8200 Compressor Installation, Operation & Service Instructions
Contents
1. 1 3 Figure 3 1 Electrical Terminal Enclosure with Cover in 3 2 Figure 3 2 Assembly of Conductors to Terminal Block 3 3 Figure 3 3 8200 Compressor Cooling Water Flow and Pressure Ld a eat e sarees oe 3 5 Figure 3 4 8200 Compressor Water Cooling Requirements 3 5 Figure 3 5 Typical 8200 Compressor Installation 3 8 Figure 4 1 Disconnecting Connecting the Adsorber Self Sealing eod TTE 4 2 Figure 4 2 Removing the Adsorber from the Compressor 4 2 Figure C 1 8200 Compressor Electrical Schematic P N 8032563P001 2250 fici d ab alee mara dtr die ab RE E NUS C 2 Figure C 2 8200 Compressor Electrical Schematic P N 8032564P001 iD TT C 3 Figure D 1 Components in the Electrical Control Chassis of the 8200 Compressor Three Phase Scott T 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 Compressor E 2 Figure E 2 Flow Diagram of the 8200 Water Cooled Compressor E 3 2003 Helix Tech2. lt 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 B 3 8200 Compressor Installation Operation and Service Instructions X Appendix C Electrical Schematics for 8200 Compressor The following electrical schematics for the 8200 Compressor are in this appendix e Figure C 1 8200 Compressor Electrical Schematic P N 8032563P001 Rev 100 e Figure 2 8200 Compressor Electrical Schematic P N 8032564P001 Rev D A 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 C 1 FELIX 001 APU 1004 lt 9 lt 7 lt 08 N d gt 6 eornoopj3 10ss24dur07 0078 21 2 94n514
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4. 4 METERING OL L ORIFICE INJECTOR T FILTER t eum E a is GAS RETURN KEY dt GAS FLOW IL FLOW E SELF SEALING COUPLING Figure E 1 Flow Diagram of the 8200 Air Cooled Compressor E 2 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X PRESSURE GAUGE 4 SYSTEM HELIUM SUPPLY LINE Y X ud TO THECOLD HEAD 350 PSIG 4 4 DIFFERENTIAL SEPARATOR ree i Log ORIFICE RELI L oho 193 51 4 ptt 37 71 SOLENOID CONTROLLED VALVE iir d CLOSED WHEN COMPRESSOR ay IS IN OPERATION A OIL RETURN LINE 1 HELIUM RETURN LINE FROM THE COLD HEAD COMPRESSOR PUMP f ee 7 ROTARY VANE COMPRESSOR GAS DISCHARGE o EXCHANGER Ol BULKOIL 19 i o SEPARATOR 10 COMPRESSOR 5 COOLING OIL p 3 ooo0o00 0 6 p d 95 LA d SIGHT FILLES EXCHANGER GLASS 44241 SUMP p T OIL 1 m METERING INJECTOR Up E ORIFICE FIL COOLING OIL 4 e GAS FLOW gt OIL FLOW E SELF SEALING COUPLING Figure E 2 Flow Diagram of the 8200 Water Cooled Compressor 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16
5. X 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 Power 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 2 Jacket and 14 gauge or 2 3 mm wire Proceed as follows WARNING Do not connect the compressor 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 Electrical Code ANSI NFPA 70 1987 as well as the local codes This shall include installation of a readily accessible disconnect device into the fixed wiring supplying power An insulated earthing conductor that is identical in size insulation material and thickness to the earth and unearth branch circuit supply conductors except that it is green with or without one or more yellow stripes 1s to be installed as part of the branch circuit which supplies the unit or system The earthing conductor described is to be connected to the earth at the service equipment or supplied by a separately derived system at the supply transformer or generator 1 Prepare the input power cable by terminating each of the four condu
6. 4 Installing the Compressor Adsorber 4 3 Unscheduled VEI HIC os 45 4 3 Suggested Unscheduled Maintenance 4 3 Adding Helium Gas 4 4 Helium Circuit Decontamination 4 6 Appendix A Customer Support Information Customer Support Center Locations 1 Guaranteed Up Time Support GUTS 1 Product Inlormato 1 reds Ghee ORE eae 2 4 1 Appendix B Troubleshooting Procedures Appendix C Electrical Schematics for 8200 Compressor Appendix D Components in the Electrical Control Module of the 8200 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 V FELIX Compressor Appendix E Flow Diagrams for 8200 Air Cooled and Water Cooled Compressors Compressor Gas and Oil Flows 1 _ vi 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 Figures Figure 1 1 Air and Water Cooled 8200 Compressor Dimensions 1 2 Figure 1 2 Component
