0. .... I 0 0 z Inst allatio n and Maintenance Manual v 0 '" .... for the e; I « Omega 0. w Type DWT 1305D Deadweight Tester .... ;= and Type DWT 1327D Portable Test Pump L -' , • w 0> o 0 < • u 0 i :n u 'u 0 w ' ". t- Z < • 0 : 0 0 z u I I 0 z < < 0 I O (j u f2 :E
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Installation and Maintenance Manualv 0 for the e
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Type DWT 1327D Portable Test Pump
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Section
1
2
3
4
5
6
INDEX
Description
Scope of Manua l Safety Precautions
Product Descri ption 1305 Theory of Operat i o n Construct i on Specifications
~Product Description 1327 Theory of Operation Construction Specifications
Inspect ion I nstallation 1305 Ope ration 1305 In s t a l lat ion 1327 Operat i o n 1327
Factors Affect ing Operation of Deadweight Testers
Ma intenance Instructions
wa rranty Sh l pp1ng Instructions
L1st of Illustrations
Figure 1-1 Figure 1 -2 Figure 2-1 Figure 2-2 Dra wing 601D001 Sheet 1amp2
10 PURPOSE AND SCOPE OF MANUAL
This manual is p rovided to g uide u s ers of Mode l DWT 1 30 5D a nd DWT 1 327D pressure t esting devices in (1) Installing the equipme nt (2) Routi ne o pe rations
Th e in s tructions in thi s manua l are designed to be performed by qualified i n strume nt maintenance personn e l
Omega Engineering does not r e commend tro ub l esh ooting o r r epairs beyond the scope o f this manual Problems which can not b e r e medied by f o llowing the instructio n s in this manu a l should be r eferred to the manufacturer I mmediate assistance can often be s uppli e d by telephone De fec tive compone nt s wi ll be re paired or replaced by the manufacturer at his discretion and wi l l be returned to the user by the same mode of shi pment Airmai l or air express i s recommended f or urgent s hi pme n ts Re turned goods should be a ccompanied by information reques t e d in Sectlon 6
Additiona l Assistance Contact Custome r Servi ce at Omega Eng ineering Inc On e Omega Dri ve Stamford CT 06907 Attn Servlce Section ( 20 3 ) 359-16 60 Te l ex 996 404 Ca ble OMEGA FAX (203) 359 - 77 70
1 1 Safety Precautions
Press ure Testing Equipment must be s e l ect e d and used in a ccordance with r e c ogn ized industr y codes and safety pra ctices to avoid the poss1bility of mi s u s e or mi sappli cation which could r esult in personal injury or property d a mage Personne l re s pons ible f or se l ection and install a tion s hould also be familiar with the s af e t y recomme nd a tions o f ANSI B40 1 that a pply to elastic p r essure elements a nd the ir appli cation 1n ge neral and s pec ific services ANSI B40 1 is avail a ble from
ANSI or ASM E 1430 Broadway 345 47th Street New York NY 1 001 8 New York NY 10017
1 Press ure - Select a rang e so that the maximum applied pressure wi ll never e xceed the upper range limit
2 Vibration - Excessive vibration cou l d cau se a loosen i n g of componen ts a nd abnorma l wear resulting in l o ss o f ins trument accuracy or fai lure t o provide va lid da t a
3 Temperature - Operation of the instrume n t in an environment where t e mperatures are in e xcess of d es ign ratings may re s ul t in l oss of accuracy an d fai lure
4 Pro c ess - Pressure bo unda ry material s must b e resistant to t he pr o c e ss media Fail u r e to assure compatibility may i n pressure boundary deteriorat i o n o r failure In s t rume nt s operated at high pr ess ur es or with pot e nt ia ll y hazardo u s service such as oxyge n should be care fully se l ect ed in a c c o rdance with recognize d industry c od e s and the r e c o mme ndat ions
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Figure 1-1 Qrega Portable Dua l Pange D2adweight Tester - Type lliI 130SD
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2 0 PRODUCT DESCRIPTION - THEORY OF OPERATION - CONSTfUCTION
2 1 Product Description DWT 13050
211 Constructio n
The Omega Type DWT 1 305D Dua l Range Deadweight testers are p r ec lsio n built primary pressure standards used for te sting setting ca l ibr ating or r e pairing pressure measuring devices wlthin the t es t poi nt s 15 psi (100 kPa) to 10000 psi (70000 kPa)
The deadweight tester consists of a two stage hydraulic pump containing a manifold which is pressurize d during operation Inte gral to the pump is a shutt le valve that allows the operator to regulate the speed of pressure i nc r ease One conne ction to the manifo l d includes a cylinder a nd a fre e floating preci sion machined piston with a plate for holding calibrated weig h ts A second connec t ion to the manifo l d accommod~tes a gauge or other pressure measuring device to be calibrated o r c h ecked Incorporated lnto the manifold is a hand operated displacement va l ve that a llows small adjustme nts In fluid vol ume to be made wi thout further operation of the pump handle or release valve
The tester is dual range having two interchangeable piston and cylinder assemblies One is a l ow pressure piston having an ef fective area five times l arger t h a n that of the high pres sure piston The low pressure piston is used f or maki ng measurements below 2 000 psi (14000 kPa) The high pr essure piston wit h an area 15 that of the low pressure plston is used t o measure pressures through 10 000 ps i (70 000 kPa) The weight masses are pre - measured a nd identified with the p r essure values they produce when operated with the i n terchangeable piston and cylinder assemblies
Pressure calibrat lon points produced by the deadweight tes ter are accurate to within plusminus 01 of the reading certified traceable to the National Bureau of Standards The tester provides consistent repeatable accuracy maintaining its pressure for an appreclabl e l e ng th of time r egard l ess of temperature changes slight leaks in the pressure system or c ha nges in vo lume of the pressurized system due to movement of a Bourdon tube or other d e vice
A hand jack set thre e wrenches spare O-r i ng s a nd a special adapter for making connecti ons to pressure outlets that do not accommodate cone pipe seating are included with each unit
All deadweight teste r s are supplied with l ower and back connection offset pipe assemblies with pipe adapters for 14 or 12 NPT connections
An all metal double- l atched top handle carrying case is supplied with the complete tester for all f ittings and attachments Deadweights are packed in meta l doub l e -latched storage - ca rrying boxes
2 1 3 Spe c1fi cations -DWT 1305D
Accqracy Combined tolerance of we i ghts and piston and c ylinder assernbil l es withln 0 1 of reading Weight tolerance within 005 of mass Piston and cylinder is vi t hin 0 05 of rated me an eff ective area
Deadweight No n-magne tic d ie c a s t zinc alloy To tal wei g ht to produce maximum pressure of 1 0 000 ps i (70 000 kPa ) i s 125 lbs (56 7 kg )
Piston amp Cylind er Assemblies High s trength sta inless stee l pi s ton and c ylinder with brass co llar and aluminum weight platform
Pump Two stage leve r operated generates 10000 psi (70000 kPa ) wit h 28 pounds (127 kg) of force on lever handle
Pump Body Aluminum c orrosion inhi bited and coated wit h baked b lue epoxy finish
Shutt l e Va lve Stain l ess stee l bypass va l ve that controls rate o f pressure incre a se a nd red uces operato r effort when working at hlgh press ure
Di s placement Valve A f~ne pitched threaded valve rod permi tt~ng vern i er adjustments to flui d vo l ume to provide pre c ise pressure changes or adjustment of piston travel Limit s tops prevent rod removal during nor mal operation
Mounting Four b e nch mounting hol es l o cated i n base for pos i t i ve mo unti ng to any l e ve l s ur f a c e
Instrume nt Conne c tions Two coned pipe assemblies provide verti cal ca li brat ion capability for back and lower connected gauge s Standard 14 inch internal NPT and 12 inch inte rnal NPT fitt ing adapt e r s are supplied
Operat~ng ~luid DWT 1305D - Light grade ma chine oils automotive petrol e um base
SAE20 oils o r other equiva l e nt f luids suitab l e f or use with Buna N O-ri ng materials 1 5 pints r e quired ( 7 liters)
DWT 1305 DH - Most hydrauli c oi l s o f phosphate ester base brake f luids skydrol pydraul etc suitable for use with Butyl or Ethylene - Propylene O-ring m~terials 15 pints required (7 liters)
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
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Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
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Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
Section
1
2
3
4
5
6
INDEX
Description
Scope of Manua l Safety Precautions
Product Descri ption 1305 Theory of Operat i o n Construct i on Specifications
~Product Description 1327 Theory of Operation Construction Specifications
Inspect ion I nstallation 1305 Ope ration 1305 In s t a l lat ion 1327 Operat i o n 1327
Factors Affect ing Operation of Deadweight Testers
Ma intenance Instructions
wa rranty Sh l pp1ng Instructions
L1st of Illustrations
Figure 1-1 Figure 1 -2 Figure 2-1 Figure 2-2 Dra wing 601D001 Sheet 1amp2
10 PURPOSE AND SCOPE OF MANUAL
This manual is p rovided to g uide u s ers of Mode l DWT 1 30 5D a nd DWT 1 327D pressure t esting devices in (1) Installing the equipme nt (2) Routi ne o pe rations
Th e in s tructions in thi s manua l are designed to be performed by qualified i n strume nt maintenance personn e l
