GP1/GP2 INSTALLATION & MAINTENANCE INSTRUCTIONS

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Lucas Walters
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GP1/GP2 INSTALLATION & MAINTENANCE INSTRUCTIONS Description & identification General specifications Connection procedure Recalibration procedure Repair procedure Dimensions, ordering and accessories

1 GP1/GP2 INSTALLATION & MAINTENANCE INSTRUCTIONS Description & identification General specifications Connection procedure Recalibration procedure Repair procedure Dimensions, ordering and accessories Before you get started, please read these warnings: Examine the product. Ensure that you received what you ordered. Read this guide first before you start and save it for later use. You must have a good understanding of what the adjustments are on this product before using them. All compressed air and power should be shut off before installing, removing or performing maintenance on this product. Installation and use of this product should be under the supervision and control of properly qualified personnel in order to avoid the risk of injury or death. DESCRIPTION / IDENTIFICATION The GP series control valve is an electronic pressure regulator designed to precisely control the pressure of gaseous media proportional to an electronic signal. The GP1 operates using two normally closed solenoid valves, a pressure sensor, and a control circuit. One valve is actuated to allow unregulated supply media into the system. The second valve is actuated to allow working media to vent to atmosphere. The pressure sensor provides feedback to the control circuit. The control circuit compares the pressure sensor feedback to the user supplied electronic command signal and actuates the appropriate valve until the two signals match. The GP series can be teamed with a variety of onetoone ratio high pressure volume boosters for even greater flow. When using a volume booster, the GP2 can be used to achieve accuracy similar to the GP1 alone with higher flow capacity. GP series product comes with a monitor output signal. This output is an electrical signal originating from the internal sensor used in the control circuit of the GP1 valve. On GP2 units this signal originates from the external transducer. This allows the system parameters to be monitored and provides a signal for data acquisition needs. The output of this signal can be configured to either 0 10Vdc or 420mA. The GP2 is similar to the GP1 but uses a double loop control scheme. In addition to the internal pressure transducer, the GP2 also receives a 010Vdc feedback signal from an external sensing device. The external signal functions as the primary feedback and is compared to the command signal. A difference between the two comparisons causes one of the two solenoid valves to open allowing flow in or out of the system. A ProportionAir DSY or DSTY will work as a second loop feedback to the GP2 (See ordering information). The GP series has several other beneficial features. An on board split power supply allows true zero for command and monitor even though the GP is powered by a conventional single ended power supply. The GP utilizes advanced on board power management hardware to minimize current draw and heat build up. The GP also features status indicating LEDs for power and TTL. The TTL signal is a conditional on/off signal to use for diagnostic purposes. This signal is LOW when the pressure is within 1% of final setting. 1 INGP12

2 GENERAL SPECIFICATIONS & PERFORMANCE CHARACTERISTICS ELECTRICAL MINIMUM TYPICAL MAXIMUM Supply Voltage Supply Current Command Signal Voltage Current Command Signal Impedance Voltage Current Analog Monitor Output Voltage Current (Sourcing) TTL Satisfied NotSatisfied 2nd Loop Input 15VDC 100mADC (standby state) 4mADC 4mADC 10KΩ 100Ω 5VDC 24VDC 985mADC (operating) 1 20mADC 1 20mADC 1 PNEUMATIC MINIMUM TYPICAL MAXIMUM Input Pressure Pressure Range Flow Rate Filtration Required Accuracy (Pressure) Accuracy (Monitor) Hysteresis/Linearity Repeatability Port Size (all) Critical Volume Vacuum Vacuum 0 SCFM (0 m³/hr) 40 micron ±0.1%F.S. 0%F.S. 110% of full scale calibration 5 SCFM (8.5 m³/hr) 20 micron ±0.25%F.S. ±0.3%F.S. ±0.2%F.S. ±0.05%F.S. 1/8 inch NPT female 3 in³ 1100 psig (75.84 bar) 1000 psi (68.95 bar) 10 SCFM (17 m³/hr) ±0.5%F.S. ±0.5%F.S. ±0.5%F.S. Depends on Hysteresis PHYSICAL MINIMUM TYPICAL MAXIMUM Operating Temperature Environment Protection Weight Electrical Connector (Note 1) (Note 2) (Note 3) (Note 4) (Note 5) (Note 6) 32ºF (0ºC) 3.75 lbs (1.75 kg) 6 pin molded 16 gauge wire 158ºF (70ºC) NEMA 4/IP65 (Note 1) (Note 2) (Note 3) (Note 4) (Note 5) (Note 6) Pressure ranges are customer specified. Pressure range up to 250 PSI (17.24 BAR) may be ordered as PSIG or PSIA. Pressure range above 251 PSI (17.3 BAR) may be ordered as PSIS or PSIA. User adjustable The minimum downstream closed volume is determined by the pressure range, orifice size, hysteresis window, plumbing, as well as other factors. Consult factory for small volume applications. CE approval pending Depends on density of manifold material Fig 1 Pressure [% of scale] LINEARITY Command [Volts] This chart shows linear characteristics of GP products when given a ramp signal from 010 volts. Characteristics would be similar for 420 ma units. Fig 2 % of Scale RESPONSE TO STEP INPUT Command Pressure Time (seconds) Volume = 5 cu.in. [82mL] Times for GP to fill/exhaust a closed chamber. Step command signal is superimposed over pressure trace. Time is determined by difference between command signal and pressure achieved. 2 *Dependent on orifice size, pressure range and supply pressure. INGP12