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8. 2 Compressor operating helium pressure reads 270 psig or below To add helium gas 1 Attach a pressure regulator 0 3000 0 400 psig and charging line to a helium gas 99 9999 pure bottle DO NOT OPEN THE BOTTLE AT THIS TIME Purge the regulator and charging lines as instructed in steps a through e below Do not use helium gas that is less than 99 999 pure a Open the regulator a small amount by turning the adjusting knob clockwise until it contacts the diaphragm then turn approximately 1 8 to 1 4 turn more so that the regulator 1s J oec 4 4 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X barely open b Slowly open the bottle valve and purge the regulator for 10 to 15 seconds Turn the regulator knob counterclockwise until the helium stops flowing c Connect the charge line to the helium pressure regulator d Remove the flare cap of the gas charge fitting on the rear of the compressor Loosely connect the charge line to the charge fitting e Setthe helium pressure regulator to 10 to 25 psig 70 125 kPa Allow helium gas to flow through the charging line and around the loosened flare fitting for 30 seconds to purge the charging line of air Then tighten the flare nut at the end of the char
9. 213 250 213 220 220V 2 Ensure that water is turned on for the water cooled compressor Set the compressor ON OFF switch 3 to OFF Connect the input power cable to the power source Refer to Table 1 1 for electrical power requirements 4 Turn the compressor switch to the ON position and allow the compressor to run for 15 minutes to stabilize the oil circuit Make sure that the compressor fan operates freely in the air cooled compressor 5 Switch off the compressor and disconnect the input power cable 6 Install the compressor in its permanent location on a level surface Air cooled units must have a minimum clearance of 12 inches at the front and back for adequate airflow ut EL LLLLLLLLULLLLLULLLZULLLLLILLLLZLLLLLLLLLLLLLLLLLLLLILLLLLLLLLLLLLLL X 3 6 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Connecting the Compressor to the Cold Head Make the connections between the cryopump and compressor See Figure 3 5 l Remove dust plugs and caps from the supply fittings and return lines compressor and cold head Check all fittings Connect the helium gas return line from the gas return connector on the rear of the compressor to the gas return connector on the cold head Connect the helium gas supply line from the gas supply connector on the rear of the compressor to the gas sup
10. JSNVM Nd 8 O193NNOO M3 MOASNVY CW LW LM 6d 8d SOIO3NNOO 4012 80123 O LO3NNOO NOS LV LSOWYSH SO ASNV YL JNNOO GIONS TOS NOIO3NNOO dfld NOIO3NNOO Qv3HQO OO Ld ANI AVIS Q3Sdv 13 S313 9d y y Gd f E 1 ta LYVLS OLOW H3Wv3 H3Wv3 Ma Loo eg Lo M34Vv38SBg LINQYO NVA 316 YOLIOVdvo NOM 419 MOLIOVdVO NOM 506 2 ANSE NI ud OVA 08 802 LYVLS HOLIOVdvO NOY LYS cag cga 89 9 co LO C 3 ECO No 16098 Pub No 8040353 Rev 104 4 22 03 2003 Helix Technology Corporation 8200 Compressor Installation Operation and Service Instructions X Appendix D Components in the Electrical Control Module of the 8200 Compressor The following illustrations are shown in this chapter e Figure D 1 Components in the Electrical Control Chassis of the 8200 Compressor Three Phase Scott T Configuration e Figure D 2 Components in the Electrical Control Chassis of the 8200 Compressor Single Phase RC Configuration 1 Overtemperature Resistor R1 9 2 Run Capacitor 35 uf C1 Circuit Breaker 3ACB3 3 Start Capacitor 119 uf C2 10 Voltage Selector Switch 51 4 Transformer T2 11 Frequency Selector Switch 52 5 Phase Monitor PM 12 Overtemperatu
11. allow it to run until it has stopped several times allowing the oil temperature to rise and the com pressor to operate continuously for one hour minimum 3 Recheck for proper cooling water temperature per Cooling Water Requirements Water Cooled Compressors Only 4 Provide a free flow of air to the compressor Confirm a 12 inch 30 cm clearance at the front and back of the compressor Confirm unobstructed and clean heat exchanger surfaces 5 Add helium per Unscheduled Maintenance 6 Confirm that oil 1s visible in the compressor sight glass air compressor only 7 Contact the Product Service Department 2 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Table B 1 Compressor Troubleshooting Procedures Possible Cause Corrective Action 4 Compressor pump 1 Intermittent power source 1 Confirm power source voltage stops after several min voltage between 198 250V 60 Hz or 180 utes of operating and 220V 50 Hz and restore if neces then switches ON and Sary OFF at short intervals 5 Compressor operates 1 Loose or defective cable 1 Check cold head cable but cold head motor does not run
