Fluke GPC1-10000-AF User Manual

GPC1-10000-AF™

Gas Pressure Controller

Operation and Maintenance Manual

NSN 6685-01-529-6990 RN

(1 of 3)

GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL

This equipment described in this manual is designed and manufactured for the intended purpose of generating high pressure gas. Certain precautions need to be followed during installation and operation of this device. Reading and understanding this material is essential to the safe and correct operation of the unit.

Pressurized equipment is potentially dangerous. The equipment described in this manual generates and

controls very high gas pressures. It should not be operated by anyone who has not become thoroughly familiar with this manual. Additional training in general and pressure specific safety procedures will help assure protection from harm or damage to personnel or property. Responsibility for the proper and safe operation of this instrument rests with the user.

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.

This instrument is not to be operated in any other manner than that specified by the manufacturer.

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, RPM4 and HPMS 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. 550135b-01 070628 Printed in the USA

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TABLE OF CONTENTS ...............................................................I

TABLES.................................................................................III

FIGURES................................................................................III

ABOUT THIS MANUAL...............................................................I

1. INTRODUCTION ................................................................. 3

1.1 PRODUCT OVERVIEW ...........................................................................................................................3

1.2 SPECIFICATIONS ...................................................................................................................................4

1.3 INSTRUMENT LAYOUT ..........................................................................................................................5

1.3.1 FRONT PANEL..............................................................................................................................................5

1.3.2 OVERALL DIMENSIONS...............................................................................................................................5

1.3.3 SYSTEM SCHEMATIC ..................................................................................................................................6

2. INSTALLATION .................................................................. 7

2.1 UNPACKING AND INSPECTION ............................................................................................................7

2.1.1 REMOVING FROM PACKAGING..................................................................................................................7

2.1.2 INSPECTING CONTENTS.............................................................................................................................7

2.2 PGC-10000-AF SYSTEM.........................................................................................................................8

2.3 SITE REQUIREMENTS............................................................................................................................9

2.4 INITIAL SETUP......................................................................................................................................10

2.4.1 SET UP GPC1..............................................................................................................................................10

2.4.2 CONNECT PNEUMATIC POWER (DRIVE AIR) .........................................................................................10

2.4.3 CONNECT HIGH PRESSURE GAS SUPPLY (GB-152-AF).......................................................................11

2.4.4 MAKE TEST PRESSURE INTERCONNECTIONS......................................................................................12

2.4.4.1 CONNECT THE SYSTEM REFERENCE PRESSURE MEASURING DEVICE (RPM4/HPMS

2.4.4.2 CONNECTING TO A DEVICE UNDER TEST..........................................................................................12

2.4.4.3 CLEANLINESS CONSIDERATIONS WHEN CONNECTING DUTS....................................................13

2.5 POWER UP AND VERIFICATION.........................................................................................................15

2.5.1 APPLY THE HIGH PRESSURE SUPPLY...................................................................................................15

2.5.2 ADJUST THE INLET PRESSURE...............................................................................................................15

2.5.3 APPLY PDVV DRIVE PRESSURE..............................................................................................................16

2.5.4 CHECK OPERATION OF COMPONENTS..................................................................................................16

2.5.5 PRECAUTIONS TO TAKE BEFORE WORKING WITH HIGH PRESSURE GAS / SAFETY

2.6 STORAGE AND SHIPPING...................................................................................................................18

A70M/A20M-AF).......................................................................................................................................12

CONSIDERATIONS.....................................................................................................................................17

GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL

3. OPERATION..................................................................... 19

3.1 OPERATING PRINCIPLE......................................................................................................................19

3.2 OPERATIONAL FUNCTIONS................................................................................................................21

3.2.1 SETTING INLET SUPPLY PRESSURE, TEST INLET SET REGULATOR ADJUSTMENT.......................21

3.2.2 ROUGH PRESSURE GENERATION/CONTROL, INLET AND OUTLET VALVE OPERATION................21

3.2.3 FINE PRESSURE ADJUSTMENT, PDVV (+) AND (-) VALVE OPERATION .............................................22

3.2.4 CONNECTING A DEVICE UNDER TEST....................................................................................................23

3.2.5 PURGING LIQUIDS FROM THE DUT/SYSTEM UNDER TEST .......................................................23

3.3 TYPICAL OPERATING SEQUENCE FOR A COMPLETE CALIBRATION OR TEST..........................24

4. MAINTENANCE AND ADJUSTMENTS .................................. 25

4.1 OVERVIEW............................................................................................................................................25

4.2 PURGING THE SUMP (DRAIN).............................................................................................................26

4.3 C L E A NI N G / R E P L AC I N G P D V V DR I V E A IR F I L T E R E L E M E N T ................................................ 26

4.4 ILLUSTRATED PARTS BREAKDOWN.................................................................................................27

5. TROUBLESHOOTING ........................................................ 31

6. APPENDICES................................................................... 33

6.1 GPC1 TERMS, LABELS, AND SYMBOLS (GLOSSARY)....................................................................33

6.2 WARRANTY STATEMENT....................................................................................................................34