Omega Engineering does not r e commend tro ub l esh ooting o r r epairs beyond the scope o f this manual Problems which can not b e r e medied by f o llowing the instructio n s in this manu a l should be r eferred to the manufacturer I mmediate assistance can often be s uppli e d by telephone De fec tive compone nt s wi ll be re paired or replaced by the manufacturer at his discretion and wi l l be returned to the user by the same mode of shi pment Airmai l or air express i s recommended f or urgent s hi pme n ts Re turned goods should be a ccompanied by information reques t e d in Sectlon 6
Additiona l Assistance Contact Custome r Servi ce at Omega Eng ineering Inc On e Omega Dri ve Stamford CT 06907 Attn Servlce Section ( 20 3 ) 359-16 60 Te l ex 996 404 Ca ble OMEGA FAX (203) 359 - 77 70
1 1 Safety Precautions
Press ure Testing Equipment must be s e l ect e d and used in a ccordance with r e c ogn ized industr y codes and safety pra ctices to avoid the poss1bility of mi s u s e or mi sappli cation which could r esult in personal injury or property d a mage Personne l re s pons ible f or se l ection and install a tion s hould also be familiar with the s af e t y recomme nd a tions o f ANSI B40 1 that a pply to elastic p r essure elements a nd the ir appli cation 1n ge neral and s pec ific services ANSI B40 1 is avail a ble from
ANSI or ASM E 1430 Broadway 345 47th Street New York NY 1 001 8 New York NY 10017
1 Press ure - Select a rang e so that the maximum applied pressure wi ll never e xceed the upper range limit
2 Vibration - Excessive vibration cou l d cau se a loosen i n g of componen ts a nd abnorma l wear resulting in l o ss o f ins trument accuracy or fai lure t o provide va lid da t a
3 Temperature - Operation of the instrume n t in an environment where t e mperatures are in e xcess of d es ign ratings may re s ul t in l oss of accuracy an d fai lure
4 Pro c ess - Pressure bo unda ry material s must b e resistant to t he pr o c e ss media Fail u r e to assure compatibility may i n pressure boundary deteriorat i o n o r failure In s t rume nt s operated at high pr ess ur es or with pot e nt ia ll y hazardo u s service such as oxyge n should be care fully se l ect ed in a c c o rdance with recognize d industry c od e s and the r e c o mme ndat ions
I -shy
Figure 1-1 Qrega Portable Dua l Pange D2adweight Tester - Type lliI 130SD
- ---- shy
2 0 PRODUCT DESCRIPTION - THEORY OF OPERATION - CONSTfUCTION
2 1 Product Description DWT 13050
211 Constructio n
The Omega Type DWT 1 305D Dua l Range Deadweight testers are p r ec lsio n built primary pressure standards used for te sting setting ca l ibr ating or r e pairing pressure measuring devices wlthin the t es t poi nt s 15 psi (100 kPa) to 10000 psi (70000 kPa)
The deadweight tester consists of a two stage hydraulic pump containing a manifold which is pressurize d during operation Inte gral to the pump is a shutt le valve that allows the operator to regulate the speed of pressure i nc r ease One conne ction to the manifo l d includes a cylinder a nd a fre e floating preci sion machined piston with a plate for holding calibrated weig h ts A second connec t ion to the manifo l d accommod~tes a gauge or other pressure measuring device to be calibrated o r c h ecked Incorporated lnto the manifold is a hand operated displacement va l ve that a llows small adjustme nts In fluid vol ume to be made wi thout further operation of the pump handle or release valve
The tester is dual range having two interchangeable piston and cylinder assemblies One is a l ow pressure piston having an ef fective area five times l arger t h a n that of the high pres sure piston The low pressure piston is used f or maki ng measurements below 2 000 psi (14000 kPa) The high pr essure piston wit h an area 15 that of the low pressure plston is used t o measure pressures through 10 000 ps i (70 000 kPa) The weight masses are pre - measured a nd identified with the p r essure values they produce when operated with the i n terchangeable piston and cylinder assemblies
Pressure calibrat lon points produced by the deadweight tes ter are accurate to within plusminus 01 of the reading certified traceable to the National Bureau of Standards The tester provides consistent repeatable accuracy maintaining its pressure for an appreclabl e l e ng th of time r egard l ess of temperature changes slight leaks in the pressure system or c ha nges in vo lume of the pressurized system due to movement of a Bourdon tube or other d e vice
A hand jack set thre e wrenches spare O-r i ng s a nd a special adapter for making connecti ons to pressure outlets that do not accommodate cone pipe seating are included with each unit
All deadweight teste r s are supplied with l ower and back connection offset pipe assemblies with pipe adapters for 14 or 12 NPT connections
An all metal double- l atched top handle carrying case is supplied with the complete tester for all f ittings and attachments Deadweights are packed in meta l doub l e -latched storage - ca rrying boxes
2 1 3 Spe c1fi cations -DWT 1305D
Accqracy Combined tolerance of we i ghts and piston and c ylinder assernbil l es withln 0 1 of reading Weight tolerance within 005 of mass Piston and cylinder is vi t hin 0 05 of rated me an eff ective area
Deadweight No n-magne tic d ie c a s t zinc alloy To tal wei g ht to produce maximum pressure of 1 0 000 ps i (70 000 kPa ) i s 125 lbs (56 7 kg )
Piston amp Cylind er Assemblies High s trength sta inless stee l pi s ton and c ylinder with brass co llar and aluminum weight platform
Pump Two stage leve r operated generates 10000 psi (70000 kPa ) wit h 28 pounds (127 kg) of force on lever handle
Pump Body Aluminum c orrosion inhi bited and coated wit h baked b lue epoxy finish
Shutt l e Va lve Stain l ess stee l bypass va l ve that controls rate o f pressure incre a se a nd red uces operato r effort when working at hlgh press ure
Di s placement Valve A f~ne pitched threaded valve rod permi tt~ng vern i er adjustments to flui d vo l ume to provide pre c ise pressure changes or adjustment of piston travel Limit s tops prevent rod removal during nor mal operation
Mounting Four b e nch mounting hol es l o cated i n base for pos i t i ve mo unti ng to any l e ve l s ur f a c e
Instrume nt Conne c tions Two coned pipe assemblies provide verti cal ca li brat ion capability for back and lower connected gauge s Standard 14 inch internal NPT and 12 inch inte rnal NPT fitt ing adapt e r s are supplied
Operat~ng ~luid DWT 1305D - Light grade ma chine oils automotive petrol e um base
SAE20 oils o r other equiva l e nt f luids suitab l e f or use with Buna N O-ri ng materials 1 5 pints r e quired ( 7 liters)
DWT 1305 DH - Most hydrauli c oi l s o f phosphate ester base brake f luids skydrol pydraul etc suitable for use with Butyl or Ethylene - Propylene O-ring m~terials 15 pints required (7 liters)
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
10 PURPOSE AND SCOPE OF MANUAL
This manual is p rovided to g uide u s ers of Mode l DWT 1 30 5D a nd DWT 1 327D pressure t esting devices in (1) Installing the equipme nt (2) Routi ne o pe rations
Th e in s tructions in thi s manua l are designed to be performed by qualified i n strume nt maintenance personn e l
Omega Engineering does not r e commend tro ub l esh ooting o r r epairs beyond the scope o f this manual Problems which can not b e r e medied by f o llowing the instructio n s in this manu a l should be r eferred to the manufacturer I mmediate assistance can often be s uppli e d by telephone De fec tive compone nt s wi ll be re paired or replaced by the manufacturer at his discretion and wi l l be returned to the user by the same mode of shi pment Airmai l or air express i s recommended f or urgent s hi pme n ts Re turned goods should be a ccompanied by information reques t e d in Sectlon 6
Additiona l Assistance Contact Custome r Servi ce at Omega Eng ineering Inc On e Omega Dri ve Stamford CT 06907 Attn Servlce Section ( 20 3 ) 359-16 60 Te l ex 996 404 Ca ble OMEGA FAX (203) 359 - 77 70
1 1 Safety Precautions
Press ure Testing Equipment must be s e l ect e d and used in a ccordance with r e c ogn ized industr y codes and safety pra ctices to avoid the poss1bility of mi s u s e or mi sappli cation which could r esult in personal injury or property d a mage Personne l re s pons ible f or se l ection and install a tion s hould also be familiar with the s af e t y recomme nd a tions o f ANSI B40 1 that a pply to elastic p r essure elements a nd the ir appli cation 1n ge neral and s pec ific services ANSI B40 1 is avail a ble from
ANSI or ASM E 1430 Broadway 345 47th Street New York NY 1 001 8 New York NY 10017
1 Press ure - Select a rang e so that the maximum applied pressure wi ll never e xceed the upper range limit
2 Vibration - Excessive vibration cou l d cau se a loosen i n g of componen ts a nd abnorma l wear resulting in l o ss o f ins trument accuracy or fai lure t o provide va lid da t a
3 Temperature - Operation of the instrume n t in an environment where t e mperatures are in e xcess of d es ign ratings may re s ul t in l oss of accuracy an d fai lure
4 Pro c ess - Pressure bo unda ry material s must b e resistant to t he pr o c e ss media Fail u r e to assure compatibility may i n pressure boundary deteriorat i o n o r failure In s t rume nt s operated at high pr ess ur es or with pot e nt ia ll y hazardo u s service such as oxyge n should be care fully se l ect ed in a c c o rdance with recognize d industry c od e s and the r e c o mme ndat ions
I -shy
Figure 1-1 Qrega Portable Dua l Pange D2adweight Tester - Type lliI 130SD
- ---- shy
2 0 PRODUCT DESCRIPTION - THEORY OF OPERATION - CONSTfUCTION
2 1 Product Description DWT 13050
211 Constructio n
