PM205

PRESSURE CALIBRATOR

USER’S MANUAL
Thank you for purchasing our pressure meter.
This product is manufactured in accordance with our strict standards for
quality in design, components, and workmanship to fulfill our vision:

“To be the leading company in high quality self-contained

products”

Scan-Sense AS reserves the right to make improvements or alterations

to their products without incurring any responsibility to make the same
improvements or alterations to products previously sold.

© Scan-Sense AS.
All rights reserved. No part of this publications may be reproduced,
stored in a retrieval system, or transmitted in any form by any means,
electronic, mechanical, photocopying, recording, or otherwise without
the prior permission of Scan-Sense AS.

All efforts have been made to ensure the accuracy of this handbook.
We at Scan-Sense AS are always striving to improve our products and
handbooks, therefore we would greatly appreciate being informed of
any errors found in our product or its handbook. The above
notwithstanding, Scan-Sense AS can assume no responsibility for any
errors in this handbook or the consequences.

Symbol used to identify an action that can cause personal

injury or damage to equipment.

Always release internal pressure at connectors before

disconnecting.
Uncontrolled release of high pressure can result in
personal injury and damage to equipment.

Scan-Sense AS Phone: + 47 33 36 30 00
Bekkeveien 163 Fax: + 47 33 36 30 01
N-3173 Vear, Email: [email protected]
Norway www.scansense.no
 Table of Contents

1 DESCRIPTION OF THE PM205………………………………………. 1

1.1 CALIBRATION LABEL………………………………………………..... 1
1.2 CERTIFICATION………………………………………………………... 1
1.3 WARRANTY…………………………………………………………….. 2
1.4 CONVENTIONS USED IN THIS DOCUMENT……………………… 2
1.5 BATTERY CHANGE/ BATTERY LIFE……………………………… 2
1.6 PM205 NOT OPERATING/ FAILED ……………………………….. 3

2 CONTROLS AND INDICATORS………………………………………4

2.1 DISPLAY, CONTROLS AND CONNECTIONS……………………… 5
2.2 MEASURING PROCEDURE OF THE PEAK-MODE………………. 7
2.3 INSTALLATION…………………………………………………………. 7
2.4 RANGES/ CALIBRATION ……………………………………………... 7

3 SPECIFICATION OF PM205………………………………………….. 8

4 LTP1, LOW PRESSURE HAND PUMP……………………………....9

4.1 LTP1, CONTROLS AND ORIENTATION……………………………..9
4.2 OPERATION OF THE LPT1…………………………………………… 10
4.3 LTP1 FAULT INVESTIGATION……………………………………….. 11

5 TP1, HAND HELD PRESSURE TEST SYSTEM………………........ 12

5.1 TP1 CONTROLS AND ORIENTATION………………………………. 12
5.2 OPERATION OF THE TP1…………………………………………….. 13
5.3 TP1 FAULT INVESTIGATION………………………………………….14

6 HTP1, HYDRAULIC HAND HELD PRESSURE TEST SYSTEM…. 15

6.1 HTP1 CONTROLS AND ORIENTATION…………………………….. 16
6.2 OPERATIONS OF THE HTP1………………………………………….16

7 PV411 PNEUMATIC/HYDRAULIC HAND-PUMP SYSTEM………. 18

7.1 PV411 CONTROLS AND ORIENTATION………………………….... 19
7.2 PV411 PNEUMATIC OPERATION………………………………….... 20
7.3 PV411 HYDRAULIC OPERATION………………………….………… 22
7.4 PV411 FAULT INVESTIGATION……………………………..………..25

8 PM205 ACCESSORIES……………………………………………….. 26

9 CERTIFICATES………………………………………………………… 28

i
1 DESCRIPTION OF THE PM205
The PM205 Pressure Calibrator has been designed as a self-contained,
portable pressure meters that have been calibrated to precision
pressure equipment traceable to national standards.

Each unit is marked with:

• Calibration label, next calibration date
• Serial number
• Production year
• Pressure range.
1.1 CALIBRATION LABEL
Scan-Sense AS certifies that this product meets published
specifications at the time of shipment from the factory. Scan-Sense AS
further certifies that its calibration measurements are traceable to
accredited international standards. Each pressure calibrator has a
calibrated label showing the last date of calibration and the date when
the next calibration is due. Calibration is scheduled annually, unless
you believe the unit to be defective, whereupon the unit will be
calibrated after repair and receive a new label showing the date
calibrated and the new calibration-due date. Check the calibrated label
to ensure the Pressure Meter Calibrator has a valid calibration date
before using the unit. Calibration must be done by Scan-Sense AS
or a certified supplier/service center.
1.2 CERTIFICATION
Scan-Sense AS certifies that the PM205 complies with its published list
of specifications at the time it was manufactured. Scan-Sense AS also
certifies that its calibration measurements are traceable to Norwegian
Accreditation and to the calibration facilities of other International
Standards Organization (ISO) members. Scan-Sense AS confirms that
the PM205 complies with the following standards:
Electromagnetic compatibility as established in the
guidelines of the European Community, EMC
89/336/EWG . The following norms are applied:
EN 61000-6-2, EN 61000-6-3.

