Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176 - TestEquipmentDepot.com
P5515, P5515-V, &
P5515-EP
Hydraulic Comparison Test Pump
Users Manual
Table of Contents
Title Page
Introduction........................................................................................................ 1
How to Contact Fluke ........................................................................................ 2
Safety Information ............................................................................................. 2
Safety Summary ............................................................................................ 2
Compressed Liquid........................................................................................ 2
Personal Protective Equipment...................................................................... 2
Symbols Used in this Manual ............................................................................ 2
Preparation ......................................................................................................... 3
Operating Fluid Compatibility........................................................................... 3
Connections ....................................................................................................... 3
Test Port Insert................................................................................................... 7
Priming .............................................................................................................. 7
Operation ........................................................................................................... 8
Maintenance and Servicing................................................................................ 8
Top Plate Removal ........................................................................................ 8
Screw Pump Assembly.................................................................................. 9
Priming Pump Assembly............................................................................... 11
Disassembly .............................................................................................. 11
Reassembly ............................................................................................... 11
Check Valves................................................................................................. 13
Inlet Check Valve...................................................................................... 13
Outlet Check Valve ................................................................................... 13
Reservoir Assembly....................................................................................... 14
Fault Finding...................................................................................................... 16
System Will Not Prime.................................................................................. 16
System Will Not Pressurize........................................................................... 16
Priming Pump Malfunction ........................................................................... 17
Cannot Reach Maximum Pressure ................................................................ 17
Pressure Falls Away ...................................................................................... 17
Storage and Transportation................................................................................ 17
Ancillary Equipment.......................................................................................... 18
Angle Adapter, P5543 ................................................................................... 18
Pointer Remover/Punch, P5551..................................................................... 18
Liquid Separator, P5521................................................................................ 19
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P5515, P5515-V, & P5515-EP
Users Manual
ii
List of Tables
Table Title Page
1. Symbols.................................................................................................................. 3
2. Increased Fluid Compatibility Models................................................................... 3
3. Test Port Insert - Parts............................................................................................ 7
Screw Pump Assembly - P
4.
5. Priming Pump Assembly - Parts List ..................................................................... 13
6. Check Valve Assemblies - Parts List
7. Reservoir Assembly - Parts List.............................................................................
arts List ........................................................................ 10
..................................................................... 14
16
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P5515, P5515-V, & P5515-EP
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iv
List of Figures
Figure Title Page
1. Hydraulic Circuit Schematic .................................................................................. 1
2. Screw on Gauge Adapter........................................................................................ 4
3. Mount Gauge.......................................................................................................... 5
Adjust Gauge Position............................................................................................ 5
4.
5. Tighten Gauge........................................................................................................ 6
Do Not Over-Tighten ............................................................................................. 6
6.
7. Test Port Insert ....................................................................................................... 7
8. Screw Pump Assembly .......................................................................................... 10
Priming Pump Assembly........................................................................................ 12
9.
10. Check Valve Assemblies........................................................................................ 14
11. Reservoir Assembly ............................................................................................... 15
12. Angle Adapter ........................................................................................................ 18
13. Pointer Remover/Punch.......................................................................................... 18
14. Liquid Separator..................................................................................................... 19
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P5515, P5515-V, & P5515-EP
Users Manual
vi
Introduction
This manual contains operation and routine and preventive maintenance instructions for
the Model P5515, P5515-V, and P5515-EP Hydraulic Comparison Test Pump. The
manual will refer to all model numbers of the instrument listed above generically as a
Model P5515, unless denoted as only applicable to a specific model number.
The Comparison Test Pump is used for checking pressure-measuring instruments against
Master Test Gauges.
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.
Note
DEVICE
UNDER
TEST
MASTER
TEST
GAUGE
SCREW PUMP
Figure 1. Hydraulic Circuit Schematic
RESERVOIR
PRIMING PUMP
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P5515, P5515-V, & P5515-EP
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.
W Warning
If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
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.
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 Hydraulic
Comparison Test Pump.
2
Symbols used on the Hydraulic Comparison Test Pump and in this manual are explained
in 1.
Preparation
The comparison test pump 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 prevent “rocking”.