The Omega Type DWT 1 305D Dua l Range Deadweight testers are p r ec lsio n built primary pressure standards used for te sting setting ca l ibr ating or r e pairing pressure measuring devices wlthin the t es t poi nt s 15 psi (100 kPa) to 10000 psi (70000 kPa)
The deadweight tester consists of a two stage hydraulic pump containing a manifold which is pressurize d during operation Inte gral to the pump is a shutt le valve that allows the operator to regulate the speed of pressure i nc r ease One conne ction to the manifo l d includes a cylinder a nd a fre e floating preci sion machined piston with a plate for holding calibrated weig h ts A second connec t ion to the manifo l d accommod~tes a gauge or other pressure measuring device to be calibrated o r c h ecked Incorporated lnto the manifold is a hand operated displacement va l ve that a llows small adjustme nts In fluid vol ume to be made wi thout further operation of the pump handle or release valve
The tester is dual range having two interchangeable piston and cylinder assemblies One is a l ow pressure piston having an ef fective area five times l arger t h a n that of the high pres sure piston The low pressure piston is used f or maki ng measurements below 2 000 psi (14000 kPa) The high pr essure piston wit h an area 15 that of the low pressure plston is used t o measure pressures through 10 000 ps i (70 000 kPa) The weight masses are pre - measured a nd identified with the p r essure values they produce when operated with the i n terchangeable piston and cylinder assemblies
Pressure calibrat lon points produced by the deadweight tes ter are accurate to within plusminus 01 of the reading certified traceable to the National Bureau of Standards The tester provides consistent repeatable accuracy maintaining its pressure for an appreclabl e l e ng th of time r egard l ess of temperature changes slight leaks in the pressure system or c ha nges in vo lume of the pressurized system due to movement of a Bourdon tube or other d e vice
A hand jack set thre e wrenches spare O-r i ng s a nd a special adapter for making connecti ons to pressure outlets that do not accommodate cone pipe seating are included with each unit
All deadweight teste r s are supplied with l ower and back connection offset pipe assemblies with pipe adapters for 14 or 12 NPT connections
An all metal double- l atched top handle carrying case is supplied with the complete tester for all f ittings and attachments Deadweights are packed in meta l doub l e -latched storage - ca rrying boxes
2 1 3 Spe c1fi cations -DWT 1305D
Accqracy Combined tolerance of we i ghts and piston and c ylinder assernbil l es withln 0 1 of reading Weight tolerance within 005 of mass Piston and cylinder is vi t hin 0 05 of rated me an eff ective area
Deadweight No n-magne tic d ie c a s t zinc alloy To tal wei g ht to produce maximum pressure of 1 0 000 ps i (70 000 kPa ) i s 125 lbs (56 7 kg )
Piston amp Cylind er Assemblies High s trength sta inless stee l pi s ton and c ylinder with brass co llar and aluminum weight platform
Pump Two stage leve r operated generates 10000 psi (70000 kPa ) wit h 28 pounds (127 kg) of force on lever handle
Pump Body Aluminum c orrosion inhi bited and coated wit h baked b lue epoxy finish
Shutt l e Va lve Stain l ess stee l bypass va l ve that controls rate o f pressure incre a se a nd red uces operato r effort when working at hlgh press ure
Di s placement Valve A f~ne pitched threaded valve rod permi tt~ng vern i er adjustments to flui d vo l ume to provide pre c ise pressure changes or adjustment of piston travel Limit s tops prevent rod removal during nor mal operation
Mounting Four b e nch mounting hol es l o cated i n base for pos i t i ve mo unti ng to any l e ve l s ur f a c e
Instrume nt Conne c tions Two coned pipe assemblies provide verti cal ca li brat ion capability for back and lower connected gauge s Standard 14 inch internal NPT and 12 inch inte rnal NPT fitt ing adapt e r s are supplied
Operat~ng ~luid DWT 1305D - Light grade ma chine oils automotive petrol e um base
SAE20 oils o r other equiva l e nt f luids suitab l e f or use with Buna N O-ri ng materials 1 5 pints r e quired ( 7 liters)
DWT 1305 DH - Most hydrauli c oi l s o f phosphate ester base brake f luids skydrol pydraul etc suitable for use with Butyl or Ethylene - Propylene O-ring m~terials 15 pints required (7 liters)
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
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Figure 1-1 Qrega Portable Dua l Pange D2adweight Tester - Type lliI 130SD
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2 0 PRODUCT DESCRIPTION - THEORY OF OPERATION - CONSTfUCTION
2 1 Product Description DWT 13050
211 Constructio n
The Omega Type DWT 1 305D Dua l Range Deadweight testers are p r ec lsio n built primary pressure standards used for te sting setting ca l ibr ating or r e pairing pressure measuring devices wlthin the t es t poi nt s 15 psi (100 kPa) to 10000 psi (70000 kPa)
The deadweight tester consists of a two stage hydraulic pump containing a manifold which is pressurize d during operation Inte gral to the pump is a shutt le valve that allows the operator to regulate the speed of pressure i nc r ease One conne ction to the manifo l d includes a cylinder a nd a fre e floating preci sion machined piston with a plate for holding calibrated weig h ts A second connec t ion to the manifo l d accommod~tes a gauge or other pressure measuring device to be calibrated o r c h ecked Incorporated lnto the manifold is a hand operated displacement va l ve that a llows small adjustme nts In fluid vol ume to be made wi thout further operation of the pump handle or release valve
The tester is dual range having two interchangeable piston and cylinder assemblies One is a l ow pressure piston having an ef fective area five times l arger t h a n that of the high pres sure piston The low pressure piston is used f or maki ng measurements below 2 000 psi (14000 kPa) The high pr essure piston wit h an area 15 that of the low pressure plston is used t o measure pressures through 10 000 ps i (70 000 kPa) The weight masses are pre - measured a nd identified with the p r essure values they produce when operated with the i n terchangeable piston and cylinder assemblies
Pressure calibrat lon points produced by the deadweight tes ter are accurate to within plusminus 01 of the reading certified traceable to the National Bureau of Standards The tester provides consistent repeatable accuracy maintaining its pressure for an appreclabl e l e ng th of time r egard l ess of temperature changes slight leaks in the pressure system or c ha nges in vo lume of the pressurized system due to movement of a Bourdon tube or other d e vice
A hand jack set thre e wrenches spare O-r i ng s a nd a special adapter for making connecti ons to pressure outlets that do not accommodate cone pipe seating are included with each unit
All deadweight teste r s are supplied with l ower and back connection offset pipe assemblies with pipe adapters for 14 or 12 NPT connections
An all metal double- l atched top handle carrying case is supplied with the complete tester for all f ittings and attachments Deadweights are packed in meta l doub l e -latched storage - ca rrying boxes
2 1 3 Spe c1fi cations -DWT 1305D
Accqracy Combined tolerance of we i ghts and piston and c ylinder assernbil l es withln 0 1 of reading Weight tolerance within 005 of mass Piston and cylinder is vi t hin 0 05 of rated me an eff ective area
Deadweight No n-magne tic d ie c a s t zinc alloy To tal wei g ht to produce maximum pressure of 1 0 000 ps i (70 000 kPa ) i s 125 lbs (56 7 kg )
Piston amp Cylind er Assemblies High s trength sta inless stee l pi s ton and c ylinder with brass co llar and aluminum weight platform
Pump Two stage leve r operated generates 10000 psi (70000 kPa ) wit h 28 pounds (127 kg) of force on lever handle
Pump Body Aluminum c orrosion inhi bited and coated wit h baked b lue epoxy finish
Shutt l e Va lve Stain l ess stee l bypass va l ve that controls rate o f pressure incre a se a nd red uces operato r effort when working at hlgh press ure
Di s placement Valve A f~ne pitched threaded valve rod permi tt~ng vern i er adjustments to flui d vo l ume to provide pre c ise pressure changes or adjustment of piston travel Limit s tops prevent rod removal during nor mal operation
Mounting Four b e nch mounting hol es l o cated i n base for pos i t i ve mo unti ng to any l e ve l s ur f a c e
Instrume nt Conne c tions Two coned pipe assemblies provide verti cal ca li brat ion capability for back and lower connected gauge s Standard 14 inch internal NPT and 12 inch inte rnal NPT fitt ing adapt e r s are supplied
Operat~ng ~luid DWT 1305D - Light grade ma chine oils automotive petrol e um base
SAE20 oils o r other equiva l e nt f luids suitab l e f or use with Buna N O-ri ng materials 1 5 pints r e quired ( 7 liters)
DWT 1305 DH - Most hydrauli c oi l s o f phosphate ester base brake f luids skydrol pydraul etc suitable for use with Butyl or Ethylene - Propylene O-ring m~terials 15 pints required (7 liters)
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
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Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
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operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
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The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
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Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
2 0 PRODUCT DESCRIPTION - THEORY OF OPERATION - CONSTfUCTION
2 1 Product Description DWT 13050
