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Polycold Closed Loop Gas Chiller (825131)

1. PGGL2 V3 PID Process amp Instrumentation Diagram Page 79 82513100 REVA pm T Ba 1 Md DAG PGCL2V3 1 71151517158 Electrical Schematics 4809 825131 00 REVA
2. om m m ____ mm BROOKS AUTOMATION Customer Instruction Manual POLYCOLD CLOSED LOOP GAS CHILLER MODEL 2XCL 3 SE 440VAC Part 700188 06 MODEL 2XCL 3 SE 2 440VAC Part 700188 07 MODEL 2XCL 3 SE 2 480V 480VAC Part 700188 09 Serial Cool Solutions 80512100 REV A Page 1 TABLE OF CONTENTS 1 0 INTRODUCTION 4 13 FOREWORD Es 12 SERVICE 222 13 BEFORE YOU START 2 2 2 14 HAZARD ALERTS INFORMATION 5 15 USER PRECAUTIONS 2 18 SAFETY INFORMATION 5 ras 17 SAFETY TRAINING GUIDELINES 18 LOCKOUT TAG OUT PROCEDURE 19 20 INSTALLATION 20 21 SYSTEM DIAGRAMS 20 Figure 1 Electrical Distribution Diagram ns Figure 2 System Block Diagram er Figure 3 Dimensions Front version 6 123 22 ABOUT THE 2XCL 2 ee 3 Unit Features 2 28 23 INSPECT AND INSTALL THE 520 24 CONNECT THE COOLING WATER 39 25 INSTALL THE EXTERNAL GAS CIRCUIT AND GAS FILL LINE do 26 EMERGENCY OFF CIRCUIT idi 42 30 OPERATION d 3 1 INTIAL START UP oa 22 Ie 32 BAKE OUT AND POST BAKE COOLING RENS Le 33 RESETTING SAFETY INTERLOCKS AFTER FAULT 40 INSPECTION amp MAINTENANCE d 50 DISCONNECTION STORAGE AND RESHIPMENT 4 TROUBLESHOOTING 48 6 1 GENERAL TROUBLESHOOTING MATRIX rj 62 REFRIGERATION COMPRESSOR FAULT MODES s Indicator Lamps Based Troubleshooting M
3. Relay oF 5 OF Relay n A OF Or 3 Run unit has been fied and nitrogen compressor is on SHC Pressure T zd Green indicator on SHC Re Nestor SM Relay 4 On On Relay 5 n 2 Aol Sono Valve On OF 82513100 REV A Page 6 7 AUTOFILL RELAYS AND SOLENOID VALVE 24 Relays and Solenoid Valve 825131 00 REVA Page 6S 6 8 ADJUSTING AUTOFILL CONTROL SETTINGS This section describes how to adjust the of the controler PSA ACAUTION INCORRECT ADJUSTMENT MAY RESULT IN UNIT FAULTS Do nat adjust these setings unless specifically authorized by the tool manufacturer Contact the col manufacturer before making any control sting adjustments The controller has been factory set with the following setings Uni of measure psig Set point when gas compressor of 70 psig Reset point when gas compressor off n1 75 psig Sot point when gas compressor on 19 psig Setpoint when gas compressor on 3 23 psig Even when not powered the controler wil retain these settings for 5 10 years Readjustment is not needed under normal circumstances Do not adjust hese unless specifically authorzed by the ol manufacturer Failure to so may result in tool downtime Procedure verify Pressure Switch Set up
4. eom Loans J SEISMIC ANCHOR PONTS 2 EACH FRONT AND REAR MAXIMUM TILT ANGLE LESS THAN 10 FIGURE 9 2XCL version 07 440V Weight Distribution 825131 00 REV A Page 7 Connect the electrical power A WARNING HAZARDOUS VOLTAGES Electrical power to the 2XCL must be connected by qualified personnel according to local codes A WARNING HAZARDOUS VOLTAGE EXISTS AT ALL TIMES AFTER THE POWER IS CONNECTED Only qualified elecrcians should electrical work Power should be removed at the point of electrical connection and following standard tag out procedures A lockout device may be placed on the supply power circuit breaker provided by others or on the supplied electrical power plug The host equipment is to provide the main disconnect device and a circuit breaker that serves as the overcurrent protection fr the electrical supply circuit Before connecting he 2XCL to your power source verily the following Tha disconnect device is readily accessible to the operator located in sight and within 25 of the 2468 and clearly marked indicate the equipment that protects The disconnect device locks in the de onergized poston only complies with IEC 947 1 and 47 3 standards and meets he requirements of SEMI S2 section 17 Your actual voltage falls within the acceptable range listed in Table Your electrical supply has eno
5. 0183 ey M 1 Rm Ra Figure 5 Dimensions Front version 07 825131 00 REV A Page 25 COE Un proram End ER Figure 6 Dimensions Rear version 07 82813100 REV A Page 26 2 2 ABOUT THE 2XCL 1 What itis and what it does Coo Solutions 2XCL is a reffgeraion unit that cools a stream of gas to temperatures It consists of Mo separate subsystem the upper porbon known asthe Refrigeration Unt which provides the cooling of fn qas stream and the lower pardon which provides the secondary loop culation of the gas stream The Refrigeration Unit has a refrigerant cui and a gas circuit The refigerant is located entry within the 2XCL The 2XCL s compressor circulates refrigerant in continuous loop through the stack The water cooled condenser removes the heat of Compression from the rafigerant by circulating cooling water through coaxial col and the Stack cools the refigerant lo ulraiow temperatures The refigerant a proprietary mixture of refrigerants provided by Brooks Automation The gas circuit consists of a continuous copper tube that runs through the refegerant The gas is cooled as it runs through the Polycold stack The gas compressor compresses customer supplied nirogen or helium gas and uses a heat exchanger cool it to room temperature
6. Mater PFC CT FL cece yp ee on ered te Bre cr on race otha nie an sar emen ton warranty Customer Pie a ao Prat mses he Broke Automaton ne Grr Toms and Candin Pei Prt onl nama nm Bt we E mat pisa saone om rca com 825131 00 REV A Pues 1 0 INTRODUCTION 1 1 FOREWORD Poiycoks Coo Solutions low temperatura gas chillers are used to allow low temperature vacuum processing of semiconductor device wafers as well as other appicalons Vacuum processing systeme se recirculating fuids to Keep the wafer at controled temperature The wafer sits on a pedestal or table In vacuum and is processed typically ina vacuum wth specific gases and metalic vapors to create a uniform coating on the wafer Gas circulating in the secondary of the ZXCL closed loop gas chiler is cooled in the gas chiller The temperature of tha gas leaving the gas chiler can reach temperatures of 100 The chilled gas s recirculated by a secondary gas compressor The customer installed Ines connecting tne gas chier and pedestal are vacuum jacketed o minimize the heat leaks from the ambient to the chilled gas The system consists of a refigerabon system which chils the secondary gas a secondary gas recirculating compressor interconnecting gas lines and the table in the vacuum system The
7. Van VCD VCE WAVE WAVE I Zan Zt Connon Cat Con Sn Cab i Men M lr On nd rata Rama Si ln inr rs Aviation 200 Righe Reserved The information lode in his tans Boks Propeictary Irion pra came and cannot te md dia pct de wit IS Elizabeth Drive Clean MA 01804 Poe 1 978 2622400 Fax 1 078 262 2500 Fur emergencies contact Technical Support 078 262 2900 www broom This manual aval in the following languages Engl Tus technology is o United Stes export Administration Regulations and authorized to ihe destination aly conr o U S law is probit ists ta the US 0 2006 by Brooks Polycold Systems Ine eights reserve Pied the United Stats of Amis Trademark Recognition Armaflexs is a reghtered trademark of Armstons World lass Ie i a tademar of Parker anii Corporation Philipe is a registered trademark of Philips Screw Company Palycold is a regie dena of Brooks Technology Corporation VCRs a registered of Con Company 13 BEFORE YOU START Please have the folowing information avaliable to help us assist you Serial No Date Manufactured The above information on The nameplals your ZKEL You may wish to enter this information now before the ZXCL is installa 825131 00 REVA 14 HAZARD ALERTS INFORMATION VISUAL HAZARD
8. exposed threads Use four ing eyes with an adequate Wing harness and mechanism Ling harness must be centered between the ling eyes Lift vertically with horizontal component WARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Over pping leaning this device may cause it to fall over rasuling in severa injury death The equipment should be removed rom shipping palet by using ing eyes installed ontop of he unt WARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Over ipping leaning this device may cause it to fall over resulting in severe injury or death Read the manual before moving s equipment using the casters Move the equipment slowly and avoid rapid acceleration and deceleration Apply force lo move the system below the equipment canter of gravity Do not place yourself between the moving equipment and fixed obstructions A WARNING Dus to ts weight a ruck or overhead crane is required to place and remove the fom the transport unit WARNING u to righ cenis of gravity care must be taken to avoid tipping the unit 1 While transporting pallet to which the unit is strapped and 2 While positing the unit on casters See lustraton figures 3 amp 4 Tho 2XCL should only be above using its ing eyes and a sing system 5 Install 2XCL seismic ancho
