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Fluke P3100 Series User Manual

Fluke P3100 Series User Manual

Hydraulic deadweight tester
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P3100 & P3200 Series
Hydraulic Deadweight Tester
Users 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.

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  • Page 1 P3100 & P3200 Series Hydraulic Deadweight Tester Users 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents Chapter Title Page 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 ....................
  • Page 4 P3100 & P3200 Series Users Manual Calibration in Different Pressure Units ..........5-1 Calibration in Different Pressure Units.............. 5-1 Conversion Weights ..................5-1 Software......................5-1 Maintenance and Servicing ..............6-1 Maintenance and Servicing................6-1 PCU Assembly - 10 mm Nominal Diameter ..........6-1 Piston Disassembly ...................
  • Page 5 Contents (continued) Pointer Remover/Punch, P5551..............9-2...
  • Page 6 P3100 & P3200 Series Users Manual...
  • Page 7 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.
  • Page 8 P3100 & P3200 Series Users Manual...
  • Page 9 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......................
  • Page 10 P3100 & P3200 Series Users Manual viii...

  • Page 11: General Information

    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) •...

  • Page 12: Safety Information

    Symbols used on the Hydraulic Deadweight Tester and in this manual are explained in Table 1-1. Table 1-1. Symbols Symbol Description AC (Alternating Current) Earth Ground Important Information: refer to manual Shock Hazard Do not dispose of this product as unsorted municipal waste. Go to Fluke’s website for recycling information.

  • Page 13: Operating Principle

    General Information Operating Principle 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.
  • Page 14 P3100 & P3200 Series Users Manual DEVICE UNDER HIGH RESERVOIR TEST PRESSURE PRESSURE SCREW PUMP PRIMING 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.

  • Page 15: Environmental Corrections

    General Information Environmental Corrections 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.

  • Page 16: Head Of Fluid

    P3100 & P3200 Series Users Manual 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.
  • Page 17 General Information Model Variations 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...
  • Page 18 P3100 & P3200 Series Users Manual...

  • Page 19: Preparation

    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...

  • Page 20: Connections

    P3100 & P3200 Series Users Manual Connections Fit the device under test (DUT) to the test port using the method described below: W 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.
  • Page 21 Preparation Connections 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. gjn007.bmp Figure 2-2. Making Pressure Connections gjn008.bmp Figure 2-3. Adjusting Pressure Connections 3. To adjust the position to face forward, hold the gauge adapter and turn the instrument COUNTER-CLOCKWISE, so that it faces forward.

  • Page 22: Test Port Insert

    P3100 & P3200 Series Users Manual gjn009.bmp Figure 2-4. Adjust Gauge Position 4. Hold the instrument steady, while turning the gauge adapter COUNTER-CLOCKWISE until it pulls down onto the O-ring. gjn010.bmp Figure 2-5. Tighten Gauge 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.
  • Page 23 Preparation Connections gjn012.eps Figure 2-6. Test Port Insert Table 2-1. Test Port Insert Parts List Item Description Part O RING 3865142 TEST PORT INSERT 3919892 O RING 3883397 TEST PORT 3921414 To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle Adapter (Refer to Chapter 9, Ancillary Equipment).
  • Page 24 P3100 & P3200 Series Users Manual...
  • Page 25 Chapter 3 Priming Priming 1. Open reservoir valve one turn counter-clockwise and turn capstan fully in. 2. Pump the priming pump two times. 3. Close valve and turn capstan fully out. 4. Open valve and turn capstan fully in. Note During this operation, bubbles may appear in the reservoir, as trapped air is expelled.
  • Page 26 P3100 & P3200 Series Users Manual...
  • Page 27 Chapter 4 Operation Operation 1. Select the required weights and stack them on the appropriate piston assembly. The pressure measured is the sum of the weights plus the piston/weight carrier. Dual PCU models: The PCU’s are matched in a ratio of effective areas, 20:1 or 10:1, depending upon model, and the weights will be marked accordingly with both high and low pressure values.
  • Page 28 P3100 & P3200 Series Users Manual 3. 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 4-2.
  • Page 29 Operation Operation Note 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.
  • Page 30 P3100 & P3200 Series Users Manual...

