HELIX 8200 Operating And Service Instructions

8200 Compressor

Installation, Operation and Service

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HELIX TECHNOLOGY CORPORATION

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Instructions

8040353

Rev. 101 (11/2001)

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HELIX TECHNOLOGY CORPORATION

http://www.helixtechnology.com

The inform ation in this docu m en t is believed to be accu rate and reliable. However, Helix Technology Corporation, cannot acce pt any fi na ncial or other responsibili ties th at ma y result from the use of this information. No warranties are granted or extended by this document.

Helix Technology Corporation reserves the right to change any or all information cont ai ne d herein without prior wri tten notice. Revisions may be issued at the time of such changes and/or de le ti ons.

Any duplication of this manual or any of its par ts without expressed written pe rmission from Helix Technology Corporation is strictly prohibited.

Any correspondenc e regarding this docume nt should be forwarded to:

Helix Technology Corporation Mansfield Corpora te Center Nine Hampshire Street Mansfield, Massachu s et ts 02048-9171 U.S.A.

Telephone: (508 ) 337-5000 FAX: (508) 337-5464

The following H e li x Technology Corporat io n tra demarks and service ma rks m ay appear in this document:

Conductron™

Cryogenerator GOLDLink

Helix RetroEase

ThinLine™

Convectron

Cryo-Torr Granville-Phillips™

Micro-Ion RetroFast TurboPlus

Cryodyne CTI-Cryogenics GUTS

Mini-Ion™

Stabil-1 Vacuum Assurance

Cryogen FastRegen™

Helix Technology . . Your Vacuum Connection

On-Board

Stabil-Ion

All other tradem a rks or registered tradema rks are the property of th eir respective hol ders.

8200 Compressor

Section 1 - Introduction

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Installation, Operation and Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section 2 - Inspection

Packaging of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3 - Installation

Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Preparing the Compressor Input-Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Cooling Water Requirements (Water-Cooled Compressors Only) . . . . . . . . . 3-3

Cooling Water: General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Cooling Water: Flow and Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . 3-4

Cooling Water: Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Final Preparation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Connecting the Compressor to the Cold Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Table of Contents

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Section 4 - Maintenance Procedures

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removing the Compressor Adsorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Installing the Compressor Adsorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Unscheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Suggested Unscheduled Maintenance Equipment . . . . . . . . . . . . . . . . . . . . . . . 4-3

Adding Helium Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Helium Circuit Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Appendix A - Customer Support Information

Appendix B - Troubleshooting Procedures

Appendix C - Electrical Schematics for 8200 Compressor

Appendix D - Components in the Electrical Control Module of the 8200 Compressor

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8200 Compressor

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Table of Contents (continued)

Appendix E - Flow Diagrams for 8200 Air-Coo led and Water-Cooled Compressors

Figures

Figure 1-1: Air and Water Cooled 8200 Compressor Dimensions . . . . . . . . . . 1-2

Figure 1-2: Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Figure 3-1: Electrical Terminal Enclosure with Cover in Place . . . . . . . . . . . . 3-2

Figure 3-2: Assembly of Conductors to Terminal Block . . . . . . . . . . . . . . . . . 3-3

Figur e 3-3: 8200 Co m pressor Cooling Wat er Flow and Pressure Requireme nts 3-5

Figure 3-4: 8200 Compressor Water Discharge Temperature Increase (°F) . . . 3-6

Figure 3-5: Typical 8200 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . 3-9

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Figure 4-1: Disconnecting/Connectin g th e A dso rber Self-Sealing Coupling . . 4-2

Figure 4-2: Removing the Adsorber from the Compressor . . . . . . . . . . . . . . . . 4-2

Figure C-1: 8200 Compressor Electrical Schematic P/N 8032563P001

Rev. 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Figure C-2: 8200 Compressor Electrical Schematic P/N 8032564P001 Rev. D C-3

Figure D-1: Components in the Electrical Control Chassis of the

8200 Compressor Three-Phase Scott-T Configuration . . . . . . . . . . D- 1

Figure D-2: Components in the Electrical Control Chassis of the

8200 Compressor - Single-Phase RC Configuration . . . . . . . . . . . D-2

Figure E-1: Flow Diagram of the 8200 (Air-Cooled) Compre ssor . . . . . . . . . . E-2