12. ing temperature Ambient operating 50 to 100 F 10 to 38 C temperature range LLL _ _ _ 1 4 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Table 1 2 General Specifications Continued Interface Cold head power receptacle Mates with plug on cold head power cable On Board power receptacle Mates with plug on cold head power cable Compressor input power terminal block enclosure Mates with input power cable fabricated by customer or available from CTI CRYO GENICS Gas supply connector 1 2 inch self sealing coupling Gas return connector 1 2 inch self sealing coupling A dsorber service schedule Replace every 12 months Cooling water requirements 100 F 38 C maximum discharge temperature water cooled only Refer to Table 1 page 4 Figure 3 3 page 5 and Figure 3 4 page 5 for parameters Free lt 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 1 5 8200 Compressor Installation Operation and Service Instructions X Section 2 Inspection Packaging of the System A High Vacuum Pump or Refrigerator System is packaged in separate cartons for each major compo
13. needed 2 Check the compressor against its electrical schematic Figure C 1 EE Pub No 8040353 Rev 104 4 22 03 ECO No 16098 B 1 FELIX Table B 1 Compressor Troubleshooting Procedures Possible Cause Corrective Action 3 Compressor stops after several minutes of operation and remains off 1 High temperature of the compressor is caused by insuf ficient cooling water resulting in the opening of thermal pro tective switch water cooled compressor only 2 After turn off very cold cooling water was left running through the compressor The resulting low oil temperature has caused a restriction of oil flow through the metering ori fice during startup 3 Very cold cooling water is circulating through the com pressor The resulting low oil temperature causes a restriction of oil flow through the metering orifice during startup 4 Ambient temperature 15 unusually high resulting in the opening of the thermal protec tive switch air cooled com pressor only 5 Insufficient helium supply pressure 16 indicated by the sup ply pressure gauge 6 High temperature of the compressed helium in the dis charge line from the compres sor pump has tripped the thermal protective switch 7 Mechanical seizure 1 Confirm that cooling water to the compressor 1s flowing Con firm that proper cooling water flow rate and pressure exist by referring to Figure 3 3 2 Turn on the compressor and
14. power source Unscheduled Maintenance Suggested Unscheduled Maintenance Equipment It is advisable to keep on hand the unscheduled maintenance equipment and disposable supplies listed below 1 Helium 99 999 pure C ooo 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 4 3 Unscheduled Maintenance I LIX 2 Pressure regulator 0 3000 0 400 psig 3 Maintenance manifold P N 8080250K003 4 Helium charging line terminating in a 1 4 1nch female flare fitting P N 7021002P001 5 Installation and Scheduled Maintenance Tool Kit P N 8032040G004 Available from stock consult the factory or your sales representative Adding Helium Gas Use only 99 999 pure helium gas CAUTION If the compressor helium pressure gauge reads 0 decontamination 1s required Refer to decontamination procedures under Helium Circuit Decontamination or contact the Product Service Department 1 A User supplied helium charging line terminating in a 1 4 inch female flare fitting and a two stage pressure regulator rated at 0 3000 0 400 psig is required for this operation 2 Ifyou need to add helium more than once every several months check for leaks caused by improperly connected self sealing connections or any mechanical joint within the compressor There are two conditions that require the addition of helium gas 1 Compressor not operating helium pressure gauge reads 245 psig or below
15. will change viscosity and thicken causing the compressor to overheat and shut off at startup In this event repeatedly restart the compressor allowing it to run until it has shut off several times The oil temperature will rise and thereby allow continuous compressor operation 3 Drain and purge water from the compressor before shipping it back to the factory or subjecting it to freezing conditions Purge water from the compressor by blowing compressed air regulated to 30 to 40 psig 200 to 275 kPa into the compressor output connection and allowing water to exit from the water input connection Table 3 1 Cooling Water Specifications Maximum Inlet Temperature 90 F 32 C Minimum Inlet Temperature 50 F 10 C Flow Rate 1 0 50 5 gpm 3 8 1 9 Ipm Pressure Drop inlet to outlet See Fig 1 3 Min max Inlet Presure 5 to 100 psi 6 9 bars Alkalinity 7 0 8 7 pH Calcium Carbonate lt 75 ppm Resistivity lt 100k Ohm cm NOTE Water conditioning may be required for applications not meeting these requirements 3 4 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Cooling Water Flow and Pressure Requirements Use graphs Figure 3 3 8200 Compressor Cooling Water Flow and Pressure Requirements and Figure 3 4 8200 Compressor Water Cooling Requirements to determine the minimum acceptable cooling wa