  • Page 31: Calibration In Different Pressure Units

    Chapter 5 Calibration in Different Pressure Units Calibration in Different Pressure Units The deadweight tester can be used to calibrate in different pressure units in either of two methods. Conversion Weights A set of Conversion Weights can be supplied, marked in the required pressure unit, and adjusted to the correct mass for use with the existing piston(s).
  • Page 32 P3100 & P3200 Series Users Manual...

  • Page 33: Maintenance And Servicing

    Chapter 6 Maintenance and Servicing Maintenance and Servicing Note The piston/cylinder assembly is the most critical and sensitive part of the deadweight tester. To maintain accuracy, the piston must always slide freely in the cylinder, and the hydraulic fluid must remain clean. The Figures on the following pages detail the components of each assembly, together with the relevant part numbers.

  • Page 34: Piston Re-Assembly

    P3100 & P3200 Series Users Manual 8. Place piston carefully on a NEW tissue where it will not be damaged while the cylinder is cleaned. W Caution Never touch the working surface of a clean piston with bare fingers—the natural oil in your skin can cause the piston and cylinder to stick.

  • Page 35: Replacement Pcu Assembly

    Maintenance and Servicing Maintenance and Servicing Replacement PCU Assembly W Caution The piston and cylinder assembly is a matched pair, which is calibrated and adjusted to a calculated mass figure. If, for any reason, the piston or cylinder becomes damaged, then the entire assembly must be replaced.

  • Page 36: Pcu Assembly - 2 & 3 Mm Nominal Diameters

    P3100 & P3200 Series Users Manual Table 6-1. PCU Assembly - 10 mm Parts List Item Description Part Item Description Part Weight Carrier Spec Piston Spec Cylinder Spec O Ring 3864802 O Ring 3867553 LP PCU Body 3921406 Support Ring 3918481 Sump Ring 3921391...

  • Page 37: Piston Re-Assembly

    Maintenance and Servicing Maintenance and Servicing Piston Re-Assembly 13. Replace O-ring (7) in the counter-bore in the underside of the cylinder (F), ensuring that it is located correctly and evenly. 14. Holding the piston by the larger “head” end, dip the other end into a container of clean operating fluid, and transfer to the bore in the underside of the cylinder.
  • Page 38 P3100 & P3200 Series Users Manual gjn015.eps Figure 6-2. PCU Assembly - 2 and 3 mm Table 6-2. PCU Assembly - 2 and 3 mm Parts List Item Description Part Item Description Part Carrier Ring Spec O Ring 3883397 Carrier Tube Spec Piston Spec...

  • Page 39: Pcu Assembly - 5 Mm Nominal Diameter

    Maintenance and Servicing Maintenance and Servicing PCU Assembly - 5 mm Nominal Diameter Piston Disassembly 1. Lift off the weight carrier assembly (1 & 2), and unscrew the piston nut (5). Use the dowel hole if the nut is tight. Remove the piston/cylinder assembly. 2.

  • Page 40: Replacement Pcu Assembly

    P3100 & P3200 Series Users Manual 16. Insert piston/cylinder assembly into piston nut (5) through the threaded end, such that the shoulder on the cylinder is located within the central bore of the nut. 17. Replace piston cap (4), and secure with set screw (3), DO NOT OVER-TIGHTEN. 18.
  • Page 41 Maintenance and Servicing Maintenance and Servicing gjn016.eps Figure 6-3. PCU Assembly - 5 mm Table 6-3. PCU Assembly - 5 mm Parts List Item Description Part Item Description Part Carrier Ring Spec Piston Spec Carrier Tube Spec O Ring 3864782 Piston Cap Spec Bearing Ring...

  • Page 42: Top Plate Removal

    P3100 & P3200 Series Users Manual Top Plate Removal Note In order to perform maintenance procedures on the hydraulic system, the Top Plate Assembly must first be removed from the instrument case. 1. Depressurize the system, open the reservoir valve, and turn the capstan fully in. 2.
  • Page 43 Maintenance and Servicing Maintenance and Servicing 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.

