Fluke GPC1-10000, GPC1-16000 User Manual

GPC1-10000/GPC1-16000™

Gas Pressure Controller

Operation and Maintenance Manual

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.
Document No. 550126A
041029
Printed in the USA

TABLE OF CONTENTS

TABLE OF CONTENTS ...............................................................				I
TABLES .................................................................................				III
FIGURES ................................................................................				III
ABOUT THIS MANUAL ..............................................................				V
1 .	INTRODUCTION .................................................................			1
	1.1	PRODUCT OVERVIEW ...........................................................................................................................		1
	1.2	SPECIFICATIONS ...................................................................................................................................		2
	1.3	INSTRUMENT LAYOUT ..........................................................................................................................		3
		1.3.1	FRONT PANEL ..............................................................................................................................................	3
		1.3.2	OVERALL DIMENSIONS...............................................................................................................................	3
		1.3.3	SYSTEM SCHEMATIC ..................................................................................................................................	4
2 .	INSTALLATION ..................................................................			5
	2.1	UNPACKING AND INSPECTION ............................................................................................................		5
		2.1.1	REMOVING FROM PACKAGING..................................................................................................................	5
		2.1.2	INSPECTING CONTENTS.............................................................................................................................	5
	2.2	SITE REQUIREMENTS............................................................................................................................		6
	2.3	INITIAL SETUP........................................................................................................................................		7
		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

2.3.4.1CONNECTING TO A DHI RPM OR PG7202 USING THE STANDARD

		GPC1 INTERCONNECTIONS KIT.............................................................................................................	8
	2.3.4.2	OTHER HIGH PNEUMATIC PRESSURE INTERCONNECTIONS .........................................................	9
	2.3.4.3	RECOMMENDATIONS FOR TEST PORT CONNECTION, USE AND DUT CLEANLINESS
		CONSIDERATIONS .................................................................................................................................	10
2.4	POWER UP AND VERIFICATION .........................................................................................................		12
	2.4.1	APPLY THE HIGH PRESSURE SUPPLY ...................................................................................................	12
	2.4.2	ADJUST INLET PRESSURE .......................................................................................................................	12
	2.4.3	APPLY PDVV DRIVE PRESSURE ..............................................................................................................	12
	2.4.4	CHECK OPERATION OF COMPONENTS..................................................................................................	13
	2.4.5	PRECAUTIONS TO TAKE BEFORE GENERATING PRESSURE/SAFETY CONSIDERATIONS.............	14
2.5	STORAGE AND SHIPPING ...................................................................................................................		14
2.6	SPECIAL CONSIDERATIONS FOR HYDROCARBON FREE OPERATION........................................		15

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GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL

3 . OPERATION ..................................................................... 17

	3.1	OPERATING PRINCIPLE ......................................................................................................................	17
	3.2	OPERATIONAL FUNCTIONS................................................................................................................	19
		3.2.1 SETTING INLET SUPPLY PRESSURE, TEST INLET REGULATOR ADJUSTMENT...............................	19
		3.2.2 ROUGH PRESSURE GENERATION/CONTROL, INLET AND OUTLET VALVE OPERATION ................	20
		3.2.3 FINE PRESSURE ADJUSTMENT, PDVV (+) AND (-) VALVE OPERATION .............................................	20
		3.2.4 CONNECTING A DEVICE UNDER TEST (DUT).........................................................................................	21
		3.2.5 PURGING LIQUIDS FROM THE DUT/SYSTEM UNDER TEST ..................................................	22
	3.3	TYPICAL OPERATING SEQUENCE FOR A COMPLETE CALIBRATION OR TEST ..........................	22
4.	MAINTENANCE AND ADJUSTMENTS ..................................		23
	4.1	OVERVIEW ............................................................................................................................................	23
	4.2	PURGING THE SUMP (DRAIN).............................................................................................................	24
	4.3	CLEANING/REPLACING PDVV DRIVE AIR FILTER ELEMENT ............................................	24
5 .	TROUBLESHOOTING ........................................................		27
6 .	APPENDICES ...................................................................		29
	6.1	GPC1 TERMS, LABELS, AND SYMBOLS (GLOSSARY) ....................................................................	29
	6.2	WARRANTY STATEMENT....................................................................................................................	30

