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P.A. HILTON LTD.

EXPERIMENTAL

OPERATING

AND

MAINTENANCE MANUAL

OPTIONAL
DEADWEIGHT TESTER

F110A

F110A/E/1/001

APR 09
This page intentionally blank
(i)

POLICY STATEMENT

After Sales Service


We, P.A. Hilton Ltd., attach considerable importance in being able to retain the confidence and goodwill
of our clients in offering an effective after sales service. Every effort is made to answer clients
correspondence promptly and to provide a rapid follow up of spares and replacement parts by maintaining
comprehensive stocks of components usually available ex-stock.

Should our clients encounter any difficulty in operating or maintaining a Hilton product we would ask
that as a first step they contact the Hilton representative in their country or, in the absence of a local
representative, write direct to P.A. Hilton Ltd.

In the extreme case a problem may arise in the operation of equipment which could seriously disrupt a
teaching or research schedule. In such circumstances rapid advice from the manufacturers is desirable
and we wish our clients to know that Hiltons' will accept from them a transfer charge telephone call from
anywhere in the world.

We ask our clients to treat this service as an emergency service only and to use it sparingly and wisely.
Please do be aware of the time differences that may exist and, before making a telephone call, make notes
of the problem you wish to describe. English is a preferred language. Our telephone number is "Romsey
(01794) 388382" and the telephone is normally manned between 0800 and 1700 hrs GMT every day.
Advance notice of an impending telephone call by Fax would be appreciated.

Each product manufactured by P.A. Hilton Ltd., is tested under operating conditions in our permanent
installations before despatch. Visitors to Horsebridge Mill are encouraged to operate and evaluate our
equipment with initial guidance from a Hilton engineer.
(ii)

EDUCATION AND TRAINING EQUIPMENT

Declaration of Conformity:
Directives (where applicable) 2006/42/EC
2006/95/EC
2004/108/EC

We declare that the following unit complies with the above EEC directives:

F110A Deadweight Tester

The use of the apparatus outside the classroom, laboratory, study area or similar such place invalidates
conformity with the protection requirements of the Electromagnetic Compatibility Directive
(2004/108/EC) and could lead to local prosecution.

For and on behalf of


P.A. HILTON LIMITED

Technical Director

P.A. HILTON LIMITED


Horsebridge Mill, King's Somborne,
Stockbridge, Hampshire, SO20 6PX,
England.

Tel No. National (01794) 388382


International+44 1794 388382
Fax No. +44 1794 388129
E-mail: sales@p-a-hilton.co.uk
(iii)

INDEX

Page
Schematic Diagram 1
SYMBOLS AND UNITS 2
SCHEMATIC DIAGRAM NOTATION 3
INSTALLATION AND COMMISSIONING 3
Ready for Operation 5
System Unloaded 5
INTRODUCTION 6
DESCRIPTION 7
USEFUL DATA 8
OPERATION 9
MAINTENANCE 10
Cleaning 10
Draining 10
Re-Filling 10
Pressure Gauge 10
EXPERIMENTAL CAPABILITIES 11
Suggested Experimental Procedures
1. Investigation Deadweight Pressure calibration. 12

2 Examination of the Difference Between Absolute and Gauge Pressure. 16

Blank Record Sheet 18


1
Schematic Diagram

Front View Showing base unit F110A and OPTIONAL Pressure Transducer and Digital Display
F110B (Shown *)

Diagram Key
1. Deadweight Tester( Base Unit)
2. Main Control Valve
3. Standard Weight Set
4. Oil Reservoir
5. Bourdon Tube Pressure Gauge
6. Weight Carrier and Piston
7. Drain Valve(Hidden)
8. Optional Digital Display Console
F110B*
9. Optional Pressure Transducer
F110B*
10. Optional Digital Display F110B*
11. Optional Display power On Light
F110B*
2

SYMBOLS AND UNITS

Symbol Quantity
Fundamental Unit
A Area m2
g Acceleration due to gravity m/s2
h Height m
2
p Pressure N/m (Pascal),
Bar or mBar
Note
The pressure units used in this manual are N/m2 as these are made up from fundamental units
(Newtons and m2) however the Pascal is the derived SI unit for pressure. 1Pa = 1N/m2
3
SCHEMATIC DIAGRAM NOTATION
Please refer to the schematic diagram on page 1
To assist in identifying all of the components there is an annotated schematic diagrams on page 1.
Each relevant component has a number identifier that is the same in both diagrams. In order to simplify
component identification in the text the relevant number is placed alongside the component name
which is also in bold text. For example on page 1 deadweight tester would be identified in text as
deadweight tester(1).
This convention is used throughout the manual.