9. should rot jt Tap rese a We gaa Wen causes uncon The compressor ca a 825131 00 REV A Page 16 TSE Compressor Sha gh A NN awh Sul he gas comprar whan Temperate Sitch shot cause t uncon The compressor Ts Gas Fgh Si non 2 8 gas causes Io funcion Te compressor Ege Sitch A CAUTION Safety devices are installed the ZXCL to help protect fom Permanent damage Some of the protective devices are seifreseting with a system status ouput he integrating equipment When tne system status Indicates that a safety component has functioned the integrating equipment should not enable operation unti he cause of the fault is corrected 1 protective device is the cause of the problem must be before continuing to use the 2XCL Please see Section 6 0 Trouble Shooting or call Polycold Sonice Deparment for assistance Bypassing or repeated resetting of a protective device expose personnel and or the facito hazards permanently damage the equipment and may vod your warranty TABLE A CIRCUIT BREAKER AND FUSE PROTECTION Reference Protection Provided
10. RECENSE present Damaged pins on remote I usr remote falls to start compressor but the remote jumper does conditon of pins 5 and 6 for possible damage The signal may be absent for several reasons including incorrect wiring at the integrating equipment Incorrect controls programming by the integrating equipment or correct funcion of the integrating equipment nthe event of unit fault resulting in conolinterrupt latching FASE ERROR ON LCD Display TOT BRS E OTT This Tau cycle latched To rese Provide clockwise rotation for the supply power 825131 00 REV A Possibie Cause Corrective Raton aa of several ERROR ON LCD posstis ses below DISPLAY MOTOR TEMP Excess gas dacharge PSST laiched electronically and mechanically ERROR ON LCD pressure dust Requires manual reset and reset of DISPLAY Excessive low through LCD display verily that no other Due to faults are present Hi Pressure PS3 Flow restriction in ine Fault 1 no other faults present follow the steps below 1 Vent gas to achieve D pei using the refrigeration valve 17 al the rear of the unit 2 Press the green switch on PS3 to reset it RESET SWITCH or PSS 3 Fil the gas system with a fresh charge of dry gas 70 psig min 90 psig max Restart the System and f the hgh
11. TER RATS 1 12412411 Shy eo ri ed i abe tbved f Fe uit pid 7777 2XCL 2XCL 2XCL cad feriae ACCES ror vew vont Row wey be pba sie she bre 73 Yam win end eng oe ACCES ACCES cea eared ME ME 2 UA 82813100 REV A Page LOCATION OF po WHEEL PIVOT S PONT X 1 rob m SEISMIC Me SEISMIC ANCHOR POINTS ANCHOR POINTS 71 2209 0 ca 3646 ELT M T A Li 15717 Css 17 82 POINT LOADS J 215 PONT LOADS SEISMIC ANCHOR POINTS MAXIMUM TILT ANGLE LESS THAN 10 FIGURE 8 2XCL version 06 440V Weight Distribution 825131 00 REV A Page 33 LOCATION OF WHEEL PIVOT PONT al VE WHEEL SEISMIC li sop seismic ANCHOR POINTS M v POINTS 98 4 ee b p im d sl 1782 20125
12. efigeraton system uses a propriety and patented blend of refigerants The secondary loop compressor Uses an gas whose dew point is below The refrigeration system as wel as the secondary gas requires cooing walor There is no co mixng ofthe refigeramt and the secondary gas The equipment is designed fr continuous operation Electicy cooling water and pressurized dry nirogen the only required uites Pressures are stated as gauge not absolute is pounds per square inch gauge and kPa is Kiopascale gauge This technical manual contains Safety Service Induction Specifcaions Installation Operation Maintenance and Paris information for he equipment in the system Notes ZATTENTION REVIEW THE INSTRUCTION MANUAL BEFORE OPERATING THIS EQUIPMENT Upon arrival of the equipment and prior to staring installation or operation confi that the balance pressure shown on the suction pressure gauge is between 165 190 psi Refer io section 2 3 1 825131 00 REV A Page 4 12 SERVICE Glug Ain ein gd oa toe Ep BAL Bare Reticle Stocker Hercules Hercules Express loser nine Express Linear chun 7 Mags am Marathon Exess Mare Maan PASTY 0 Pope Rance ATR Balance DPR WER SENTRY Tine Tec Tusce NT
13. 4 38 16 NC or 13 NC threaded barrels are provided for seismic anchoring and can be used install seismic anchorfack screws 11 LIFTING EYES These ling eyes 4 are provided as an accessory to safely it the unit into Place These eyes are mounted in 38 16 NC threaded barrels A WARNING LIFTING HAZARD 900 pounds 400 kg Faure to property this device may result in severe injury or death Read the manual before iting this equipment using the fing eyes Assure that ihe eyes engaged in the rame wih exposed threads Use all four ifing eyes with an adequate Ming harness and mechanism Liting harness must be centered between the ding eyes Lit vertically with horizontal componant 12 CASTERS Enable the unit to be rolled into place for installation and for maintenance etc 13 WATER IN CONNECTION FNPT connection 14 WATER OUT CONNECTION 7 FNPT connection 15 EMO LOOP J1 CONNECTOR This is the FEMALE connector that access lo the dedicated emergency machine circuitry It is wired in SERIES with the EMO bution 16 EMO LOOP J2 CONNECTOR This is MALE connector that allows access to the dedicated emergency machine off circuitry Iis wired in SERIES with the EMO button 17 VENT VALVE VS This valve is piped to the high pressure side of the HC 10 compressor 18 REMOTE CONNECTOR This connector provides switch contact opening for status of refrigeration and gas compressor us 1
14. can see other error conditions that lead up to the latest Clearing Error Conditions The prefered reset method is to cycle CB Alternatively the faults can ba cleared by pressing the ON and DISPLAY buttons simultaneously Restarting after an Error Condition When the shutdown is caused by any of the high temperature switches the compressor wil restart only ater t has cooled enough forthe switch waiting forthe compressor 10 clea the error message then push the ON button to restart Should the compressor fail to star alow more cooling ime Repeat the restart procedure Check cooling water temperature and flow Compare with Specifications The motor high winding temperature relay automaticaly resets after the compressor shuts down and the relay This typically takes about 30 minutes To restart the compressor cer the error message and han push the button Ifthe compressor fas to star allow more cooling Repeat the restart procedure Note The display refers to lum Forihis system all messages showing helium refer to he nitrogen gas being used 825131 00 REV A Page 6 6 4 AUTOFILL TROUBLESHOOTING BASICS 1 the nitrogen supply pressure is in the correct range 70 90 psi 2 Verity that the auto refil switch is ON and the red dspayiluminates on the SMC pressure switch 3 Verily thatthe SMC pressure does not lnk does tum off auto refill switch
15. 1 Tum on the auto switch Red display on SMC should illuminato 2 Push set button for more than 2 seconds Display should show push s push the or ian scroll button unti display PST then push set Dutton button If Display should show nC If not push the left or ight scroll button unl display Inc Push set buon 4 Display should show 2nC If not push the lef or right scroll button unti display 220 Push sot button 5 Display should show 7687 not push the left or right sol button unti display 768 Push sot bution 6 Display should show y n n If not push the left or right scroll button unti display BA n Push set button 7 Push set button for less than 2 seconds Display should show n and 75 If itis not TS push te lef or ight scroll bution unti display 75 Push s t button 8 Display should show n_Z and 70 If not 70 push the or right scroll button uni display TO Push set bution 9 Display should show n_3 and 23 If not 23 push the left or right scroll button unti display 237 Push set button 10 Display should show n 47 and 19 H not 19 push the left or right scroll button uni display 197 Push set button 825131 00 REV A Page 66 7 0 APPENDIX 7 1 BRAZING SPECIFICATION Tools and materials needed Tubing cute Reamer Sand paper or wire brush or steel wool Pressure or regulated dry nitrogen GAS Oxyacetylene
16. Circuit the path of the refrigerant which goes from the refrigeration unit through the feed ine through the cryosurace through the reum ine and back to the refrigeration unit Refrigerant Expansion Tank tank inside the a safe pressure when the unit is not at operating temperature Refrigerant Line insulated feed and return lines that carry refrigerant o and from the cryosurlace igeraion unit that maintains the gaseous refrigerant at Refrigeration Unit tho machine containing the compressor condenser and Polycokd stack that cools refigerant mixture to cryogenic temperatures Return Line the copper tube in the refigerant ine that caries refrigerant rom the cryosurlace lo the refrigeration unit SAE Society of Automotive Engineers TC thermocouple Charge refigarant mixture that can be added to the refrigerant in the cryopump TOV Technical Supervision Society organization that verifies compliance with EN and IEC standards UL Underwriters Laboratories organization that vis compliance with NEC standards Vacuum Jacketed Gas Lines Connect the compressor to the vacuum process system The supply as ine cares high pressure inert gas from the compressor o the host equipment and another gas ine tums low pressure gas fom the host equipment back to the compressor 825131 00 REV A Page 76 9 0 PROCESS amp INSTRUMENTATION AND ELECTRICAL SCHEMATICS 825131 00 REV A Page uo
