Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
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P3000 Series
Pneumatic Deadweight Tester
PN 3952260
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
Table of Contents
Chapter Title Page
1 General Information ............................................................................ 1-1
Introduction........................................................................................................ 1-1
How to Contact Fluke ........................................................................................ 1-1
Safety Information ............................................................................................. 1-1
Safety Summary ............................................................................................ 1-1
Compressed Gas ............................................................................................ 1-2
Heavy Weights .............................................................................................. 1-2
Personal Protective Equipment...................................................................... 1-2
Symbols Used in this Manual ............................................................................ 1-2
Operating Principle ............................................................................................ 1-2
Operating & Storage Specification................................................................ 1-3
Environmental Corrections ................................................................................ 1-3
Gravity........................................................................................................... 1-3
Temperature................................................................................................... 1-4
Model Variations ............................................................................................... 1-4
2 Preparation .......................................................................................... 2-1
Introduction........................................................................................................ 2-1
Connection to External Pressure/Vacuum Supplies........................................... 2-1
Connections ....................................................................................................... 2-2
Test Port Insert .............................................................................................. 2-5
3 Operation ............................................................................................. 3-1
Introduction........................................................................................................ 3-1
Single PCU Models — Pressure ........................................................................ 3-1
Single PCU Models — Vacuum ........................................................................ 3-2
Dual PCU (Pressure & Vacuum) Models .......................................................... 3-2
4 Calibration in Different Pressure Units ............................................. 4-1
Introduction........................................................................................................ 4-1
Conversion Weights........................................................................................... 4-1
Software............................................................................................................. 4-1
i
P3000 Series
Users Manual
5 Maintenance & Servicing.................................................................... 5-1
Introduction........................................................................................................ 5-1
PCU Assembly — 10 mm Nominal Diameter — Pressure ............................... 5-1
Piston Disassembly........................................................................................ 5-1
Piston Cleaning.............................................................................................. 5-1
Piston Re-Assembly ...................................................................................... 5-2
Replacement PCU Assembly ........................................................................ 5-2
PCU Assembly — 10 mm Nominal Diameter — Vacuum ............................... 5-3
Piston Disassembly........................................................................................ 5-3
Piston Cleaning.............................................................................................. 5-3
Piston Re-Assembly ...................................................................................... 5-4
Replacement PCU Assembly ........................................................................ 5-4
PCU Assembly — 16 mm Nominal Diameter................................................... 5-5
Piston Disassembly........................................................................................ 5-5
Piston Cleaning.............................................................................................. 5-5
Piston Re-Assembly ...................................................................................... 5-6
Replacement PCU Assembly ........................................................................ 5-6
PCU Assembly — 22 mm Nominal Diameter................................................... 5-7
Piston Cleaning.............................................................................................. 5-7
Piston Re-Assembly ...................................................................................... 5-8
Replacement PCU Assembly ........................................................................ 5-8
Top Plate Removal............................................................................................. 5-9
Handpump Assembly......................................................................................... 5-10
Disassembly................................................................................................... 5-10
Cleaning and Inspection ................................................................................ 5-10
Re-Assembly ................................................................................................. 5-10
System Selector Valve ....................................................................................... 5-12
Disassembly................................................................................................... 5-12
Cleaning & Inspection................................................................................... 5-12
Re-Assembly ................................................................................................. 5-12
Safety Valve....................................................................................................... 5-13
Disassembly................................................................................................... 5-13
Re-Assembly ................................................................................................. 5-13
6 Fault Finding........................................................................................ 6-1
Poor PCU Spin/Sensitivity................................................................................. 6-1
System Will Not Pressurize ............................................................................... 6-1
High PCU Fall-Rate ...................................................................................... 6-2
Handpump Malfunction................................................................................. 6-2
7 Storage & Transportation ................................................................... 7-1
Instrument .......................................................................................................... 7-1
Weights .............................................................................................................. 7-1
8 Ancillary Equipment............................................................................ 8-1
Dirt/Moisture Trap, P5531................................................................................. 8-1
Angle Adapter, P5543........................................................................................ 8-2
Pointer Remover/Punch, P5551......................................................................... 8-2
ii
List of Tables
Table Title Page
1-1. Symbols.................................................................................................................. 1-2
1-2. Operation and Storage Specifications .................................................................... 1-3
2-1. Test Port Inserts - Parts List ................................................................................... 2-5
5-1. PCU Assembly - 10 mm - Pressure - Parts List ..................................................... 5-3
5-2. PCU Assembly - 10 mm - Vacuum - Parts List ..................................................... 5-5
5-3. PCU Assembly - 16 mm - Parts List...................................................................... 5-7
5-4. PCU Assembly - 22 mm - Parts List...................................................................... 5-9
5-5. Handpump Assembly - Parts List........................................................................... 5-11
5-6. System Selector Valve - Parts List......................................................................... 5-13
5-7. Safety Valve - Parts List ........................................................................................ 5-14
iii
P3000 Series
Users Manual
iv
List of Figures
Figure Title Page
1-1. Single PCU Instrument .......................................................................................... 1-4
1-2. Single PCU Instrument with Handpump................................................................ 1-5
1-3. Dual PCU (Pressure & Vacuum) Instrument ......................................................... 1-5
1-4. Dual PCU (Pressure & Vacuum) Instrument with Handpump .............................. 1-6
1-5. Vacuum Instrument................................................................................................ 1-6
1-6. Vacuum Instrument with Handpump ..................................................................... 1-7
2-1. Screw on Gauge Adapter........................................................................................ 2-2
2-2. Connect Assembly to Test Port.............................................................................. 2-3
2-3. Hand-Tighten Only ................................................................................................ 2-3
2-4. Adjust Gauge Position............................................................................................ 2-4
2-5. Tighten Gauge........................................................................................................ 2-4
2-6. Test Port Insert ....................................................................................................... 2-5
3-1. Weight Rotation ..................................................................................................... 3-3
5-1. PCU Assembly - 10mm - Pressure......................................................................... 5-3
5-2. PCU Assembly - 10mm - Vacuum......................................................................... 5-5
5-3. PCU Assembly - 16 mm ........................................................................................ 5-7
5-4. PCU Assembly - 22 mm ........................................................................................ 5-9
5-5. Handpump Assembly ............................................................................................. 5-11
5-6. System Selector Valve ........................................................................................... 5-13
5-7. Safety Valve ........................................................................................................... 5-14
8-1. Dirt/Moisture Trap ................................................................................................. 8-1
8-2. Angle Adapter ........................................................................................................ 8-2
8-3. Pointer/Remover Punch.......................................................................................... 8-2
v
P3000 Series
Users Manual
vi 1-1
Introduction
This User’s Manual covers the following pressure instruments: P3011, P3011P, P3012P,
P3013P, P3014P, P3015, P3015P, P3022, P3022P, P3023, P3023P, P3025, and the
P3025P.