Rotate reservoir dust cover through ¼ turn and fill reservoir approximately ¾ full with
the appropriate fluid. Rotate dust cover back to cover hole.
Table 1. Symbols
Symbol Description
B AC (Alternating Current)
J Earth Ground
W Important Information: refer to manual
Do not dispose of this product as unsorted
~
municipal waste. Go to Fluke’s website for
recycling information.
Hydraulic Comparison Test Pump
Preparation
W Caution
To avoid damage to the instrument, the operator should check
the quality of the operating fluid during use. If the fluid
becomes discolored, cloudy or particles appear in the reservoir,
the system should be drained and flushed with clean fluid.
Operating Fluid Compatibility
W Caution
The standard system is designed for use with a wide range of fluids,
however, the reservoir tube is Acrylic, and the O-ring seals are Nitrile; use
of solvents, fuel oils, brake fluids or other, similar aggressive fluids can
damage the seals and the reservoir tube.
The table below details the two alternative versions of this instrument, which offer
increased compatibility with other fluids.
Table 2. Increased Fluid Compatibility Models
Model O Rings Reservoir Tube
P5515 Nitrile Acrylic
P5515-V Viton Anodized Aluminum
P5515-EP Ethylene Propylene Anodized Aluminum
Connections
Fit the device under test (DUT) to the test port using the method described below:
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.
W Caution
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P5515, P5515-V, & P5515-EP
Users Manual
To avoid cross-contamination from other fluids, and protect the
system from particulates, we recommend the use of a Liquid
Separator, (refer to section Ancillary Equipment).
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.
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.
W Warning
Note
1. Screw the appropriate gauge adapter fully on to the instrument to be tested.
Figure 2. Screw on Gauge Adapter
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4
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.
Hydraulic Comparison Test Pump
Connections
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Figure 3. Mount Gauge
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Figure 4. Adjust Gauge Position
3. To adjust the position to face forward, hold the gauge adapter and turn the instrument
COUNTER-CLOCKWISE, so that it faces forward.
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P5515, P5515-V, & P5515-EP
Users Manual
Figure 5. Tighten Gauge
4. Hold the instrument steady, while turning the gauge adapter
COUNTER-CLOCKWISE until it pulls down onto the O-ring.
Figure 6. Do Not Over-Tighten
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Hydraulic Comparison Test Pump
Test Port Insert
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.
1
2
3
4
Item Description
To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle
Adapter (see Chapter 8, Ancillary Equipment).
Priming
1. Open reservoir valve one turn counter-clockwise and turn capstan fully in.
2. Pump the priming pump two times.
3. Close valve (see caution below) and turn capstan fully out.
4. Open valve and turn capstan fully in.
Figure 7. Test Port Insert
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Table 3. Test Port Insert - Parts
Part
P5515 P5515-V P5515-EP
1 O Ring 3865142 3865163 3867888
2 Test Port Insert 3919892
3 O Ring 3883397 3883521 3867895
4 Test Port 3921414
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P5515, P5515-V, & P5515-EP
Users Manual
During this operation, bubbles may appear in the reservoir, as trapped air
is expelled. For large volumes, repeat steps 3 &.4 until no further bubbles
appear.
5. With valve open, turn capstan fully out and close valve. The tester is now ready for
use.
Turning the capstan out with the reservoir valve closed will
generate approximately 15 inHg / 0.5 bar vacuum. If the DUT is
vacuum sensitive, leave valve open during priming operation.
Operation
1. Turn the screw press in (clockwise) to generate pressure.
The priming pump is intended for system priming only, and cannot be used
to generate high pressures.
2. Allow a few moments for the system to stabilize before taking any readings,
especially after large changes in system pressure.
Note
W Warning
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.
3. Compare the reading of the gauge under test with that of the master gauge.
4. For the next, higher calibration point, repeat from step 1 above.
5. To measure reducing pressures, turn the screw press out (counter-clockwise).
6. Depressurize the system by turning the screw press FULLY OUT, then open the
reservoir valve—
W Caution
Never release the system pressure by using the reservoir valve
alone, as sudden depressurization will “shock” the system,
which may cause damage to sensitive instruments attached
to it.
