Fluke P5523 User Manual

P5523

Liquid to Gas Separator

PN 3952355
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.

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

Table of Contents

Title Page

General Information........................................................................................... 1

How to Contact Fluke ........................................................................................ 2

Safety Summary................................................................................................. 2

Compressed Liquid & Gas ............................................................................ 2

Personal Protective Equipment...................................................................... 2

Symbols Used in this Manual ............................................................................ 2

Preparations ....................................................................................................... 3

Connect the Gauge ........................................................................................ 4

Connect the Test Port Insert .......................................................................... 4

Priming .............................................................................................................. 5

Operation ........................................................................................................... 6

Disconnecting the Unit from the Deadweight Tester......................................... 6

Ancillary Equipment.......................................................................................... 7

Angle Adapter, P5543 ................................................................................... 7

Pointer Remover/Punch, P5551..................................................................... 7

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List of Tables

Table Title Page

1. Symbols.................................................................................................................. 2

2. Test Port Insert - Parts List..................................................................................... 5

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List of Figures

Figure Title Page

1. Hydraulic/Pneumatic Circuit Schematic ................................................................ 1

2. Connecting the Gauge ............................................................................................ 4

3. Test Port Insert ....................................................................................................... 5

4. Angle Adapter ........................................................................................................ 7

5. Pointer Remover/Punch.......................................................................................... 7

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General Information

The P5523 is used for calibrating high-pressure gas measuring instruments against a
hydraulic Deadweight Tester.

The terms ”Master Test Gauge” and “Gauge” in this document refer to
any pressure-measuring instrument such as Transfer Standards, Digital
Calibrators and Transducers.

An external high-pressure gas source is applied through a series of liquid traps, to the
hydraulic system of the deadweight tester. Typically, dry Nitrogen from a commercially
available compressed gas cylinder is used. With the deadweight tester system correctly
primed, gas pressure from the external supply is adjusted to reach equilibrium with the
weights on the deadweight tester.

Note

Figure 1. Hydraulic/Pneumatic Circuit Schematic

5523 SEPARATOR

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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 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 Liquid & Gas

Use of compressed liquids and 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 hydraulic and 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 Liquid to Gas
Separator.

.

.

.

Symbols used on the Liquid to Gas Separator and this manual are explained in Table 1.

Symbol Description

W Important Information: refer to manual

2

Table 1. Symbols

B AC (Alternating Current)

J Earth Ground

Do not dispose of this product as unsorted

~

municipal waste. Go to Fluke’s website for
recycling information.

Liquid to Gas Separator

Preparations

Preparations

This section assumes that the deadweight tester is completely primed with the correct
fluid. The P5523 should be placed on a level, stable workbench or similar surface, to the
right-hand side of the deadweight tester.

Level the P5523 using the four adjustable feet to prevent “rocking”, and fit the
connection hose supplied with the instrument to the bulkhead coupling on the top plate.

The other end of the hose must be attached the test port of the deadweight tester in the
same manner as a conventional pressure gauge or transducer. The hose is pre-assembled
with a flat-faced fitting for this purpose; see notes below on making correct connections.

The external gas supply is connected to the ¼ NPT port in the rear of the P5523 case. A
compressed gas cylinder fitted with a suitable pressure regulator is recommended.
Factory (compressor) air lines or gas multipliers should only be used if a series of filters
are fitted to ensure that the supply is clean and dry.

W Caution

The external pressure supply must be regulated to either the
maximum range of the P5523 (3000 psi / 210 bar), or 10% above
the maximum pressure required, whichever is the lower. DO
NOT OVER-PRESSURIZE THE P5523.

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 valve seats.

W 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.

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Figure 2. Connecting the Gauge

Connect the Gauge

Refer to Figure 2 for steps 1-4.

1. Screw the appropriate gauge adapter fully on to the instrument to be tested.

gle11.eps

2. Screw assembly down COUNTER-CLOCKWISE onto test port.

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.

4. Hold the instrument steady, while turning the gauge adapter

COUNTER-CLOCKWISE until it pulls down onto the O-ring.

Connect the 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 3.

Note

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Liquid to Gas Separator

Priming

1

2

3

4

To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle
Adapter. (Refer to section, Ancillary Equipment.)

Priming

1. Unscrew and remove reservoir cap from left-hand reservoir. Note the position of the

2. Using the priming pump on the deadweight tester, slowly drive fluid from the

3. Allow a few moments for the system to stabilize, and then bring the fluid up to the

Figure 3. Test Port Insert

gle012.eps

Table 2. Test Port Insert - Parts List

Item Description Part Number

1 O Ring 3865142

2 Test Port Insert 3919892

3 O Ring 3883397

4 Test Port —

groove inside the reservoir body — this is the Fluid Datum Level.

deadweight tester through the connection pipe, into the left-hand reservoir, until it is
just below the Fluid Datum Level.

Datum Level by slowly turning the screw press in (clockwise).

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Note

The fluid height must not be above this level during operation — turn the
screw press out (counter-clockwise) to reduce the fluid level.

4. Replace the reservoir cap.

Operation

W Warning

ALWAYS reduce the system pressure with the Exhaust Valve —
NEVER use the deadweight tester reservoir valve.

1. Ensure both Inlet and Exhaust valves are closed.

2. Place the weights necessary to achieve the desired calibration point on the

deadweight tester.

3. Slowly open and close the inlet valve until the piston floats. To avoid

over-pressurization due to “fluid-stick”, the weights can be gently rotated close to the
calibration point. The monitor gauge fitted to the separator can be used as a guide to
the system pressure.

4. Use the screw press for fine adjustment of the PCU float height — do not turn screw

press more than 2 turns in or out from its priming position.

5. Ensure that the weights are rotating freely, and 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.

6. Compare the reading of the gauge under test with that of the master gauge.

7. For the next, higher calibration point, repeat from step 2 above.

8. To measure reducing pressures, remove the necessary weights from the deadweight

tester, and slowly open and close exhaust valve, reducing the system pressure until
the piston is floating at its mid-operating position.

9. Ensure that the weights are rotating freely, and allow a few moments for the system

to stabilize before taking any readings.

10. During long periods of use, the fluid level in the left-hand reservoir should be

checked, and adjusted if necessary, to maintain the correct datum level. Ensure that
the system is FULLY DEPRESSURIZED before removing the reservoir cap.

11. To depressurize the system fully, slowly open and close the exhaust valve —

NEVER depressurize the system quickly.

Disconnecting the Unit from the Deadweight Tester

1. With the system fully depressurized, remove the reservoir cap from the left-hand

reservoir.

2. Ensure reservoir valve is closed on the deadweight tester, and turn the screw press

out to draw fluid back into the deadweight tester reservoir. (Observe fluid level in
P5523 reservoir.)

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Liquid to Gas Separator

Ancillary Equipment

3. When the fluid has been withdrawn from the separator, the connection hose can be

disconnected from the deadweight tester.

Periodically, the right-hand reservoir body should be inspected and cleaned, to remove
any fluid that may be present.

Ancillary Equipment

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.

Pointer Remover/Punch, P5551

To remove and refit the pointer of a pressure gauge, use the Pointer Remover/Punch. This
tool has a spring-loaded plunger to quickly and consistently refit the pointer.

Figure 4. Angle Adapter

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Figure 5. Pointer Remover/Punch

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