Figure E-2: Flow Diagram of the 8200 (Water-Cooled) Compressor . . . . . . . . E-3

Tables

Table 1-1: Power Requirements (Steady-State Conditions) . . . . . . . . . . . . . . . 1-4

Table 1-2: General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Table 3-1: Voltage Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Table A-1: CTI-C RY OGENICS Produc t Cu stom er Support Centers . . . . . . . . A-2

Table B-1: Compressor Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . B-1

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8200 Compressor

General

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Section 1 - Introduction

The manual provides instructions for installing, operating and servicing the 8200 Compressor. This compressor is available in two versions: air-cooled, P/N 8032549G001/ G 002 and water cooled , P/N 803255G001/G002.

If you are installing or ope rating a Cryo-Torr or On-Board System you should also have av ailable the appro priate cryopump or re frigerator.

When you purchase a system, you will receive two m anuals necessary for system installation, plus a l oose- leaf binder with index ta b separators, allowing you to co mpile a complete inde xe d system notebook.

Installation, Operation and Servicing Instructions

Installation, Opera tion and Servicing Instruct ion s for your 8200 Compressor provide ea sil y ac c essi ble inf orm a ti on. All perso nne l wi th installation, operation, and servicing responsibilities should become familiar with the content s of these instruct ions to ensure high quality, safe, reliable performance.

P/N 8040353 1-1

Introduction

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Air Cooled

Figure 1-1: Air and Water Cooled 8200 Compressor Dimensions

1-2 P/N 8040353

Water Cooled

8200 Compressor

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Rear View - Air Cooled

6 7

8 9

10 11

Rear View - Water Cooled

Front View - Air and W ater Cooled

1. Compressor Input Power Block

2. Cold Head Power Receptacle

3. On-Board Power Receptacle

4. Helium Gas Fitting and Charge Valve

5. Helium Supply Pressure Gauge

6. Helium Gas Return Connector

7. Helium Gas Supply Connector

8. Rear Panel

9. Rear Grill

Figure 1-2: Component Locations

LEGEND

10. Cooling Water Output

11. Cooling Water Input

12. Rear Plate

13. 50/60 Hz Frequency Selector Switch

14. 208/220 Voltage Range Selector Switch

15. Resettable Circuit Breakers

16. Compressor ON/OFF Switch

17. Front Panel

18. Front Grill

P/N 8040353 1-3

Introduction

HELIX TECHNOLOGY CORPORATION

Table 1-1: Power Requirements (Steady-State Conditions)

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Part Number Cooling Phase Hz

8032549G001 Air

Air

8032549G002 Air

Air

8032550G001 Water

Water

8032550G002 Water

Water

Table 1-2: General Sp ecification s

Specification Description

We ig ht 140 lbs (63.5 kg) approx im a te

3 3

1 1

3 3

1 1

50 60

Operating Voltage

Range

180-220 198-250

Nominal

Operating

Current

10A 10A

8.5A

Weight

(shipping)

Power

consumption

Compressor input-power

cable

(customer-supplied)

Helium pressure Static: 245-255 psig (1688-1757 kPa) at 70 to 80°F (21 to

Ambient op er ating

temperature range

145 lbs (70.5 kg) approx im a te

2.0 kw, nominal operating(water), 2.1 kw nom inal operating (air)

Recommended type SO-4 conduct or, 600V, neopre ne jacket and 14-gauge wire. Install per Figure C-1, El ec trical Schematic di agram, ensuring compliance with all national, state and local sta ndards.

27°C) Supply: nominal opera ti on: 270-290 psig (1860-200 0 kPa ) at operating tempe ra ture.

50 to 100°F (10 to 38°C)

1-4 P/N 8040353

8200 Compressor

Adsorber service schedule Replace ever y 12 m onths.

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Table 1-2: General Sp ecification s

Specification Description

Interface Cold head power receptacle: Mates with plug on cold head

power cable. On-Board power re ce pt acle: Mates with plug on cold-he ad power cable. Compressor input-power terminal block enclosure: Mates with input power cable, fabricated by customer or available from CTI-CRYOGENICS. Gas-supply connect or: 1/2-inch self-seali ng coupling Gas-return connec to r: 1/ 2-i nch self-sealing coupl ing

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Cooling water requi re-

ments (water cooled only)

100°F (38°C) maxim um disc ha rge temp era ture Refer to Figures 3-5 and 3-6 for parameters.