1.3 WARRANTY
This product is guaranteed free from defects in material and
workmanship for one (1) year from the date of shipment. During this
1
 warranty period, Scan-Sense AS will, at its option, either repair or
replace the PM205 should it prove to be defective. The product must be
returned to a service facility designated by Scan-Sense AS for warranty
service or repair. The foregoing warranty will not apply to defects
resulting from improper maintenance by the purchaser, purchaser-
supplied software or interfacing, unauthorized modification or misuse,
operation exceeding the environmental specifications for the PM205, or
improper site preparation. No other warranty is expressed or implied by
Scan-Sense AS, and Scan-Sense AS shall not be liable for any direct,
indirect, special, incidental or consequential damages, whether based
on contract, tort, or any other legal theory.

1.4 CONVENTIONS USED IN THIS DOCUMENT

We have provided this section of the Handbook to help you identify
noteworthy symbols, terms and conventions used in this handbook.
Look for the following:
Symbol used to Terms and definitions:
identify an action that
We define calibration as being
can cause personal
able to compare the ability of
injury or damage to
the equipment to perform to a
equipment.
known standard. Pressure
calibration provides a means of
Conformité quantifying uncertainties in
Européenne pressure measurement in order
to optimize sensor and/or
system accuracy.

1.5 BATTERY CHANGE/ BATTERY LIFE

When the battery starts weakening, a low battery warning (BAT LOW)
will appear in the upper left corner of the display.
Battery change: Open the instrument (turn the display ring beyond the
limit stop). Open the battery compartment and change the battery (type
CR2430). Make sure that the O-ring remains embedded in the cover.
The battery life is 150 hours in Peak-mode (at continous operation) and
1000 hours in normal measuring mode.
*

2
1.6 PM205 NOT OPERATING/FAILED
Repairs must be done by manufacturer or supplier certified for
service/repair. Replacement parts must be obtained from the
manufacturer.

Manufacturers address:
Scan-Sense AS Phone: + 47 33 36 30 00
Bekkeveien 163 Fax: + 47 33 36 30 01
N-3173 Vear, Norway Email: [email protected]

3
2 CONTROLS AND INDICATORS

2.1 DISPLAY, CONTROLS AND CONNECTIONS

The PM205 has two operating keys. The left key (SELECT) serves to
select the functions and the pressure units. The right key (ENTER)
activates the selected function or pressure unit. The right key is also
used to switch between the MAX.- and MIN.-value in both the Mano-
and Peak-mode.

4
 Turn-on:

Pressing the SELECT key turns the instrument on.

The instrument subsequently displays the software version

(year/week), the full-scale pressure range, the actual pressure (top
display) and the last measured MAX.-value (bottom display).

The instrument has the following functions:

RESET: Max.-/Min.-value and Peak-value are set to the

actual pressure
OFF: Turns off the instrument
MANO: Releases the following functions:
PEAK off: Normal measuring mode with 2 measurements
per second
PEAK on: Fast measuring mode with 5000
measurements per second
ZERO SEt: Sets a new Zero reference
ZERO rES: Sets the Zero to factory setting
CONT on: Deactivates the automatic turn-off function
CONT off: Activates the automatic turn-off function (the
instrument turns off 15 minutes after the last key
function)followed by the unit selection: bar, mbar/hPa,
kPa, MPa, PSI

Example: Setting a new Zero Reference:

--> Turn on the instrument by shortly pressing the SELECT-key.
--> Wait for the instrument’s measuring mode (approx. 3
seconds).
--> Press the SELECT-key 3 times: MANO appears.
--> Press ENTER: PEAK on or PEAK off appears.
--> Press SELECT: ZERO SEt appears.
--> Press ENTER: The new Zero reference is set. The
instrument returns to the measuring mode.

5
 Display of the Minimum Pressure Value
When in the measuring mode (Display: Actual Pressure and Max.-
value), you may display the Min.-value for 5 seconds by shortly pres
sing the ENTER-key.