Chapter 1
General Information
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.
If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
W Warning
P3000 Series
Users Manual
Compressed Gas
Heavy Weights
Personal Protective Equipment
Symbols Used in this Manual
Use of compressed gas 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 connections are properly and tightly made prior to applying
pressure. Personnel must wear eye protection to prevent injury.
Lifting and movement of heavy weights can create an environment of strain and impact
hazards. Care must be taken during testing to ensure that weight masses are lifted in a
manner that avoids over-reaching or twisting, and that the masses are not dropped.
Personnel must wear reinforced safety shoes to prevent injury.
Wear eye protection and reinforced safety shoes approved for the materials and tools
being used.
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 Deadweight
Tester.
Symbols used on the Pneumatic Deadweight Tester and in this manual are explained in
Table 1-1.
Symbol Description
B AC (Alternating Current)
J Earth Ground
W Important Information: refer to manual
~
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.
Table 1-1. Symbols
Do not dispose of this product as unsorted
municipal waste. Go to Fluke’s website for
recycling information.
PRESSURE =
FORCE
AREA
1-2
Each weight is marked with the tester serial number, and the pressure measured when
placed on a correctly spinning and floating piston. The total pressure measured is the
summation of the weights plus the piston weight carrier assembly.
General Information
Environmental Corrections 1
When the gas pressure within the system balances the combined downward force of the
piston and weights, the piston and weights will float freely and the system is in
equilibrium.
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 gas to
pass between the components, providing a lubricating film, and preventing
metal-to-metal contact.
Operating & Storage Specification
Temperature and relative humidity ranges for operation and storage of the deadweight
tester.
Table 1-2. Operation and Storage Specifications
Operation Storage
Temperature 18 °C to 28 °C
64 °F to 82 °F
Relative Humidity
(Non-Condensing)
20 % to 75 % 0 % to 90 %
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.
Due to the significant change in gravity throughout the world (0.5%), ensure that the
tester has either been manufactured to your local gravity, or that you have applied the
correction from the calibrated gravity.
Example:
Deadweight Tester calibrated gravity 980.665 cm/s²
(980.665 cm/s² is the International Standard Gravity)
Gravity at site 981.235 cm/s²
10 °C to 50 °C
50 °F to 122 °F
Indicated Pressure 250 psi
The ability to determine the local gravity value will depend on the data available in the
country that the instrument is to be used in. Some countries have geographic/geological
survey/mapping organizations that have the data readily available. If not, the countries’
National Standards Laboratory may be able to recommend a source of suitable
information.
Temperature
235.981
250
xPRESSURETRUE =
665.980
psiPRESSURETRUE 1453.250=
1-3
P3000 Series
Users Manual
Temperature and Air Density variations are less significant than gravity.
Variations should be corrected for when maximum accuracy is required.
Temperature variation example:
Deadweight Tester calibrated temperature 20 °C
Operating temperature 24 °C
Percentage change per °C 0.002%
Indicated Pressure 250 psi
Model Variations
This manual covers many pressure ranges and models within the P3000 series of
instruments.
The following illustrations detail the physical appearance of the six basic models:
Model 3015
()
2420250 xxPRESSURETRUE −+=
002.0
100
psiPRESSURETRUE 98.249=
250
1-4
Figure 1-1. Single PCU Instrument
gjn024.bmp
General Information
Model Variations 1
Model 3012P, 3013P, 3014P and 3015P
Figure 1-2. Single PCU Instrument with Handpump
gjn025.bmp
Model 3022, 3023 and 3025
Figure 1-3. Dual PCU (Pressure & Vacuum) Instrument
gjn026.bmp
1-5
P3000 Series
Users Manual
Model 3022P, 3023P and 3025P
Figure 1-4. Dual PCU (Pressure & Vacuum) Instrument with Handpump
Model 3011
gjn027.bmp
1-6
Figure 1-5. Vacuum Instrument
gjn028.bmp
General Information
Model Variations 1
Model 3011P
Figure 1-6. Vacuum Instrument with Handpump
gjn029.bmp
1-7
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