GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases
can be released unexpectedly and with extreme force. High pressure systems should be assembled
and operated only by personnel who have been instructed in proper safety practices.
Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any
form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, a
Fluke Company 4765 East Beautiful Lane Phoenix AZ 85044-5318 USA.
DH Instruments makes sincere efforts to ensure accuracy and quality of its published materials; however, no warranty, expressed
or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the
use of the information in this manual or products described in it. Mention of any product or brand does not constitute an
endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently
translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version
and other language versions, the English version predominates.
DH Instruments, DH, DHI, DH500, GPC1, OPG1, PG7000, PG7202 and RPM are trademarks, registered and otherwise, of DH
Instruments, a Fluke Company.
Swagelok is a registered trademark of Swagelok Company.
Teflon is a registered trademark of 3M Corporation.
Krytox is a registered trademark of the Dupont de Nemours Company.
1.3.1 FRONT PANEL..............................................................................................................................................3
1.3.3 SYSTEM SCHEMATIC ..................................................................................................................................4
2.3.1 SET UP GPC1................................................................................................................................................7
2.3.2 CONNECT PNEUMATIC POWER (DRIVE AIR) ...........................................................................................7
2.3.3 MAKE HIGH PRESSURE GAS SUPPLY CONNECTION.............................................................................8
2.3.4 MAKE HIGH PRESSURE GAS INTERCONNECTIONS...............................................................................8
2.3.4.1 CONNECTING TO A DHI RPM OR PG7202 USING THE STANDARD
2.3.4.2 OTHER HI G H P N E U M A T I C P R E S S U R E I N T E R C O NN E C T I O N S .........................................................9
2.3.4.3 RECOMMENDATIONS FOR TEST PORT CONNECTION, USE AND DUT CLEANLINESS
2.4 POWER UP AND VERIFICATION.........................................................................................................12
2.4.1 APPLY THE HIGH PRESSURE SUPPLY...................................................................................................12
This manual provides the user with the information necessary to operate a GPC1 Gas
Pressure Controller. It also includes a great deal of additional information provided to help you optimize
GPC1 use and take full advantage of its many features and functions.
FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 2.3 TO SET UP YOUR GPC1.
THEN GO TO SECTIONS 2.4.5 and 3.1. THIS WILL GET YOU RUNNING QUICKLY WITH MINIMAL RISK OF
CAUSING DAMAGE TO YOURSELF OR YOUR GPC1. THEN… WHEN YOU HAVE QUESTIONS OR START TO
WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET INTO THE MANUAL!
(Caution) is used throughout the manual to identify user warnings and cautions.
(NOTE) is used throughout the manual to identify operating and applications advice and additional
The GPC1 Gas Pressure Controller is a stand alone, pressure setting and adjusting component intended to
be used as the means of pressure control in high pressure pneumatic calibration and test systems. There are
two models. GPC1-16000 is capable of both setting and precisely adjusting pressure from atmosphere to
110 MPa (16 000 psi). GPC1-10000 covers the range from atmosphere to 70 MPa (10 000 psi).
GPC1 combines the versatility, speed and reliability of direct operator control with the convenience and
effort-free operation of automation. It is the standard pressure control component in a DHI PG7202™
piston gauge system or with a DHI RPM™ digital reference pressure monitor to configure a transfer
standard based calibration system.
GPC1 requires an external pressure supply equal to the maximum pressure to be adjusted.
This is usually supplied by a gas booster. GPC1’s inlet pressure regulator and indicating gauge are used
to set the inlet pressure to the desired value for the test being run. Two (2) progressive, half-turn needle
valves control the inlet of pressure from the regulator to increase pressure and outlet to atmosphere to
decrease pressure. Very fine pressure adjustment and generation of small pressure excursions is
accomplished using a Pneumatically Driven Variable Volume (PDVV) with push button control.
Pneumatic power (drive air) of up to 850 kPa (120 psi) is needed to drive the PDVV. All of the test
connections are routed through an inclined manifold that serves as a sump to collect liquids and other
contaminants that may return from devices connected to GPC1. The sump includes a drain for purging.
GPC1 is delivered, along with its standard accessories, in a corrugated container with
corrugated and polyurethane inserts to hold it in place.
Remove GPC1 and its accessories from the shipping container and remove each item from
its protective plastic bag.
2.1.2 INSPECTING CONTENTS
Check that all items are present and have NO visible signs of damage.
Verify the items received against the parts list in Table 1.
Table 1. GPC1 Parts List
DESCRIPTION PART #
GPC1-16000 or GCP1-16000 (Hydrocarbon free version)
or
GPC1-10000 or GPC1-10000 (Hydrocarbon free version)
ACCESSORIES INCLUDING:
1 Mat, Top Surface Protection 123481
1 Operation and Maintenance Manual 550126
1 Wrench, Open End, 5/8 in. 103044
1 General Accessories Disk (white CD) 102987
INTERCONNECTIONS KIT: 401536
2 ea. Nipple, 2.75 in. (70 mm), DH500 100207
1 ea. Nipple, 6 in. (152 mm), DH500 100208
2 ea. Nipple, 12 in.(305 mm), DH500 100209
1 ea. Union, DH500 100295
1 ea. Elbow, DH500 100168
1 ea. Tee, DH500 100291
2 ea. Gland, DH500 100271
3 ea. Plug, DH500 100285
5 ea. Collar, DH500 101201
1 ea. Nipple, 5 in. x 1/8 in. (127 mm x 3 mm), DH500 tips 123019
2 ea. Adaptor, DH500 F x 1/8 in. NPT M 102819
1 ea. Adaptor, DH500 F x 1/4 in. NPT F 102820
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
2.2SITE REQUIREMENTS
The GPC1 system installation is affected by the other components that make up the system in which
GPC1 is being used. Generally, a pressure measuring reference such as a piston gauge or transfer
standard is included.
When selecting and preparing a site to setup a GPC1 system, the following should be considered:
•Bench Stability: GPC1 weighs about 24 kg (53 lb). Consider its weight and that of other
components, including possible items to be tested, when selecting a bench.