Notes:

1) The functions and units can also be called up by

keeping the SELECT-key depressed. Releasing the key
enables the displayed function or unit to be activated with
the ENTER-key.

2) If the selected function or unit is not activated within 5

seconds with the ENTER-key, PM205 returns to the
measuring mode without changing any settings.

3) Turning PM205 on and off does not influence any of

the previous settings.

4) If the PEAK on or CONT on function is activated, it is

indicated with a flashing sign on the display.

5) If a pressure can not be represented on the display,

OFL (overflow) or UFL (underflow) appears on the
display.

6) If the actual pressure goes beyond the measuring

range, the last valid pressure value starts flashing on the
display.

2.2 MEASURING PROCEDURE OF THE PEAK-MODE

6
2.3 INSTALLATION
Ref. A) Screw the G
“ male port of PM205 into the choosen pressure
pump and tighten using the lower hexagon of the transducer. Loosen
the upper hexagon and rotate the PM205 to the desired position. Re-
tighten. Ref. Chapter 4 to 7 for further details.

Ref. B) The face of the PM205 can be rotated trough 355 Degrees.
This feature allows the PM205 to be mounted in all possible positions;
vertical, horizontal or upside down.

2.4 RANGES/ CALIBRATION

The factory setting of the Zero for the ranges -1…3 bar or -1…30 bar is at 0
bar absolute. For sealed gauge pressure measurements, activate “Zero Set”
at ambient pressure. Instruments with ranges >30 bar are calibrated in a
sealed gauge mode at ambient pressure.

7
3 SPECIFICATIONS OF PM205
Pressure Ranges, Resolution, Overpressure:
Range Resolution Overpressure
-1 to 3 bar 1mbar 10 bar
-1 to 30 bar 10 mbar 60 bar
0 to 60 bar 10 mbar 120 bar
0 to 300 bar 100 mbar 400 bar
0 to 700 bar 200 mbar 700 bar
0 to 1000 bar 200 mbar 1000 bar

Readings per second 5000 (PEAK mode)

Zero function Yes
Peak function Max. or Min.
Auto power off 15 min.
Power supply Battery
Battery life 1000 hours continous operation
MANO-Mode
150 hours of continous operation in
PEAK-Mode
Litium battery 3.0V size CR2430
Display LCD
Selectable read out bar, mbar/hPa, kPa, MPa,
PSI, kp/cm2
Standard process coupling
” BSP MALE, Swivel
Protection class (EN 60529) IP65
Dimentions 118mm (h) x 42mm (d), ø76mm (w)
Weight 0,21 kg
Accuracy RT (room temperature) * < 0,1 %FS
Total Error Band (0 to 50 °C) < 0,2 % FS
Storage-/ Operating Temperature -20 to 70 °C / 0 to 50 °C
Compensated Temperature Range 0 to 50 °C

8
4 LTP1, LOW PRESSURE HAND PUMP
Provides low pressure of -0,9 to 3 bar.
Scan-Sense part no. 3PPM02050
Always release the internal pressure at the connectors before
disconnecting. Uncontrolled release of high pressure can result in
personal injury and damage to equipment.
Do not connect LTP1 to external pressure source!

4.1 LTP1 CONTROLS AND ORIENTATION

Drawing key:

Pressure-release valve.
Fine-adjustment control.

 Pressure or Vacuum selector.
 Two push-fit connectors to accept 4mm OD hoses to item
under test and PM205 (master instrument).
 Pressure port:
-inch BSP female connector to suit adapters/item
under test.
 Pump handle.
 Nylon seals (see seal kit provided). DO NOT use PTFE tape for
sealing with parallel threads.
 Pressure-relief valve.

9
 RELEASE VALVE 
Can be used to reduce or release pressure in
the system. The rate of pressure reduction is dependent upon the
degree of rotation when operating the valve. Minimal force is required
to seal the system.
FINE-ADJUSTMENT CONTROL  The generated pressure can
be fine adjusted by turning the fine-adjustment valve either in or out to
increase or decrease the pressure.
IMPORTANT
Do not wind the fine-adjustment valve 
 any further when the
top of the pump body is visible.

PRESSURE/VACUUM SELECTION  Press the selector

 as indicated on the label to engage the desired mode. Ensure that
the release valve
 is fully closed (clockwise motion) prior to
pumping.
PRESSURE PORTS  The hoses 
are fitted by pushing
them into the connectors  until resistance is felt. To remove the
hoses, press the collar “in” on the connector while pulling on the hose.
PRESSURE RELIEF VALVE  
The maximum output pressure can be set
using the pressure relief valve  located
inside the main piston, and is accessed via
the handle-retaining “Grub Screw”.