3 GP CONNECTION PROCEDURE Pneumatic Connections: 1. A typical 20 micron (minimum 40 micron) inline filter is recommended on the inlet of the GP. 2. Connect supply pressure to the I inlet port (figure 1) not to exceed rated supply pressure. (Table 1) 3. Connect one of the O outlet port (figure 1) to the device being controlled and plug the unused one. 4. Proceed with electrical connection. TABLE 1 RATED PRESSURE FOR GP VALVES MAX calibrated pressure of: Vacuum up to 15 psig (Vac. to 1.03 bar) Max inlet pressure is: 30 psig (2.07 bar) 16 up to 30 psig (1.1 to 2.07 bar) 60 psig (4.14 bar) 31 up to 50 psig (2.14 to 2.45 bar) 100 psig (6.89 bar) 51 up to 100 psig (3.52 to 6.89 bar) 200 psig (13.79 bar) 101 up to 250 psig (6.96 to bar) 500 psig (34.47 bar) 251 up to 500 psig (17.31 to bar) 600 psig (41.37 bar) 501 up to 1000 psig (34.54 to bar) 1100 psig (75.84 bar) Electrical connections: 1. Ensure all power is off before making any electrical connections. 2. Figure 2 shows the location of the GP electrical connector and figure 3 shows the connector. Table 2 identifies the color codes Note: Both current and voltage command units require that both the command (+) and command ( ) pins be connected. 3. See figure 4 and 5 for second loop connections. TABLE 2 O OUTLET PORT I INLET PORT Figure 1 Figure 2 O OUTLET PORT WIRE COLOR* FUNCTION WHITE COMMAND (+) RED GREEN ORANGE ANALOG OUTPUT DC COMMON TTL OUT BLACK 1524 VDC POWER BLUE COMMAND () Figure 3 * H6DC6 POWER CORD COLORS 3 INGP12