INSTALLATION AND COMMISSIONING

Remove the unit from the packing case and stand it on a flat and level bench or table. Do not destroy any
packing materials until the packing list has been checked.

Examine the unit for damage in transit - if any is found, the insurers should be notified immediately.
The Pressure Measurement Bench F110 has a number of optional accessories. These are:- a
Deadweight Tester F110A, a Pressure Transducer and Digital Display F110B and a Data
Acquisition Option FC110A.
Each of these options has a dedicated manual detailing its installation, operation and maintenance,
together with suggested experimental procedures and example results.

The Deadweight Tester F110A is normally shipped without oil in the hydraulic system. It is first
necessary to fill the unit before it can be used and this also involves fitting the pressure gauge(5)
supplied.

In order to ensure the unit can be maintained and does not require special materials ,it has been
designed to operate on conventional mineral based engine oil. Oils in the 20/30 range are preferred to
thinner oils as this will result in less spillage with time.

It is essential that the oil used to fill and top up the F110A Deadweight Tester is new and un-used
as grit or debris will cause the highly machined barrel and piston to jam and damage the bore of
the unit.

The procedure for filling the unit is as follows.


Please refer to the schematic diagram on page 1
Take a quantity of approximately 200cc of mineral based 20/30 engine oil in an open container and
place this in hot water for several minutes order to warm it and allow it to flow easier.

Pour sufficient of this warmed oil into the oil reservoir (4) to just fill it. open the main control valve(2)
completely by unscrewing the central screw fully(turn anti-clockwise) . This is the device being
gripped below.

Note that the outer knurled nut is a locking device and does not open the valve.
The pressure gauge(5) is not fitted at this stage. Ensure that the drain valve(7) at the rear of the
pressure gauge holder is closed by screwing this fully in (clockwise).
4
Get an assistant to put a finger over the threaded hole for the pressure gauge to seal it.
When the valve is open pull out the weight carrier and piston(6) from the barrel. This should have the
effect of drawing some oil into the piston barrel from the reservoir(4).

The oil can be seen shining at the bottom of the piston barrel shown above. It is necessary to get the oil
to flow into the piston barrel as shown and also into the pressure gauge holder. If the oil is pre-warmed
this will take less time.
While waiting for the oil to flow around the system prepare the pressure gauge by winding about
300mm of the PTFE tape supplied around the thread of the pressure gauge. Note that this should be
wound onto the thread by turning the gauge in the same direction as if screwing it into the
thread(clockwise). This will ensure that when the gauge is screwed into the carrier the tape does not un-
wind and gives an oil tight seal..

The oil in the reservoir(4) should be allowed to fill the piston barrel and the pressure gauge carrier up
to the level of the thread in the gauge carrier. The gauge carrier is lower than the piston barrel and this
should fill sooner than the piston barrel. It may be necessary to top up the reservoir as the unit fills.
In order to increase the speed with which the oil flows through the unit it is possible to use a hand
around the top of the reservoir and gently blow into the reservoir to force the oil through the system.

Once the oil level has reached at least half way up the thread of the gauge carrier, start to screw the
pressure gauge into the carrier. Take care to engage the thread correctly and do not continue if the
thread is crossed. If this happens unscrew the gauge, remove the PTFE tapeand check the thread
engages correctly before re-taping and trying again.

Screw the gauge in until the majority of the thread is inserted. Do not over tighten and allow the PTFE
tape to seal the thread. Orientate the gauge so that it can be seen from a convenient angle.