•Location of Other Components: Plan the space required and a convenient layout for the complete
system in which GPC1 is the pressure control component. GPC1 has a TEST2 port on its left rear
side. In order to position GPC1 to the right for right-handed access, this is where the reference is
usually connected in a calibration system. If necessary, as an alternative, either of the two (2) top
TEST ports can also be used (see Section 2.3.4). Select interconnecting tubing and fittings rated to
handle the maximum pressure that will be generated. GPC1 high pressure
(equivalent to AE F250C, HIP HF4, etc.). The female DH500 TEST ports and SUPPLY port fittings
are delivered with glands nuts and dummy plastic plugs installed.
If you do not plan to use either of GPC1’s top TEST ports, consider where a device or system under
test (DUT) will be connected. Note, however, that the top rear TEST1 port is the “clean” TEST port
(see Section 2.3.4.3). Unused TEST ports must be plugged for operation using the DH 500 plugs
supplied in the GPC1 interconnections kit.
fittings are all DH500
If GPC1 is to be used with
a DHI RPM or PG7202 reference device, the hardware necessary for setting
up in a standard configuration is included in the GPC1 interconnections kit (see Section 2.3.4.1).
•High Pressure Supply
: Plan the high pressure supply to GPC1. If the high pressure is being supplied by a DHI gas booster, interconnecting hardware to connect the booster output to GPC1
SUPPLY port is included with the booster (see the gas booster Operation and Maintenance Manual). The GPC1 SUPPLY port is DH500 female (DH500 is equivalent to AE F250C, HIP HF4, etc.).
•Drive Air Supply: Plan the PDVV drive air supply. The maximum drive air supply is 850 kPa (120
psi) but may be lower depending on the maximum test pressure to be adjusted (see Section 2.3.2,
Table 2). The drive air PDVV DRIVE AIR port is on the right, rear side of
GPC1. The connection is
1/4 in. NPT female.
•System Interconnections: Plan the interconnections between GPC1 and other components in the
system. Minimizing the volume and maximizing the mass of all interconnecting elements will reduce
pressure generation and stabilization time (see Section 2.3.4).
ALWAYS use external tubing and fittings rated for pressures equal to or greater than the maximum
pressure which GPC1 will be used to control.
DH500 F fittings are delivered with disposable, orange, plastic dummy plugs installed. These are NOT
intended to hold high pressure. They should be removed and replaced with appropriate fittings or
stainless steel plugs before high pressure operation. Each dummy plug carries a DH500 collar.
Remove and retain the collar for use in connecting to the fitting.
Before setting up GPC1, see Section 2.2 for general information on site requirements.
To prepare a GPC1 for check out and operation:
Set up GPC1 (see Section 2.3.1).
Connect drive air (see Section 2.3.2).
Connect the high pressure supply (see Section 2.3.3)
Make the system high pressure gas interconnections (see Section 2.3.4).
2.3.1 SET UP GPC1
To set up GPC1 proceed as follows:
Place GPC1 on the site table in the proper orientation with the front panel controls
conveniently accessible.
Install the mat delivered with the GPC1 accessories on the top, front surface of the
GPC1.
2.3.2 CONNECT PNEUMATIC POWER (DRIVE AIR)
GPC1 requires pneumatic power to drive its pneumatically driven variable volume (PDVV)
(see Figure 3).
The drive air requirements
low and cleanliness of the gas is important, the supply is usually regulated Nitrogen or
instrument grade air from a compressed air bottle.
Connect the pneumatic pressure source to the 1/4 in. NPT F
DRIVE on the right side of GPC1 housing. Use Teflon™ tape or another thread sealant to
minimize leakage.
GPC1 must be supplied with NON-LUBRICATED drive air. The internal components are
permanently lubricated. The oil in lubricated air can contaminate the small diameter
tubing inside GPC1 and lead to erratic behavior requiring difficult and costly cleaning.
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
2.3.3MAKE HIGH PRESSURE GAS SUPPLY CONNECTION
GPC1 requires a high pressure gas supply equal to or less than the maximum desired test
pressure. This is often supplied by a DHI gas booster.
If a DHI gas booster is being used for the high pressure gas supply, interconnections to
connect the booster output to the GPC1 SUPPLY port are supplied with the booster. See
the booster Operation and Maintenance Manual for details on setting up the connection.
The high pressure gas supply is connected to the GPC1 SUPPLY port. The SUPPLY port is a
DH500 female (DH500 is equivalent to AE F250C, HIP HF4, etc.). Before connecting a high
pressure supply, be sure that the TEST INLET SETregulator is fully backed off and the INLET valve is closed. (Do not apply the supply pressure before reading Sections 2.4.1 and 2.4.5).
Do not connect a gas supply greater than 110 MPa (16 000 psi) to the GPC1-16000
SUPPLY port. Do not connect a gas supply greater than 70 MPa (10 000 psi) to the
GPC1-10000 SUPPLY port.
Highly pressurized gas can be extremely hazardous. Before applying pressure to GPC1
and/or the system connected to it, be sure that all pressure vessels and connections are
rated for the pressure levels that will be applied and that all connections have been
properly tightened (see Section 2.4.5). Ensure that the GPC1 TEST INLET SET regulator
is fully backed off and the INLET valve is closed (see Section 2.4.1).
DH500 F fittings are delivered with disposable, orange, plastic dummy plugs installed. These
are NOT intended to hold high pressure. They should be removed and replaced with
appropriate fittings or stainless steel plugs before high pressure operation. Each dummy
plug carries a DH500 collar. Remove and retain the collar for use in connecting to the fitting.
2.3.4 MAKE HIGH PRESSURE GAS INTERCONNECTIONS
2.3.4.1 CONNECTING TO A DHI RPM OR PG7202 USING THE
STANDARD GPC1 INTERCONNECTIONS KIT
GPC1 is delivered with an interconnections kit (see Section 2.1.2, Table 1).