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18. 8200 Compressor Installation Operation and Service Instructions 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 No 16098 Printed in USA HELIX TECHNOLOGY CORPORATION http www helixtechnology com FELIX The information in this document is believed to be accurate and reliable However Helix Technology Corporation cannot accept any financial or other responsibilities that may 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 contained herein without prior written notice Revisions may be issued at the time of such changes and or deletions Any duplication of this manual or any of its parts without expressed written permission from Helix Technology Corporation is strictly prohibited Any correspondence regarding this document should be forwarded to Helix Technology Corporation Mansfield Corporate Center Nine Hampshire Street Mansfield Massachusetts 02048 9171 U S A Telephone 508 337 5000 FAX 508 337 5464 The following Helix Technology Corporation trademarks and service marks may appear in this document Conductron Convectron Cryodyne Cryogen Cryogenerator Cryo Torr CTI Cryogenics FastRegen GOLDLink Granville Phillips GUTS Helix Technology Your Vacuum Connection M Helix Micro Ion Mini Ion On Board RetroEase RetroFast Stabil 1 Sta
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20. Adsorber from the Compressor 4 2 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Installing the Compressor Adsorber 1 Install the replacement adsorber as follows a Remove the dust caps from the self sealing coupling halves at each end of the replacement adsorber b Write installation date on the adsorber decal c Install the replacement adsorber following the steps for compressor adsorber removal in reverse order Use the hardware saved in step 5 above 2 Connect the adsorber to the compressor internal piping Refer to Figure 4 1 a Check the self sealing connector flat rubber gasket to make sure that it is clean and properly positioned CAUTION Make sure to hold fast on the left coupling nut while tightening the right coupling nut as shown in Figure 4 1 b Make the first turns by hand and then firmly seal the connection using the two wrenches until the fittings bottom Refer to Figure 4 1 for proper coupling of the self sealing connection 3 Replace the cover and the front and rear grilles and secure them 4 Ensure that the pressure gauge reads 245 250 psig 1690 1725 kPa If additional gas pressure is required follow the instructions in Adding Helium Gas 5 Reconnect the return and supply flex lines to the compressor 6 Connect the compressor input power cable to the electrical
21. On Board Cryopump Installation Operation and Maintenance manual for information on helium circuit decontamination E __ _ i 4 6 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Appendix A Customer Support Information Customer Support Center Locations To locate a Customer Support Center near you please visit our website www helixtechnology com on the world wide web and select CONTACT on the home page Guaranteed Up Time Support GUTS For 24 hour 7 day per week Guaranteed Up Time Support GUTS dial 800 367 4887 Inside the United States of America 508 337 5599 Outside the United States of America Product Information Please have the following information available when calling so that we may assist you e Product Part Number e Product Serial Number e Product Application e Specific Problem Area Hours of Operation e Equipment e Vacuum System Brand Model Date of Manufacture E mail For your convenience you may also e mail us at techsupport helixtechnology com Se R E 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 1 8200 Compressor Installation Operation and Service Instructions FELIX Appendix B Troubleshooting Pro