211 Constructio n
The Omega Type DWT 1 305D Dua l Range Deadweight testers are p r ec lsio n built primary pressure standards used for te sting setting ca l ibr ating or r e pairing pressure measuring devices wlthin the t es t poi nt s 15 psi (100 kPa) to 10000 psi (70000 kPa)
The deadweight tester consists of a two stage hydraulic pump containing a manifold which is pressurize d during operation Inte gral to the pump is a shutt le valve that allows the operator to regulate the speed of pressure i nc r ease One conne ction to the manifo l d includes a cylinder a nd a fre e floating preci sion machined piston with a plate for holding calibrated weig h ts A second connec t ion to the manifo l d accommod~tes a gauge or other pressure measuring device to be calibrated o r c h ecked Incorporated lnto the manifold is a hand operated displacement va l ve that a llows small adjustme nts In fluid vol ume to be made wi thout further operation of the pump handle or release valve
The tester is dual range having two interchangeable piston and cylinder assemblies One is a l ow pressure piston having an ef fective area five times l arger t h a n that of the high pres sure piston The low pressure piston is used f or maki ng measurements below 2 000 psi (14000 kPa) The high pr essure piston wit h an area 15 that of the low pressure plston is used t o measure pressures through 10 000 ps i (70 000 kPa) The weight masses are pre - measured a nd identified with the p r essure values they produce when operated with the i n terchangeable piston and cylinder assemblies
Pressure calibrat lon points produced by the deadweight tes ter are accurate to within plusminus 01 of the reading certified traceable to the National Bureau of Standards The tester provides consistent repeatable accuracy maintaining its pressure for an appreclabl e l e ng th of time r egard l ess of temperature changes slight leaks in the pressure system or c ha nges in vo lume of the pressurized system due to movement of a Bourdon tube or other d e vice
A hand jack set thre e wrenches spare O-r i ng s a nd a special adapter for making connecti ons to pressure outlets that do not accommodate cone pipe seating are included with each unit
All deadweight teste r s are supplied with l ower and back connection offset pipe assemblies with pipe adapters for 14 or 12 NPT connections
An all metal double- l atched top handle carrying case is supplied with the complete tester for all f ittings and attachments Deadweights are packed in meta l doub l e -latched storage - ca rrying boxes
2 1 3 Spe c1fi cations -DWT 1305D
Accqracy Combined tolerance of we i ghts and piston and c ylinder assernbil l es withln 0 1 of reading Weight tolerance within 005 of mass Piston and cylinder is vi t hin 0 05 of rated me an eff ective area
Deadweight No n-magne tic d ie c a s t zinc alloy To tal wei g ht to produce maximum pressure of 1 0 000 ps i (70 000 kPa ) i s 125 lbs (56 7 kg )
Piston amp Cylind er Assemblies High s trength sta inless stee l pi s ton and c ylinder with brass co llar and aluminum weight platform
Pump Two stage leve r operated generates 10000 psi (70000 kPa ) wit h 28 pounds (127 kg) of force on lever handle
Pump Body Aluminum c orrosion inhi bited and coated wit h baked b lue epoxy finish
Shutt l e Va lve Stain l ess stee l bypass va l ve that controls rate o f pressure incre a se a nd red uces operato r effort when working at hlgh press ure
Di s placement Valve A f~ne pitched threaded valve rod permi tt~ng vern i er adjustments to flui d vo l ume to provide pre c ise pressure changes or adjustment of piston travel Limit s tops prevent rod removal during nor mal operation
Mounting Four b e nch mounting hol es l o cated i n base for pos i t i ve mo unti ng to any l e ve l s ur f a c e
Instrume nt Conne c tions Two coned pipe assemblies provide verti cal ca li brat ion capability for back and lower connected gauge s Standard 14 inch internal NPT and 12 inch inte rnal NPT fitt ing adapt e r s are supplied
Operat~ng ~luid DWT 1305D - Light grade ma chine oils automotive petrol e um base
SAE20 oils o r other equiva l e nt f luids suitab l e f or use with Buna N O-ri ng materials 1 5 pints r e quired ( 7 liters)
DWT 1305 DH - Most hydrauli c oi l s o f phosphate ester base brake f luids skydrol pydraul etc suitable for use with Butyl or Ethylene - Propylene O-ring m~terials 15 pints required (7 liters)
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
2 1 3 Spe c1fi cations -DWT 1305D
Accqracy Combined tolerance of we i ghts and piston and c ylinder assernbil l es withln 0 1 of reading Weight tolerance within 005 of mass Piston and cylinder is vi t hin 0 05 of rated me an eff ective area
Deadweight No n-magne tic d ie c a s t zinc alloy To tal wei g ht to produce maximum pressure of 1 0 000 ps i (70 000 kPa ) i s 125 lbs (56 7 kg )
Piston amp Cylind er Assemblies High s trength sta inless stee l pi s ton and c ylinder with brass co llar and aluminum weight platform
Pump Two stage leve r operated generates 10000 psi (70000 kPa ) wit h 28 pounds (127 kg) of force on lever handle
Pump Body Aluminum c orrosion inhi bited and coated wit h baked b lue epoxy finish
Shutt l e Va lve Stain l ess stee l bypass va l ve that controls rate o f pressure incre a se a nd red uces operato r effort when working at hlgh press ure
Di s placement Valve A f~ne pitched threaded valve rod permi tt~ng vern i er adjustments to flui d vo l ume to provide pre c ise pressure changes or adjustment of piston travel Limit s tops prevent rod removal during nor mal operation
Mounting Four b e nch mounting hol es l o cated i n base for pos i t i ve mo unti ng to any l e ve l s ur f a c e
Instrume nt Conne c tions Two coned pipe assemblies provide verti cal ca li brat ion capability for back and lower connected gauge s Standard 14 inch internal NPT and 12 inch inte rnal NPT fitt ing adapt e r s are supplied
Operat~ng ~luid DWT 1305D - Light grade ma chine oils automotive petrol e um base
SAE20 oils o r other equiva l e nt f luids suitab l e f or use with Buna N O-ri ng materials 1 5 pints r e quired ( 7 liters)
DWT 1305 DH - Most hydrauli c oi l s o f phosphate ester base brake f luids skydrol pydraul etc suitable for use with Butyl or Ethylene - Propylene O-ring m~terials 15 pints required (7 liters)
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
22 Product Descr iption DWT 13 2 7D
2 2 1 Construction
The Omega Type DWT 1 327D Portabl e Test Pumps are rugged v e r satl1e pressure trans f er standar ds used f or t est i ng setting cal ibrating o r repairi ng pressure measuring devices with ranges up t o 10 000 psi (70 000 kPa) A se l ect i on of hig h accuracy test gauges with a prec i s ion of plus minus 025 o f span are supplied as the standard to which the devi ce under test is compared
The main component to the t e ster is a two stage hydraulic pump containing a manifold which is pressurized during operation Integral to the pump is a shuttle valve that allows the operator t o regulate the speed o f pressure inc r ease One connect ion to the manifo ld has a s t raight pipe with a p r ecision t est gauge a ttached serving as the ref e r e nce standard A second connection to the manifold accommodates a gauge or o ther press ure measuring device to be ca librated or checked Incorporated into the manifol d is a hand operated displacement valve that a llows small adjustments in f l uid volume to be made without f urth e r operation of the pump handle or r elease va l ve
Pressure v alues produced by the pump are able to be clearly read to within plu sminus 0 25 accuracy of the span of the precision test gauge selec t ed fo r testing Certifica tion of test gauge accurac y traceable to the Nat i o nal Bureau of Standards is available upon request A hand jack set thr ee wre nc hes spa r e O-rings and a special adapter for making connectio n s to press ur e o utle t s t hat do not accommodate cone pipe seating are i ncl uded wi th each unit
Tes t pump a ccessories l nclude lower and back connectlon o ffset pipe assemblles with pipe adapters for 14 or 12 NPT connect i ons
An all metal double- latched top handle carrying case is supplied with t h e complete tester to hold all fittings and attachment s
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
Fiqure l-i Clrrega Portable Test P1iIrp - Type 01 1327D lt
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
The operatirg principle behi-ld the DWr 1327D Test Pump is c simple form of son Pressure produced by the pump is equaLly distributed by
the nanifold to a test gauge and to a device be~ng calibrated or checked The reading of the test gauge serves as te reference to vlhich ather device readings are compared against
selection of the test gauge ranqe is the determining factor in establishing the precis10n to which a compari sor check is to be fTade Test qauge accuracy is e~pcessed as a percentcge of its span~
selection of the test gauge range mus~ be made to ni~inize the amount of the unit error~ If a 5000 psi (35000 kPa) range test gauge were used to test devices whose span va2ues were ess tan ) fourth of tJ1E test gauge range the unit error of 12 5 psi (87 zPa) vlould be greater than 1 of the test pressure~ Therefore it is important to select a test gauge tha~ has a fuli scale range in excess of the pressure value to be measured
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
2 23 Specificat~ons DiT 1327D
Accuracy 14 of 1 of test gauge spa~
Test Gauges Orrega solid front type 4 ~21 di3l size (120 ITT1 case) ~ Bourdon tube materials for DWT 13270 and DB are bronze and alloy steel Bourdon tube materials for DWT 132700 are bronze and liUTI copper ~
Pump TvlO stage I lever operated generates le 000 psi (70 ODe kPa) with 28 pounds of (12 7 ) force on lever handle~
Puytp Alurll_nUffi corrosion inhLbi ted and coated wi tt blke-d bJ ue epnzy finish ~
Shuttle Valve Stalnless steel bypass valve that controls rate of pressJre increase and reduces operator effort w~en workir1g at high pressure~
Displacement Valve A fine threaded vcl ve rod permi ttirg VBrr1er adjustments Lo fluid volume to provide precise pr-essure changes Ll1nit stops prevent rod removal during normal operat1on
Mountinq Four bene mountilg holes loated in base for positive gtlountirg to any level surface~
Instrull~ert Connections Tvo coned assemblies provide vertical calibrat1 capaoity for back and lower connected gauges Standard 14 lnch ~nternal NP1 and ~2 internal NPT fltt1nq adapters are supplied~
Operating Fhlid DWT 1327D - grade m21cbife oi Is autOlroti ve petroleLL1 base SAE20 oils or ot~her equivalent fluids suitable for use with Bura N O-rirg materials 15 required 7 liters)
DNT 1327DH ~ Host hydraulic oiJ5 of es-cer base byEtke f1ulds l skydrol pydraul etc suitable for use with Butyl or Ethylene-Propylene O~ring materials 15 (~7 litersL
mvI 1327D0 Distilled water with compatible corrosion in~ibiLo~ A 1 solution of sodium dichromate is a suitcble inhibitor 5 requIred (7liters)
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
Up 7he Tester
31 Inspection
31 1 Component ChecK DvT J 3C50
The deadweight tester as shipped from the factory contains all of the cornponens necessary for operation except pUJPp tluid~ Figure 1-1 provides an illustrated break-out of these items for quick verification ~ Depending upon the nodel and pressure range selected I the total number of weights weigh~ hoxes and and cylindeshyassemblies iLl va-y Refer to lons Section 21 TtiDle 2-1 for model clarification
bull 1 2 Component Check DWT 1327D
The potable test pump as shipped froi the contains all of thef
components necessary for excep pUtlp fluid 1-2 provides an illustrated break-out of these i~ers for quick veriricatlon Depend~~ng upon the model and pressure range selected the total number and their ra~ges will vary Refer to Srecifications Sect lOr 2~21
Table 2-2 for model clarification
3~1 3 Claim For Missing Or Damageci Goods
In the event i is determined that an item is Jssing or damaged~ contact Custorrer Service iImediately a~ the address irdicaed in secton 190~ Damaged I~erchandise ard the packaging materials must be held for inspect~on by authorJzed Omega Engineerirg Inc personnel or the resronsible carrier Disp8sitlo of damaged or missing vli 1 be de~ermin2d after has beer per formed on location or at the dJscretion of the Jalupoundacturer at tte may be aived it circumstances as by the manufacturer f its necessity
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
3 2 Installation Type DWT 1305D
3 2 bull 1 Set-up Procedure (See figures 1 - 1 and 2 -1 )
To r e move t he t ester from the case release the spring cl ip (93) depressing the c l ip by hand grasp the pump r eservoir and lift up the back end of the pump assembly
Having removed the pump assembly t wo plastic shipping plugs (57)
from its carrying case (91) ~ remove t h e
Se l e ct a lower connectio n (64) or connect to inner pump body outlet
back connection (66) offset pipe and as s hown in Fig 2 - 1
Remove fluid
the reservoir fi ller p lug ( 35) and f ill r eservoir with operating
32 2 Be nc h Space Required (See Figure 1-1)
Allow a space 10 in c h e s (25 4 27 inche s (68 6 22 inc hes (55 9
cm) cm) cm)
width depth height - a llows for maximum l oad of d eadweights
323 Storage Space Required
One Tes t e r Box 10-1 2 inch (2 6 cm) 22-1 2 inch (57 cm) dept h 10 One Weight Box 10 in c h (25 cm) width 10 inch (25 em) 10 inch (25
inch (25 cm)
cm) height
height
Storage space dimensions are l~rger than actual size of tester carrying case and deadweurolght carrying case by approximately 1 2 inch ( 1 3 em) in order to f ac ilitate ease of handling in storage
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
I
I r--~ r ~ I l Ii ~ ~
Figure 2-1
Omega Portable Deadweight Tester DWT l305D
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
3 3 Operation OWT 13050
3 3 1 Pi ston a nd Cylinder Selection
The middotDWT 1305D Tester is a dual rang e device in that most mode l s u tilize t wo interchangeab le piston and cylinde r assemblies for measure me nt of pressur e throughout the entire range Eac h pist o n a nd cylinde r a ss embly has a minimum and maximum operating r a ng e First det e rmine what pre ssure points need to b e meas u red and select the appr opriate assembly The pressure range of the assemblies i s s hown in Table 2 -1 When priming the pump the high pressure pi ston a nd cylind e r assembl y s hould be used
3 3 2 Priming the Pump
The offset pipe (64 or 66 Figure 2 - 1) shou l d a lready b e secured in place a nd the reservoir should contain t h e operating f luid (refer to Ins tallation Section 3 2)
Cl ose the r e l ease va l ve (37) by turning it c l ockwi se and open the air vent b y loosening the fill er p lug (35) a few turns The shuttle val ve (30) shou l d be pu lled o u twa r d from the pump body the end of the knob appro ximatel y even wl t h t he edge of drip pan In this position the high volume di s placemen t mode is selected a nd the pump is self -priming Op e rat e the pump ha nd l e severa l times using full strokes u n til you see fluid appear in t he outer pump body o utlet
The cone seat (82) i s l ocated in the base of the outer-pump body outlet and serves as the sea ling s urface between the bottom of the p iston and cylinder assembly and the pump body Confirm the coned end o f the seat is facing up and the c ylindri ca l e nd of it i s f acing down Thread the high pressure piston a nd cyl i nder assembl y (79) or ( 67) into the o uter body outlet as shown using the wrenches provided
Operate the pump h a ndl e a f e w more times until fluid is observed at the end of the offs e t pipe Connect the gauge o r oth er device to be t ested to the offse t pipe Fo r purposes of priming the device must be des i g n ed to withstand the ful l o perat ing pressure of 10000 psi (70 000 kPa) I f a lower range d e vice must be used extreme care must be exercised t o a void overpressuring its pressure e l e me nt Seal the connection to the dev i ce by tighteni ng nut adapter (62) a nd adapter (60) until the coned end of the pipe is forced in to it s inlet If n e cessary rotate the devi ce for v iewing by l oosening nut adapter (62) set it to the proper posit ion and retight en nut adapt e r
Again operate t h e pump handle a few more times After a f e w stro~es positive pressure will develop and the pump handle will begin to resist pumping act i on Rai s e t h e pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwis e and slowly opera t e the pump ha ndle thro ugh a downward stroke until fluid flows st eadily f rom the b l eed v e n t Cl ose the bleed screw just prior to completing the d o wnward ha ndl e motion Repeat this action until no air bubbl es a r e o b ser ved in the fluid flow (Note - the bleed screw must be c losed wh e n the handle is being raised ) Push the shuttl e valve in towards the pump bod y and continue pumping t o the desi r ed test pressure Open the r elease va l ve (37) to vent t he pressure To check operat ion pull t he s hutt l e valve o utward close the r e l ease valve a nd
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
--
operate the pump handle several time s ~ When handle re sis tance is felt push the shuttle valve inwa rd and continue pumping within the range o f the tes t device
Entrapped air will prevent t he pump from operating in the high pressure valve position or cause it to a chieve o nly partia l pressure Repeat t he abov e bleeding procedure as necessar y to as sure all ai r is r emoved Once air is removed the pump will continue to operate~ without further attention p~oviding the r eservoi r l evel i s maintained
3 3 3 Weights
The we i ght set consists of a selection of various masses that wil l produce desired pressure incre me nts when operated with the appropriate piston and cylinder assembl y Each we~ght is stamped with two pressure values When applied to the high pres sure piston and cylind e r a ssembly the equivalent pres sure value is indicated next to t he letter H Conversely when applied to the l ow p r essure pi ston and cylinder assembl y t he equivalent pr es s ure value is indicated next to the letter L The pis ton and piston platform a lso contrib ute to the total mass The ir equivalent pressure value is s tamped on the t o p of t he p l atform
During nor mal operation selected we ights are added t o the plate a nd piston assembl y t o equal the desire d pressure value
3 34 Levelness
Th e deadwei ght t ester must be leve l to function proper ly The unit may be leveled by placing a bubble type l evel on top of t he pi ston plat e an d r evolving lt s lowly_ Shim s may be use d betwe e n d rip pan and be nch t o leve l the plsto n plate The unit is l evel whe n the posi tion of t he bubbl e does not chang e within the g lass as it i s rotated o n t op of the pisto n a ssembl y
33 5 Making the Test
Add we i ght (99 Figure 1-1) to the piston plat e to give desired calibrating pressur e
Pull t he s huttle va l ve (30) outwa r d from the body and close the pres~ure release va l ve (37) Operate the pump hand l e un t il the fl uid pr~ssure f orces the piston to r ai se t he weight s When pumping the we i ghts should be r otated s l owly to decrease cy linder wa l l friction I f pump handle res i stance is difficult and the weights have not risen pus h the shut tle va l ve inward and continue pumping With the shuttle va l ve pushed in the f lu id displacement of each stroke i s reduced I thereby requir ing les s e ffort t o continue pumping