4 GP2 second loop connections: For GP2 valves to work properly a 010Vdc second loop input source must be connected to the GP2. 1. Make electrical connections according to the section titled Voltage command valves for a voltage command unit or Current command valves for a current command unit 2. If ProportionAir DS series transducer is used as the external feedback source, attach it to the auxiliary receptacle on the GP2 unit. (Figure 4) 3. If another source of transducer is used, H23 cable must be ordered to facilitate connection of that source to the GP2. (Figure 5) Note: Power & common connections on the 2nd loop receptacle are fed through from the main connector and are provided to facilitate wiring of the 2nd loop sensor. 2nd LOOP FEEDBACK RECEPTACLE ON GP2 Figure 4 Figure 5 H23 COLOR CODE Red/White Signal In Red/Black Green Power Common RECALIBRATION PROCEDURE All GP valves come precalibrated from the factory using precision calibration equipment. If the GP valve needs recalibration, use the procedure described below: GP1 VALVES: 1. Wire servo according to the section titled Electrical Connections. 2. Connect a precision measuring gage or pressure transducer to the unplugged outlet port of the GP. 4. Locate the calibration access cap on top of the GP valve and locate the ZERO and SPAN adjustment potentiometers (figure 6). The 420mA potentiometers should be set at the factory and do not need to be recalibrated. NOTE: Only use this step if your device is totally out of calibration. If it is slightly out of calibration, omit this step and move on to paragraph 5. Using a small screwdriver, turn both potentiometers 15 turns clockwise. Then turn them 7 turns counter clockwise. This will put the GP roughly at mid scale. 5. Set the electrical command input to MAXIMUM value. Adjust the SPAN potentiometer until MAXI MUM desired pressure is reached (clockwise to increase pressure). 6. Set the electrical command input to 10 percent of full value (1Vdc for 010Vdc unit or 5.6mA for 420mA unit). 7. Adjust the ZERO potentiometer until 10 percent of maximum desired pressure is reached. (clockwise increases pressure). 8. If at any time during the calibration procedure the servo oscillates or becomes unstable for more than one second, turn the hysteresis potentiometer HW (see figure 12 for location) clockwise until the oscillation stops, then turn it one more complete turn (same direction). 9. The ZERO and SPAN potentiometers interact slightly. Repeat steps 510 until no error exists. 10. Verify unit shuts off by going to zero command. Check linearity by going to at least six pressures throughout the full range. GP2 VALVES: This calibration procedure assumes there is a properly scaled and calibrated transducer for use as 2nd loop feedback signal. (The GP2 series accepts a 010Vdc 2nd loop signal.) Follow, in order, steps 110 as noted in the section titled GP1 VALVES. Make sure the 2nd loop is connected before you start the calibration. NOTE: There must be a closed volume of at least 3 cu.in. (49cc) between the valve outlet and the measuring device for the valve to be stable. 3. Provide supply pressure to the inlet port of the GP. (See figure 1). Make sure supply pressure does not exceed the rating for the valve. (see table 1) Figure 6 4 INGP12

5 REPAIR PROCEDURE: 1.) Disassemble GP unit: A. Remove the two 832 flat head screws and o rings on the GP lid. Figure 7 B. Unplug main connector wires and LED wires from the board. Figure 8 C. Remove lid, lid o ring and can assembly from manifold. Figure 9 D. Unplug valve and sensor wires from board. Figure 8 E. Remove the two 832 SHCS screws and o rings from manifold to remove both the regular tall standoff and the board standoff. Figure 10 F. Of each valve assembly, remove hex nuts and disassemble valve tube from coil and valve housing. (Keep coil washer, valve housing and hex nut because they are not included in the repair kit and can be reused) Figure 14 G. Using span wrench (figure 11), remove valve tube from manifold cavity. H. Remove poppet and o ring spacer from manifold. See figure 12 for o ring spacer location and figure 14 for valve orientation I. If sensor needs to be replaced, unthread sensor from manifold. See figure 13 for sensor location CA FIGURE 7 FROM MAIN CONNECTOR FIGURE 9 FROM SENSOR EXHAUST VALVE INLET VALVE FIGURE 10 2ND LOOP INPUT FROM 3 PIN MICRO CONNECTOR. (IF TTL LED POWER LED FIGURE 8 FIGURE 11 FIGURE 12 5 INGP12

