover/Punch, P5551
To remove and refit the pointer of a pressure gauge, use a pointer remover/punch. This
tool has a spring-loaded plunger to quickly and consistently refit the pointer.
gla10.bmp
Figure 11. Pointer Remover/Punch

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