17. TET are electronically latched afar resetting switch Scrol through LCD display to that no other faults are present ful present determine which one s accurred reset allow 20 minutes for thermostats to cool and reset Then CB to reset electronics Verily water and temperature are within specication Table C 325131 00 REV A Page 59 Problem Possible Cause Corrective Raton Excessive discharge temperature at gas compressor Oi has been pumped from the coolant oop fo the compressors lower sump chronically latched To reset cycle proper operating pressures for gas compressor suction pressure of 12 psi to 25 psi charge of 70 ps to 130 pel Verily water low and temperature are within specication Table C Try to restart compressor times does nol start check ne evel in the upper sight glass of the compressor Oil should be visible afer the compressor has been operating for 15 minutes Contact Palycold Service the alls not visible System shutdown LCD reads Motor Amps ERR current switch opened cycle To reset 1f water and power checks indicate uitis are within specifications nterlocks may be faulty Consult Service TED reads Locked Rotor ERR Loss of one power phase Compressor has shutdown on three 3 Moto
18. Verily user remote signal is provided on pins 1 and 2 Musee remote fails to start compressor but the remote jumper does inspect condition tpn 1 2 for possible damage Tho signal may be absent for several reasons including incorrect wiring at the integrating equipment incorrect control programming he integrating equipment or correct funcion of the integrating equipment n the vent of unt rosuting in latching REVA Problem Possible Cause Corrective Aeon FAULT MODE 1 compressor not working C24 is ON AND faut ight is ON Pressure Such 251 is tipped due to Excess load Cooling water flow or temperature of specication Problem wih refrigerant charge Refrigerant Pressure Switch Low Side PSA is tripped due to Loss of refrigerant charge Temperature switch tip 151 water flow or temperature of specication PSTIs a latching switch Mandal reset required Excess load Verily nitrogen compressor pressures 19 23 psi uring operation lower values used wi long ines are within control parameters of aut contra see sections 6 410 68 I not troubleshoot auto Verity gas retur temperature below 327 C During post bake the gas compressor can be used bul the refrigeration compressor must remain off tl the retum temperature is be
19. _ Rated Voltage Amperage interrupting Designation And Amperage Capacity Dre VT TR 5500 Ges NET 36097 SA 5007 Darren 3007 cat ARN TIG 5000 FUT Darren FUZ FUE PAT ART FUT VT ART VT ART US Darren PAT ART FUT VT ART Vour eel must have enough capacity ta anda be 82813100 REV A Page 17 17 SAFETY TRAINING GUIDELINES This chapter provides summary of ho safety information that is to be successful conveyed service personnel as part of their training on tha POLYCOLD GAS CHILLER 2XCL The training program is Intended to ensure hat any person who undertakes the service of the 2XC can demonstrate Competence to perform the required tasks safely Accordingly training equi for each task includes not to the flowing 12 2 1 E A review of applicable safety standards and procedures as well as those presented in this chapter A review of maintenance and safety recommendations applicable to vendor supplied equipment An explanation of the purpose of subsystems their operation An explanation of the specif tasks and responsibilities of each person operator service personnel ele assigned o the Polycold GAS Chiler 2XCL equipment The person s denied by name loca
20. are operating normaly indicating that the compressor contactor closed green LED 80513100 REV A Page 28 5 FAULT INDICATOR REFRIGERATION UNIT Wil iluminate if a problem such as over pressure or high temperatures should occur red LED 6 LINE INDICATOR REFRIGERATION UNIT AND GAS COMPRESSOR UNIT 10 Mamnates when ine voltage is present and Gas Compressor circuit breaker C81 amp CB2 are closed yellow LED 7 emergency machine BUTTON Used to power down the unit s in the event an emergency stuaton should occur This circuit is wired taa dedicated safe voltage supply and i acivaled al unit functions wil cease and cause power contactors o open with the exception of power to this circuit This bution latches in the positon and must be rotated clockwise lo disengage Hazardous voltages remain n the uni om point of electrical connection he ine sica of the compressor contactors The cuslomer s responsible for removing power from the Palycoid uni supply when the EMO circuit is activated 8 RECIRCULATING GAS SUPPLY GAUGE This dial represents supply pressure from the Gas Compressor Unit HC 10 partion of the cooling unit the host equipment During normal operation the dial typically reads 85 115 PSI 9 REFRIGERANT SUCTION GAUGE Tris dial represents intemal Refrigeration Unit pressure suction During normal operation the dial typically reads 25 35 PSI 10 SEISMIC ATTACHMENT POINTS These
21. assistance troubleshooting or repairing your 2XCL Be sure to do this the compressors have an intemal problem if ho refrigerant circuit has leak or if the cooling water cir is obstructed Also see Section 3 3 for roseting safety mit switches 825131 00 REV A Page 44 6 1 GENERAL TROUBLESHOOTING MATRIX Probie Possible Cause Corrective and no indicating iluminated on eunt EMO Fpped on user system or 240 Determine EMO ins s the reason make sure is sate then reset and restart the system Ns poner Star Hat upstream power source is adequate Reconnect ine equipment Apply power 55555 power problem and Supply adequate power the equipment For poner Fequrements see table Bin Poiycol e 825105 Customer Instruction Manual Compressors do not Sar and make s No SECS I GBA stays in the ON position verify the flowing Refigeration Unit has power Power supply is adequate 2 CBI and CBZ are in he ON positon is nat ripped I CBA has tipped to the OFF position verity the folowing Power supply adequate Check Tat power sources and the power cordis connected Confirm that the EMO switch isn the extended normally closed postion sich on ihe 2XCL and the user system is in he correct ON position Correct power problem and sup
22. is used to adjust stings for the aulofll controler 32 FILL POWER SWITCH This switch is used to enable or disable the autfl controller 33 GAS COMPRESSOR UNIT HC 10 Fault Mode LCD Display 2 3 INSPECT AND INSTALL THE 2XCL ACAUTION No operator serviced parts within Access restricted to rained service personnel only Review table 7 3 for fci requirements prior ta Tools and materials needed Fork for overhead it pallet ruck or overhead crane Power cable from voltage source suitably sized for this equipment Wire strppers 2 Philips head screwdriver 1 Inspect and document any visible damage on the 2 crate 2 Open the crate and inspect the 2XCL the carrier immediately if you suspect the 2XCL was damaged during shipping Read the dal of the RECIRCULATING GAS SUPPLY GAUGE and record the pressure psig Read the dial ofthe REFRIGERANT SUCTION GAUGE and record the pressure 825131 00 REV A Page 30 3 Determine i the seismic anchorack screws screws per the procedure shown in 75 installed If not install the seismic anchor ack Remove the 2XCL from the using the top mounted ling eyes A WARNING LIFTING HAZARD 000 pounds 400 Faure properly If this device may result in severe injury or death Read the manual before iting this equipment using the fing eyes Assure that he eyes are fully engaged he rame with
23. is warmer than the dew point of the room in which the 2XCL is installed Maximum working pressure of the cooling water circus 200 psig 1380 kPa Your cooing water should be clean and suitable for use in copper based heat exchangers We recommend that you your cooling water iis very or has abrasives in chemical Impurities in your cooing water must be compatible win copper 2 Connect a supply and a ine to the refrigeration unit Make certain you use the correct size eee Tools amp Materials Needed at the beginning of this section For the 2XCL the COOLING WATER connections have 172410 female NPT fitings Connect your supply ine to the port labeled IV Connect your dran line to the port labeled OUT The coating water must in this direction to properly cool the unit TABLE C Refrigeration Water niet Minimum Flow Rate Pressure Drop Heat Rejacton Unt Temperature Gom Limi Inside the Unit FCC kPa 5905 364 03 7504 8008 M 29 000 68 5 87630 10 6 1670115 3 Verity that the water plumbing has no leaks ACAUTIO EQUIPMENT DAMAGE Do not tum on the unit unti the cooling water has been connected and turned on 82813100 REV A Page 39 2 5 INSTALL THE EXTERNAL GAS CIRCUIT AND GAS FILL LINE Tools and materials needed 1 1 Tubing or hoses wih 38 LD or Vacuum Jacke Li