P/N 8040353 1-5

8200 Compressor

Packaging of the S ystem

The Compressor

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Section 2 - Inspection

A High-Vacuum Pump or Refrigerator System is packaged in separate cartons for each maj or c omponent. An Instal la ti on, Op e ration, and Servicing Manual i s inc lud ed in the carton for the com ponent packaged in that carton.

On receipt, remove the 8200 Compre ssor from it s sh ip pin g carton and inspect the compressor for evidence o f d amage as describ ed in this Section.

1. Unpack and remove the compressor from its shi ppi ng c art on.

2. Check the carton contents. It shou ld contain: a. 8200 Compresso r (ai r cooled or water cooled). b. Compressor Manua l P/N 8040353.

3. After unpacking, inspect the compressor for evidence of damage as follows:

a. Inspect the compre ssor overall exterior for da ma ge . b. Report damage to the shipp er a t on ce. c. Retain shipping cart ons for st orage or return shipment.

When installing your system, CTI recomm en ds th at as you unpack a component, you pe rform an inspection and the nec essary ta sks for syst em installation for the component according to the manual included with the component. Fina l system installation and operat ion will be performed following proce dure s in t he hi gh-vacuum pump or re fri ge rator manual.

4. Check the helium pressure gauge. The gauge should indicate 250 psig (1725 kPa) minimum at 70° F. If additional gas pressure is requ ired, follow the instructions in Adding Helium Gas.

P/N 8040353 2-1

8200 Compressor

Section 3 - Installation

Compressor Installation

Installation of your compressor requires no special tools other than those supplied in the Installation and Scheduled Maintenance Tool Kit.

Preparing the Compressor Input-Pow er Cable

To supply input power to the 8200 compressor requires the fabrication of a 600-volt power cable that has an SO-4 conductor, 600-volt rating neoprene

jacket and 1 4-gauge or 2.3 mm

wire. Proceed as follows:

WARNING

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Do not conne ct the compres s or to the power source at this time. All of the preparation must be completed and all panels reinstalled before electrically connecting the compressor.

Unit must be wired by an authorized electrician in accordance with the national Electri ca l Code, ANSI/NFPA 70-1987, as well as the local codes. This shall include installation of a readily accessible disconnect device into the fix ed wiring supplying power.

An insulated ear th ing cond uctor that is identica l in size, ins ulation material and thickness to the ea rth and unearth branch circuit supply conductors, except that it is green w ith or w i tho ut one or more yellow stripes is to be installed as part of the branch circuit which supplies the unit or system. The earth ing conductor descri bed is to be connected to the earth at the service equipm e nt, or supplied by a separatel y de rived system at the supply transforme r or ge ne rator.

1. Prepare the input power cable by te rminating each of the four conductors with a #10 ring terminal. Foll ow th e te rm inal manufacturer’s instructions to insure proper crimping.

2. Disas s emble the elect r i cal terminal enc l o s ur e cover, mounted on the compressor rear panel, as shown in Figure 3-1. Remove the two screws securing the cover and lift it off.

3. If necessary, back off strain relief screws.

P/N 8040353 3-1

Installation

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4. Thread input power cable end up through the strain relief i nto the enclosure.

5. Attach the power conductors onto the appropriate terminals of the termin al block.

a. For three-phase hookups, attach the three power leads to ter-

minals X, Y and Z.

b. For single-phase hookups, attach the two power leads to ter-

minals X and Y. DO NOT USE TERMINAL Z.

6. Tighten all terminals to 18-22 in.-lbs. torque.

7. Tighten down screws on strain relief.

CAUTION

Ensure that strain relief is tightened down on the outer insulation of the input power cable and that the cable does not slide.

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8. Remount the te rm i n al enclosure cover and se cure with two screws .

9. Refer to Final Preparation of Compressor for correct phasing checkout pr ocedure.

WARNING

Insure that the grou nd wire is returned to a suitable ground in a noninterrupting manner.

Figure 3-1: Electrical Terminal Enclosure with Cover in Place

3-2 P/N 8040353

Cover Scre ws

+ 25 hidden pages

HELIX 8200 Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual