Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
TestEquipmentDepot.com
P3100 & P3200 Series
Hydraulic Deadweight Tester
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.
Users Manual
Table of Contents
Chapter Title Page
1 General Information ............................................................................ 1-1
Introduction........................................................................................................ 1-1
How to Contact Fluke ........................................................................................ 1-1
Safety Information ............................................................................................. 1-2
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 ............................................................................................ 1-3
Environmental Corrections ................................................................................ 1-5
Gravity........................................................................................................... 1-5
Temperature................................................................................................... 1-5
Head of Fluid................................................................................................. 1-6
Model Variations ............................................................................................... 1-6
2 Preparation .......................................................................................... 2-1
Introduction........................................................................................................ 2-1
Operating Fluid .................................................................................................. 2-1
Connections ....................................................................................................... 2-2
Test Port Insert .............................................................................................. 2-4
3 Priming ................................................................................................. 3-1
Priming .............................................................................................................. 3-1
4 Operation ............................................................................................. 4-1
Operation ........................................................................................................... 4-1
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5 Calibration in Different Pressure Units ............................................. 5-1
6 Maintenance and Servicing ................................................................ 6-1
Calibration in Different Pressure Units.............................................................. 5-1
Conversion Weights ...................................................................................... 5-1
Software......................................................................................................... 5-1
Maintenance and Servicing................................................................................ 6-1
PCU Assembly - 10 mm Nominal Diameter ................................................. 6-1
Piston Disassembly ................................................................................... 6-1
Piston Cleaning ......................................................................................... 6-1
Piston Re-Assembly.................................................................................. 6-2
Replacement PCU Assembly .................................................................... 6-3
PCU Assembly - 2 & 3 mm Nominal Diameters .......................................... 6-4
Piston Disassembly ................................................................................... 6-4
Piston Cleaning ......................................................................................... 6-4
Piston Re-Assembly.................................................................................. 6-5
Replacement PCU Assembly .................................................................... 6-5
PCU Assembly - 5 mm Nominal Diameter ................................................... 6-7
Piston Disassembly ................................................................................... 6-7
Piston Cleaning ......................................................................................... 6-7
Piston Re-Assembly.................................................................................. 6-7
Replacement PCU Assembly .................................................................... 6-8
Top Plate Removal ........................................................................................ 6-10
Screw Pump Assembly.................................................................................. 6-10
Priming Pump Assembly............................................................................... 6-12
Disassembly .............................................................................................. 6-12
Re-Assembly............................................................................................. 6-12
Check Valves................................................................................................. 6-14
Inlet Check Valve...................................................................................... 6-14
Outlet Check Valve ................................................................................... 6-14
Reservoir Assembly....................................................................................... 6-15
7 Fault Finding........................................................................................ 7-1
Poor PCU Spin/Sensitivity................................................................................. 7-1
General .......................................................................................................... 7-1
PCU Assembly - 10 mm................................................................................ 7-1
PCU Assembly - 2 and 3 mm ........................................................................ 7-1
PCU Assembly - 5 mm.................................................................................. 7-2
High PCU Fall-Rate........................................................................................... 7-2
System Will Not Prime ...................................................................................... 7-2
System Will Not Pressurize ............................................................................... 7-3
Priming Pump Malfunction ............................................................................... 7-3
Cannot Reach Maximum Pressure..................................................................... 7-3
8 Storage and Transportation ............................................................... 8-1
Storage and Transportation................................................................................ 8-1
Instrument...................................................................................................... 8-1
Weights.......................................................................................................... 8-1
9 Ancillary Equipment............................................................................ 9-1
Ancillary Equipment.......................................................................................... 9-1
Liquid Separator, P5521 or P5522 ................................................................ 9-1
Angle Adapter, P5543 ................................................................................... 9-2
ii
Contents (continued)
Pointer Remover/Punch, P5551..................................................................... 9-2
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P3100 & P3200 Series
Users Manual
iv
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. PCU Assembly - 5 mm Parts List .......................................................................... 6-9
6-4. Screw Pump Assembly Parts List .......................................................................... 6-12
6-5. Priming Pump Assembly - Parts List ..................................................................... 6-14
6-6. Check Valves Assemblies Parts List...................................................................... 6-15
6-7. Reservoir Assembly Parts List ............................................................................... 6-18
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P3100 & P3200 Series
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vi
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........................................................................................................ 2-4
2-6. Test Port Insert ....................................................................................................... 2-5
4-1. Float-Height Indicator Post .................................................................................... 4-1
4-2. Weight Rotation ..................................................................................................... 4-2
6-1. PCU Assembly - 10 mm ........................................................................................ 6-3
6-2. PCU Assembly - 2 and 3 mm................................................................................. 6-6
6-3. PCU Assembly - 5 mm .......................................................................................... 6-9
6-4. Screw Pump Assembly .......................................................................................... 6-11
6-5. Priming Pump Assembly........................................................................................ 6-13
6-6. Check Valves Assemblies ...................................................................................... 6-15
9-1. Liquid Separator..................................................................................................... 9-1
9-2. Angle Adapter ........................................................................................................ 9-2
9-3. Pointer/Remover Punch.......................................................................................... 9-2
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P3100 & P3200 Series
Users Manual
viii
Introduction
This manual covers the following pressure instruments:
Oil Operated Instruments: P3111, P3112, P3113, P3114, P3115, P3116, P3123, P3124,
and P3125.