The objective of the method ensures that the minimum amount of air is trapped between the surface of
the oil and the gauge.
5
At this stage the oil level in the piston barrel should be approaching the open top of the barrel. If not it
is permitted to add oil directly using a suitable pouring device. Once the oil level is approximately
20mm from the top of the piston barrel close the main control valve(2) by turning fully clockwise
until it locks.

Slowly insert the weight carrier and piston(6) into the barrel. There is likely to be some spillage and
the pressure gauge will register a pressure of approximately 20kN/m2 under the weight of the carrier.
DO NOT push the piston into the barrel by force and exceed the 250kN/m2 maximum range of
the gauge, or permanent damage will result.

Ready for Operation


The weight carrier and piston(6) should be in approximately the position shown below at the start of
a test procedure(with no weights added).

System Unloaded
Note that if the unit is not going to be used immediately it is advised that the main control valve(2) is
fully opened(by turning fully anti-clockwise)so that the weight carrier and piston(6) slides into the
piston barrel and this allows the oil to return to the reservoir. Leave the main control valve(2) open
and this prevents a build up of pressure due to ambient temperature changes and oil spillage.
6
INTRODUCTION
Please refer to the schematic diagram on page 1

The measurement of pressure, is one of the fundamental requirements of many engineering applications.
There are several different ways of measuring pressure and the purpose of the Hilton, F110 Pressure
Measurement Bench and its options, is to allow students to investigate many of these.

One of the simplest, and most accurate methods, of measuring low pressures is the use of a vertical or
inclined tube manometer. The basic F110 Pressure Measurement Bench consists of one U tube
manometer(5), a combined vertical and inclined tube manometer(3,4), a differential pressure
gauge(6) and a positive pressure gauge(1).
Both of the manometers rely upon measurement of the difference in height of a column of liquid of
known density. The unit allows students to undertake these measurements in a fundamental way in order
to understand the procedure and the mechanics of how the manometer operates.
The two pressure gauges fitted both bourdon tube devices. One illustrates differential and/or positive,
negative pressures and the other positive or gauge pressure relative to atmosphere.

The optional Deadweight Tester F110A allows students to calibrate a Bourdon tube gauge in order to
understand the fundamental fact that pressure is simply force per unit area.
In order to understand the mechanics of the Bourdon tube gauge, the gauge on the deadweight tester has a
clear front panel, allowing the mechanism to be clearly seen operating.

The optional Pressure Transducer and Digital display F110B combines with the Deadweight Tester
F110A to allow students to investigate, the output of a pressure transducer in terms of voltage. Here, a
voltage signal is used to represent pressure and students calibrate this, together with the Bourdon gauge.

A third option, the Data Acquisition Option FC110A enables students to record the signal from the
pressure transducer on a computer and analyse the results using most standard spreadsheets.
7
DESCRIPTION

Please refer to the schematic diagram on page 1.


The Hilton Deadweight Tester F110A is designed to complement the Hilton Pressure Measurement
bench .

The Deadweight Tester F110A is designed not as a laboratory standard but as a teaching unit for student
use and practical understanding by hands on operation. The design enables students to visualise the
Force/unit Area of pressure and to understand the way in which a known pressure is generated.
The unit is mounted on a base(1) and consists of an oil reservoir(4) which feeds oil to the main control
valve(2) at the base of a piston barrel. The weight carrier and piston(6) slides in the piston barrel and
applies a known pressure onto a column of oil. This is connected to a pressure gauge carrier. Supplied
with the unit and for fitting into the pressure gauge carrier on installation is a bourdon tube pressure
gauge(5) with a clear background dial allowing the gauge operating mechanism to be clearly seen.

The unit uses calibrated weights(3) that are stamped in units of force so that students understand that they
are applying a force to the piston and hence to the oil.

The combination of the weight carrier and standard weights supplied allows students to calibrate the
pressure gauge up to 240kN/m2 at regular increments.

An optional pressure transducer(9*) is available as part of the F110B , together with an electronic
digital display(8*) also part of the F110B. These allow students to compare the pressure transducer
electronic output with the mechanical pressure gauge. The F110B is supplied with its own electrical
power supply for operation from the local mains supply.