22. become familiar with the contents of these instructions to ensure high quality safe reliable performance The remainder of this chapter contain the following figures and tables e Figure 1 1 Air and Water Cooled 8200 Compressor Dimensions e Figure 1 2 Component Locations e Table 1 1 Power Requirements Steady State Conditions e Table 1 2 General Specifications I 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 1 1 Installation Operation and Servicing Instructions 19 85 MAX 504MM 3 00 76MM 563MM 4 48 114MM 16 75 425MM 14 20 361MM 1 96 50MM 12 00 19 62 pele 12 00 305MM 498MM 305MM MINIMUM MINIMUM CLEARANCE CLEARANCE NOT TO SCALE NOT TO SCALE Air Cooled 18 85 504MM 3 00 76MM GS 563MM 4 48 114MM 16 75 425MM 2 25 57MM 14 20 361MM 5 18 132MM 1 06 27MM 19 62 8 25 498MM 210MM Water Cooled Figure 1 1 Air and Water Cooled 8200 Compressor Dimensions EE 1 2 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X WATER OUT A a Front View Air and Water Cooled LEGEND 1 Compressor Input Power Block 10 Cooling Water Output 2 Cold Head Power Receptacle 11 Cooling Water Input 3 On Board Power Receptacle 12 Rear Plate 4 Helium Ga
23. bil Ion ThinLine TurboPlus Vacuum Assurance All other trademarks or registered trademarks are the property of their respective holders CopyrightO 2003 Helix Technology Corporation Printed in U S A d A I i iii 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 CEO No 16098 Table of Contents Section 1 Introduction Gul mM P v hae E 1 1 Installation Operation and Servicing Instructions 1 1 Section 2 Inspection Packaging of the System 2 1 CODPDICSSO caes 65 ave erreper dues ee E ase ea 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 5 Cooling Water Heat Load and Temperature 3 6 Final Preparation of Compressor 3 6 Connecting the Compressor to the Cold 3 7 Section 4 Maintenance Procedures bcheduled Gace ee ee TET ew eee eb Edd S 4 Removing the Compressor
24. cedures WARNING Disconnect the compressor before performing any troubleshooting procedures The compressor pump 16 hot after operating Wait for the pump to cool down before working on the inside of the compressor You can find compressor troubleshooting procedures in Table B 1 Table B 1 Compressor Troubleshooting Procedures 1 System power ON OFF switch CB1 and compressor switch S1 remains in the ON posi tion when switched on but the compressor will not run Refer to Figure C 1 for identification of all electrical components 2 System power ON OFF switch CB1 remains in the ON posi tion but the compressor will not run 2003 Helix Technology Corporation 1 The thermal protective switch TS1 is closed activat ing the relay trip coil in the ON OFF switch SW1 2 Incorrect phasing at input power 3 Excessive current drain has activated the series trip in the compressor ON OFF switch 1 No power coming from the power source 2 Incorrect or disconnected wiring within the compressor 1 Test switch TS1 on air cooled compressor test TS1 and TS2 on water cooled compressor If continuity is found in any switch contact the Product Service Department 2 Correct phase sequence at input power cable 3 Measure and record the current and contact the Product Service Department 1 Check service fuses circuit breakers and wiring associated with power source and repair as
25. ctors with a 10 ring terminal Follow the terminal manufacturer s instructions to insure proper crimping 2 Disassemble the electrical terminal enclosure 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 Ifnecessary back off strain relief screws Hee 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 3 Preparing the Compressor Input Power Cable HEL 4 Thread input power cable end up through the strain relief into the enclosure 5 Attach the power conductors onto the appropriate terminals of the terminal block a For three phase hookups attach the three power leads to terminals X Y and Z b For single phase hookups attach the two power leads to terminals X and Y DO NOT USE TERMINAL Z Tighten all terminals to 18 22 in Ibs torque HOO Tighten down screws on strain relief CAUTION Ensure that strain relief 15 tightened down on the outer insulation of the input power cable and that the cable does not slide 8 Remount the terminal enclosure cover and secure with two screws 9 Referto Final Preparation of Compressor for correct phasing checkout procedure WARNING Insure that the ground wire is returned to a suitable ground in a non interrupting manner Cover Screws Figure 3 1 Electrical Terminal Enclosure with Cover in Place 3 2 2003 Helix Technol