This kit includes the high pressure hardware necessary to connect GPC1 to a
DHI RPM or PG7202 and operate at pressure up to 110 MPa (16 000 psi)
(limited to 70 MPa (10 000 psi) with GPC1-10000). See Figure 4 for the
recommended layout and to identify the parts used from the interconnection kit.
These setups assume that one (1) of the TEST ports on the top of GPC1 or an
open leg of the interconnecting tee will be used to connect to the device or
system under test. To convert a DH500 F to another fitting, install one (1) of the
DH500 F x 1/8 in. NPT M or DH500 F x 1/4 in. NPT F adaptors on to one of the
2.75 in. (70 mm) DH500 nipples and install the nipple into the DH500 F port.
If the reference device is a PG7202, it should always be connected to the left,
2. TEST2 port 8a. PG7202
3a. 12 in. (305 mm) DH500 nipple 8b. RPM
3b. 6 in. (152 mm) DH500 nipple 9. PG Terminal
4. DH500 tee 10. TEST3 port
5. DH500 plug 11. TEST1 port
6a. 2.75 in. (70 mm) DH500 nipple
6b. 5 in. (127 mm) DH500 1/8 in. tube
weld nipple (slightly flexible)
Figure 4. Connecting GPC1 to PG7202 or RPM
Highly pressurized gas can be extremely hazardous. Before applying pressure to
GPC1 and/or the system connected to it, be sure that all pressure vessels and
connections are rated for the pressure levels that will be applied and that all
connections have been properly tightened (see Sections 2.3.4 and 2.4.5).
2.3.4.2 OTHER HIGH PNEUMATIC PRESSURE INTERCONNECTIONS
GPC1 is delivered with an interconnections kit (see Section 2.1.2, Table 1). This
kit is designed to provide a standard connection to a DHI RPM or PG7202 (see
Section 2.3.4.1). It is configured of standard DH500 tubing and fittings and c
be adapted for a variety of connections to operate up to 110 MPa (16 000 psi)
(limited to 70 MPa (10 000 psi) with GPC1-10000).
The 1/8 in. (3 mm ) diameter tube with DH500 tips can be very useful when a
small amount of flexibility is needed to make a connection. Use caution not to
kink the tube.
The GPC1 has DH500 F fittings. The DH500 x 1/4 in. NPT F and DH500 x 1/8
in. NPT M adaptors and the 2.75 in. (70 mm) nipples can be used to convert a
DH500 tube or a DH500 F TEST port to standard NPT connections.
an
Highly pressurized gas can be extremely hazardous. Always use external
tubing and fittings rated for pressure equal to or greater than the maximum
pressure GPC1 will be used to generate.
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
When planning system interconnections, consider that the time required to
generate and stabilize a pressure is a direct function of the test volume and the
mechanical stability of the test tubing and vessels. Always minimize volume to
the extent possible and use thick walled, high pressure tubing and vessels.
DH500 F fittings are delivered with disposable, orange, plastic dummy plugs
installed. These are NOT intended to hold high pressure. They should be
removed and replaced with appropriate fittings or stainless steel plugs
before high pressure operation. Each dummy plug carries a DH500 collar.
Remove and retain the collar for use in connecting to the fitting.
2.3.4.3 RECOMMENDATIONS FOR TEST PORT CONNECTION, USE
AND DUT CLEANLINESS CONSIDERATIONS
The interconnections kit supplied with the GPC1 includes hardware to adapt
from a DH500 F TEST port to a 1/8 F or 1/4 in. M NPT fitting. To convert a
DH500 F TEST port to one of these fittings, install either the DH500 F x 1/8 in.
NPT M or DH500 F x 1/4 in. NPT F adaptors onto one of the 2.75 in. (70 mm)
DH500 nipples and install the nipple into the DH500 F port.
Special design features are included in GPC1 to avoid excessive contamination
of GPC1 if liquids should return from the system to which it is connected.
For this purpose, GPC1 is equipped with an inclined manifold that serves as a
liquid sump (see Figure 5). A DRAIN port is provided at the low point so that the
sump can be easily purged. The TEST ports all go directly through the sump so
that any liquids
returning from the system under test will collect there rather than
being carried throughout GPC1. The top, rear TEST1 port is supplied directly
from the SUPPLY port so that it is always filled with clean gas from the supply.
Even if liquids are present in the sump, they will not enter the TEST1 port as gas
that may have been exposed to liquids never flows into the port from GPC1
(see Figure 5).
Below are recommendations for use of the three (3)
GPC1 TEST ports.
If there is no risk of return of liquids from the devices that will be connected to
GPC1, it is not necessary to discriminate TEST port usage.
•TEST1 port (top, rear): This port is supplied directly from the
SUPPLY port and should be reserved for connecting devices that are known
to be liquid free and must be protected from any risk of liquid contamination.
If no such devices will be connected to GPC1, then this port may be used as
any TEST port would.
•TEST2 port (left lateral): Normally, the reference in a calibration system,
such as a PG7202 piston gauge or an RPM digital pressure monitor is
connected here.
•TEST3 port (top, front): This port is connected to the lowest point on the
drain and should be used for connecting test devices that may contain
liquids.
If you are using a hydrocarbon free version GPC1 (P/N 401801) DO NOT
connect devices to GPC1 that may contaminate it with hydrocarbons
(see Section 2.6).
By design, the TEST1 port is always filled directly with clean gas from the
SUPPLY port and exhausted away from the port. Do not break the TEST1
port connection under pressure. If unclean gas is present in GPC1, flowing
out the TEST1 port will contaminate the port.
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
2.4 POWER UP AND VERIFICATION
2.4.1 APPLY THE HIGH PRESSURE SUPPLY
This section assumes that the GPC1 system has already been set up, including pressure
interconnection (see Section 2.3.1).
Proceed as follows (numerical references refer to Section 3.1, Figure 6):
Fully back off the TEST INLET SET regulator (5).
Close the TEST INLET valve (12).
Open the TEST OUTLET valve (15).
Highly pressurized gas can be extremely hazardous. Before applying pressure to GPC1
and/or the system connected to it, be sure that all pressure vessels and connections are
rated for the pressure levels that will be applied and that all connections have been
properly tightened (see Section 2.4.5). Ensure that the GPC1 TEST INLET SET regulator
is fully backed off and the INLET valve is closed (see Section 2.4.1).