Maintenance and Servicing
The figures on the following pages detail the components of each assembly, together with
the relevant part numbers. Where “SPEC” appears as a part number, this indicates that
this particular component varies with the specification of the comparison test pump, and
is usually associated with other components in an assembly for replacement purposes.
The part number for the seal kit for the P5515, P5515-V, and P5515-EP is P5515SK,
P5515SK-V, and P5515SK-EP, respectively
Note
.
8
Top Plate Removal
1. Depressurize the system, open the reservoir valve, and turn the screw press fully in.
2. Disconnect any DUT from the test ports, and drain the fluid from the system; the
reservoir is fitted with a drain plug, which can be accessed from the underside of the
instrument, see Chapter 5, Reserve Assembly.
Hydraulic Comparison Test Pump
Maintenance and Servicing
3. Remove the spokes from the hub on the front of the instrument.
4. Remove the 4 screws from the instrument top plate, (1 at the mid-point of each edge).
5. Hold the top plate assembly by the test port, and tilt the plate so that the rear edge is
lifted, but the front edge remains in contact with the instrument case.
6. Slide the top plate towards the rear until the capstan hub is clear of the front lip of the
instrument case.
7. Lift out the top plate assembly.
Screw Pump Assembly
1. Unscrew the large union nut (just behind the inner hub) of the screw press assembly.
2. Withdraw the lead screw assembly from the barrel (4), taking care not to drop the
rambler assembly (8).
3. The white, anti-extrusion ring (7) is a PTFE spiral, and can be removed by
“unwinding” it from the rambler.
4. When removing the rambler seal (6), take care not to use any tool that may have a
sharp edge that will scratch the surfaces of the rambler, otherwise it may leak when
reassembled.
5. The replacement rambler seal can be eased over the front of the rambler, and into the
groove.
6. Similarly, the new anti-extrusion ring can be “wound” into the groove in the rambler,
behind the rambler seal.
7. If it is necessary to remove the barrel (4), the locknut (3) must be loosened
approximately ½ turn. The barrel can then be unscrewed from the test station (1).
Note
It is often easier to remove the barrel support bracket (5) to allow greater
movement, (remove the 2 screws from the upper side of the top plate).
8. Before re-fitting the barrel, ensure that the barrel seal (2) is correctly located in the
counter-bore in the front of the barrel. Screw the barrel fully in to the test station, and
secure with the locknut.
9. Re-align the barrel support bracket (if removed), and secure through the top plate
with the 2 screws.
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. Push the lead screw assembly fully in to the barrel, ensuring that the key in the nut
locates correctly in the slot in the barrel.
12. Re-tighten the barrel union nut.
W Caution
If the lead screw assembly shows signs of excessive wear, then
it is very likely that the associated components have worn also;
therefore, the screw press assembly is available as a spare
part — see diagrams for part numbers.
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P5515, P5515-V, & P5515-EP
Users Manual
1
2
3
4 5
6
7
8
9
10
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Figure 8. Screw Pump Assembly
10
Table 4. Screw Pump Assembly - Parts List
Part
Item Description
P5515 P5515-V P5515-EP
1 Test Port 3921414
2 O Ring 3864922 3865332 3865565
3 Barrel Locknut 3921438
4 Barrel 3921450
5 Barrel Support 3821492
6 O Ring 3867566 3867920 3867901
7 Back-Up Ring 3919118
8 Rambler 3919129
9 Ball 3917855
10 Lead Screw Assembly 3885994
Hydraulic Comparison Test Pump
Maintenance and Servicing
Priming Pump Assembly
Disassembly
1. On the underside of the top plate, disconnect the hydraulic tubing from the pump
block assembly (14).
2. On the upper side of the top plate, unscrew locknut (3) ½ turn, and remove clip pin
from clevis (2).
3. The pump arm assembly can be swung out of the way.
4. Remove locknut (3) and clevis (2).
5. Unscrew union nut (4), and withdraw pump assembly from below the top plate.
6. Withdraw pump shaft (6), taking care not to drop shaft bearing (5) or rambler
assembly (8).
7. The white, anti-extrusion ring (9) is a PTFE spiral, and can be removed by
“unwinding” it from the rambler.
8. When removing the rambler seal (10), take care not to use any tool that may have a
sharp edge that will scratch the surfaces of the groove in the rambler, otherwise it
may leak when reassembled.
