DH Instruments PGC-10000-AF Operation And Maintenance Manual

Gas pressure controller

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GPC1-10000-AF™

Gas Pressure Controller

Operation and Maintenance Manual

NSN 6685-01-529-6990 RN

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Page 1 GPC1-10000-AF™ Gas Pressure Controller Operation and Maintenance Manual NSN 6685-01-529-6990 RN (1 of 3) © 2005 DH Instruments, Inc.
Page 2 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, Inc.
Page 3: Table Of Contents
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 CONSIDERATIONS .............................17 STORAGE AND SHIPPING ........................18 Page I © 2005 DH Instruments, Inc.
Page 4 A P P E N D I C E S ..............3 1 GPC1 TERMS, LABELS, AND SYMBOLS (GLOSSARY) ..............31 WARRANTY STATEMENT ........................32 © 2005 DH Instruments, Inc. Page II...
Page 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.
Page 7: A B O U T T H I S M A N U Al
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.
Page 9: I N T R O D U C T I On
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.
Page 10: Specifications
2 cc (0.12 in Pneumatically Actuated Variable Volume (PDVV) Displacement: PGC-10000-AF SYSTEM 18 to 28 °C Temperature: Operating: -20 to 70 °C Storage: Operating: 15 to 70%RH (non-condensing) Relative Humidity: Storage: 10 to 90%RH (non-condensing) © 2005 DH Instruments, Inc. Page 4...
Page 11: Instrument Layout
Test inlet valve knob PDVV increase fast and slow buttons PDVV decrease fast and slow buttons Test outlet valve knob Figure 1. Front panel view 1.3.2 OVERALL DIMENSIONS Figure 2. Front and side views with dimensions Page 5 © 2005 DH Instruments, Inc.
Page 12: System Schematic
8. TEST3 port (front top) 18. PDVV plunger position indicator 9. DRAIN port (right lateral) 19. PDVV DRIVE air connection (right lateral) 10. Test liquid collection sump 20. DRIVE air filter Figure 3. System schematic © 2005 DH Instruments, Inc. Page 6...
Page 13: I N S T A L L A T I On
DESCRIPTION PART # GPC1-10000-AF instrument 402190 ACCESSORIES: Mat, Top Surface Protection 123481 1 ea. 402189 PGC-10000-AF Documentation Disk including: (Shipped with • RPM4/HPMS A70M/A20M-AF Operation and RPM4/HPMS accessories Maintenance Manual, p/n 550136 in transport case) • GPC1-10000-AF Operation and Maintenance Manual, p/n 550135 •...
Page 14: Pgc-10000-Af System
GB-152-AF: Gas booster package used to supply gas pressure up to 10 000 psi (70 MPa) to the GPC1-10000-AF pressure controller. Each of the three components of the PGC-10000-AF system has its own Operation and Maintenance Manual and individual setup and start up instructions. Figure 4 shows the typical setup configuration of the complete PGC-10000-AF system.
Page 15: Site Requirements
2. INSTALLATION SITE REQUIREMENTS The GPC1-10000-AF is typically delivered as part of a PGC-10000-AF Pneumatic Gauge Calibrator (see Section 2.2). The PGC-10000-AF system also includes a GB-152-AF gas booster and an RPM4/HPMS A70M/A20M that have their own Operation and Maintenance Manuals.
Page 16: Initial Setup
Supply 45 psi (300 kPa) * This is very low flow. For 7 500 psi (50 MPa): Supply 87 psi (600 kPa) For 10 000 psi (70 MPa): Supply 100 psi (700 kPa) © 2005 DH Instruments, Inc. Page 10...
Page 17: Connect High Pressure Gas Supply (Gb-152-Af)
GPC1 requires a high pressure gas supply of 10 000 psi (70 MPa) or lower. If the GPC1 is part of a PGC-10000-AF Pneumatic Gauge Calibrator, the high gas pressure supply is provided by a GB-152-AF gas booster. Hardware to connect the booster output to the GPC1 SUPPLY port is supplied with the booster.
Page 18: Make Test Pressure Interconnections
2.4.4.2 CONNECTING TO A DEVICE UNDER TEST In a PGC-10000-AF system, the device under test (DUT) is intended to be connected to one of the TEST connections on the top surface of the GPC1. See Section 2.4.4.3 concerning cleanliness considerations before connecting a DUT.
Page 19: Cleanliness Considerations When Connecting Duts