Apply the high pressure supply to the SUPPLY port (1).
2.4.2 ADJUST INLET PRESSURE
This section assumes that the GPC1 system has already been set up, including pressure
interconnection (see Section 2.3.1).
Be sure the INLET valve is CLOSED before adjusting the TEST INLET SET regulator. If the
INLET valve is open, the supply pressure will be admitted to GPC1 components and
TEST ports.
Turn the TEST INLET SET regulator clockwise while observing the TEST INLET gauge.
Set the pressure as indicated by the TEST INLET gauge to the desired maximum
test pressure. The pressure set by the TEST INLET SET regulator is applied to the inlet of
the INLET valve.
2.4.3 APPLY PDVV DRIVE PRESSURE
This section assumes that the GPC1 system has already been set up, including pressure
interconnections (see Section 2.3).
Apply drive pressure to the PDVV DRIVE port. See Section 2.3.2, Table 2 to determine the
necessary PDVV drive pressure value.
Highly pressurized gas can be extremely hazardous. Before applying pressure to GPC1
and/or the system connected to it, be sure that all pressure vessels and connections are
rated for the pressure levels that will be applied and that all connections have been
properly tightened (see Section 2.4.4).
When the GPC1 INLET valve is opened, the SUPPLY pressure may be applied to the test
system rapidly. Before operating the INLET valve, ALWAYS adjust the TEST INLET SET
regulator pressure low enough so that the SUPPLY pressure does not exceed the
maximum pressure rating of the devices or system to which GPC1 is connected (see
Sections 0 and 3.2.1).
Proceed as follows:
Connect a high pressure indicating device to one of GPC1’s TEST ports (see Section
3.2.4). Plug all other TEST ports using DH500 plugs.
There are three (3) TEST ports: One (1) on the left, rear side and two (2) on the top (see
Section 2.3.4.3).
Fully close the OUTLET valve.
Slowly open the INLET valve.
The pressure indicated by the reference and/or device under test should begin to
increase. If the pressure does not increase, possible explanations are:
• The TEST INLET SET regulator has not been properly adjusted (see Section 2.4.2).
• There is no supply pressure.
• There is a large leak in the system to which GPC1 is connected or in GPC1 itself.
Keep the INLET valve open until the desired gas pressure is set.
Fully close the INLET valve.
Leak Check: The pressure indicated by the high pressure device connected to the
TEST port should stabilize and hold. If it does not, there is a leak in the system to which
GPC1 is connected or in GPC1 itself.
The time required for pressure to stabilize after the pressure has been changed is directly
proportional to the volume connected to GPC1, to the magnitude of the pressure change
and to the mechanical stability of the volume's connections and vessels. It may take up
to 10 minutes to stabilize pressure well enough to perform a valid leak test. To reduce
stabilization time, go beyond the pressure set point and return. If in doubt as to the
validity of a leak test, consider running the leak test overnight and to observe the change
in pressure over a very long time period.
When leak checking is complete, slowly open the OUTLET valve to reduce pressure and
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
2.4.5 PRECAUTIONS TO TAKE BEFORE GENERATING
PRESSURE/SAFETY CONSIDERATIONS
Highly pressurized gas can be extremely hazardous if proper procedures are not followed or
incorrect hardware is used. Before using GPC1 to set and adjust pressure, consider
the following:
• Check that all connections, vessels and DUTs connected to GPC1 are rated for the
pressure to be set and that all fittings are properly tightened.
• Opening the INLET valve opens to the gas pressure supply. To avoid accidental
overpressure of the items to which GPC1 is connected, BEFORE opening the
INLET valve, ALWAYS adjust the TEST INLET SET regulator so that the supply to the
INLET valve is lower than the maximum pressure that is intended to be set with the
GPC1 (see Sections 0).
At high pressure, the
•
than at low pressure. Observe pressure evolution carefully when operating these valves
(see Section 3.2.3).
Drain/purge the GPC1 sump regularly to remove any contaminants that may have
•
entered the system from the supply gas or devices connected to GPC1 (see Section
3.2.5).
Put the PDVV plunger in the START position when starting a calibration or test sequence
•
(see Section 3.2.3).
•
Systems and DUTs connected to GPC1 should be emptied of liquids before they are
pressurized (see Section 3.2.5, 4.2).
and push button valves increase pressure much more quickly
2.5 STORAGE AND SHIPPING
When leaving GPC1 at rest but still setup for operation:
Fully close the INLET valve.
Release gas pressure by fully opening the OUTLET valve.
Open the DRAIN port.
Release pneumatic supply pressure by fully backing off the TEST INLET SET regulator.
To prepare GPC1 for long term storage or shipping:
Disconnect all pneumatic pressure connections and plug the DH500 connections using DH500 plugs
or dummy plugs held by gland nuts. Plug the 1/4 in. NPT port with a plastic plug.
When shipping GPC1, use the original shipping materials, if possible. If it is necessary to use alternate
materials, use caution and ensure that: a) the front panel controls and indicators are protected;
and, b) the tubing and components exposed through GPC1’s open bottom are protected. GPC1 must
ride on its four (4) feet - NOT on its internal components.
2.6 SPECIAL CONSIDERATIONS FOR HYDROCARBON
FREE OPERATION
A special “hydrocarbon free” version of GPC1 (P/N 401801 or P/N 402201) is available. This part number is
delivered free of known sources of hydrocarbon in the GPC1 high pressure gas circuit. Of course, GPC1 will
remain hydrocarbon free only so long as hydrocarbons are not introduced from an external source.
To maintain a hydrocarbon free GPC1, only connect devices to it that are known to be hydrocarbon free.
If using a gas booster to supply the high pressure, the gas booster must be a hydrocarbon free version.
If using a PG7202 piston gauge, the PG7202 must be a hydrocarbon free version and used with Krytox®
lubricated piston-cylinder modules.
Numerical references in this section refer to Section 3.1, Figure 6.