9. The replacement rambler seal can be eased over the front of the rambler, and into the
groove.
10. Similarly, the new anti-extrusion ring can be “wound” into the groove in the rambler,
behind the rambler seal.
11. If it is necessary to remove the barrel (12), the locknut (11) must be loosened
approximately ½ turn. The barrel can then be unscrewed from the pump block
assembly (14).
Reassembly
1. Before re-fitting the barrel, ensure that the O-ring (13) is correctly located in the
counter-bore in the front of the barrel. Screw the barrel fully in to the test station, and
secure with the locknut.
2. Ensure that the rambler assembly is correctly located on the end of the pump shaft.
Carefully introduce the rambler into the open end of the barrel; making sure that it
does not tilt when entering the barrel.
3. Slide the pump bearing (5) over the shaft, and locate it inside the barrel.
4. Re-introduce the pump assembly from the underside of the top plate, and secure with
the union nut (4).
5. Replace locknut (3) and clevis (2), reconnect pump arm assembly, and secure with
pin clip.
6. Reconnect hydraulic tubing.
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P5515, P5515-V, & P5515-EP
Users Manual
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1
3
4
5
11
6
12
7
8
9
10
Figure 9. Priming Pump Assembly
13
11
14
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Hydraulic Comparison Test Pump
Maintenance and Servicing
Table 5. Priming Pump Assembly - Parts List
Item Description
P5515 P5515-V P5515-EP
1 Pivot Clip 3920224
2 Clevis 3920236
3 Locknut 3918713
4 Pump Union Nut 3921527
5 Shaft Bearing 3867744
6 Pump Shaft 3921509
7 Ball 3917855
8 Rambler 3919165
9 Back-Up Ring 3920516
10 O Ring 3864782 3922070 3865541
11 Barrel Locknut 3921438
12 Pump Barrel 3921511
13 O Ring 3864711 3865359 3922004
14 Pump Block Assembly
Part
Check Valves
Inlet Check Valve
The inlet check valve is a bought-in item, and is not readily user-serviceable.
To remove:
1. Disconnect nylon tubing from connector (10), by pressing in the collar at the top of
the connector, and gently pulling on the tubing.
2. Unscrew and remove connector.
3. Remove check valve assembly (9).
4. When replacing the check valve assembly, take care to remove all traces of PTFE or
Teflon sealing tape on the mating threads of elbow (7). New tape (or similar sealing
method) must be applied to ensure a pressure-tight joint.
5. Reassembly is the reverse of removal.
Outlet Check Valve
6. Remove screws (7) and lift off flange (6), taking care not to drop the check valve
bullet (4) and spring (5).
7. Inspect the parts for cleanliness and damage—particularly the sealing surfaces.
8. When removing O-rings, take care not to use any tool that may have a sharp edge that
will scratch the surfaces of the mating groove, otherwise it may leak when
reassembled.
9. Reassembly is the reverse of removal, but care mast be taken to ensure that the spring
and bullet are seated correctly.
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P5515, P5515-V, & P5515-EP
Users Manual
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1
2
3
4
9
Figure 10. Check Valve Assemblies
10
5
6
7
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Table 6. Check Valve Assemblies - Parts List
Item Description
P5515 P5515-V P5515-EP
1 Pump Block 3921530
2 O Ring 3864766
3 O Ring 3867636 3867912 3867874
4 Bullet 3920584
5 Spring 3920600
6 Pump Check Flange 3921744
7 Screw 3909261
8 Elbow 3862616
9 Check Valve 3867767 3966453 3966468
10 Connector 3923564
Part
Reservoir Assembly
1. To drain the fluid from the reservoir, raise the instrument a few inches by placing
suitably sized blocks under the feet.
14
2. Place a suitable catchment tray or bowl below the reservoir drain (15).
3. Open the valve by turning valve stem (1) counter-clockwise.
4. Remove gland nut and plug (15 & 14), and allow the fluid to drop into the
catchment tray.
Hydraulic Comparison Test Pump
Maintenance and Servicing
5. To completely disassemble the reservoir, the top plate must be removed from the
instrument case.
6. Disconnect the high-pressure tubing by unscrewing the gland nuts fitted to the
reservoir body (12).