24. out remaining water fom the lines 10 Remove the insulated interconnection plumbing from the transport path of the 2XCL unit 11 Verity that the casters are fy affixed to the base of the 2 unit 12 Raise the seismic anchorjack screws so that the weight of the unit rests on the casters Slowly transport the uni o an area where can be Hed onto the Over ipping this device may cause it to fall ver resulting in severe injury or death Read the manual before moving this equipment using the casters Move the equipment slewy and avoid rapid acceleration and deceleration Apply force to move the System below the equipment canter of gravity Do not place yourself between the moving equipment and fixed obstructions AWARNINGI TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE 825131 00 REV A Page 46 Using the eyebalts the top of the 2XCL unit Ht the system and depending on the cate design remove seismic anchorjscks screw AWARNINGI TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Over ipping leaning this device may cause it to fall over resulting in severe injury or death Tho equipment should be removed rom ts shipping palet by using the Installed Hg eyes WARNING LIFTING HAZARD 000 pounds 400 kg Faure to property If this device may resul in severe injury or death Read the manual before ing this equipment using th
25. pressura switch tps heck tor restictons in the customer installed ines 825131 00 REV A GAS COMPRESSOR UNIT TROUBLESHOOTING MATRIX CONTINUED Problem Possible Cause Corrective MOTOR TEMP Tow auction pressure M gas PSZTs Tatched electronically reset to ERROR ON LCD ine due to clear fault after resetting switch DISPLAY Scrol through LCD display very no other faults dueto are present Low Press PS2 Fault Low nitrogen chargalgas 23 Mechanical obstruction in control mafunctan To reset the switch the nitrogen pressure must be raised above 70 psi then cycle to reset electronics With gas compressor off check the recirculating gas pressure gauge tem 8 which should show a minimum pressure of 70 psi If below 70 psi check 2 Adequate nitrogen fl source 70 psi minimum Leaks in lines inked ines or other obstructions in ine Verity nitrogen supply meets required dryness dow point 80 Note Smal leaks can be compensated for with the intemal control switches 33 and PS5 32 set properly see section 7 6 verily gas is connected gas fil 22 and that ts supply pressure adequate very customer instated are not locked Soo autofll troubleshooting section 6 4 and 65 ON LOD DISPLAY and compressor runs temperature caused TS3 or Tso tie TET and
26. terminal lock see photo below on the terminal block Terminal Block with Plastic Guard Note Use 10 AWG wire for your power cord 4 Insert power cord through the liquid ght fling located on the back side of the 2XCL unit see label 1 in Power Inlet photo below Power Inlet Terminal Block with Power Cord Connected Connect power cord terminal block using the 10 32 screws provided Tighten screws on the terminal block using a torque wrench set to 20 IN LBS Connect ground wire to terminal lug labeled potential earth GND and tighten screws securely phola labeled Terminal Block wth Power Cord Connected above 825131 00 REVA Page 36 Reinstall plastic guard soe photo below Termin Installation of seismic anchorage brackets Make sure seismic anchorjack screws installed See Appendix 7 5 for more information Install 52 approved seismic anchorage brackets Install seismic anchorage brackets that secure the Seismic anchorjack screws toe facilty oor Seismic anchorage brackets must be suitabie lo stand a seismic load of 1400 Ibs per SEMI 52 requirements See semi rg for more information on 52 requirements WARNING A TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Maintain weight castors at times 2XCL Safety Circuit Connector A WARNING THIS UNIT MUST WIRED INTO THE CUSTOMER S SAFETY CHAI
27. 29 C 85 F 2 Verity that the insulation on the GAS OUT line is adequate The insulation should be airtight It should not be cracked holding moisture If necessary disconnect power to the 2XCL and replace insulation See Section 24 Install the External GAS Cru 3 Very that the refrigerant circuit does not have a leak Disconnect power to the ZXCL and 24 hours The balance pressure should be within 7 psig of the pressure recorded in Section 23 Inspect Instat the 2XCL Stop 1 IT ho pressure is lower he refrigerant circuit may have leak 4 Remove moisture from the GAS circuit Moisture may accumulate in tne GAS circuit and wil freeze when the 2XCL is operating which may restrict GAS fon To purge moisture from the gas line allow the instructions in Section 2 5 of this document Allow the GAS supply from the host equipment to at about 50 SCFH through the GAS circuit uni the exiting GAS is dry The exiing GAS should bo dry in about 10 minutas ACAUTIO Ifthe host equipment is sensitive o water condensation can be avoided while the system is natin use by plugging the open ends ofthe GAS circuit or allowing a small amount about SGH ofarynitogen to purge the GAS circu 82512100 REV A Page Adsorber Molecular Sieve Replacement The adsorber must be replaced as a part of routine maintenance after every 10 000 hours of operation of Gas Compress
28. 9 THERMOCOUPLE CONNECTOR Miniature Supply temperature 20 THERMOCOUPLE CONNECTOR Miniature Retum Temperature 21 THERMOCOUPLE CONNECTOR Spare 825131 00 REV A Page 29 22 GAS FILL PORT This is a compression iting used for charging the coolant loop tis Connected check valve to prevent pressurized gas from releasing through tnis iting when it is open 118 piped to the suction side ofthe compressor See procedure 23 GAS SUPPLY Bayonet adapter fis here Parker Ultraseal x Linde 16 24 GAS RETURN Bayonet adapter fis here Parker x Linde Y 25 POWER INLET Liquid tight conduit iting diam 1 245 1 1 88 W 25 MAIN CIRCUIT BREAKER This is tho main circuit breaker for the gas compressor Aor inital start up switch must remain in the ON postion if unit functions are io be accessed remotely 27 CB 3 Circuit breaker for control component 28 GAS VENT VALVE WRENCH This wrench is provided to open and close the gas vent valve ws 29 REMOTE JUMPER The jumper is used to simulate the remote interface GO signals for the refrigeration chiler and the gas compressor unt jumper allows the 2XCL to operated without being connected tors remoto user interface 30 FLOW INDICATING METER Provides indication of gas rate This is not calibrated and is for nication only 31 AUTOFILL CONTROL PS 5 This display shows the gas suction pressure It also
29. ALERTS USED IN THIS MANUAL AND AS LABELS ON THE EQUIPMENT SHOULD BE REVIEWED AND UNDERSTOOD PERSONNEL PRIOR TO USE OF THE SYSTEM Hazard warnings are provided in this manual before each step that may involve hazards to personnel See the following hazard icons and lex for information on ions which eni potently hazardous Sluatonsleonsequences of not avoiding the hazard Hazard alors used in the manual and the equipment follow ANSI 2535 and use the signal words DANGER WARNING CAUTION The signal words have the flowing meanings Pictogram con depicting nature of hazard Hazard Keyword Level AWARNING ELECTRICAL HAZARD High Voltage can cause severe injury or death Disconnect power before removing acces panelt Text describing how to avoid the hazard ELM Text descrbing hazard and what 02 HAZARD KEYWORD LEVELS DANGER An imminent hazardous situation that fat avoided wil result in serious injury or death WARNING A potentially hazardous situation that not avoided could resul in severe injury death CAUTION A potentially hazardous situation tha avoided could result in moderata of minor injury or property or equipment damage Hazard Warning Labels Identified by Number 1 CAUTION 80513100 REV A Extreme Temperatures Can cause burns or frostbite Do not touch exposed piping 2 WARNING Hazardous Voltage Dis
30. Based Troubleshooting Matrix Normal Modes REFRIGERATION UNIT STATIC MODE 1 uu NOT RUNING NOUNE POWER PRESENT e 8 sans REFRIGERATION UNIT FE STATIGMODE2 UNEPOVER PRESENT AND WAN NO E REQUIRES USER REMOTE START REFRIGERATOR UNIT RUN MODE RUNG SYSTEM OW 825131 00 REV A Page S1 Indicator Lamps Based Troubleshooting Matrix Fault Modes REFRIGERATION UNIT FAULTMODEi NOTRURNNG PRESSTEMFTRE OCCURRED REFRIGERATION UNIT FAULTMODE2 WO RUNING gt RET UREA Co REFRIGERATION UNIT FAULT ODE 3 qorRUWRG COMPRESSOR OVERLOAD TRIPPED 82813100 REV A Page S2 REFRIGERATION UNIT FAULT MODE FUNRING URE POWER PRESENT AND ONG REFRIGERATION UNIT INDICATOR LAMP FAULT CONDITIONS EXPLAINED Problem Possible Cause Corrective Reon STATICMODEZ Refigeration compressors not working AND is ON and Line ight is ON Tir delay relay is sil ace User remote signal not provided Walbro mince for meri Check timer relay stings delay is in excess of 2 minutas