If the system has not been used for a period of time, it may be difficult
to operate on the first stroke.

Seal replacement: Depending on the frequency of use, the main piston

seal (and others) may need replacing. Replacement seals and
instructions for fitting are contained in the seal kit (LTPK1).

4.2 OPERATION OF THE LTP1.

Refer to the orientation drawing to locate the controls.
1. Choose the correct adapters and seals and connect to the
pressure port  at one end of the flexible hoses .
2. Choose the correct adapters and seals and connect the item under
test to the pressure port at the end of the second flexible hose 
Ensure seals are fitted and adapters tightened to a maximum
torque of 15Nm.
3. Screw the fine-adjustment valve  fully clockwise.

10
 4. Screw the fine-adjustment valve  counter-clockwise 4 to 6 full
turns.
5. Screw the pressure-release valve
 fully clockwise, tightening to
ensure a good seal.
6. Using a small screwdriver, adjust the pressure-relief valve 
to
set the desired maximum output pressure. Turn the “Grub Screw”
located in the main piston clockwise to increase or counter-
clockwise to decrease the pressure setting.
7. Operate the handle  until the pressure is close to that which is
finally required.
8. Wind the fine-adjustment valve  “in” to increase pressure or
“out” to decrease pressure until the required pressure is reached.
After increasing the pressure, it may take up to 30 seconds for the
pressure to settle due to thermodynamic effects, setting of seals or
expansion of the flexible hose.

STOP unscrewing the fine-adjustment valve 

when the top of the pump body becomes visible!
9. Reductions in pressure can also be achieved by careful use of the
pressure-release valve
.
10. Vacuum is achieved using the above procedure and having the
changeover valve  pushed completely towards the vacuum
position.
11. End of operation procedure.

4.3 LTP1 FAULT INVESTIGATION

In the event that the system appears to lose pressure, check the
connections to ensure that they are tight and the seals are good.
Replace poor seals and repeat the operation. When testing for leaks
you may notice that air is drawn in or expelled from around the
changeover valve , this is normal and should not be a cause for
concern.
Connection to the handheld test system is sealed with “o”-ring or
bonded seals and should not leak. The pipe or body connection can be
checked but should not be tightened more than 2 Nm.

DO NOT attempt to tighten the other fittings to the test system as this
can cause damage to the sealed joints!

11
5 TP1, HAND HELD PRESSURE TEST SYSTEM
Provides pneumatic pressure of -0,8 to 40 bar.
Scan-Sense part no. 3PPM40050
Always release internal pressure at connectors before
disconnecting. Uncontrolled release of high pressure can result in
personal injury and damage to equipment.
Do not connect TP1 to external pressure source!

5.1 TP1 CONTROLS AND ORIENTATION

Drawing key:

3/8-inch to
-inch BSP connector for PM205 (master instrument).
Fine-adjustment valve (volume control).

 Pressure-release valve
 Pressure or Vacuum selector.
 Adjustable stroke for varying maximum pressure output.
 Pressure port:
-inch BSP female connector to suit adapters/item
under test.
 Flexible hose to item under test.
 Nylon seals (see seal kit provided). DO NOT use PTFE tape for
sealing with parallel threads.

12
 RELEASE VALVE  Can be used to reduce or release pressure in
the system. The rate of pressure reduction is dependent upon the
degree of rotation when operating the valve. Minimal force is required
to seal the system.
VOLUME CONTROL  The generated pressure can be fine-
adjusted by turning the fine-adjustment valve either clockwise or
counter-clockwise to increase or decrease the pressure accordingly.
IMPORTANT
Under no circumstances should the fine-adjust
valve
 be wound back beyond the read-line
indicator on the body. Should this occur, then the
pressure must be released from the system before
attempting to re-engage the fine-adjustment valve.
OVER PRESSURE PROTECTION
 To adjust the maximum
output pressure of the system, turn the nuts to increase or decrease the
stroke length.
PRESSURE/VACUUM SELECTION  Press the selector
 as indicated on the label to engage the desired mode. Ensure that
the release valve  is fully closed (use a clockwise motion) prior to
pumping.

If the system has not been used for a period of time, it may be difficult
to operate on the first stroke. The cylinder has been lightly greased at
assembly, but if additional lubrication is ever required, apply a minimal
amount to the inside of the cylinder. Access is via the three retaining
screws located under the black collar.