The pumpi ng assembl y has a maximum lift of34 i nch ( 1 9 em) It i s recommended that readings be take n at mid-point or 38 inch ( 1 em) lift Sma ll adjustments to the pis t o n lift can be made with t he pump handle o r the d isplacement valve (41)
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
Improper readings wlll result if the piston plate is on the bushing or so high that the internal stop on is touching the underside of the bushing
so low that it rests the piston assembly
Spin the weights by spinning Speed of more convenient and
hand and take readings only when the weights are rotation is unimportant although a slow speed is recommended
To release pressure turn release valve (37) counterclockwise slowly
336 To Dismantle (See Figure 1-1)
To replace the tester in its case remove the gauge offset pipe assembly (64 or 66) and the piston and cylinder assembly (67 or 79) Install shipping plugs (57) in body outlet holes Screw in the displacement valve (41) until it stops Close the vent plug (35) Open the release valve (37) approximately 12 turn Replace the tester in its case reservoir last Engage the spring clip catch
337 General Precautions
It is important system
that the deadweight tester be connected to a leak tight
The deadweight tester should be set-up so that the axis of the loaded piston is vertical the welghts carefully centered on that axis and the piston rotated during use The purpose of the rotation is to spread tb lubricant over the entire suface between piston and cylinder so that there will be no metal-to-metal contact If rotation is not maintained the lubrlcant film will not cover the surface properly and readings will be in error
~-~
The high and low pressure piston assemblies have an internal overload stop which prevents the piston and cylinder from being forced apart if weights are accldentally removed
338 Operating Fluids Standard Tester
Any medium weight 20 or 30) SAE
oil may be used (including 20-W recommended
automotive oils SAE 10
Hydraulic Tester
Any hydraulic suitable
fluid (silicate or phosphate base) Skydrol or pydraul is
For normal operation it is not necessary to change the for various pressures A lighter oil may be used where being checked and a heavier oil where higher pressures
weight of oil low pressures are are being tested
The reservoir pressure
can be refilled while the tester is operating under
The high and low pressure piston assemblies have an internal overload
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
3 3 9 Caution
Standard testers designed for oil service may no t be used ~i th water for oxyg en serVlce
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
34 Installation Type DWT 1327D
341 Set-Up Procedure (See Figures 1-2 and 2-2) To remove the test pump from the case release the spring clip (93) depressing the clip by hand grasp the pump reservoir and lift up the back end of the pump assembly
Remove the two plastic shipping plugs (57) from the outlet connections Remove the threaded filler plug (35) from reservoir filling hole Remove the offset pipe (64) or (66) from the carrying case and connect to the inner pump body outlet as shown in figure 2-2 Remove the straight pipe extension (58) and assemble to outer vertical pump bodYmiddotmiddotmiddot9utlet as shown in figure 2-2
342 Connecting The Gauge (See Figure 2-2)
select a test gauge that is adequate for the pressure range desired Assemble the test gauge to the straight pipe extension uSlng adapter nut (62) collar (61) adapter (60) and reducer bushing (59)
Seal the connection by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into the gauge socket Rotate the gauge for viewing by loosening nut adapter (62) setting the gauge to the desired position and re-tightening nut adapter
Repeat the above procedure to connect the gauge being tested to the offset pipe assembty (64) or (66)
343 Bench Space Required
Allow a smiddotpace 10 inch (25 em) width 23 inch (58 em) depth 22 inch (56 em) height allows for testing gauges up to 8-12 inch
( 250 nun ) size
344 Storage Space Required
10-12 inch (27 em) width 22-12 inch (57 em) depth 10 inch (25 em) height
Storage space dimensions are larger than actual size of test pump carrying case by approximately 12 inch (13 cm) in order to facilitate ease of handling in storage
I
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
I
i I bull
tL I
l ~ I U
Fiqure 2-2 Omega Portable Test Pump - Type DWT l327D
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
35 Operation DWT 1327D
351 Test Gauge Selection
The portable test pump is used for calibrating instruments such as pressure gauges pressure switches or other pressure device rated up to 10000 psi (70000 kPa)
First select the proper test gauge depending upon the pressure range desired When priming the pump a test gauge rated to 10000 psi (70000 kPa) should be used
352 Priming the Pump
The offset pipe (64 or 66 Figure 2-2) and straight pipe extention (58) should already be secured in place and the reservoir should contain the operating fluid (refer to Installation Section 34)
Close the release valve (37) by turning it clockwise and open the air vent by loosening the filler plug (35) a few turns The shuttle valve (30) should be pulled outward from the pump body the end of the knob approximately even with the edge of drip pan In this position the high volume displacement mode is selected and the pump is self-priming~ Operate the pump handle several times using full strokes until you see fluid appear at the top of the straight pipe extension Connect the test gauge to it (refer to Installation Section 34 for proper gauge connection)
Operate the pump handle a few more times until fluid lS observed at the end of the offset pipe Connect the gauge or other device to be tested to the offset pipe For purposes of primingr the device must be designed to withstand the full operatlng pressure of 10000 psi (70000 kPa) If a lower range device must be used extreme care must be exercised to avoid overpressuring its pressure element Seal the connection to the device by tightening nut adapter (62) and adapter (60) until the coned end of the pipe is forced into its inlet If necessary rotate the device for viewing by loosening nut adapter (62) set it to the proper positlon and retighten nut adapter
Again operate the pump handle a few more times Afer a few strokes positive pressure will develop and the pump handle will begin to resist pumping action Raise the pump handle to its uppermost travel position Loosen the bleed screw (51) a half turn counter clockwise and slowly operate the pump handle through a downward stroke until fluid flows steadily from the bleed vent Close the bleed screw just prior to completing the downward handle motion~ Repeat this action until no air bubbles are observed in the fluid flow (Note - the bleed screw must be closed when the handle is being raised) Push the shuttle valve in towards the pump body and continue pumping to the desired test pressure Open the release valve (37) to vent the pressure To check operation pull the shuttle valve outward middotclose the release valve and
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
operate the pump handle several times vJ hen handle r esistance is felt push the shutt le valve inward and continue pumping within the rang e of the test device
Entrapped air will p r event the pump from operating in the high pres s ure valve pos ition o r cau se it to achieve only part ial pressure Repeat the above bleeding procedur e as neces sary to assure all air is removed Once ai r is removed the pump il l continue to operat e without further a ttention providing the reservoir level is ma lntained
353 Making The Test
Turn displacement piston handle (41) t o mid-position so t hat it may be used for setting an exact pressure o n the gauge The displacement p iston has i nte rnal stops which prevent unscrewing o r accidental los s of pressure Clockwise rotation of displ acement pisto n wi ll produce an increase in pressure counterc l ockwi se wi ll decrease pressure
Pri or to taking readings both gauges should be finger-tapped l i g ht l y a t the cente r of the gauge face to eliminate any movement frlc tion Not e the pressure r eadings on the test gauge and the gauge under test If the p r essure i ndi cated on the gauge under t est is not equal (within the t olerance of t h e gauge) to the pres sures of the maste r test gauge the gauge being tested requires cal ibration
CAUTION
Do not pump handle t o pressures greater than th e pressure rang e of the gauges connected to the test pump as this may damage the gauges
3 5 4 To Release Pressure
Open rel ease valve slowly (37 ) until pre ssure returns t o zero Do not loosen any connections u ntil pressure i n the gauge tes ter has r eached zero as indicated on the test ga uge
If additional gauges a re t o be t es ted c l ose the r elease va lve when the pressure reaches zero Thi s wi ll p re ven t compl e te drainage o f oil in the t ester back to the reser voir
Unsea l the gauge that has been t ested by unscrewing adapter nut (62) from connector (60) severa l turns Unscrew the gauge from b ushing (59) if used or connector (60) and r emove
Remove the tes t gauge in the same manner as the gauge under t est
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
35 5 To Dismantle