  • Page 44: Priming Pump Assembly

    P3100 & P3200 Series Users Manual Table 6-4. Screw Pump Assembly Parts List Item Description Part Item Description Part Test Port 3921414 O Ring 3867566 O Ring 3864922 Back-Up Ring 3919118 Barrel Locknut 3921438 Rambler 3919129 Barrel 3921450 Ball 3917855 Barrel Support 3921492 Lead Screw...
  • Page 45 Maintenance and Servicing Maintenance and Servicing 5. Replace locknut (12) and clevis (13), reconnect pump arm assembly, and secure with pin clip. 6. Reconnect hydraulic tubing. gjn018.eps Figure 6-5. Priming Pump Assembly 6-13...

  • Page 46: Check Valves

    P3100 & P3200 Series Users Manual Table 6-5. Priming Pump Assembly - Parts List Item Description Part Item Description Part Pivot Clip 3920224 Rambler 3919165 Clevis 3920236 Back-Up Ring 3920516 Locknut 3918713 O Ring 3864782 Pump Union Nut 3921527 Barrel Locknut 3921438 Shaft Bearing 3867744...

  • Page 47: Reservoir Assembly

    Maintenance and Servicing Maintenance and Servicing gjn019.eps Figure 6-6. Check Valves Assemblies Table 6-6. Check Valves Assemblies Parts List Item Description Part Item Description Part Pump Block 3921530 Pump Check Flange 3921744 O Ring 3864766 Screw 3909261 O Ring 3865142 Elbow 3862616 Bullet...
  • Page 48 P3100 & P3200 Series Users Manual 9. Remove three screws from reservoir spacers that hold the assembly to the top plate. The assembly can now be withdrawn from the underside of the top plate. 10. The reservoir body (11) and reservoir cap (5) are a close fit to the reservoir tube (7), and both rely on the O-ring seal (6) to hold them in place.
  • Page 49 Maintenance and Servicing Maintenance and Servicing gjn020.eps Figure 6-7. Reservoir Assembly 6-17...
  • Page 50 P3100 & P3200 Series Users Manual Table 6-7. Reservoir Assembly Parts List Item Description Part Item Description Part Valve Stem 3886430 Washer 3205770 Spring 3922786 Valve Vent 3921582 Nylon Washer 3916458 Back-Up Ring 3921912 Reservoir Cover 3921624 O Ring 3865142 Reservoir Cap 3921613 Reservoir Body...

  • Page 51: Fault Finding

    Chapter 7 Fault Finding Poor PCU Spin/Sensitivity General The weights floating on a clean PCU assembly will rotate freely, slowing down gradually to a complete stop. If the rotation stops quickly, then the PCU may be dirty and require cleaning. W Caution Do not rotate the piston if it is dirty as permanent damage can occur.

  • Page 52: Pcu Assembly - 5 Mm

    P3100 & P3200 Series Users Manual PCU Assembly - 5 mm Plug the test station to prevent leakage, and open the reservoir valve. Remove the weight carrier assembly (1 & 2). Hold the piston cap (4), and lift gently up and down, the piston should slide freely within its cylinder.

  • Page 53: System Will Not Pressurize

    Fault Finding System Will Not Pressurize System Will Not Pressurize 1. Ensure correct valve operation during priming process. 2. Check DUT is not leaking. 3. Clean system externally, check for fluid leak by continually trying to pressurize. Wherever fluid appears, replace the seal—check sealing faces are clean and undamaged before re-assembly.
  • Page 54 P3100 & P3200 Series Users Manual...

  • Page 55: Storage And Transportation

    Chapter 8 Storage and Transportation Storage and Transportation Instrument 1. With the test station plugged, open the reservoir valve and turn capstan fully in, close reservoir valve. 2. Remove spokes from capstan hub, and store in tool-roll. 3. Remove screw-in handle from pump arm, and store in tool-roll. 4.
  • Page 56 P3100 & P3200 Series Users Manual...

  • Page 57: Ancillary Equipment

    Chapter 9 Ancillary Equipment Ancillary Equipment Liquid Separator, P5521 or P5522 If there is any doubt that the instrument to be tested is not internally clean, then the addition of the P5521 Liquid Separator will protect the deadweight tester from contamination and possible damage.

  • Page 58: Angle Adapter, P5543

    P3100 & P3200 Series Users Manual 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.

This manual is also suitable for:

P3200 series

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