Seal replacement: Depending on the frequency of use, the main piston

seal (and others) may need replacing. Replacement seals and
instructions for fitting are contained in the seal kit (TPK1).

5.2 OPERATION OF THE TP1

Refer to the orientation drawing to locate the controls.
1. Choose the correct adapters and seals and connect item under
test to pressure port  at the end of the flexible hose .
Ensure seals are fitted and adapters tightened to a maximum
torque of 15Nm.
2. Screw the fine-adjustment valve  fully clockwise.
3. Screw the fine-adjustment valve  counter-clockwise 4 to 6 full
turns.

13
 4. Screw the pressure-release valve  fully clockwise, tightening to
ensure a good seal.
5. Operate handles until the pressure is close to that which is finally
required. Ensure handles are fully squeezed together on each
stroke to achieve maximum pressure output.
6. Wind the fine-adjustment valve 
(clockwise to increase
pressure or counter-clockwise to decrease pressure) until the
required pressure is reached. After increasing the pressure, it may
take up to 1 minute for the pressure to settle due to
thermodynamic effects, setting of seals or expansion of the flexible
hose.

NEVER screw the fine-adjustment valve  beyond

the red line indicator!
7. Reductions in pressure can also be achieved by careful use of the
pressure release valve .
8. Vacuum is achieved using the above procedure and having the
changeover valve  pushed completely towards the vacuum
position.
9. End of operation procedure.

5.3 TP1 FAULT INVESTIGATION

In event that the system appears to lose pressure, check the
connections to ensure they are tight and the seals are good. Replace
poor seals and repeat the operation. When testing for leaks you may
be notice that air is drawn in or expelled from around the changeover
valve , this is normal and should not be a cause for concern
Connection to the handheld test system is sealed with “o”-ring or
bonded seals and should not leak. The pipe or body connection can be
checked but should not be tightened more than 2 Nm.

DO NOT attempt to tighten the other fittings to the test system as this
can cause damage to the sealed joints!

14
6 HTP1, HYDRAULIC HAND HELD PRESSURE TEST
SYSTEM
Provides hydraulic pressure of 0 to 700 bar
Scan-Sense part no. 3PPM70150
Always release the internal pressure at the connectors before
disconnecting. Uncontrolled release of high pressure can result in
personal injury and damage to equipment. Excessive pressure can
crack or break the fluid reservoir case!
Reservoir fluid level: If the fluid level in the reservoir falls considerably
during use, a partial vacuum may be created in the reservoir that can
affect the performance of the pump. To avoid this, simply allow air to
enter the reservoir by partly unscrewing the filling plug.

Seal replacement: Depending on the frequency of use, the main piston

seal (and others) may need replacing. Replacement seals and
instructions for fitting are contained in the seal kit (HTPK1).

6.1 HPT1 CONTROLS AND ORIENTATION

Drawing key:

3/8-inch to
-inch BSP connector for PM205 (master
instrument).

15
 Pressure-release valve.

 Fine control
 Pressure port: M16 x 1.5 mm quick connector for flexible hose to
switch adapters or item under test.
 100cc reservoir. Fluid level to maximum fill marker.
 Reserve-filling plug.
 Prime/High pressure selector.
 Fluid-inlet tube.
 Rear port: for Pressure Relief Valve ONLY. DO NOT use for any
other purpose.

6.2 OPERATION OF THE HTP1

Refer to the orientation drawing to locate the controls.
1. Remove the filling plug  and fill the reservoir  to 6mm level
with the recommended fluid and replace the filling plug.
2. Connect the instrument under test to the flexible hose/gauge
adapter and attach to the pump via the quick-fit connection .
3. Adjust the fine control  to mid-travel.
4. Ensure that the pressure-release valve
is open (turn fully
clockwise, then one turn counter-clockwise). Fully squeeze the
handles “in” and turn the selector  to the “prime” position.
5. Operate the handles several times to expel air from the pump
(ensure that the fluid-inlet tube remains immersed in fluid at all
times).
6. Close the release valve fully clockwise.
7. Prime the system by squeezing the handles together and then
releasing them, to allow the oil to enter the pump cylinder. Repeat
as necessary until the system is fully primed and low pressure is
indicated on either the master or test instrument.
8. With the handles fully squeezed “in” select the “high” pressure
position on the selector  and operate the handles to generate
approximate pressure. Note: Smaller handle strokes enable
easier pressure generation at high pressures.
9. Adjust pressure to the required value using the fine control .
Note that the pressure will fall slightly, immediately after pressure
generation due to the thermodynamic effect but will stabilize after a
short time.