GPC1 is a self-contained system designed to set and adjust gas pressure into static pressure test and
calibration systems. GPC1-16000 operates from atmosphere (zero gauge) to 110 MPa (16 000 psi).
GPC1-10000 operates to 70 MPa (10 000 psi). GPC1 combines the capability to execute large pressure
changes very quickly with very fine pressure adjustment.
GPC1 uses two different techniques to set and adjust pressure. These are rough pressure control using
the TEST INLET valve (12) and TEST OUTLET valve (15) and fine pressure control using the PDVV (+)
(13) and (-) valves (14).
The first means of generating and adjusting pressure uses the external gas pressure supply (1) with the
TEST INLET SET regulator (5), TEST INLET valve (12) and TEST OUTLET valve (15). This combination
is used for filling the system under test, making large pressure changes and for rough pressure control.
The valves are Belleville spring loaded, half-turn needle valves. Their operation is highly progressive
over a half-turn with mechanical stops at each end so they cannot be over tightened. The regulator is self
venting and its output is indicated by the TEST INLET gauge (4). The valve is turned clockwise (CW) to
close and counter-clockwise (CCW) to open. A WHITE dot on the handle body indicates the valve’s
current open/close position. The TEST INLET SET regulator (5) and TEST INLET gauge (4) are used to
set the supply pressure to the TEST INLET valve (12). Opening the INLET valve (12) allows the supply
pressure to enter GPC1 and reach the TEST ports (6,7,8). Opening the OUTLET valve (15) exhausts
gas, reducing pressure in the system.
The second means of generating and adjusting pressure is the Pneumatically Driven Variable Volume
(PDVV) (16) combined with the PDVV (+) (13) and (-) valves (14). This combination is used for smaller
pressure changes and fine pressure control. The PDVV is a pneumatically actuated variable volume. A
piston or plunger in a cylinder is exposed to the high pressure gas to be adjusted.
The other end of the plunger is connected to a dome loaded pneumatic actuator. Changing the
pneumatic pressure on the dome loaded actuator causes the plunger to move, increasing or decreasing
the high gas pressure. A spring returns the plunger to its minimum stroke position when there is no
pressure on the dome. A mechanical system tracks movement of the plunger and an indicator (18)
displays the plunger position on the front panel. The PDVV (+) (13) and (-) valves (14) are momentary,
poppet valves that open when pressed. The (+) valves (13) admit drive air pressure to the PDVV
actuator causing the PDVV piston to move forward, compressing the high pressure gas and increasing
the pressure. The (-) valves (14) have the opposite effect, causing pressure to decrease when they are
operated.
All GPC1 operational functions are accessed from the instrument front panel. Sections 3.2.1 to 3.2.5
detail the various functions.
1. PDVV drive air/test gas pressure
gauge
2. PDVV piston position indicator
3. Test inlet pressure gauge
4. Test inlet pressure regulator
5. Test inlet valve knob
6. PDVV increase fast and slow
buttons
7. PDVV decrease fast and slow
buttons
8. Test outlet valve knob
Figure 7. Front Panel View
3.2.1 SETTING INLET SUPPLY PRESSURE, TEST INLET
REGULATOR ADJUSTMENT
Numerical references in this section refer to Section 3.2, Figure 7. For information on the
GPC1 operating principle, see Section 3.1.
Setting inlet supply pressure generally done at the beginning of a test or calibration based on
the maximum pressure of the calibration. It is good practice to set the inlet pressure just
below the maximum pressure desired to avoid accidental overpressure. The PDVV can then
be used for the final pressure adjustment at the maximum pressure (see Section 3.2.3).
With the INLET valve (5) closed, use the INLET SET regulator (4) and the INLET gauge (3)
indication to set the maximum desired test pressure.
The TEST INLET SET regulator sets the pressure to the TEST INLET valve. When the TEST
INLET valve is opened, this pressure can be generated rapidly in the system connected
to GPC1. Use caution in setting the TEST INLET regulator pressure and always check the
setting and adjust if necessary before using the TEST INLET valve (see Section 2.4.2).
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
3.2.2 ROUGH PRESSURE GENERATION/CONTROL, INLET
AND OUTLET VALVE OPERATION
Numerical references in this section refer to Section 3.2, Figure 7. For information on the
GPC1 operating principle, see Section 3.1.
The INLET valve (5) and OUTLET valve (8) are used to execute large pressure changes in the
test system and for rough pressure control. The INLET valve is used to increase pressure and
the OUTLET valve, decreases pressure and vents the system to atmosphere, setting zero gauge
pressure. If finer pressure control, use the PDVV valves (see Section 3.2.3).
To increase pressure in the GPC1 system, open the INLET valve (5) slowly. Use the
progressive nature of the valve to control the rate of pressure increase. Close the valve
when the desired pressure has been reached. When a gas booster is used to supply high
pressure, the booster may not be able to keep up with the flow rate needed to set the desired
pressure. In this case, with the INLET valve open, wait for the booster to reach the desired
pressure.
To decrease pressure in the GPC1 system, open OUTLET valve (8) slowly. Open the valve
fully to vent the system to atmosphere (set zero gauge).
The TEST INLET valve connects the pressure supply to the test system. When the TEST
INLET valve is opened, high pressure can be generated rapidly in the system connected to
GPC1. Use caution in opening the TEST INLET valve and always check the TEST INLET
pressure gauge before doing so (see Section 2.4.2).
3.2.3 FINE PRESSURE ADJUSTMENT, PDVV (+) AND (-)
VALVE OPERATION
Numerical references in this section refer to Section 3.2, Figure 7 except where
specified otherwise. For information on the GPC1 operating principle, see Section 3.1.
Use the valves labeled
plunger to back off and pressure to decrease. Use the valves labeled
to the PDVV actuator, causing the PDVV plunger to move forward and pressure to increase.
The
and valves are for high speed PDVV operation. The and valves are for slow speed
PDVV operation.
The PDVV (+) (6) and (-) valves (7) are utilized to make small pressure changes and for fine
pressure control. Brief momentary action on the
pressure in very small amounts around a pressure point.