31. ING LIFTING HAZARD 900 pounds 400 0 Failure to propery lit this device may result in severe injury or death King using the iting eyes shown below Assure hat he eyes are fully engaged in the frame wth no exposed threads Use four ing eyes wi an adequate ifing and mechanism Lifing hamess must be centered between th fing eyes Lit vertically only wih no horizontal component King from the bottom using forkif use appropriate equipment persed by employees Sap he unio beck support of he orto prevent the unit rom tipping over when on the forks 825131 00 REVA Page 71 3 Install eadod rod in front of uni Locate opening on bottom side of frame centered in the font and beled Seismic Anchor Pont dently end of threaded rod with machined fats This the tp Insert top of threaded rod trom below and thread up through frame unt fats are exposed Install pad of threaded rod Use a wrench on the pad and the fats to Thread leveling foot Higher up that the pad not contact the fior wen the machine is lowered to the ground 4 The remaining seismic anchorjack screws can installed with the unit the floor supported by the casters unit on floor and remove or fing hamess 825131 00 REVA Page 72 5 Screw in oer thee seismic anchorjack screws from top amd put the pad from bottom For these seismic ancho
32. MAX TILT ANGLE D9 NOT Lie CASTER Wes OFF Tre FLOOR 82813100 REV A 9 erin 06 13 version Fight Side View Interior Label Placement 2513 00 REV A 9 version Left Side View Interior Label Placement Continued 80513100 REV A Exterior Left Front Oblique Exterior Right Rear Oblique Top View Exterior Label Placement 80513100 REV A 1 5 USER PRECAUTIONS A CAUTION REVIEW THE INSTRUCTION MANUAL BEFORE PERFORMING ANY PROCEDURE OTHER THAN THE ROUTINE OPERATION OF THE 2XCL Performance of procedures ater those specified herein may result in hazardous exposures io electrical temperature or moving parts hazards Additional precautions are located in the appropriate section of this manual CAUTION THEZXCL CONTAINS PRESSURIZED GAS DO NOT OPEN THE REFRIGERANT CIRCUIT TO THE ATMOSPHERE Al reigeraion work must be performed by qualified Type 2 High Pressure refrigeration technicians Do not loosen any valve packing or tings unless you are specficaly folowing the instructions in ho recharge procedure Discharge of refegerant may cause personal injury due to Nigh pressures or ultra low temperatures In action i refngerant slot the 2XCL may need recharged before it be used A WARNING HAZARDOUS VOLTAGE EXISTS AT ALL TIMES AFTER THE POWER IS CONNECTED Only qualified el
33. N HAZARDOUS VOLTAGE EXISTS AT ALL TIMES AFTER THE POWER IS CONNECTED Orly qualified eleciicians should electrical work Power should be removed at he paint af electrical connection and locted aut following standard ag out procedures lockout device may be placed on the supply power circuit breaker provided by others or onthe supplied electrical power plug Tho safety circuit connector provides the two folowing distinc functions 1 Pressure switch fault statu either high discharge side or low suction side pressure 2 Remote monitoring of the thermostat Suche coupled to he discharge and ine temperatures 10 2XCL Thermocouple Connectors The thermocouple connector provides remote temperature monitoring of the refrigerant temperature as leaves the evaporator and the discharge temperature o the compressor RETURN Measures the nitrogen temperature retuming to the 2 from the customer process SUPPLY Measures the temperature of tre trogen supplied by the 2XCL optional Customer supplied 825131 00 REVA Page 37 11 Machine Remote Connector The Machine Remote Connector is used for the remote User operation of the ZXCL This connection enables User controled start up and provides the remote system wih 2XCL contactor status signals The 2XCL may be tested witout connection ta tha User system by use of jumper Under normal operation the 2XCL shouldbe under the co
34. Y LESS THAN 10 MAX TILT ANGLE ver ipping leaning this device may cause it to fall over resulting n severe injury death Read the manual before moving this equipment using the casters Move the equipment on level floors only Move slowy and avoid rapid acceleration and deceleration Apply force io move the system below the equipment center Da not place yourself between moving equipment and fixed obstructions A CAUTION SYSTEM PRODUCES AND CIRCULATES COLD GAS AT TEMPERATURES AS LOW AS 110 C Assure that integrating systems and components aro suitable for rapid exposure to these ow temperaturas gt WARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Maintain weight on casters at all times 82813100 REV A Page 15 1 6 SAFETY INFORMATION Safety Hazards and Safeguards NOTE The user is advised to retain curent copies of material safety dala sheets MSDS for refrigerants and cleaning agents used in the operation and maintenance of this equipment One copy at he MSDS forthe system refrigerant has been attached this user s manual Safety Devices incorporated in the 2XCL and ther function is described below IGERATION COMPRESSOR UNIT Name Function oh Pressure Such pressure switch incorporated in the discharge of he Compressor The sch open contacte ihe reingeran pressure exceeds
35. ation unit that removes heat rom the refrigerant vapor af compressor Cryopump Polycold s cryogenic chamber It consists of a refrigeration unit a refrigerant ine and ryosuraco with cryogenic feedthrough Cryosurface the or inthe vacuum chamber that captures water molecules by freezing them figeraion system tat captures water molecules in a vacuum to its surtace Discharge Line portion of the refrigerant circuit containing high temperature high pressure refrigerant just ater has exiled the compressor EC European Community EEC European Economic Community EMC electromagnetic compatibiity EN European norm or standard Feed Line the copper tube in the refrigerant line that carries refrigerant from the refrigeration unit to the Field Replacement Charge refrigerant mixture that replaces refigerant in NPT Female national pipe thread HC I0E1 Compressor Located inside the 2XCL it provides recirculating inert high pressure helium gas to the host equipment IEC Intemational Electrotechnical Commission VO input output Liquid Line portion the refrigerant circuit containing high pressure refigerant just air the water cooled condenser has cooled it Manifold service manifold gauge set 82512100 REV A Page 15 NEC national electrical code Refrigerant a proprietary mixture of refrigerants made by Systems International Refrigerant
36. atrix Normal Modes rd indicator Lamps Based Troubleshooting Matrix Fault Modes 63 GAS COMPRESSOR UNIT HC 10 FAULT MODES 2 84 AUTOFILL TROUBLESHOOTING BASICS 65 AUTOFILL TROUBLESHOOTING MATRIX e 66 AUTOFILL STATUS TABLES 222 67 AUTOFILL RELAYS AND SOLENOID VALVE 65 88 ADJUSTING AUTOFILL CONTROL SETTINGS se 70 APPENDIX 67 71 BRAZING SPECIFICATION 2 2261 72 THERMOCOUPLE ATTACHMENT SPECIFICATION 73 SPECIFICATIONS oo s EE DESIGN DATA 75 INSTRUCTIONS FOR INSTALLATION OF SEISMIC ANCHORJACK SCREWS 70 80 GLOSSARY 75 80 PROCESS amp INSTRUMENTATION AND ELECTRICAL SCHEMATICS 7 825131 00 REV A Page 2 Oye Aga Tf Pool Comput ale Rept Sens nd Crit Sym cogn coal water vapor opamp PFC PCT FL PGC PECL Compa Coder PCC and mere Coed posse ne taut and Serves ter any repas warned t rra ndr Tr sir Rap Prat iid component prs ecd rp pad y re root Cater resonet rl ches and expenses tr roc Sones pde Customers cao by Bons m Reloaded fear amd warm aang Pre merae coon and cam aed pais and matti rts ra Spar
37. connect and lockout power cire serving 3 CAUTION B25131 00 REV A 4 ATTENTION THIS COMPRESSOR IS CHARGED WITH AN SELECTED SPECIFICALLY FOR THIS EQUIPMENT REFILL ONLY WITH POLYCOLD PART NUMBER 081009 00 Page 7 5 CAUTION Heavy Object cause muscle strain or back injury Use iting aids and proper tig techniques when removing or replacing 6 ATTENTION The inlormation displayed by these rod LED s are not saloly related This Information is process menitorngjprocess control purposes only See the manual for additional deal 7 WARNING WARNING This valve is to remain sealed open I this valve ls closed when servicing the unit the Unit must be attended until the valve is reopened and rasoalod ACHTUNG Dieses Venti mu im offenen Zustand Veralegel bleiben das Venti wahrend Jer Wartung des Garates geschlossen werden uti das Geral Goerwacht werden bis cas und versiogolt wurde 80513100 REV A Pues CAUTION A CAUTION PREVENT LEAKS CAP THE VALVE VORSICHT uw EIN APP 3 SEISMIC ANCHOR POINT v REVIEW THE INSTRUCTION MANUAL BEFORE STARTING THIS EQUIPMENT 80513100 REV A Page 9 TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Gr pen ited sc en are ce CENTER OF GRAVITY LESS THAN 10