6 2.) Sensor Assembly: A. Install the sensor before installing the valves. B. Place sealant compatible with media in use on the second or third full threads of the pressure sensor (exercising care not to get sealant into the manifold passages), and thread into 1/8 NPT port on top of manifold. See Figure 13 for sensor location. 4.) Final Assembly: A. Place o rings on two 832 SHCS screws line up with holes through bottom side of manifold. Figure 10 B. Place board standoff, pots facing up, on valve side, opposite sensor, and fasten with 832 SHCS screw. Figure 10 C. Place regular tall standoff on sensor side of manifold and fasten with 832 SHCS screw tighten 78 in. lb. of torque. Figure 10 D. Plug valve, sensor wires into board. Figure 8 E. Place can on manifold until edge of can is flush with manifold. NOTE: Turn can while pressing downward. D. Obtain an assembled lid and plug the main connector and LED wires to the board. Figure 8 FIGURE 13 3.) Valve Assembly: Note: Do not use any kind of thread sealant. A. Remove repair kit V52PAK from box. Figure 14. V52PAK (repair kit) includes: (2) O ring spacers, (2) poppets, (2) valve tubes & span wrench (figure 11) B. Place new o'ring spacers in valve cavity of manifold. Figure 12 C. With poppet installed in the valve tube, thread valve tubes into manifold cavities tightly using span wrench. See figure 14 for poppet orientation. D. Check to make sure valve tubes are tight! Place coil washer and valve housing on valve tube, refer to figure 14 for assembly order. Turn square end of valves toward sensor. Figure 13. Tighten the hex nuts 1/8 turn past finger tight. Do not over tighten! 5.) Closing Lid: A. Assemble o ring to 832 flat head screws. Figure 7 B. Place lid o ring on inner edge of can. Figure 9. If not already done, plug the main connector wires and LED wires into the board, refer to figure 8 NOTE: Make sure while fastening the lid to the can that the o ring is flat and seals evenly with lid. C. Orient lid so the power LED is inline with the inlet port of the manifold. Figure 15 D. Fasten lid down with 832 flat head screws. Figure 7 FIGURE 15 HEX NUT VALVE HOUS COIL VALVE TUBE POPPET O RING SPACER V52PAK (Repair Kit) FIGURE 14 6 INGP12

7 DIMENSIONS GP1/GP2 Inches [mm] SERIES GP=1/8 in NPT GX=1/8 in NPT Cleaned for O2 service GL=1/8 in BSPT GN=1/8 in BSPT Cleaned for O2 service ORDERING INFORMATION GP 1 0 A 1000 E C B 2 A I 1=Single loop MINIMUM CALIBRATED PRESSURE RANGE (PSI) A=Absolute G=Gauge S=Sealed gauge COMMAND SIGNAL E=01 I=420mADC (both differen MAXIMUM CALIBRATED PRESSURE RANGE (PSI) MONITOR SIGNAL E=01 C=420mADC (Sourcing) ACCESSORIES MANIFOLD MATERIAL B=Brass S=303 Stainless ORIFICE SIZE 1=0.012 inch 2=1/32 3=3/64 Factory determined ELECTRICAL CONNECTOR A=6 pin Brad Harrison standard VALVE WETTED PARTS I=Teflon/Viton standard H6DC6 H23 V52PAK DSY 100 DSTY 1000 BKT01 6 Pin, 6 Foot Power Cord * Required for all GP units Consult factory for other length 3 Pin Mini Connector 3 Foot Cord * Required to facilitate connection to the external sensing device (GP2). Consult Factory for other length Valve Repair Kit Includes Inlet and Exhaust Valve Replacement Parts With Spanner Wrench Pressure Range Specify (psi) External Pressure Transducer For Range Up to 500 psi (34.47 bar) Pressure Range Specify (psi) BRACKE Stainless Steel External Pressure transducer For Range psi (82.6 bar) ProportionAir products are warranted to the original purchaser only against defects in material or workmanship for one (1) year from the date of manufacture. The extent of ProportionAir's liability under this warranty is limited to repair or replacement of the defective unit at ProportionAir's option. ProportionAir shall have no liability under this warranty where improper installation or filtration occurred. All specifications are subject to change without notice. THIS WARRANTY IS GIVEN IN LIEU OF, AND BUYER HEREBY EXPRESSLY WAIVES, WARRANTIES OR LIABILITIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING WITHOUT LIMITATION ANY OBLI GATION OF PROPORTIONAIR WITH REGARD TO CONSEQUENTIAL DAMAGES, WARRANTIES OF MERCHANTABILITY, DE SCRIPTION, AND FITNESS FOR A PARTICULAR PURPOSE.... WARNING: Installation and use of this product should be under the supervision and control of properly qualified personnel in order to avoid the risk of injury or death. PROPORTIONAIR, INC. BOX 218 MCCORDSVILLE, IN USA PHONE: (317) FAX: (317) INTERNET info@proportionair.com 7 INGP12

MM1/MM2 INSTALLATION & MAINTENANCE INSTRUCTIONS

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