To ace test pump in case renove gauges and both tube assemblies Put (57 ) into pUlp and Lighten Close filler ug (35)
35 6 Fluids Standard Test Pump~
Any mediu-- o~l rtay be used (including eutomotive oils S AE 18 20 or 3C) SAE 20~r~ recortmended
For normal operatJon it is not necessary to change [he weight of oil for various pressures A 1 ~~_ghter oil nay be used here low pressures are checked a heavier oil where higher pressures ere being tested
The reserVOlr can be refJl1ed whi~e the test pliIp is operat~ng under pressure
stardard testers OEsqned for o~__ l servce rray not be used with water for oxygen serv~ce
L
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
4 0 Factors Affecting of Deadweight Testers
4 ~ 1 Deaoweight Tester Accuracy
Excellent accuracy is fX)sslble usirg the deaddeight tester through analysis ard control of certain factors If the testers rated accuracy of llOth of 1 is adequate th~n the nominal pressure (sur of the denomlnatJons of the elghts loading the piston) nay be assurted to be correct The pressure normal developed is determined by this formula Dead-weight Tester Pressure -
p (tc-ph) L A g8
pressnre H mass of the load on the piston A effective area of the 1n sq inches or sq em gigs ratio of the value (g) of gravity at the point of use to the
standard value of gravity (gs P density of liquid used in test h diference in level between gauge being tested and the bottom
of the
T~e deadweigh tester is of measuring pressures tO even greater accuracies the use makes proper corrections after analyzing these factors ~
42 Gravity I Calibrated fJeighs
Weigh-s furnished are c3librated at standard gravity of 980665 gals If accuracy ]S the error intrcduced by change of w8lght due
to change in gravity at the locality should be calculated and ircluded in results
T~e mechanism of an Omega Pressur2 Gauqe includes a Bourdon tube and movement which is unaffected by i1 gravity Conversely
the pressure developed by a deadleight tester is proportional to the value of of this type pressure gauge wi~l corresf-Ond to those of a deadweight tester wher the tester is subjected to sandard gravity (gs 980 c 665 ga 1 s ~ in the Interrational System) ~ In southern sectiors of t-te United States the value of gravity JWY be several thousandths less than the sta1dard value If the latitude (0) arid the elevation above sea level (a) for an area are kno1 the approximate value of (g) in gals may he caculated from this formula
9 ~ 980632 - 2586 COS 20 + 003 COS 40 - 000094a
o Lati t Hde (Degrees) a = Elevation above sea level (ft)
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
43 Effective Measured Area Charmer
The effective area of the deadweigh-t tester may be determined by the ave_~age of the cross sectional a_~ea of the piston and the area of the cylinder bore o This effective area is affected somewhat by texperature and by the elastic distortion of the piston and cylinder when pressuYe is being applied The effective area of a stainless steel piston and cylinder increases approximately 068 with a 50 dEgree F (28 degree C) change in temperature~ The pressure will theref9r-e be less than indicated a-t high temperatures amp
404 Mass Height and Buoyancy
The densi ty of air at room temperature and sea level pressure is abou-t 0~0012 gramsc~c~ and the mass of the piston assembly and weights undermiddot these conditions will be reduced by about one part in 7000 or 014L When the subYlerged part of the pison has a uniform cross section as wi th the 1305D Deadweight Tes-ter a buoyancy correction is not necessary Ir other designs the piston is sometimes enlarged to provJde a stop for i -5 upward motion or for increased strength If these enlargements are0
submerged in liquid a buoyancy correction is necessary
445 Absence of Friction
By rotating the weights and piston friction effects are greatly reduced~
4~6 Head of Transmitting Fluid
Ofte1times the gauge being tested I or the rxgtint at which pressure lS being measured lS not at the same level as the lower end of the piston~ A correction I therefore should be made for the _pressure distance between these points the height is conside_~ed positive when the gauge is above the piston When oil is used in the gauge tester the correction will be approximately 003 pSI (2 kPa) for each inch (254 cm) difference in level~
47 vlethod of Ope_~ation
It is important tha-t the pistn be kept floa-ting in mid-positior ei ther spinning or oscillating
The piston assembly should be veytical to within plusminus I degree Pgt 3 degree tilt to piston axis rray cause a 13 of 1 error The deadweight tester is mi3nufactured and tested to llOth of 1 accuracy to this degree of levelness A tilt to pistoncylinder axis causes excessive friction due to side loading of the piston against the cylinder~
49 Cleanliness
The weights have been lllanufactured and tested to a precision of 005 A bui1dup of dirt and grease may cause the weight value to exceed i ts original tolerance and produce erroneous pressure readings
Periodically clean the weights to assure proper performance
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
5~1 Haintenance Instructlon
52 General Maintenance
he tester and test pllfrp are deslgneo tlto serve as pressure measuring standards~ They are precisio1 built units nnd should be cared for In the same manner as other sensitive laboratory General rrai1tenance is lirited to cleaning and replacement 0
ings whicr~ can be done with tools supplied with the a1d only llnted dsassemb1y of the gauge tester ~
The p_iston supporting the weight platform has been manufactured to very close tolerances It has an area accuracy of 120th of 1 and a accuracy of 120th of 1 The deadweights have been cexcified traceable to Natlonal Bu-eau of Standards tiith the accuracy of the finished better than 120th of 1 To maintaln deadweight tester accuracy handle the eights wi th care and keep the piston and cylinder in clean condt tion ~
The tester should be flushed wlth a solvent occasional y every six months so that operating fluid is alviays cean~ This will prolong COITponent llfe land provide protectlon against actior betweer the piston and cyllnder After c1eard ng I ub2lcate )arts before assembly
never operates in a dry state~ When or the stont it should be rotated back and forth
Should a piston 0 cyllnder wcar the tester will leak oil at a hlgh rate and will not be operable A rew and assenbly should be installeo
Pis Lon wear will result from improper or contaminated lubricatlOTl excessive dirt or frorr~ severa years 0 continuous use~
5~3 Cleanins
Both the ester and Test Pump should be cleaned thoroughly henever the operatng fluid 1S seriously contaminated with dirt grit~ or chemicals A good practice is to clean the test unit to periods when the unit wlll not be in use~
YCS 1e
I a deadeight tester piston and cyl inder assembly is being refoveo fom the cylinder and coated with the
tirre or if a sbolld be
fl uid so that it
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
5 ~ 4 To Disasserrble for Cleani_ng
See Drawing 601D001 Figure 2-1 and tigure 2-2)
It 1S necessary to dlsassemble only those components which come in contact with the operating fluid3 Complete disassembly ts rarely necessary
a Remove pipe extension asserrbly (58) or piston and cyHnder assembly (61) (79)
b Them remove lower or back connection pipe assembly (64 (66)~
5 5 RerrQving Pump Handle and Piston
d emove four retaining ri_ngs (8) b~ Slide out two clevis pins (9) ~ c Remove clevls (10) d Lift handle assembl y (4) Wl th plston pin (7) piston (20)
O-ri_ng packing (12 19) and back-up ring (11) attached to i-t Out of piston sleeve (6)~
e Remove back-up washers (18 11) and O-ring packing (12 19L f ~ Jnsc rew stem (20) tj Remove piston 51eeve (6) and O-ri ng packing (45 I 16) and
washers (46 17)
5~ 6 RerrQving Reservoir and Pi 1 Tube
a Jnscrew filler plug (35) from reservoir b ~ Remove gasket (36) c+ Remove reservoir (5) by removing three screws (24)~
d~ TWlst rpservoir to free O-rlng pacKng (21) seal e Remove O-rl ng packing (21) from body (2) ~
f Remove flll tube assembly (23) and O-ring packing (27) g ReJQve pluq (22)
5 7 Removing Shuttle Valve~ Shuttle Valve Plug and Check Valve
a Remove set screw (33) and spring (32) b Slide shuttle valve pston (31) out o~ body ( 2) Operate back rind
forth as necessary to dislodge pn ~ 31) engagement~
c ~ Remove shuttle pin (30) by pushing it into the shuttle val ve pIston cavity using a plastic shaft Jess lhan 18 inch (3mm) in diameter
do- UnscreoJ shuttle valve plug (43) and remove O-ring packng (27) e~ Remove check valve spring (14) and check valve (44) I Remove O-ring packlng (15) from check valve (44)~
5 8 Removing Bleeder Valve and Check Valve lssembly
a Unscrew bleeder valve (51) b Unscrew bleed plug (50) and remove O-ring pack (27) bull c ~ Remove valve spacer (29) cheCK valve spring (14) and check
valve (44) d Remove (5) from check valve (44)
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
59 Removlng High Pressure Check Valve
a Urscrew plug (28) and rernov(~ O-x-ing (27) b Urscrew adjusti1g sccew (26) ~
c~ Remove guide rod (1]) check valve (14)t and check valve (44)
d Remove O-rilg packing IS) frof check valve (44)
5~lO Removi1g Release Valve
a~ Remove release valve assembly (]7) and O-ring packing (27) b Disassemble valvt~ assembly by rotating handle counter-clockwise
until valve sterr_ is free from valve body c Remove O-ring packi1g from valve stem d Remove screw (38) and seat (39) by turning coun-Ley-clockwise~ e Remove O-rieg packing (40)
5~11 Rerlovirg Displacement Valve
a Remove displacement valve assembly (41) b ReElove O-ring packing C27J c ReIDve ha1dle from stem rotaTing handle counter-clockwise