Page II

TABLES AND FIGURES

TABLES

Table 1.	GPC1 Parts List .............................................................................................................................	5
Table 2.	Pneumatic Power (Drive Air) Requirements..................................................................................	7
Table 3.	GPC1 Troubleshooting Checklist.................................................................................................	27
Table 4.	DHI Authorize d Service Providers ..............................................................................................	30

FIGURES

Figure 1.	Front Panel View ..........................................................................................................................	3
Figure 2.	Front and Side Views with Dimensions ........................................................................................	3
Figure 3. System Schematic ........................................................................................................................		4
Figure 4. Connecting GPC1 to PG7202 or RPM .........................................................................................		9
Figure 5. Clean TEST Port, Sump and Drain Port.....................................................................................		11
Figure 6. System Schematic ......................................................................................................................		18
Figure 7.	Front Panel View ........................................................................................................................	19
Figure 8.	PDVV Plunger Position Indicator................................................................................................	21
Figure 9.	Drain Port Location .....................................................................................................................	24
Figure 10.	PDVV Drive Air Filter ................................................................................................................	25

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GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL

NOTES

Page IV

ABOUT THIS MANUAL

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!

Manual Conventions

(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 explanations.

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GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL

NOTES

Page VI

1. INTRODUCTION

1.INTRODUCTION

1.1PRODUCT OVERVIEW

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.

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GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL

1.2SPECIFICATIONS

Electrical Power Requirements None

Pneumatic Power Requirements Clean, dry, low flow, compressed gas. Maximum pressure needed depends on maximum pressure to be adjusted. Max flow 200 sccm:

	Working P	Drive Air P
	- For 5 MPa (750 psi):	300 kPa (45 psi)
	- For 50 MPa (7 500 psi):	600 kPa (87 psi)
	- For 70 MPa (10 000 psi)	700 kPa (100 psi)
	- For 110 MPa (16 000 psi):	850 kPa (120 psi)
Operating Temperature Range	10 to 35 °C
Weight	24 kg (53 lb)
Dimensions	21.5 cm H x 30 cm W x 53.5 cm D (8.5 in. x 11.8 in. x 21.1 in.)
Pressure Range	GPC1-16000: 0 to 110 MPa (16 000 psi)
	GPC1-10000: 0 to 70 MPa (10 000 psi)
	Maximum adjustable pressure depends on pneumatic power
	supply (see above).
Operating Medium	Any non-corrosive gas
Pneumatic Power Connection(s)	1/4 in. NPT F
Test Connections	(3) DH500 F test connections ((1) left rear side and (2) on top)

	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.

Pneumatically Actuated	2 cc (0.12 in3)
Variable Volume (PDVV)
Displacement

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Fluke GPC1-10000, GPC1-16000 User Manual

1. 4BINTRODUCTION

1.3INSTRUMENT LAYOUT

1.3.1FRONT PANEL

The front panel provides all of the controls and indications needed to set and adjust pressure.

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 1. Front Panel View

1.3.2OVERALL DIMENSIONS

Figure 2. Front and Side Views with Dimensions

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GPC1-10000 / GPC1-16000™ OPERATION AND MAINTENANCE MANUAL

1.3.3SYSTEM SCHEMATIC

Figure 3. System Schematic

1.High pressure gas SUPPLY connection (left lateral)

2.Supply accumulator

3.Supply filter (not shown)

4.TEST INLET gauge

5.TEST INLET SET regulator

6.TEST1 port (rear top)

7.TEST2 port (left lateral)

8.TEST3 port (front top)

9.DRAIN port (right lateral)

10.Test liquid collection sump

11.Sump filter (not shown)

12.TEST INLET valve

13.Fast and slow PDVV increase valves

14.Fast and slow PDVV decrease valves

15.TEST OUTLET valve

16.Pneumatically driven variable volume (PDVV)

17.PDVV drive pressure gauge

18.PDVV plunger position indicator

19.PDVV DRIVE air connection (right lateral)

20.DRIVE air filter

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