DO NOT EXCEED the maximum operating pressure indicated

on the pump label! Fluid reservoir can crack or break if excess
pressure applied.

16
10. To totally release pressure from the system, turn the release valve
 one turn counterclockwise and select the “prime” position on the
selector  after first squeezing the handles fully “in”. Note:
Careful use of the release valve 
and fine control  enables a
controlled release of pressure, essential for calibration purposes.
11. End of operation procedure.

17
7 PV411 PNEUMATIC/HYDRAULIC HAND-PUMP SYSTEM
Pressure ranges (maximum safe working pressure is 700 bar):
• Provides pneumatic pressure of 0 to 60 bar
• 0 to –0.95 bar (near vacuum)
Scan-Sense part no. 5PV-411
• Provides hydraulic pressure of 0 to 700 bar
Scan-Sense part no. 5PV-411-115

Always release the internal pressure at the connectors before

disconnecting. Uncontrolled release of high pressure can result in
personal injury and damage to the equipment.

Reservoir-fluid level: If the fluid level in the reservoir falls considerably

during use, a partial vacuum may be created in the reservoir that can
affect the performance of the pump. To avoid this, simply allow air to
enter the reservoir by partly unscrewing the filling plug. Hydraulic fluids
must be compatible with stainless steel, anodized aluminum, nitrile
rubber, PTFE, polypropylene, delrin, acrylic and nylon. Hydraulic fluid
must have a maximum viscosity of 150 cSt at 40°C. Other fluids that
can be used are de-mineralized water or mineral-based oils (SAE 40W,
ISO viscosity grade 150).

Seal replacement: Depending on frequency of use, the main piston

seal (and others) may need replacing. Replacement seals and
instructions for fitting are contained in the seal kit (PV411K1).

18
7.1 PV411 CONTROLS AND ORIENTATION

PV411, drawing key 1

Drawing key 1:

Inlet (reservoir) port

-inch to
-inch BSP connector for PM305 (master instrument)
 Volume adjuster

 Limit adjuster
 Scissor-action handles
 Pressure port: M16 x 1.5 mm quick connector for flexible hose to
suit adapters and item under test.
 Selector valve
 Pressure-relief valve

19
7.2 PV411 PNEUMATIC OPERATION
7.2.1 Pneumatic-selector valve and scissor-action handles limit-
adjuster of the PV411
Selector valve 
Pressure
Turn the selector valve fully clockwise
(“in”) position.
Vacuum
Turn the selector valve fully counter-
clockwise (“out”) position.
Vent
Slowly turn the selector valve to the
center position.
Scissor-action handles limit-adjuster
Turning the limit adjuster  clockwise reduces the stroke of the
scissor-action handles . Turning the limit adjuster 

counter-clockwise increases the stroke.

For maximum pneumatic pressure generation, turn the limit adjuster

fully counter-clockwise.

7.2.2 Pneumatic Operation of the PV411

As a pneumatic pump, selector valve  vents the system to
atmosphere, between selection of pressure and vacuum. Operating the
scissor-action handles  provides the pumping stroke for generating
pressure. A volume adjuster  allows small adjustments of the
system pressure.

In pressure mode, air/fluid is drawn through the inlet port
 on top of

the pump and forced out through the two outlet ports ( and ). In
vacuum mode, the air/fluid flow is reversed as air/fluid is drawn in
through the top and rear outlet ports ( and ) and expelled
through the inlet port
.

Volume adjuster

20
Low pressure__ With the selector valve  set to vent (“open”), turn
the volume adjuster fully counter-clockwise to the
“out” position. Turn the selector valve fully clockwise
to the “in” position to select pressure. Turn the volume
adjuster
 clockwise to generate pressure.
High pressure _ Turn the volume adjuster 
to the mid-position. In
this position, fine adjustments of the generated
pressure can be made. Using the scissor-action
handles , generate the approximate pressure;
then turn the volume adjuster
 clockwise to the “in”
position to increase the pressure or turn the volume
adjuster
 counter-clockwise to the “out” position to
decrease the pressure.
Vacuum ______ Turn the selector valve  fully counter-clockwise to
the “out” position. Turn the volume adjuster to the
mid-position. In this position, fine adjustments of the
generated vacuum can be made. Using the scissor-
action handles , generate the approximate
pressure; then turn the volume adjuster
 clockwise
to the “in” position to increase the pressure or turn the
volume adjuster
counter-clockwise to the “out”
position to decrease the pressure.
Refer to the orientation drawing to locate the controls.
Pressure
1. Connect the PV411 to the item under test using the hoses, pipes
and adapters.
2. Turn the selector valve  fully clockwise to the “in” position.
3. Operate the scissor-action handles  to generate the
approximate pressure, allowing time for thermal stabilization.
4. If necessary, use the volume adjuster
 to adjust to the required
pressure.
5. After attaining the required pressure, operate the scissor-action
handles  to generate a higher pressure. Alternatively, vent
pressure to atmosphere by slowly turning the selector valve 
counter-clockwise to the center position.
6. End of procedure. Depressurize the pump and disconnect from
the pipes and equipment.