26. ect the adsorber inlet self sealing coupling as shown in Figure 4 1 8 Remove the bolts nuts and washers that secure the adsorber to the base of the compressor Save all nuts bolts and washers for installing the replacement adsorber 9 Carefully lift the adsorber inward until the outlet self sealing coupling clears the rear panel and remove the adsorber as shown in Figure 4 2 10 Remove the adsorber from the compressor as shown in Figure 4 1 ppe M OOHOHXAAAAAEEMEEAEAMAME EAA AEAeEAXAXXAILIBLLLLZLEELZELL IZCILLLLDILIZDLDBULULDJDU I J J DLCU U UULELLLC eY 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 4 1 Scheduled Maintenance I Rear Panel This 1 1 8 in This 1 3 16 in wrench This 1 1 8 in This 1 3 16 in wrench wrench holds is used to loosen the wrench holds is used to tighten the the coupling in self sealing the coupling in self sealing coupling coupling connector connector Note the To Disconnect The Coupling To Connect The Coupling Figure 4 1 Disconnecting Connecting the Adsorber Self Sealing Coupling WARNING Depressurize the adsorber before disposing of it Attach the depressurization fitting included in the Installation and Scheduled Maintenance Tool Kit to the coupling half at either end of the adsorber and tighten it slowly Compressor Base Figure 4 2 Removing the
27. ge line This procedure is required to ensure that both the regulator and the charging line will be purged of air and that the air trapped in the regulator will not diffuse back into the helium bottle For best results CTI suggests a dedicated helium bottle regulator and line which are never separated for adding helium 2 Setthe helium pressure regulator to 300 psig 2070 kPa Depending on the compressor operating state add helium gas a Ifthe compressor is running approximately 2 hours operating time under normal operating conditions slowly open the helium charge valve on the rear of the compressor When the helium pressure gauge rises to 270 290 psig 1860 2000 kPa tightly close the charge valve b Ifthe compressor is not running slowly open the helium charge valve When the helium pressure gauge rises to 245 255 psig 1688 1757 kPa tightly close the charge valve CAUTION Add helium gas slowly to prevent relief valve blow off 3 Ensure that the helium charge valve on the compressor is tightly closed Shut off the helium pressure regulator on the helium bottle and remove the charging line from the male flare fitting Shut off the helium gas bottle valve Reinstall the flare cap 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 4 5 Helium Circuit Decontamination I iB Helium Circuit Decontamination Refer to Section 4 Maintenance of the appropriate
28. igh vacuum pump cold head b Connect the compressor input power cable to the power source c Turn on compressor d Your system is now ready for operation User s Vacuum Chamber On Board Cryopump Roughing Pump Air Pressure 60 80 psi Nitrogen 40 80 psi Figure 3 5 Typical 8200 Compressor Installation 3 8 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Section 4 Maintenance Procedures WARNING Always disconnect the compressor from all sources of electrical power before performing any maintenance procedures Scheduled Maintenance The only scheduled maintenance required on the 8200 Compressor 1s replacement of the compressor adsorber P N 8080255K 001 every 12 months Removing the Compressor Adsorber 1 Shut down the compressor 2 Disconnect the compressor input power cable from its electrical power source 3 Disconnect the flex lines from the gas return and gas supply connectors at the rear of the compressor 4 Remove the screws holding the compressor rear grille rear panel front panel and cover Figure 1 2 Front and rear panels remain in place 5 Use the two wrenches supplied to avoid loosening the body of the coupling from its adapter 6 Unscrew the two self sealing coupling halves quickly to minimize gas leakage as shown in Figure 4 1 7 Disconn
29. lity to carry heat produced during compression Helium 1s then compressed and passed through a heat exchanger for removal of compression caused heat The helium flows through a bulk oil separator oil mist separator and helium filter cartridge where oil and contaminants are removed A differential pressure relief valve in the compressor limits the operating pressure differential between the helium supply and return lines thereby allowing compressor operating without cold head operation When cold head operation reaches a steady state condition further pressure regulation is unnecessary 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 1 Compressor Gas and Oil Flows I 18 A A r0 f SS PRESSURE cauce QO SYSTEM HELIUM SUPPLY LINE Y 2 X NIE TO THECOLO HEAD 350 PSIG ADSORBER OIL MIST DIFFERENTIAL SEPARATOR PRESSURE ORIFICE RELIEF VALVE L A aa 193PS1 4 gt t 11 E SOLENOIO CONTROLLED VALVE M M CLOSED WHEN COMPRESSOR IS IN OPERATION OIL RETURN LINE m HELIUM RETURN LINE FROM THE COLD HEAD COMPRESSOR PUMP COMPRESSOR V Ist GAS DISCHARGE oi el i Ru E ERATOR 2nd GAS DISCHARGE i COMPRESSOR COOLING OIL o 6 6 SIGHT NE GLASS 9 r p J Bre d SIRE un BENT EE dt ave 24