If required the digital display(8*) may also be connected to the optional Computerised data Acquisition
FC110A.
8

USEFUL DATA

Common units of Pressure

1 Pascal = 1N/m2
1 Psi (pound force / square inch) = 6894.76 N/m2
1 Bar = 1 x 105 N/m2 = 14.5037 Psi
1 105
1mBar = 100 N/m 2
1000
Weight Carrier and Piston(6) applied force = 2.5N

Note
The pressure units used in this manual are N/m2 as these are made up from fundamental units
(Newtons a force and an area m2) however the Pascal is the derived SI unit for pressure.
9
OPERATION

It is assumed that the Deadweight Tester F110A has being installed and commissioned as details on
page 3.
It is assumed that the main control valve(2) is open and that the pressure gauge is not loaded.
Record the pressure gauge zero reading(if the needle is not on the zero stop).

If the unit has been left in the unloaded condition described on page 5 then all that should be
necessary is to ensure that the main control valve(2) is fully opened by turning fully anti-clockwise
and then SLOWLY lifting up the weight carrier and piston(6). This should draw oil from the
reservoir into the piston barrel.

When the weight carrier and piston(6) is in approximately the above position, support it and close
the main control valve(2) by turning this fully clockwise until it locks.

The pressure gauge should show a pressure of approximately 20kN/m2 when the weight carrier and
piston(6) is released.
10
MAINTENANCE

Cleaning
The panel and tubes may be cleaned with a damp cloth and a little soap if necessary. Do not use any
solvent or aggressive cleaner.

Draining
If it is necessary to drain the reservoir this can easily be achieved by inverting the unit reservoir over a
suitable container.
If it is necessary to completely drain the unit then withdrawing the weight carrier and piston(6) will
allow the piston barrel to be drained.
If it is necessary to drain the pressure gauge carrier either the gauge can be removed or alternatively the
drain valve(7) may be opened with a piece of tube attached.

Re-Filling
If it is necessary to re-fill the unit with clean engine oil follow the procedure outlined on page 3
onwards under Installation and commissioning.

Pressure Gauge
The pressure gauge, does not contain any user serviceable parts. No attempt should be made to
dismantle the pressure gauge.
11
EXPERIMENTAL CAPABILITIES

1. Investigation of Deadweight Pressure Gauge Calibration.


2. Examination of the Difference Between Absolute and Gauge Pressure
12
1. INVESTIGATION OF DEADWEIGHT PRESSURE GAUGE CALIBRATION

Procedure
It is assumed that the Deadweight tester F110A has being installed and commissioned as details on
page 3.

The deadweight tester operates by application of a known force to a known area piston. This piston slides
in a suitably machined barrel that allows a very thin film of liquid(in this case engine oil) to squeeze
between the piston and the barrel. Hence there should be little of no direct frictional contact between the
piston and the barrel.
Force = F N

Area = A m2

If the area of the piston is A m2 and the force applied is F Newtons then the pressure applied to the fluid
is
F Newton

A m2

If when the load is applied the piston is gently spun then this ensures that the film of oil between the
piston and barrel is maintained and there should be the minimum frictional resistance.

If the area of the piston is 0.00125m2 and a 2.5N load is applied then the pressure applied to the oil will be
F 2.5 N

A 0.000125 m 2
N
20000 2
m
Hence if the weight is increased in increments of 2.5N then the applied pressure (in increments of
20kN/m2) may be compared with the indication on the gauge.

The weight carrier and piston(6) is specially adjusted so that its deadweight effect is 2.5N. Hence with
the weight carrier and piston(6) only the pressure applied is 20,000N/m2 or 20kN/m2.
13
When the weight carrier and piston(6) is in the extended position. Gently spin the carrier and tap the
pressure gauge.

Record the applied load(2.5N) and the gauge reading(it may be necessary to estimate readings visually
between gauge markings).
Next apply the 2.5N weight to the carrier and repeat the procedure and record the readings.
It is necessary to remove and apply weights as necessary so that the increase is 2.5N each time.