If the PDVV plunger reaches end of stroke during a calibration or test, use the INLET valve (5)
and/or OUTLET valve (8) to increase or decrease the pressure, as needed (see Section 3.2.2).
and to release gas from the PDVV actuator, causing the PDVV
are to admit gas
and valves is used to bump or jog
The actual rate of pressure change caused by the PDVV (+) valves and PDVV (-) valves is
dependent on the test volume that is connected to GPC1 and the current pressure value.
Increasing the test volume lowers the pressure change rate and pressure step size.
Increasing the volume increases the rate and the pressure step size. The maximum
pressure that can be generated by the PDVV (+) valves is dependent on the PDVV drive air
supply (see Section 2.3.2, Table 2).
The position of the PDVV plunger is indicated
by the PDVV POSITION indicator (2).
The RED index (Figure 8, Ref 4) on the
START
indicator tracks the movement of the PDVV
plunger. Minimum and maximum end of
stroke positions (Figure 8, Refs 3 and 1) as
well as a recommended start position
(Figure 8, Ref 2) are indicated. The full stroke
displacement of the GPC1 PDVV plunger from
maximum to minimum end of stroke is
2 cc (0.12 in.
3
).
1. Maximum End of Stroke
2. Recommended Start Position
3. Minimum End of Stroke
4. Current Position (red/white line)
Figure 8. PDVV Plunger Position Indicator
PDVV
POSITION
The current air drive pressure on the PDVV actuator and approximate corresponding gas test
pressure are indicated by the PDVV DRIVE/TEST gauge (1). The gas test pressure
indication is highly approximate and only valid when the PDVV plunger is NOT at an end of
stroke position.
For the PDVV (+) (6) and (-) valves (7) to have an effect, the PDVV plunger must have
stroke available. If the PDVV is at its end of stroke position (Figure 8, Refs 1 and 3), the
plunger cannot move to change pressure. The recommended PDVV START position (Figure
8, Ref 2) puts the plunger at the middle of its stroke so 50 % of PDVV displacement is
available in either direction. The PDVV plunger can be positioned without affecting test
pressure using the
and valves when the OUTLET valve (8) is open (pressure vented).
The plunger is returned to minimum end of stroke position by a spring. The PDVV plunger is
usually set to the desired position at the start of a calibration or test.
The PDVV (+) valves generate pressure indefinitely when opened. Particularly when
operating at very high pressure, use caution when operating these valves so that they do
not generate more pressure than is desired.
3.2.4 CONNECTING A DEVICE UNDER TEST (DUT)
For information on the GPC1 operating principle, see Section 3.1.
The device to be tested or calibrated should be connected either to a TEST port configured
on the interconnections external to GPC1 or to one of GPC1 top TEST ports
(see Section 3.1, Figure 6, and Section 2.3.4.3). The test connection is a DH500 F (DH500
is a gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand threaded tube.
DH500 is equivalent to AE F250C, HIP HF4, etc.).
The DH500 test connection can be converted to 1/8 in. NPT M or 1/4 in. NPT F using the
2.75 in. (70 mm) tube and DH500 F X 1/8 in. NPT M or DH500 F x 1/4 in. NPT F adaptor
supplied with GPC1 accessories. Install the tube into the adaptor. Then install that
adaptor/tube assembly onto the DH500 F TEST port.
GPC1 can be used at very high gas pressure. It is the user’s responsibility to ensure that
fittings and devices connected to GPC1 are rated for the pressures at which they will be used.
By design, TEST1 port is always filled directly with clean gas from the SUPPLY port and
exhausted away from the port. Do not break the TEST1 port connection under pressure
as, if unclean gas is present in GPC1, this could cause it to flow to the TEST1 port.
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
3.2.5PURGING LIQUIDS FROM THE DUT/SYSTEM UNDER TEST
GPC1 includes a sump to collect liquids that may return from the device or system under test
to which it is connected. However, the amount of liquid that the sump can handle without
liquids entering other GPC1 internal circuitry is limited. Excessive fluids in GPC1 and test
connections can cause erratic pressure control and introduce unexpected uncertainty in
measurements. DUTs and the system under test should be cleaned of liquids to the extent
reasonably possible before being connected to GPC1. Also, see Section 2.3.4.3 for
information about the appropriate GPC1 TEST port connection to use.
The procedure to purge the GPC1 sump and/or a DUT connected to GPC1 is:
Use GPC1 to pressurize the system, including the DUT, to approximately
3 500 kPa (500 psi) (or maximum pressure of the DUT if less than 3.5 MPa (500 psi)).
Open DRAIN port. Use the 5/8 in. open end wrench supplied in the GPC1 accessories to
slowly and then more fully open the port allowing gas to exhaust as quickly as is safe and
practical.
Observe whether the gas coming out of the DRAIN port contains liquid or liquid vapor.
Repeat steps through until there is no evidence of liquid in the gas escaping from the
DRAIN port.
3.3 TYPICAL OPERATING SEQUENCE FOR A COMPLETE
CALIBRATION OR TEST
GPC1 is most often used to set and adjust pressure to a reference measuring device and a DUT when
performing a test or calibration. The reference measuring device may be a pressure monitor such as a
digital indicator or a piston gauge or deadweight tester. The typical operational sequence is as follows:
Connect the DUT to the appropriate GPC1 TEST port or to a test port on the external system to
which GPC1 is connected (see Sections 3.2.4, 2.3.4.3).
Set the TEST INLET SET regulator (see Section 3.2.1)
Position the PDVV plunger (see Section 3.2.3).
Purge the DUT (if necessary) (see Section 3.2 5).
Take the starting zero reading on the DUT: With the OUTLET valve open, and the INLET valve
closed, the pressure in the test system is zero gauge.
Set ascending test pressures: Carefully open the INLET valve and control the gas input to set the
pressure in the test system just under the desired test point (see Section 3.2.2). Pause a moment.