Vacuum
1. Connect the PV411 to the item under test using the hoses, pipes
and adapters.

21
 2. Turn the selector valve  fully counter-clockwise to the “out”
position.
3. Operate the scissor-action handles  to generate the
approximate vacuum, allowing time for thermal stabilization.
4. If necessary, use the volume adjuster  to adjust to the required
vacuum.
5. After attaining the required vacuum, operate the scissor-action
handles  to generate more vacuum. Alternatively, vent vacuum
to atmosphere by slowly turning the selector valve  counter-
clockwise to the center position.
6. End of procedure. Depressurize the pump and disconnect.

7.3 PV411 HYDRAULIC OPERATION

7.3.1 Setting pressure relief valve of the PV411
The pressure relief valve (PRV) can be set at pressures from 30 to 700
bar.
Do not exceed 700 bar as this can damage the internal seals of
the PRV and the PV411
If the system pressure exceeds the set pressure, the PRV opens and
vents fluid through the inlet port to the reservoir. When system
pressure decreases below the set pressure, the PRV closes.
Drawing key 3:

 PRV locking screw (quantity 2).
 PRV locknut (with left-hand thread).
 PRV adjusting nut (with left-hand thread)
PRV, drawing key 3
Refer to the orientation drawing PRV411 drawing key 1 and PRV
drawing key 3 to locate the controls.
1. Connect a suitable pressure indicator to either outlet port  or

(see PRV411, drawing key 1). Fit a blank to the unused port.
2. Squeeze the scissor-handles  together to increase pressure
until the relief valve operates.
3. Loosen the two PRV locking screws
.
4. Loosen the locking nut by turning it clockwise.
5. Set the relief pressure by turning the PRV adjusting nut .
Turn counter-clockwise to increase pressure.
Turn clockwise to decrease pressure.
6. After setting the PRV, hold the adjusting nut  in position and
tighten the locking nut . Remember that the locking nut has a
left-hand thread.
7. Check operation of the PRV. If necessary, reset the PRV.

22
 8. Secure the locking nut  by tightening the two locking screws
.
9. End of procedure.

7.3.2 Hydraulic Operation of the PV411

As a hydraulic pump, selector valve  vents the system to the
reservoir, between selections of pressure and vacuum (using a priming
process). The volume adjuster  generates the required system
pressure. To complete the hydraulic circuit, the fluid reservoir (see
drawing key 2) is screwed into the inlet port
 (marked RESERVOIR)
on top of the hand-pump. A pressure relief valve  can be adjusted
to set the pressure between 30 and 70 bar. Operating the scissor-
action handles  provides the pumping stroke for generating
pressure. A volume adjuster  allows small adjustments of the
system pressure.
The fluid-reservoir body (see drawing key 2) is transparent acrylic to
provide a clear view of the contents. The reservoir can be removed
from the pump without the need to empty the fluid (a self-sealing
connection prevents leakage). The spring-loaded reservoir cover 
seals under atmospheric pressure conditions but, in the event of
inadvertent pressurization, it will vent excess internal pressure
harmlessly. Ensure that the O-ring  is fitted to the inlet pot to prevent
leakage. Screw the reservoir clockwise into the inlet port marked
RESERVOIR.
Drawing key 2:

Reservoir-cover locknut.
 Reservoir-cover.
 O-ring.

 Bleed hole.
• Do not mix hydraulic fluids.
• Use only compatible fluids.
• Fit only appropriate seals.
• Damage can be caused if
equipment connected to this pump
is contaminated. Avoid particulate
contamination.
• After use, the pump should be
considered contaminated with
hydraulic fluid. Reservoir, drawing key 2

Filling the reservoir

Unscrew the reservoir cover lock
 and remove the reservoir cover
. Using clean recommended fluid, fill the reservoir to approximately

23
2/3 full. Refit the reservoir cover  and re-tighten the reservoir locknut

. Connect the required pipes and equipment to the outlet ports.