30. nent An Installation Operation and Servicing Manual is included in the carton for the component packaged in that carton The Compressor On receipt remove the 8200 Compressor from its shipping carton and inspect the compressor for evidence of damage as described in this Section 1 Unpack and remove the compressor from its shipping carton 2 Check the carton contents It should contain a 8200 Compressor air cooled or water cooled b Compressor Manual P N 8040353 3 After unpacking inspect the compressor for evidence of damage as follows a Inspect the compressor overall exterior for damage b Report damage to the shipper at once c Retain shipping cartons for storage or return shipment When installing your system CTI recommends that as you unpack a component you perform an inspection and the necessary tasks for system installation for the component according to the manual included with the component Final system installation and operation will be performed following procedures in the high vacuum pump or refrigerator manual 4 Checkthe helium pressure gauge The gauge should indicate 250 psig 1725 kPa minimum at 70 F If additional gas pressure is required follow the instructions in Adding Helium Gas ree eee L5 1 5 LLLLLLLLLLLLLLLLLALLL ILL oo 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 2 1 8200 Compressor Installation Operation and Service Instructions
31. nology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 vil Tables Table 1 2 General 1 4 Table 1 1 Power Requirements Steady State Conditions 1 4 Table 3 1 Cooling Water 3 4 Table 3 2 Voltage Specifications 3 6 Table B 1 Compressor Troubleshooting Procedures B 1 E 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 ix 8200 Compressor Installation Operation and Service Instructions X Section 1 Introduction General The manual provides instructions for installing operating and servicing the 8200 Compressor This compressor is available in two versions air cooled P N 8032549G001 G002 and water cooled P N803255G001 G002 If you are installing or operating a Cryo Torr or On Board System you should also have available the appropriate cryopump or refrigerator When you purchase a system you will receive two manuals necessary for system installation plus a loose leaf binder with index tab separators allowing you to compile a complete indexed system notebook Installation Operation and Servicing Instructions Installation Operation and Servicing Instructions for your 8200 Compressor provide easily accessible information All personnel with installation operation and servicing responsibilities should
32. ogy Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Z not used for single phase Ground Screw 4 Power Cable Figure 3 2 Assembly of Conductors to Terminal Block Cooling Water Requirements Water Cooled Compressors Only If flexible water hose connections are used install the barbed fittings supplied with the compressor on the input and output connections 1 Apply a light coating of standard plumbing thread sealant on the barbed fitting threads 2 Tighten fittings on 1 2 inch FPT input and 1 2 inch FPT output connections DO NOT OVERTIGHTEN 3 Connect flexible hoses to the fittings and secure with hose clamps If hard piping is desired install the water lines directly onto the compressor 1 2 inch FPT input and output connections DO NOT OVERTIGHTEN CAUTION Check water connections for leaks 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 3 3 Preparing the Compressor Input Power Cable HEL Cooling Water General Considerations 1 Cooling water must meet flow and pressure requirements as indicated in the following subsections 2 To conserve water the cooling water should be shut off when the compressor is not running CAUTION If cooling water below 45 F 7 C is allowed to run through the compressor while the compressor is not operating the compressor oil
33. ply connector on the cold head Attach the supply and return line identification decals CTI supplied to their respective connecting piping ends Verify proper helium supply static pressure by confirming that the helium pressure gauge reads 245 250 psig 1690 1725 kPa in an ambient temperature range of 60 to 100 F 16 to 38 C WARNING Do not operate the 8200 Compressor unless a Cryopump or Waterpump is connected to the system If the indicated pressure is higher than 250 psig 1725 kPa reduce the pressure as follows a Remove the flare cap from the gas charge fitting located on the rear of the compressor b Open the gas charge valve very slowly Allow a slight amount of helium gas to escape until the helium pressure gauge reads 250 psig 1725 kPa c Close the gas charge valve and reinstall the flare cap If the indicated pressure is lower than 245 psig 1690 kPa add helium gas as described in Adding Helium Gas 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 3 7 Connecting the Compressor to the Cold Head I 6 Make the following electrical connections WARNING The compressor ON OFF power switch on the front of the compressor must be in the OFF position before making any and all electrical con nections a Connect the cold head power cable to the rear panel of the compressor and the other end to the electrical power connector on the h