Then use the PDVV (+)and/or (-) valves to adjust the pressure to the exact test pressure desired or,
if the reference is a piston gauge, to float the piston gauge piston (see Section 3.2.3). Repeat this
process for all of the ascending increments. If the increments are small enough for the PDVV
displacement to generate the pressure, only the PDVV (+) valves may be needed to reach the next
pressure. If the PDVV runs out of stroke, use the INLET valve to generate pressure and reposition
the PDVV plunger.
Set descending test pressures: Very carefully open the OUTLET valve and control the gas
exhaust to set pressure in the test system just over the desired test point (see Section 3.2.2). Then
use the PDVV (+) and/or (-) valves to adjust the pressure to the exact test pressure desired or, if the
reference is a piston gauge, to float the piston gauge piston (see Section 3.2.3). Repeat this process
for all of the descending increments. If the increments are small enough for the PDVV displacement
to generate the pressure, only the PDVV (-) valves may be needed to generate the next pressure. If
the PDVV runs out of stroke, use the OUTLET valve to reduce pressure.
Vent the system and disconnect the DUT: Open the OUTLET valve fully and check that the DUT
GPC1 was designed for maintenance free operation. The PDVV is permanently lubricated. No
maintenance is required other than:
• Purge the sump very regularly (see Section 4.2).
• Clean/replace the PDVV driv
contaminated and restrict the free flow of pressure. It should then be cleaned or replaced
(see Section 4.3).
Maintenance and repair services for GPC1 are offered by DHI Authorized Service Providers (see Section
6.2, Table 4).
GPC1 is a sophisticated pressure setting and adjusting instrument with advanced features and
functions. Before assuming that unexpected behavior is caused by a system defect or breakdown, use
this manual and other training and troubleshooting facilities to become thoroughly familiar with GPC1
operation. For rapid troubleshooting assistance in specific situations, see Section 5.
e air filter element when needed:The drive air filter may become
GPC1 is covered by a limited 1 year warranty (see Section 6.2). Unauthorized service or repair during
the warranty period is undertaken at the owner's risk and may cause damage that is NOT covered
under product warranty and/or may void the product warranty.
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
4.2PURGING THE SUMP (DRAIN)
The GPC1 sump (see Figure 6, Ref 10) is designed to collect liquids that may be returned from the
pressure supply or system/device under test so that they do not contaminate the rest of the system. The
sump has a limited volume should be drained regularly as part of normal operation. The purge process
below should also be used when a DUT is connected that is known to contain liquids (see Section 3.2.5).
The procedure to purge the GPC1 sump and/or a DUT connected to GPC1 is:
Use GPC1 to pressurize the system, including the DUT, to approximately 3 500 kPa (500 psi) (do not
exceed the pressure of the system or the DUT connected to GPC1).
Open the DRAIN port (see Figure 9). Use the 5/8 in. open end wrench supplied in the GPC1
accessories to slowly and then more fully open the port allowing gas to exhaust as quickly as is safe
and practical.
Observe whether the gas coming out of the DRAIN port contains liquid or liquid vapor.
Repeat steps through until there is no evidence of liquid in the gas that vents through the DRAIN
port.
Figure 9. Drain Port Location
4.3CLEANING/REPLACING PDVV DRIVE AIR FILTER ELEMENT
There is a filter on the PDVV DRIVE port. If the drive air supplied is excessively dirty, this filter may
become excessively dirty and restrict air flow to the PDVV actuator (see Section 3.1, Figure 6).
The drive air filter is a filter
be removed from GPC1.
To remove and reinstall the drive air filter, proceed as follows (numerical references in this section
refer to Figure 10):
Place GPC1 on the bench, so that the front panel is up with the open bottom towards you.
Disconnect the filter downstream filter connection fitting (2) and move the 1/4 in. PFA flexible tubing
(1) away from the filter body (3). Then disconnect the upstream filter connection (4) and remove the
filter body (3).
To reinstall the filter, make the upstream filter connection (4). Then make the downstream filter
connection (2). Use caution to ensure that the filter body (3) is oriented in the correct direction
(the arrow on the filter body is in the direction of flow in from the PDVV DRIVE port).
body with a sintered element. To clean or replace the filter the filter body must
GPC1 is a sophisticated pressuring generating and adjusting instrument with advanced features and
functions. Before assuming that unexpected behavior is caused by a system defect or breakdown, the
operator should use this manual and other training facilities to become thoroughly familiar with GPC1
operation. This troubleshooting guide is intended as an aid in identifying the cause of unexpected GPC1
behavior and determining whether the behavior is due to normal operation or an internal or external
problem.
Identify the symptom or unexpected behavior you are observing from the SYMPTOMS listed in Table 3.
A PROBABLECAUSE is provided and a SOLUTION is proposed including references to manual
sections that provide information that may be of assistance.
Table 3. GPC1 Troubleshooting Checklist
SYMPTOM PROBABLE CAUSE SOLUTION
Test pressure continuously increases
even with all valves closed.
Test pressure continuously decreases
even with all valves closed.
Test pressure takes too long to
stabilize or will never stabilize.
Test pressure takes too long to
stabilize or will never stabilize.
Test pressure takes too long to
stabilize or will never stabilize.
PDVV will not increase pressure.
PDVV will not decrease pressure. PDVV is at minimum end of stroke
Opening INLET valve does not
increase pressure.
Leak in INLET valve or leak in PDVV (+) valve(s).
Leak in OUTLET valve, leak in
PDVV (-) valve(s), leak in test
system connected to GPC1 or
internal leak in GPC1 high pressure
gas system.
You are observing normal evolution
of pressure in an uncontrolled static
volume.
Leak in GPC1 or test system
connected to GPC1.
GPC1 and/or test system tubing is
contaminated with liquids that are
“plugging” tubes.
PDVV is at maximum end of stroke
position, PDVV drive air supply
pressure is not high enough, or
PDVV drive air supply is plugged.
position.
TEST INLET SET regulator is set
too low and/or external pressure
supply to low.
Isolate leak to INLET valve or PDVV (+) valve(s) by checking whether pressure
continues to increase when PDVV is at end
of stok e. Replace or repair valve(s) if qualified
to do so. 3.1, 3.2.3.