Once the applied pressure has reached 240kN/m2 the procedure can be reversed by removing weights in
2.5N increments and the data again recorded.
Typical results are shown overleaf.
14

Sample test results

Applied Applied Indicated Pressure Difference


Load N Pressure kN/m2 kN/m2
kN/m2
0 0 0 0
2.5 20 20 0
5.0 40 40 0
7.5 60 58 2
10.0 80 78 2
12.5 100 100 0
15.0 120 120 0
17.5 140 138 2
20.0 160 160 0
22.5 180 181 1
25.0 200 200 0
27.5 220 220 0
30.0 240 240 0
27.5 220 220 0
25.0 200 198 2
22.5 180 178 2
20.0 160 158 2
17.5 140 138 2
15.0 120 118 2
12.5 100 100 0
10.0- 80 80 0
7.5 60 60 0
5.0 40 40 0
2.5 20 20 0
0 0 0 0

The results should of course be a straight line relationship and the applied pressure should be as indicated
by the gauge. However it can be seen that there are slight variations in the result both on increasing and
decreasing pressures.
The data is plotted for reference on the following page.
15
16

2. EXAMINATION OF THE DIFFERENCE BETWEEN ABSOLUTE AND GAUGE


PRESSURE.

A typical bourdon tube pressure gauge operates as shown below.


The sealed C shaped tube a has the applied
pressure inside. This causes it to try and straighten out
(open up) in the direction of arrow b. This pulls on
the tie bar and causes the lever to rotate in the
direction of arrow c. The segment of gear teeth can
a be seen at the end of this lever and on the shaft of the
spindle of the dial needle are corresponding gear
teeth. Hence this causes the needle to move in the
c
direction of arrow e.
e
b The pressure gauge(depending upon calibration and
mechanical arrangement will indicate pressures
above(or below) atmosphere.

If a pressure gauge is fitted with an evacuated capsule


or an evacuated gauge body then the pressure it
indicates can be absolute pressure or relative to
absolute vacuum. If the local atmospheric pressure is known then the pressure recorded by a gauge or
manometer may be expressed in absolute terms by simply adding this to the local atmospheric pressure.

The following is a description of a device. It is NOT a suggested experiment as mercury is a


cumulative poison and should not be used in an uncontrolled manner.
If a CLOSED glass tube of approximately 900mm length is filled with mercury and then inverted into a
reservoir of mercury the column of mercury in the closed tube will fall from the closed end of the as
shown below.

Atmospheric pressure

Height of mercury

As the tube is closed at one end and this space was formerly occupied by the mercury the space above
will contain a vacuum.
The atmospheric pressure is pressing on the open surface of the mercury in the same manner as the U
tube manometer.
17
Hence the height of the mercury in the tube h represents the atmospheric pressure RELATIVE to a
vacuum.
P gh
1000 13600 h
Where in this case is the density of mercury.

This is a typical description of a mercury BAROMETER.

There are many varieties of barometer but the mercury tube barometer is one of the simplest and most
accurate.

Once the atmospheric pressure is known it is simple to add the GAUGE pressure (however
recorded) to this in order to obtain the ABSOLUTE PRESSURE. The only factor that must be observed
is that the units of atmospheric pressure and gauge pressure must be consistent(the same units e.g.
Pascals, N/m2, Psi, etc.)

(+ve) Gauge Pressure


Atmospheric Pressure
As indicated by Barometer
(-ve) Gauge Pressure

Absolute vacuum

Note that if the gauge pressure is negative(below atmospheric) this can also be added mathematically
to the atmospheric pressure. For example if the gauge pressure is -500 N/m2 and local atmospheric
pressure is 101325 N/m2 , the absolute pressure will be
P 101325 500
100825 N/m 2 Absolute

Similarly if the gauge pressure is +500 kN/m2 the absolute pressure will be

P 101325 500
101825 N/m 2 Absolute
18
Blank Results table

Applied Load N Applied Indicated Pressure Difference


Pressure kN/m2 kN/m2
kN/m2

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