Distilled Water Operated Instruments: P3211, P3213, P3214, P3223, and P3224.
Chapter 1
General Information
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P3100 & P3200 Series
Users Manual
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.
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.
W Warning
If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
Heavy Weights
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.
Personal Protective Equipment
Wear eye protection and reinforced safety shoes 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
Deadweight Tester
Symbols used on the Hydraulic Deadweight Tester and in this manual are explained in
Table 1-1.
Table 1-1. Symbols
Symbol Description
B AC (Alternating Current)
J Earth Ground
1-2
W Important Information: refer to manual
X Shock Hazard
Do not dispose of this product as unsorted
~
municipal waste. Go to Fluke’s website for
recycling information.
General Information
Operating Principle 1
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.
PRESSURE =
FORCE
AREA
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.
The schematic diagram below shows the basic hydraulic circuit for a dual-PCU (Piston
Cylinder Unit) instrument.
The system is primed with liquid from the Reservoir, and the system pressure is increased
by means of the Screw Pump. As liquids are considered incompressible, the displaced
liquid causes the pistons to rise within their cylinders to balance the downward force of
the weights.
Fluids at the same height in a system are at the same pressure, so when the system is in
equilibrium (i.e. the piston and weights are floating freely, rotating and falling at its
natural sink-rate), the pressure generated by the combined mass of the piston and weights
equals the pressure within the device under test.
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.
Therefore, during the normal operation of a deadweight tester, the working fluid in the
system will slowly pass through this clearance gap. This is perfectly normal, and there are
Sump Rings around the piston bodies to collect the excess fluid.
Although calibration is carried out using one PCU at a time, there is a point during
normal operation of a dual-PCU instrument where both PCUs will rise. This is due to the
overlap in pressure range of the two PCUs. The PCU that is not in use will seal in the
fully extended position to avoid additional fluid loss.
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P3100 & P3200 Series
Users Manual
HIGH
PRESSURE
PCU
LOW
PRESSURE
PCU
SCREW PUMP
DEVICE
UNDER
TEST
RESERVOIR
PRIMING PUMP
Figure 1-1. Hydraulic Circuit Schematic
gjn001.eps
Operating & Storage Specification are as follows:
Temperature and relative humidity ranges for operation and storage of the deadweight
tester.
Table 1-2. Operation and Storage Specifications
Operation Storage
Temperature 18 to 28 °C
64 to 82 °F
Relative Humidity
(Non-Condensing)
20 to 75 % 0 to 90 %
10 to 50 °C
50 to 122 °F
1-4
General Information
Environmental Corrections 1
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
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
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
235.981
250
xPRESSURETRUE =
665.980
psiPRESSURETRUE 1453.250=
()
2420250 xxPRESSURETRUE −+=
002.0
100
250
psiPRESSURETRUE 98.249=
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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.
To ensure accuracy is maintained, the piston and weights must be kept clean and
undamaged. The tester is accurate when the piston and weights are floating and rotating
freely.
Model Variations
This manual covers many pressure ranges and models within the P3100 and P3200 series
of instruments.
The following illustrations detail the physical appearance of the three basic models:
Models: 3123, 3124, 3125, 3223 and 3224.
1-6
Figure 1-2. Dual PCU Instrument
gjn003.bmp
General Information
Model Variations 1
Models: 3112, 3113, 3114, 3115, 3116, 3213, and 3214.
Figure 1-3. Single High Pressure PCU Instrument
Models: 3111 and 3211.
gjn004.bmp
Figure 1-4. Single Low Pressure PCU Instrument
gjn005.bmp
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