Identify and correct leak in test system if
present. Disconnect from test system and
plug GPC1 TEST ports to test GPC1 alone.
Isolate leak to OUTLET valve or PDVV (-) valve(s) by checking if pressure continues to
decrease when PDVV is in minimum end of
stroke position. Replace or repair valve(s) if
qualified to do so. 3.1, 3.2.3.
Reduce resolution of pressure reading to
appropriate level. Reduce test volume.
Increase stability of test tubings and vessels.
Wait longer for stability. Overshoot test point
and return to reduce stabilization time.
See troubleshooting tips “Test pressure
continuously increases…” and “Test pressure
continuously decreases…” above.
Thoroughly purge complete system.
3.2.5 and 4.2
Verify PDVV piston position and readjust if
necessary. Use INLET valve to increase
pressure. Increase PDVV drive air supply
pressure. Clean filter. 2.3.2, 3.1, 3.2.3
Verify PDVV piston position and readjust if
necessary. Use OUTLET valve to decrease
pressure. 2.3.2, 3.1, 3.2.3
Check value of supply pressure on TEST INLET gauge. Adjust INLET regulator,
increase supply pressure if necessary. 2.3.2,
, Fast ( ) and slow ( ), PDVV (-) valves. Used to decrease pressure and for fine
, Fast ( ) and slow (), PDVV (+) valves. Used to increase pressure and for fine
Collar
CCW
CW
DH500
DUT
Gland
PDVV (Pneumatically
Driven Variable Volume)
PDVV (+) Valves
PDVV (-) Valves
pressure adjustment.
pressure adjustment.
The DH500 fitting element that is threaded onto the tube and provides a surface for the
gland to push against.
Counter-clockwise
Clockwise
High pressure, gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand
threaded, stainless steel tubes. DH500 is equivalent to AE F250C, HIP HF4, etc.
Device or System Under Test. The device that is connected to GPC1 to be tested or
calibrated.
The “jam nut” in a DH500 fitting that pushes the collar on the tube into the seat.
A pneumatically actuated plunger in a cylinder used to increase and decrease the
volume of the high pressure gas test system and provide fine adjustment of the
test pressure.
Momentary, push button actuated, poppet valves that admit drive air drive pressure to
the PDVV actuator causing the PDVV plunger to move forward, compressing the high
pressure gas and increasing the test pressure. Used to increase pressure and for fine
pressure adjustment.
Momentary, push button actuated, poppet valves that release air drive pressure from the
PDVV actuator causing the PDVV plunger to move back, decompressing the high
pressure gas and decreasing the test pressure. Used to decrease pressure and for fine
pressure adjustment.
Analog gauge that indicates the PDVV actuator air pressure and the approximate
corresponding gas test pressure.
Analog gauge that indicates the pressure set by the TEST INLET SET regulator and
applied to the TEST INLET valve.
Progressive, half-turn, needle valve used to admit high pressure gas into the test
system. Used for rough pressure adjustment.
Self venting regulator used to regulate the external high pressure gas supply.
Sets maximum TEST INLET valve pressure.
Progressive, half-turn, needle valve used to return exhaust gas from the test system.
Used to release pressure and for rough pressure adjustment.
The high gas pressure in GPC1 PDVV, at its TEST connections and in the system to
which GPC1 is connected.
GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL
6.2WARRANTY STATEMENT
Except to the extent limited or otherwise provided herein, DH Instruments, a Fluke Company (DHI)
warrants for one year from purchase, each new product sold by it or one of its authorized distributors,
only against defects in workmanship and/or materials under normal service and use. Products which
have been changed or altered in any manner from their original design, or which are improperly or
defectively installed, serviced or used are not covered by this warranty.
DHI and any of its authorized service providers’ obligations with respect to this warranty are limited to the
repair or replacement of defective products after their inspection and verification of such defects. All
products to be considered for repair or replacement are to be returned to DHI, or its authorized service
provider, freight prepaid, after receiving authorization from DHI or its authorized service provider. The
buyer assumes all liability vis-à-vis third parties in respect to its acts or omissions involving use of the
products. In no event shall DHI be liable to purchaser or any party for any unforeseeable or indirect
damage, it being expressly stated that, for the purpose of this warranty, such indirect damage includes,
but is not limited to, loss of production, profits, revenue, or goodwill, even if DHI has been advised of the
possibility thereof, and regardless of whether such products are used individually or as components in
other products.
Items returned to DHI under warranty claim but determined to not have a defect covered under warranty
or to not have a defect at all are subject to an evaluation charge as well as applicable repair and/or
calibration costs.
The provisions of this warranty and limitation may not be modified in any respect except in writing signed
by a duly authorized officer of DHI.
The above warranty and the obligations and liability of DHI and its authorized service providers exclude
any other warranties or liabilities of any kind.
Table 4. DHI Authorized Service Providers
DH INSTRUMENTS, A FLUKE COMPANY
AUTHORIZED SERVICE PROVIDERS
COMPANY
DH Instruments, a Fluke
Company
Minerva Meettechniek B.V. Chrysantstraat 1
Nippon CalService, Inc. 2-9-1 Sengen, Tsukuba-Shi
DH Products Technical
Service Division
4765 East Beautiful Lane
Phoenix AZ 85044-5318
USA
3812 WX Amersfoort
the NETHERLANDS
Ibaraki Prefecture 305
JAPAN
National Institute of Metrology
Heat Division
Pressure & Vacuum Lab
NO. 18, Bei San Huan Donglu
Beijing 100013
PR CHINA
ADDRESS
TELEPHONE,
FAX & EMAIL
Tel 602.431.9100
Fax 602.431.9559
cal.repair@dhinstruments.com
Tel (+31) 33.46.22.000
Fax (+31) 33.46.22.218
info@minervaipm.com
Tel 0298-55-8778
Fax 0298-55-8700
n-calservice@ohtegiken.co.jp
Tel 010-64291994 ext 5
Tel 010-64218637 ext 5
Fax 010-64218703
cxcen@mx.cei.gov.cn