2. INSTALLATION The PGC-10000-AF fittings accessory kit includes adaptors to convert the DH500 F TEST connection to other commonly used fittings. The adaptors are made by combining a DH500 F adaptor with a 2.75 in., 6 in. or 12 in. DH500 nipple. The...
Page 20: Figure 7. Clean Test1 Port, Sump And Drain Port
• TEST2 port (left lateral): Normally, the system reference pressure measurement device is connected here. In a PGC-10000-AF Pneumatic Gauge Calibrator, this is an RPM4/HPMS A70M/A20M-AF. • TEST3 port (top, front): This port is connected to the lowest point on the GPC1 sump and should be used for connecting test devices that may contain liquids.
Page 21: Power Up And Verification
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. Page 15 © 2005 DH Instruments, Inc.
Page 22: Apply Pdvv Drive 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. © 2005 DH Instruments, Inc. Page 16...
Page 23: Precautions To Take Before Working With High Pressure Gas / Safety Considerations
If the GPC1 is part of a PGC-10000-AF Pneumatic Gauge Calibrator, the RPM4/HPMS A70M/A20M-AF leak test function can be used (see the RPM4/HPMS Operation and Maintenance Manual).
Page 24: Storage And Shipping
GPC1’s open bottom are protected. GPC1 must ride on its four (4) feet - NOT on its internal components. © 2005 DH Instruments, Inc. Page 18...
Page 25: O P E R A T I O
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. Page 19 © 2005 DH Instruments, Inc.
Page 26: Figure 8. System Schematic
18. PDVV plunger position indicator 8. TEST3 port (front top) 19. PDVV DRIVE air connection (right lateral) 9. DRAIN port (right lateral) 20. DRIVE air filter 10. Test liquid collection sump Figure 8. System schematic © 2005 DH Instruments, Inc. Page 20...
Page 27: Operational Functions
The INLET and OUTLET valves (5, 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 Page 21 © 2005 DH Instruments, Inc.
Page 28: Fine Pressure Adjustment, Pdvv (+) And (-) Valve Operation
GPC1 PDVV 3. Minimum End of Stroke plunger from maximum to minimum end of 4. Current Position (red/white line) stroke is 2 cc (0.12 in. Figure 10. PDVV plunger position indicator © 2005 DH Instruments, Inc. Page 22...
Page 29: Connecting A Device Under Test
DUTs and the system under test should be cleaned of liquids to the extent reasonably possible before being connected to GPC1. Also, see Section 2.4.4.3 for information about the appropriate GPC1 TEST port connection to use. Page 23 © 2005 DH Instruments, Inc.
Page 30: 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. If the GPC1 is part of a PGC-10000-AF Pneumatic Gauge Calibrator, the reference measurement device is an RPM4/HPMS A70M/A20M. The typical operational sequence is as...
Page 31: M A I N T E N A N C E A N D A D J U S T M E N T
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. Page 25 © 2005 DH Instruments, Inc.
Page 32: Purging The Sump (Drain)
(2). Use caution to ensure that the filter body (3) is oriented in the correct direction (the arrow on the filter body should be pointing in the direction of flow in from the PDVV DRIVE port). © 2005 DH Instruments, Inc. Page 26...
Page 33: Figure 12. Pdvv Drive Air Filter
Once the filter body cap is removed, the sintered filter element can be removed. 1/4 in. (6 mm) PFA tube PDVV DRIVE filter downstream connection Filter body PDVV DRIVE filter upstream connection Figure 12. PDVV drive air filter Page 27 © 2005 DH Instruments, Inc.
Page 35: T R O U B L E S H O O T I N
Check value of supply pressure on TEST Opening INLET valve does TEST INLET SET regulator is set too INLET gauge. Adjust INLET regulator, increase pressure. low and/or external pressure supply increase supply pressure if necessary. 3.2.1, to low. 2.4.3 Page 29 © 2005 DH Instruments, Inc.
Page 37: A P P E N D I C E
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 Test pressure which GPC1 is connected. Page 31 © 2005 DH Instruments, Inc.
Page 38: Warranty Statement
GPC1-10000-AF™ OPERATION AND MAINTENANCE MANUAL WARRANTY STATEMENT Except to the extent limited or otherwise provided herein, DH Instruments, Inc. (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.

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