38. e fing eyes Assure that the eyes fully engaged in the rame with exposed threads Use all four fing eyes with an adequate Wing harness and mechanism Lifing harness must be centered between the ling eyes Lif vertically only with horizontal component 14 Lower the 2XCL unit onto original shipping palet Verify that the casters no weight when the unit isin the crate Failure to do so may cause damage fo the casters and void your warranty Assemble the crate around the 2XCL unt and transport to its new locaton 82512100 REV A Page 47 6 0 TROUBLESHOOTING ACAUTO GAS is not being pumped though the GAS circuit the 2XCL wil condense water in the GAS circuit whenever stacks cold This can occur while for the stack 10 cool down afer ting onthe 2 and up to four hours afer turning off the 2 as well Ifthe host equipment is sensitive water condensation can be avoided while not in use by plugging tne open ends of the GAS or allowing small amount about 5 of nitrogen to purge the GAS circuit AATTENTION Trevefigeraton compressor control circuit features a ime delay remote signals Aer sending a remote signal on or to the refrigeration compressor wait wo minutes for this faction fo take place cont your local sales representative or the Brooks Automation Service Department if you need any
39. ecrcians should electrical work Power should be removed at the point electrical connection and locked following standard tag out procedures A lockout device may be placed on the supply power circuit breaker provided by others or on the supplied electrical power plug DANGER NOT REACH INSIDE THE 2XCL WHEN IT 1S OPERATING The uni contains hazardous voltages and extremo temperatures 4A DANGER po NOT TOUCH AN UNINSULATED GAS LINE OR THE EXITING GAS STREAM WHEN THE 2XCL IS OPERATING The system circulates gas at ultra low temperatures which on contact with skin presents the of frostbite 825131 00 REV A Page 14 WARNING LIFTING HAZARD 000 pounds 400 kg Faure to property this device may resul in severe injury or death Read the manual before ing this equipment using tha fing eyes Assure that the eyes are fully engaged in he rame wih exposed threads U al four ing eyes with an adequate Hing harness and mechanism Ling harness must be centered between the iting eyes Lif vertically only with no horizontal componant WARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Over ipping leaning this device may cause it to fall over resulting in severe injury death The equipment should be removed rom its shipping palet by using the top installed Hing eyes Pp WARNING TPPING HAZARD HIGH CENTER OF GRAVIT
40. essure ie greater than 12 red Auch led reads 12 of minimum seting See section 3 4 and nitrogen discharge pressure is less than 140 Check evidence of low via mechanical meter on front panel of unit Check against ool spociicatons Check gas supply temperature if colder than check Chuck heater contol If warmer than 70 and refigeraton compressor has been in operation for greater one hour record suction pressure and cal your service agent or Polyold Seo Polycold manual 825105 section 40 Inspection amp Maintenance Compressor hums or Saris and then EEE cumecions maybe out of phase CHEEK ar phase SETA on LCD display The crcutbreskar may Rave been tiggered the thermal overload protector on compressor may be cycling the compressor on and of Verily the folowing The compressors are not overeating The power supply voltage is adequate Very the supply voltage meets specification see Table B and that transformer taps are properly configured see section 22 step 7 te towing There are loose parts Alubeis not rubbing or rating against another surface ToT paris other conspicuous tubes or rating components 825131 00 REV A Page 50 6 2 REFRIGERATION COMPRESSOR FAULT MODES Indicator Lamps
41. figeration gauge during operation suction pressure 20 40 psig Recirculating compressor gauge discharge pressure 85 115 psig above readings are within specification tolerances lum off the refrigeration compressor and leave the N2 recirculating compressor on Tum he refrigeration compressor and run the gas compressor for one hour power off the unit for at least 18 hours Refigeraon gauge when off and at ambient temperature refrigerant balance pressure 465 100 par Recirculation compressor gauge when off and at ambient temperature gas circuit balance pressure 70 00 psig 80512100 REV A Page I the above readings are not within specification tolerances itis necessary to call for refrigeration service 2 6 EMERGENCY OFF CIRCUIT The EMO button provided on the ZXCL i contact switch that is electrically designed to be connected to customers EMO loop When properly wired into the customer provided EMO loop if the EMO button on the 2XCL or on the customers System is pressed then the AC power to the 2XCL and the customers system is shutdown 3 0 OPERATION Fry GAS is not being pumped though the GAS circuit the 2 will condense water in the GAS cuit whenever Plycold stack scold This can occur while for the stack 10 cool down afer turning onthe 2XCL and up to four hours afer turning off the 2 as well Ifthe host equipment is sensitive
42. for 1 2 minutos hon turn it back on If tis stl binking remove one lead on the of the uto elslencid valve Hit stops binking replace the 4 Verily thatthe SMC pressure switch sting Push and hold te set button Tor mare than two seconds then release it The display should show PSI Push the set button again If PSI is NOT shown push the or right scroll button until PST is displayed push the set button again The display should show InC If not push the left or right scroll button unti the display shows 1907 Then push the set button The display should show 7290 not push the left or right scro button unti the display shows 210 Then push the set button The display should show 768 If not push the lef right scroll button unti the display shows Then push the set button The display should show If not push the left or right scroll button unti the display shows A Then push the set bution Check each set point by pushing and holding the set button for less than two seconds A correct set of set points should be n_1 gt n_2 gt n_3 gt 4 gt 8 push the left or ight col bution to desired valve and then push the set bution See section 7 6 Polycolds 825105 Customer Instruction Manual lor reprogramming instructions 825131 00 REV A Page 62 6 5 AUTOFILL TROUBLESHOOTING MATRIX Problem Possible Cause Corrective Ration TFT aoe not TT d
43. he outermost hanger damp is removed completely and te inner clamp is loosened After he kruried nut has been tghtened taking care not to put undue stress on the copper ine he hanger brackets can be tightened safely 1 Assemble vacuum jacketed ines to the Polycold unit and the System Integrator making sure connections Nota tis recommended to leak check using pressure decay method a Connect a source of dry roger dew paint lt 80 C tothe gas fil port Verily that unit has power and that the control is This can be cenfemed by observing that PSS iluminated verily that the unit has power and that he uot switch is in the ON poston Pressurize the uni vacuum jacketed ines and chuck assembly to 85 psig through gas fll The control wil automaticaly pressurize tne unit This process takes 10 minutes or less Observarecord reading on PSS Switch tho such to the OFF potion Test or 30 minutes there should be no detectable leak Notes Smal leaks up to 20 psi loss par 24 hours 83 from 2XCL nes can be compensated for by using the control Leaks in excess of this must be eliminated Switch such back to the on poston Do not use tracer gas Le refrigerant for leak detection due io possible damage to adsorber Purge the ines and chuck with trogen B E Disconnect the return bayonet connector at
44. igured sce Section 22 step 7 The internal overload is a nom atching switch Call your carie service agent or Paco FAULT MODE Refrigeration compressor not working AND is ON AND the Fault ight isnot it AND CB3i OF ESS ATT YOU SERIE agent 825131 00 REV A Page 58 6 3 GAS COMPRESSOR UNIT HC 10 FAULT MODES Circuit breakers and LCD Display LCD Display Gas compressor cycling I the gas compressor cycles on and off without any indicated reset breaker 2082 825131 00 REV A Page 56 631 GAS COMPRESSOR UNIT TROUBLESHOOTING MATRIX Problem Possible Cause Corrective Raton Gas compressor mot working AND ANDIOR CB2 are OFF Gvercurentin contrat or compressor current Vey he Supply volage meets specication 666 Table and thatthe transformer aps are properly configured see section 22 step 7 Call your cored service agent or Polycol Gas compressor not working Run lights OFF 082 and are ON AND there are faults codes displayed on the 100 Vey he supply volage resis specication 666 Table and thatthe transformer aps are properly configured see section 22 step 7 all your cored service agent or Gas compressor with remote Jumper but NOT with tool remote signal