Priming the system

There are two methods for priming the system:
• Vacuum priming to extract the air or
• Pre-filing the system.
1. If air remains in the system, full pressure cannot be achieved
because the air in the fluid will compress. Air must be removed
from the system fluid.
2. Both priming methods require the pump to be held in the vertical
position to keep the reservoir bleed hole
 submerged in the
fluid. Do not allow air to enter the system through the bleed hole

.

Vacuum priming
This method should not be used with vacuum-sensitive equipment.
1. Connect the PV411 to the item under test using the hoses, pipes
and adaptors.
2. Turn the selector valve  fully counter-clockwise to the “out”
position.
3. Operate the scissor-action handles  until bubbles stop
appearing in the reservoir (this generates the vacuum in the
system).
4. Turn the selector valve  fully clockwise to the “in” position (this
action releases the vacuum and rapidly fills the system with fluid
from the reservoir).
5. End of procedure. The pump and connected system are ready for
use.
Pre-filling the system
1. Connect the PV411 to the item under test using the hoses, pipes
and adaptors.
2. Turn the selector valve  fully clockwise to the “in” position.
3. Loosen the reservoir-cover lock
 to open the reservoir cover
 and allow atmospheric pressure into the top of the reservoir.
4. Open the bleed valve on the unit under test.
5. Carefully operate the scissor-action handles  to fill the system.
Stop pumping when fluid comes out of the bleed valve.
6. Close the bleed valve on the unit under test.
7. If necessary, top-up the reservoir to the 2/3 full level.

24
8. Refit and secure (tighten) the reservoir cover  and re-tighten
the reservoir locknut
.
9. End of procedure. The pump and connected system are ready for
use.

Hydraulic Operation of the PV411

Refer to the orientation drawing to locate the controls.
1. Connect the PV411 to the item under test using the hoses, pipes
and adaptors.
2. Open the selector valve 
by 1 turn counter-clockwise to the “in”
position.
3. Screw the volume adjuster  fully counter-clockwise to the “out”
position.
4. Close the selector valve 
.
5. Operate the scissors-action handles  to generate the initial
pressure.
6. Turn the volume adjuster  clockwise to generate the required
pressure. Allow time for thermal stabilization.
7. To reduce pressure, turn the volume adjuster  counter-
clockwise (the “out” position) to the required pressure.
8. After completion, turn the volume adjuster  counter-clockwise
(the “out” position) and the selector valve 
to the center position
to depressurize the pump.
9. End of procedure. Depressurize the pump and disconnect from
the pipes and equipment.

7.4 PV411 FAULT INVESTIGATION

If the system pressure reduces, check the following:
Refer to the orientation drawing PV411 drawing key 1 to locate the
controls.
1. Check that the selector valve 
is in the correct position and
properly tightened.
2. Allow sufficient time after generating pressure for the temperature
to stabilize. The larger the system volume, the longer the time for
thermal stability.
3. Check for leaks between the pump and the equipment under test
and the adaptors, flexible pipe and connections. Tighten any
loose joints and replace any seals that are worn or damaged.
4. In hydraulic mode, if the volume adjuster can be wound fully in, but
maximum pressure cannot be achieved, there is probably air
trapped in the system. Re-prime and repeat.
5. Check the Pressure-Relief Valve  pressure setting.

25
 If, for any reason, a fault occurs within the pump, it is recommended
that the equipment be returned to Scan-Sense AS.

8 PM205 ACCESSORIES

8.1 ADAPTERS FOR THE ITEM UNDER TEST

Adapter kit 1,
-inch BSP to NPT Female, Carbon Steel
Description drawing

1/4" BSP male – 1/8" NPT female

1/4" BSP male – 1/4" NPT female

1/4" BSP male – 3/8" NPT female

1/4" BSP male – 1/2" NPT female

Adapter kit 2,
-inch BSP to BSP Female, Carbon Steel

Description drawing

1/4" BSP male –- 1/8" BSP female

1/4" BSP male – 3/8" BSP female

1/4" BSP male – 1/2" BSP female

26
Adapter kit 4 BSP-BSP Swivel, Carbon Steel
1/4" BSP male – 3/8" BSP male for LPT1 and TP1.

Test hose kit 700 bar, Carbon Steel

1/4" BSP male – 1/4" BSP male for HTP1, PV411 and PC705;
connects to M16 x1.5mm quick connector at pump
and to item with M16 x 1.5mm with
” BSP female adapter.

27
9 CERTIFICATES

28
PM205 User’s Manual Rev. 01-2009
MANP205
Copyrighted © 2009 Scan-Sense AS