This is not required f-or normal cleaning~ d Rotate the stenrmiddotclockwise (usilg screwdriver in the slot at the
top tJle s tent) unti 1 it is ree frOD body e~ Remove nut back-up washers ana ring packing from stem~
5_12 Removing Body rom Drip Pa)
a Take out three bolts ~25j This is not required fa normal
b~ Remove body assembly (2) from par (3)~ Tnis 15 rot requi Yed for rormal
5~13 Inspectlon
Vlsu211y inspect these parts for wea- dZlITliiOe chi ps cracks- and thieads
Body Assembly Threads Piston Piston Sleeve (6) Displacemert Stem and Matirg Surface in Body Back-up liashers Moving Dead Welghts Plston amp Cylinder Assembly - l305D Test Gauges - 132-D
Back--up washers must fi-L snugly into piston sleeve and lmo displacement valve body Then check static (non-movlng) packing for p~ncb marks tearing or extrusion~ Check all valve seats for scratches and
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
Replace al gtvorn or parts Replace all O-ring pack each ogt1crhaul ~ Coa~ with sui table lubrlcant~ before replacing to p-eventI and tearing during assembly and tiqhtening of connect ions ~
When reassembling use where possible the wrenches ied wi U tle eqtiprrent These wrenches t enough leverage to seal all connectio1s ~ Excessive tightening of parts ylith tools olher than those may cause distortion and eventual failure of threaded ons of the tester body asserabl y When replacilg O-ring packings f coat them Hi tit suitable lubricanL to prevent stickinq and tearlng and tightening of connection
515 To Reassemble
Body assenbly on drip pans Replace body assembly (2) on drip pan (3) us~ng bolts (25)~
5 16 Replacing
a Place between back -up wasr~er s ~
O-ring packing to valve stem wlth nut
c Thread stem into f rom the bottom - use screwdriver in the slot at top of stern
dw Screw stem body until the back-up washers and O-rirgtg are fuly enclosed in the body
b Attach
CAUTION Do not damage D-ring PackiDg hen stem body $
e Screw handle onto stem vaJve assembly (41) igtiU O-x-ing packing
( 2 ) bull
517 Release Valve
a Place O-r2og paclung (4C) io body ca (2) hole b Insert seat (39) into body casting hole c Thread amp screw (38) into body lole
CAUTION
Be sur-e that stem of seat (39) fits into screw hole
d ~ Place O-rtng packing on vav8 stem~ e~ Screw handle onto valve stem f Screw valve sterr into valve bCY3y until end of stem does not
extend beyond valve body
f
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
CAUTION
Do not darrage O-rlng packing when threading valve stem through valve body
g Repl ace O-riru( packing (27) ~ h~ Replace release valve assembly (37) in body ( 21
5 18 Replacing High Pr-essure Check valve
a~ Place a-ring packing (15) on check valve (44) ~
b Slide check valve (44) check valve spring (14) and rod (13) into body (2) bull
c Replace adjustlng screw (26) and screw it in until it stops d Then turn (26) back two complete revolutions e Replace plug (28) with O~CIng packing (27) in body assembly (2)
5~ 19 ReplaClI)g Bleeder Valve and Check Valve Assembly
a Replace O-x ing (15) on check valve (44)
b~ Slide check va]ve (44) check valve spring (14) and valve space (29) into body assembl y (2)
c~ ace bleed (50) with O~rinq ng (27) into body assembly (2)~
520 Replacing Shuttle ValvB Shuttle Valve and Valve
L InS0~t shuttle valve piston (30) into body (2)~
b Slide shuttle pln (31) into 18 inch (3mn) diameter to fill ttbe (23) port~ Apply insertion pressl1~e
to shuttle pin (31) with shaft and operate shuttle va~ve (30) to lnSUL-e proper engagement
c ~ Replace spring (32) di behind shuttle pin (31) and secure with set screw (33)~ Set screw 8ust be recessed by 050 inch (12mm) rranifurn~
C $ O-ring packinq (15) on check valve (44) ~
eo Slide check valve (44) ane check valve (14) into body asserrbly (2)
5621 Replacing Reservoir and Fill Tube
a 91ug (22) b~ fill tube assembly (23) and packing cn) c O-ring (21) or body assembly (2) d Replace reservoir (5) using three screws (24) e Replace filler plug (35 and gasket (36) on body
5$22 iog Pump Handle and Plston
do piston sleeve (6) and a-ring packing (45 16) and backshyup washes 46 17) j_o body (2) ~
b Place pacldng (l2 19) between back-up washes (18 11) c~ Attach back-up washers (18 11) and O-ring packing (12 19)
+0 piston (20)
d~ Lubricate piston and sleeve eo Attach assembled piston to handle assembly (4)~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
523 CAUTION
Do not damage O-ring packing (12( 19) when sliding assembled piston into piston sleeve (6)
g~ Attach clevis (10) to handle assembly and to body assembly (2) I using clevis pins 9) and retaining (8) ~
524 Replacing PistonCyllnder Assemblies
The pistoncylinder assenbly for a deadweight tester should be when excessive wear is detected on any component part Worn piston assemblies are usually noted by
1 ~ Excessi ve of operating fluid through ston assembly zhan under pressure
2 Seizure of pistor~ in cylinder 3 Damaged plsLon Did lee daTlaged inder threads or damage to any
component part that results in inferior performance Or malfunctioning of h8 unit
The pistoncyllnder assembly is available as a twit This assures the user of maximum accuracy in his Omega Dead-eight Tester and flaiotains certlf ied traceabili 1 to the National Buxeau of Standards
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
525 Troublpshooting Chart
Caus+ Corr~ctlv~ Actlon
Prpssurp dops not bv ild up hpo pumping handlf
Insuffici nt fluid lvl in IfgtSfgtTVoir
Piston O-rinas worn or rupturd
Add fluid
Insppct O-rin~~ ~nd lPplacp AS npcpssary If 0-lings ar nf vprify thpir fluid campaU bUH Y bull
Blppd port chpcK valvp or shuttl chcK valvp inopprativp
Ins~ct O-rings and rpplacp as npc~ssary
Fill tub assPmbly and filt r pluggPd
~PmOv and cl an fill tubP asspmbly Rpfill fPsprvoir with clpampn fl uid
Shuttl valvp pushfd in for small fluid displac~shympnt hpn 18rg fluid displacpmpnt is rpquired
Pull shutt) valv+ outward from body
High prpssurp OOPS not incrpasp ~h~n pumping handlp whil shutt)p valvp is pushd in
Air trapppd in pump piston
Rapid pump handl stroks which lpsspn fluid flow through th~ pump piston
Rpprimp pump
Oppratp pump handJ~ with SMOoth modprat~ action
Pr~ssurp builds up hen pumping handl~ but d~cryenasps whpn pumping is 5topPPd
Leakagp at outlyent or gaugp connection(s)
High pressurp chpck vaIv~ O-ring worn or rupturpd
Insppct connections and tightpn as npcpssary
lnsppct a-ring and rpplacp as npcessary
DPfectivp pressure relpasp valve
Hand tight~n relpasp valve
Insppct relpase valve seating surfaces Replac~ AS npcpssary
Remove release valvp seat and insppct a-ring undprneath Replace as fiPCfssary
Pump handl lis~s aftpr pUllpi og
Hgh pressure check valvp 0-ri09 worn or ruptur~d
Insppct O-ring and replace as necessary
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
52~ Troublpshooting Chart
s)ITp~om Causf-gt C01JPctlvP ~ctlon
bull piston platP (with dpadoltpights ) drops rapidly
Unablp to hold constant prts6ulP
bull Stackpd dpadwpights webblp whpn spinning piston plate
Worn pi ston ( cyl ind r 8ssprnbl y
Damagpd d adwpights
Usp a hpavy oi 1 t mpor a r i1 y bull Rtgtpl ac piston ( cylindpr
Chpck dpadwpights ~or visibp damagp (bPnds dpnts nicks ptc ) and aligmnpnt
bull piston platp assprnbly wi 11 not spin
-Too hpavy an oil grad bPing uSfd
Flush ( fill unit with proppr gradp of oi 1 (SAE 20 or SAE 10)
Rpplac piston (
cylind r asspmbl y
Disassemblp and fl ush complptp tpst unit vith kplospne or alcohol Rasspmblp unit
Thpsp symptoms apply only to th 1305D Deadwpight Tpstprs
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
6~O Warranty - ShipJing Irstructions - Hov To Order
61 Warrarty and LiFitation of Liahi
All prodJcts and parts carry a warranty against defective material and orkmanship for period of one (l) year froe date of shipment
A complete warranty and lirtitation of liability statement is made on the staldard quotatlon for-n at the time of sale
6 ~ 2 shipping Lnstructions For Return To Factory
Pack securely to prevent damage in shipment~
IMPORTANT - Obtain wri tten authori zat 10-1 to return i1strurnents that have been in contact with corrosive or hazardous materials such as mercury and radioactlve solutioas
Furrish the following information vnth return of instrument~
SHIPPING INSTRUC~IONS
Company Name
Phone Number
Persor to Contact
Address
Model
Ser uI1 Number
-------~
--- ~-
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
CE~~ AaOMEG4 p laquo bull
One Omega Drive Stamford cr 06907()()47 (203) 359-1660 L-336
CERTIFICATION OF ACCURACY
DEADWEIGHT TESTER
DATE JUl-Y 22 I988
CUSTOMER ORDER No 50313
OMEGA ORDER No 2KH-41900-2
We hereby certify that this deadweight tester is acc urate to within plus or minu s 110th of 1 of indicated pressure
The deadweight tester is a primary pressure measuring device Its a ccuracy depends upon the effective area of the piston and cylinder assembly and the value of the weights
The piston diame ter and cylinder bore were measured for dimensional accuracy us ing gauges which are inspected periodically against masters that are traceable to NBS Test No 738227605 and 738226977 The accuracy of this piston and cylinder assembly is within 120th of 1
The weights we re calibrated on a balance scale against reference weights whose accuracy is traceable to NBS Test No 38126 Weight values are based on Standard Gravity (g = 980665 emsecraquo The accuracy of these weights are within 120th of 1
We further certify that our calibration system complies with MIL-STD-45662 (Notice 1)
Very truly yours
Q~~~Q Richard Johnston Materials Production Mgr
RJDrjr CD-3A Rev 1-16-87
~
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