45. k performed on the refrigeration portion ofthe system Al safely related incidents or near misses should be reported to a supervisor or Brooks Automation Customer Service The user should carefully review and understand manufacturer provided material safety data sheets MSDS for materials used ths equipment 825131 00 REV A Page 18 18 LOCK OUT TAG OUT PROCEDURE LOGK OUT TAG OUT PROCEDURE ELECTRICAL Notiy personnel you are performing a Lock Out Tag Out LOTO 2 Shut down the system folowing normal procedure Remove power o the 2XCL thatthe compressor is of 3 Isolate the system from electrical supply by locing ut the breaker in the OFF position and notifying others with an identification tag 4 Use a volmeter to observe 0 volts in the area you wil be working Service can now be performed 5 To re energize reverso these steps LOGK OUT TAG OUT PROCEDURE GAS SUPPLY Notify personnel you are performing a Lock Out Tag Out LOTO 2 Isolate the system gas supply by closing the customer supplied gas connectors 3 the system is locked out by slowly opening the gas iit fting on the 2XCL Unt and allow the pressure to bleed down for 2 minutes the few should gradually slow 10 a ton Add lock and Tag supply source suo To reestablish gas supply reverse these steps 82813100 REV A Page 19 2 0 INSTALLATION 2 1 SYSTEM DIAGRAMS See Secti
46. low 32 C Verity cooling water low and temperatures are within specifications of Table Verily condenser has not accumulated excessive scale Call your certlfed service agent PS4 is a non atching switch Caliyourcorfid service agent Before caling tum on gas compressor for 30 minutes to warm the refrigerant system Record the refigerant suction pressure and check against instalation records TS is a non latching switch cooing water iow and temperatures are within specifications of Table Verily condenser has not accumulated excessive scale 82813100 REV A Problem Possible Cause Corrective Aeon FAULT MODE 2 Refrigeration compressor not AND is OFF or configuration Internal short in high voltage wiring Locked rotor condition Very the supply vitae meals specification sco Table and hat the transformer taps are propery configured sae ection 22 step 7 Call your service agent Call your ceritied service agent or Paco FAULT MODE Refrigeration compressor not working AND is ON AND the Fault ight is not it AND CBT CB and are on Traore Tap configuration intemal motor failure ihe supply voltage meets specification see Table 5 and that the transformer taps are property conf
47. max 230 104 gs veg fot ocre Requirements 5300 W Required cut breaker Acceptable Votage Range x6 Linde Bayonet connectors Weer Temperat 5553 Water Required 10 gpm 25 52 15 25 Capacy 20 AC Tenere 20 scm qus Nose Emissions SPL GA 1010 85 maximun dew pat 27 CJ Comics wth Seri 1 second loss of power without unl ripping crostbreskan angle occurance Over voltage category per EN 610101 Category 2 7 4 DESIGN DATA Balance Pressure 175 205 pelo GAS Flow Rate Range 16 24 scr Approximate Heat Relecton Rate cessor Cages Tre refigerant charge your an unt nameplate Conte sales represente or Paie fr eurent rc a CONVERSION FACTORS amp FORMULAS 1 psig 0 07 bar 007 1 inch 2 54 centimeters exactly 1 pound 046 kilograms 9 5 x C 32 1 Standard cubic foot per hour 0 47 standard Hersiminute 825131 00 REV A 7 5 INSTRUCTIONS FOR INSTALLATION OF SEISMIC ANCHOR JACK SCREWS XCL PGCL 1 and 2XCL PGCL 2 mode 14 sides Some options have 2 front an 1 Remove the four panels front sides and lower back 25131 00 REVA Page 70 2 unt up about 18 inches 0 5 meters off the ground using a fork ting hooks and a hamess WARN
48. nes recommended 2 Clean room compatible tubing insulation that is rated for extreme temperatures 3 Adhesive tape for fiberglass tubing insulation equivalent 2 1 12 inch channel lock pers Verify that the GAS source from the host equipment adequate A CAUTION ir your GAS contains moisture the water wil condense and freeze in the GAS and the 2XCL s performance wil degrade as the GAS circuit becomes blocked The 2XCL system is designed for use with inert Gases having dew point of lower than 80 C He or NZ only Contact Brooks Automation pir to intoducton of a GAS her than hose ACAUTIO Do not excoed 90 PSI max supply pressure 2XCL If this pressure is exceeded the discharge pressure switch PS3 may activate and cause a faut condition 2 Install the external gas circuit Prior to instalation the ines and chuck need to have bean conditioned to remove any moisture and contaminants Evacuating these components vacuum puro for a minimum of wo hours is recommended After conditioning hey need to be Kept dry by back filing with nitrogen and sealing uni they are ready for use Note When attaching vacuum jacketed ines or Linde Male and Female bayonet adapters special adjustments may be needed for rigid suppor of the Ines Both the supporting brackets aro adjustable via the use of slotted holes Difficulty may be experienced when ting the Female ine unless t
49. normal esse ering power t ho betes ren a Fuse Pug located o expansion tank Afusbis stale in e charge plumbing of he Compressor end serves as ine conto release pont fr fre occur he ares one 2XCL Tne Wale pug Provides a mean to reduce high pressures caused by exconsve ina manna oes not esl an igh Temperature Ahh temperature such s couple o he condenser iheiso ta so opening ho contact on hightemperature Sch THs removes power tv amon nda Tih ors rat Retigeran Low Pressure Temperate Suton A low pressure suh s incorporated the sucton side of he Compress The slt opens contact the reingeran auction drops below omar operating pressure empti power 0 te compressor Tho sat wil utres once he reigerant pressure reaches the reset ont The use CEG GAS COMPRESSOR UNIT iow presse sich a Suton OTe qs Compressor The sich opens oracle gs pressure rope alow normal operatng pressure povaria ha 5 The ver Tigh Pears SWE igh pressure swish discharge ae he des compressor The swith opens contacts the ges pressure operating erupting power toe compressor ana ing af hie Sut relies venting of trogen 100 pal and manual ese The
50. nrl of the user remota system A CAUTION safety devices are installed the 2 1 to help protect fom permanent damage Some of the protective devices are seifreseting witha system status to he integrating equipment When tne system status Indicates that a safely component has functioned the integrating equipment should not enable operation unti the cause of the fault is corrected Ita protective device triggered the cause of the problem must be corrected before continuing to use the 2XCL Please see Section 6 0 Trouble Shootng call the Polycold Service Department for assistance Bypassing or repeated resetting of protective device may expose personnel and or fac to hazards may permanent damage the equipment and may vod your warrant 825131 00 REV A Page 38 2 4 CONNECT THE COOLING WATER Tools and materials needed inch 15 mm standard size wrench Adjustable or open ended wrench supplied by customer 1 Make certain your cooling water is adequate Measure the inlet water temperature It must be 55 85 13 29 certain you have at least the minimum flow rate required for your waters temperature See Table C Cooling Water Flow Requirements Your cooing water may be warmer in the summer than in the winter Cooling water ines within the 2XCL are not insulated To prevent condensation inside the system enclosure assure that the cooling water temperature
51. o reach operating temperature 9 Tum onthe gas compressor via the remote 10 Ifthe system does not start see Section 6 Troubleshooting 825131 00 REV A Page 42 3 2 BAKE OUT AND POST BAKE COOLING Ii the responsibilty of the operatorintagrator to alow sufficient ime afer bake out cycle to bing the down to temperature slowly without subjecting the components of the integrated unit to thermal hock cessas which can cause premature failure Aera bake out cycle operate the gas compressor only unti he retum temperature is lt 22 C then the refrigeration cler User must control rate of chuck cooling that remains within the specication limits of the chuck 3 3 RESETTING SAFETY INTERLOCKS AFTER FAULT First by to determine the reason behind the fault condition and affect he proper remedy In normal operation the protective devices should not be triggered However should the need arise these devices be reset See interlock descriptions in Secton 18 Refer lo folowing usralons 825131 00 REV A Page 43 4 0 INSPECTION amp MAINTENANCE Inspect the Cool Solutions 2XCL every months or whenever moisture accumulate in the gas circuit whichever occurs more often 1 Verily that there is adequate water circulation through the condenser Check water flow requirements in section 2 4 Table C Performance specifications assume that water temperature is no higher than