7. The low pressure feed to the priming pump is disconnected by pressing down on the
black plastic ring at the top of the connector, and gently pulling on the nylon tubing.
8. Remove valve stem completely by turning counter-clockwise, taking care not to lose
the spring (2) and nylon washer (3).
9. Lift off reservoir cover (4).
10. 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.
11. The reservoir body (12) 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. These parts can be
separated by gently pulling them apart.
12. The valve vent (10) is disassembled from the reservoir body by removing the three
screws (8).
13. Reassembly is the reverse of the above procedure.
1
2
3
4
5
6
11
7
8
9
10
6
12
13
Figure 11. Reservoir Assembly
14
15
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P5515, P5515-V, & P5515-EP
Users Manual
Table 7. Reservoir Assembly - Parts List
Item Description
P5515 P5515-V P5515-EP
1 VALVE STEM 3886430
2 SPRING 3922786
3 NYLON WASHER 3916458
4 RESERVOIR COVER 3921624
5 RESERVOIR CAP 3921613
6 O RING 3864910 3865326 3865552
7 RESERVOIR TUBE 3921608 3921726 3921726
8 SCREW 3909292
9 WASHER 3205770
10 VALVE VENT 3921582
11 O RING 3865142 3865163 3867888
12 RESERVOIR BODY 3921575
13 ELBOW 3926855
14 PLUG 3068437
Part
15 GLAND NUT 3903089
Fault Finding
System Will Not Prime
1. Check reservoir valve is closed.
2. Check for sufficient fluid in reservoir.
3. Check for damaged/missing/dirty O-ring on test ports.
4. Check that the face of the DUT is contacting the O-ring, and that the surface is not
scored or dented.
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.
4. Check that the face of the DUT is contacting the O-ring, and that the surface is not
scored or dented.
16
Hydraulic Comparison Test Pump
Storage and Transportation
Priming Pump Malfunction
1. If pumping does not generate pressure, then the inlet check valve has probably failed,
and requires replacement.
2. If the system pressurizes and depressurizes in conjunction with the downward and
upward strokes of the pump, then the outlet check valve has failed completely. This
should be disassembled and inspected for dirt or damage to valve seat and seal. After
inspection, clean all parts carefully, replace as required, and re-assemble correctly.
3. If the pump handle rises during normal system pressurization, then the outlet check
valve is leaking. Inspect as above.
W Caution
Do not continue to pressurize if pump handle rises, as this can
damage the inlet check valve.
Cannot Reach Maximum Pressure
If maximum pressure cannot be reached, even after the screw press has been turned fully
in, and the checks above have been made:
1. Ensure that the screw press is FULLY OUT, and the priming pump is used for initial
pressurization.
2. If the DUT has a large internal volume or there is air in the system, then re-prime
(Refer to Chapter 3), increasing the initial pressurization with the priming pump from
100 psi/7 bar to at least 200 psi/14 bar.
Pressure Falls Away
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. Allow a few minutes to determine if the
system pressure is continuing to fall away, or is stabilizing.
Storage and Transportation
1. With the test port plugged, open the reservoir valve and turn screw press fully in,
close reservoir valve.
2. Remove spokes from hub, and store in tool-roll.
3. Remove screw-in handle from pump arm, and store in tool roll.
4. If fluid is to remain in the reservoir, ensure that the tester is kept level at all times to
avoid spills. If not, drain the reservoir as described in Chapter 5, Reserve Assembly.
5. Re-fit instrument lid, ensuring that the hinges are correctly engaged, and secure with
toggle clips at the sides.
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P5515, P5515-V, & P5515-EP
Users Manual
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 a pointer remover/punch. This
tool has a spring-loaded plunger to quickly and consistently refit the pointer.
Figure 12. Angle Adapter
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Figure 13. Pointer Remover/Punch
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Hydraulic Comparison Test Pump
Ancillary Equipment
Liquid Separator, P5521
The Liquid Separator is used to separate the working fluid of the deadweight tester to
which it is fitted from the working fluid in the device under test. This prevents
contamination of either hydraulic system and allows calibration of the device in its
specific working fluid.
Figure 14. Liquid Separator
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P5515, P5515-V, & P5515-EP
Users Manual
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