34. re Trip Relay K1 6 Voltage Selector Relay K2 13 Transformer T1 7 Main Circuit Breaker CB1 14 Motor Start Relay CR1 8 Circuit Breaker 3A CB2 15 Meter Elapsed Time EIM Figure D 1 Components in the Electrical Control Chassis of the 8200 Compressor 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 D 1 1 Coldhead Phase Shifting ResistorR3 9 Circuit Breaker _ Lol 2 Overtemperature Resistor R1 10 Circuit Breaker 3A CB3 3 Run Capacitor 35 uf C1 11 Voltage Selector Switch 51 4 Start Capacitor 119 uf C2 12 Frequency Selector Switch 52 5 Transformer T2 13 Relay Trip Relay K1 6 Run Capacitor 2 uf C4 14 Transformer T1 7 Run Capacitor 6 uf C3 15 Motor Start Relay CR1 8 Main Circuit Breaker CB1 16 Meter Elapsed Time ETM Three Phase Scott T Configuration Figure D 2 Components in the Electrical Control Chassis of the 8200 Compressor Single Phase RC Configuration N D 2 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 8200 Compressor Installation Operation and Service Instructions X Appendix E Flow Diagrams for 8200 Air Cooled and Water Cooled Compressors Compressor Gas and Oil Flows Refer to Figure E 1 or Figure E 2 while reviewing this subsection Helium returning from the cold head enters the compressor and a small quantity of oil 1s injected into the gas stream thereby overcoming helium low specific head and inabi
35. s Fitting and Charge Valve 13 50 60 Hz Frequency Selector Switch 5 Helium Supply Pressure Gauge 14 208 220 Voltage Range Selector Switch 6 Helium Gas Return Connector 15 Resettable Circuit Breakers 7 Helium Gas Supply Connector 16 Compressor ON OFF Switch 8 Rear Panel 17 Front Panel 9 Rear Grill 18 Front Grill Figure 1 2 Component Locations C R 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 1 3 Installation Operation and Servicing Instructions I IB Table 1 1 Power Requirements Steady State Conditions Operating Voltage Part Number Cooling Phase Hz P 5 5 Operating Range Current 8032549G001 Air 3 50 180 220 10A Air 3 60 198 250 10A 8032549G002 Air 1 50 180 220 10 Air 1 60 198 250 10 8032550 001 Water 3 50 180 220 8 5A Water 3 60 198 250 8 5A 8032550G002 Water 1 50 180 220 8 5 Water 1 60 198 250 8 5 Table 1 2 General Specifications Weight 155 Ibs 70 kg max shipping Power 2 0 kw nominal operating water 2 1 kw nominal operating air consumption Compressor input power Recommended type SO 4 conductor 600V neoprene jacket and 14 cable gauge wire customer supplied Install per Figure C 1 Electrical Schematic diagram ensuring com pliance with all national state and local standards Helium pressure Static 245 255 psig 1688 1757 kPa at 70 to 80 F 21 to 27 C Supply nominal operation 270 290 psig 1860 2000 kPa at operat
36. ter supply pressure at different flow rates and temperatures c KR iB Allowable Operating Range at min water flowrate Minimum Required water Pressure PSIG 1 50 1 75 2 00 Water Figure 3 3 8200 Compressor Cooling Water Flow and Pressure Requirements 90 Allowable Operating Range Water Supply Temperature F 1 00 1 50 Water Flowrate GPM Figure 3 4 8200 Compressor Water Cooling Requirements 2003 Helix Technology Corporation Pub No 8040353 Rev 104 4 22 03 ECO No 16098 3 5 Final Preparation of Compressor I 18 Cooling Water Heat Load and Temperature Rise CAUTION The temperature of the cooling water as it leaves the compressor should not exceed 100 F 1 Heat load to facility water is approximately 5000 Btu hr or 1500 Watts With a 1 0 GPM water flow this translates to an approximate water temperature rise of 10 F 5 6 C Final Preparation of Compressor 1 Using a voltmeter measure the phase to phase voltage from the power source Compare this voltage to Table 2 and position the voltage range selector switch to the 208V or 220V position as required Also set the frequency selector switch to the 50 Hz or 60 Hz position as appropriate See Figure 1 2 for location of selector switches Table 3 2 Voltage Specifications Operating Voltage Range Voltage Adjustment 60 Hz 50 Hz Switch 51 Position 198 212 180 212 208V
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