TABLES & FIGURES

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Table 1. GPC1-10000-AF Parts List............................................................................................................7

Table 2. Pneumatic power (drive air) requirements...................................................................................10

Table 3. GPC1 Main Assembly Illustrated Parts Breakdown (see Figure 13)...........................................27

Table 4. GPC1 Internal Assembly Illustrated Parts Breakdown (see Figure 14).......................................28

Table 5. GPC1 troubleshooting checklist...................................................................................................31

Table 6. DHI Authorized Service Providers ...............................................................................................34

IIGGUURREES

Figure 1. Front panel view ........................................................................................................................... 5

Figure 2. Front and side views with dimensions..........................................................................................5

Figure 3. System schematic.........................................................................................................................6

Figure 4. Typical PGC-10000-AF system installation..................................................................................8

Figure 5. Connecting GPC1-10000-AF to RPM4/HPMS A70M/A20M-AF ................................................12

Figure 6. Adapting TEST port to connect a device under test...................................................................13

Figure 7. Clean TEST1 port, sump and drain port.....................................................................................14

Figure 8. System schematic.......................................................................................................................20

Figure 9. Front panel view ......................................................................................................................... 21

Figure 10. PDVV plunger position indicator...............................................................................................22

Figure 11. Drain port location.....................................................................................................................26

Figure 12. PDVV drive air filter ..................................................................................................................27

Figure 13. GPC1 Main Assembly Illustrated Parts Breakdown.................................................................28

Figure 14. GPC1 Internal Assembly Illustrated Parts Breakdown.............................................................30

GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

ABOUT THIS MANUAL

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AANNUUAALL

This manual provides the user with the information necessary to operate a GPC1-10000-AF 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 2.4 TO SET UP YOUR GPC1. THEN GO TO SECTIONS 2.5.5 and 3.3. 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!

GPC1-1000-AF is usually delivered as part of an PGC-10000-AF system which also includes an RPM4/HPMS A70M/A20M-AF reference pressure monitor and and a GB-152-AF gas booster. The RPM4/HPMS and the GB-152 have their own Operation and Maintenance Manuals.

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.

GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL

OOTTEES

1. INTRODUCTION

11.

1.1 PRODUCT OVERVIEW

The GPC1-10000-AF Gas Pressure Controller is a stand alone, pressure setting and adjusting component intended to be used as the means of pressure control in pneumatic calibration and test systems. GPC1-10000-AF covers the range from atmosphere to 10 000 psi (70 MPa).

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 PGC-10000-AF Pneumatic Gauge Calibrator as well as in a PG7202 piston gauge system.

The GPC1-10000-AF is typically delivered as part of a PGC-10000-AF Pneumatic Gauge Calibrator. The PGC-10000-AF system includes a GB-152-AF gas booster and an RPM4/HPMS A70M/A20M that have their own Operation and Maintenance Manuals.

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GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL

1.2 SPECIFICATIONS

Electrical Power Requirements:

Pneumatic Power Requirements:

High Pressure Supply:

Operating Temperature Range:

Weight:

Dimensions:

Pressure Range:

Operating Medium:

Pneumatic Power Connection:

Test Connections:

Pneumatically Actuated Variable

Volume (PDVV) Displacement:

None

Clean, dry, low flow, compressed gas. Max flow 200 sccm (<0.01 scfm):

Working P

- 750 psi (5 MPa): 45 psi (300 kPa)

- 7 500 psi (50 MPa): 87 psi (600 kPa)

- 10 000 psi (70 MPa) 100 psi (700 kPa)

Not to exceed 10 000 psi (10 MPa)

10 to 35 °C

24 kg (53 lb)

21.5 cm H x 30 cm W x 53.5 cm D (8.5 in. x 11.8 in. x 21.1 in.)

0 to 10 000 psi (70 MPa)

Any non-corrosive gas

1/4 in. NPT F

(3) DH500 F test connections ((1) left, rear side and (2) on top)

DH500™ is a gland and collar type fitting for ¼ in. (6 mm) coned and left hand threaded tube. DH500 is equivalent to AE F250C, HIP HF4, etc.

2 cc (0.12 in

Drive Air P

)

PGC-10000-AF SYSTEM

Temperature:

Relative Humidity:

Operating: 18 to 28 °C

Storage: -20 to 70 °C

Operating: 15 to 70%RH (non-condensing)

Storage: 10 to 90%RH (non-condensing)

1. INTRODUCTION

1.3 INSTRUMENT LAYOUT

1.3.1 FRONT 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 plunger 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

1.3.2 OVERALL DIMENSIONS

Figure 2. Front and side views with dimensions

GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL

1.3.3 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

Figure 3. System schematic

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

+ 28 hidden pages

Fluke GPC1-10000-AF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

ABOUT THIS MANUAL

1. INTRODUCTION

1.1 PRODUCT OVERVIEW

1.2 SPECIFICATIONS

1.3 INSTRUMENT LAYOUT

1.3.1 FRONT PANEL

1.3.2 OVERALL DIMENSIONS

1.3.3 SYSTEM SCHEMATIC