52. on 9 for Process amp Instrumentation Diagram and Electrical Schematics 82813100 REV A Page 20 ELECTRICAL DISTRIBUTION DIAGRAM Figure 1 Electrical Distribution Diagram 825131 00 REV A Page 21 Eng EVACUATION GAS OUT VALVE REGENERATIVE HEAT EXCHANGER 8555 GAUGE ABSORBER EXPANSION TANK GAUGE RERRIGERATION COMPRESSOR UN SYSTEM BLOCK DIAGRAM Figur 2 System Block Diagram 825131 00 REV A Page 22 Sy lt 50 RUN 1 X EM stn Figure 3 Dimensions Front version 06 825131 00 REV A Page 23 Cong Water Conectons fee Ta palo minimum fo tra peg meno 87005 Um 1510 25 aom Mal Cynical Shell Seres Pr pe 7 rt Stee thant Se om Tee n Fu v4 Compression Male B 1 Sena n Figure 4 Dimensions Rear version 06 825131 00 REV A Page 1 E 5 4 NY SK 2 7 150 2 x 8 S wet 1
53. oose wiring somewhere If relay 5 is dim check the red Indicator on SMC If tiz check the votage between the White and Broun lead If he votage zero tha SMC is 24 V check to see if here is loose wiring somewhere ELL LCD reads OVER RESET VALUE during a run SES Wie BET ETT vale or SMC Check whether relay 4 has beer energized here is loose wire Iit is energized continue to next bullet Check the status of relay 5 I itis dim check the solenoid valve to fel whether 15 warm ithe col is but nitrogen filing continues replace the solenoid valve Otherwise continue to nex bullet relay 5 is lighted check the red indicator of the SMC of but the voltage between the White and Brown lead is 24 VDC the SMC is bad fasting Auton function not working power for Roh switch Ac CBZ See section 9 0 for detailed Autofill schematic 825131 00 REV A Page 63 6 6 AUTOFILL STATUS TABLES 1 inital it SW Pressure T ELS lt p Green Indicator on ed indicator Rosy Pi Relay 5 On OF Relay 6 SET Valve on On 2 ide unit has been filed but nitrogen compressor is of SHC Pressure T pur CE Green Indicator on Red indicator on
54. or Replacement numbers No 84020800 SHLAPD Part 400962 Shutdown system and allow N2 circuit to reach room temperature ent gas using the refrigeration valve VS at the rear of the unit Remove external and intemal covers to allow access to molecular sieve Loosen sieve inlet and cuit ftings Remove 2 securing screws Remove adsorber Place new adsorber on plate and secure with two 2 crews Connect inlet and outlet gas ines Charge with gas and check for leaks 10 Replace covers and rn unit 825131 00 REV A Page ds 5 0 DISCONNECTION STORAGE AND RESHIPMENT 1 The 2XCL should be transported using is original shipping materials these materials are unavailable please contact Poycok for support 2 Shut down power tothe 2XCL and allow the system to roach ambient temperature alow 24 hours to reach thermal aquirium or tum of the refioraion compressor unit and run the gas compressor Unit for one 1 hour to warm up the nes and the chuck 3 Disconnect electrical power from the 2 1 system Disconnect the gas supply ine 5 Vent gas from the Gas Compressor Unit using the refrigeration valve V5 at the rear f the unit 6 After the gas has vented disconnect the Coolant Gas Bayonet connectors 23 24 7 the Bayonet connectors to prevent diffusion of moisture into the system 8 Tum off the cooing water lines and disconnect 9 Use compressed air to blow
55. ply adequate power to the equipment For power requirements seo tabo in Polycoids 825105 Customer Instruction Manual lt Very transformer is wired to correct laps See section 22 step 7 in 825105 Customer instruction Manual is wibin specification wired correctly and breaker is ripping Your cerifed service agent Polycold rit has poner and Refrigeration and Gas compressors not operational erac TOT connected property METRE and install remote jumper if compressors start troubleshoot tool Side of user interface 1 ter compressor fails see section 62 or 6 2 compressor nor operating Gas compressor is operating EZEL Gas compressor Ts Refrigeration compressor is not operating SECTS 325131 00 REVA p Problem Possibis Cause Corrective Regeln and Gas compressor both operating but cooing is inadequate AND Nirogen has been hacked and Une abstraction or Auto o working See section 65 Incorrect vacuum jacked ines Gas supply temperature let gas flow is not within specication Ge crus a leak Water circulation through the condenser ia inadequate Theretigerant circuit has a leak Vary nivagen source is dry dew point of 80 Cor less nitrogen suction pr
56. r Ampe ERR This faults eecironically latched Ta reset cycle and then press tho three round buttons simultaneously more than two resets are required contact Polycold Service Verily that volage for each leg meets the Power requirements indicated in Table Do not attempt to restart Consult Service LCD reads ERR apo diagnostics as requred Cons Service Compressor Check pal power coolant Taw operation and of Compare with Specifications Loss or Vompressormalundion Check M power coolant Tew and pea refrigeration Compare with Specifications capacity Compressor shuts down LCD display is blank circuit breaker is closed FT or FAD Tee Cond Pape Series technician replace the fuse inside the enclosure down no error message on LCD Fa FOS oF Contact Serves is technician replace the fuse inside the enclosure 825131 00 REV A 63 2 ADDITIONAL INFORMATION ON LCD FAULT CONDITIONS Restarting After a Power Failure When the power comes on the microprocessor wil determine if the last shutdown was due to a power outage Ifthe operator turns the system by the main breaker it wil be detected as power outage If the compressor power wa
57. rjack screws See Appendix 75 Place the 2XCL as dose as possible to the desired Icaton of your cold GAS stream The 2XGL must remain vertical during transport and instalation The base rame ofthe 2XCL can be secured to the floor at the four locations labeled Seismic Anchor Point See section 7 or installation instructions gt 6 Move the 2XCL unit to installation location The 2XCL unit should be lite using the iting eyes mounted on top of the unit and sing system hen moved to area near ts instalation locaton The 2XCL uni may be transported on casters short distances level floors within tne installation location DO NOT MOVE THE UNIT UP OR DOWN RAMPS ONTTS CASTERS A WARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Over ipping leaning this device may cause it to fall over resulting in severe injury if Read the manual before moving his equipment using the casters Move the equipment on lave ors only Move slowly and avoid rapid acceleration and deceleration Apply force move the system below the equipment canter of gravity Do mot place yourself between moving equipment and faed cbstuctons 82813100 REV A Page 31 WARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Maintain weight castors at all times sew 2 0
58. rjack screws tread the rod in from he lop Keeping machined fats al top treading the rod though the and win about to inches of exposed thread below the frame install pad Use wrench on the pad and the flats to tighten 825131 00 REVA Page 6 Position the unit where it wal be installed Lower each of the four seismic anchor ack screws to the cor Tum each leveling foot by one urn DO NOT extend jack screw to pont where caster wil spn that the unit secure and wil not roll If not add more turn lo each leveling fool Repeat as needed unt unis secure and wil nol rol AWARNING TIPPING HAZARD HIGH CENTER OF GRAVITY LESS THAN 10 MAX TILT ANGLE Maintain weight casters at all times Reinstall panels after installing seismic anchorljack screws 825131 00 REVA Page 74 8 0 GLOSSARY ANSI American National Standards Institute ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers AWG American wire gauge CE European conformity Coldest Liquid partion of the refrigerant circu which obtains the lowest temperature prior to evaporation Compressor component in the refrigeration unit that raises the refrigerant pressure and causes the refrigerant to move through the circuit Compressor Compartment the partion of the refrigeration unit that contains the compressor and condenser Condenser component in the refriger
59. s interrupted by a power outage compressor and shield cooler restart automaticaly atr a one 1 second delay Ifthe compressor stops for other reasons compressor troubleshooting required system Status Display Normal conditions When al systems are operating normal with no system errors the folowing ines are displayed on the LCD in the order ted below scrolling the display Press DISPLAY button 0 serl he LCD Scroling past the bottom ofthe display wil start back at he and repeat Ifthe DISPLAY button is pressed and not pressed again afer 30 seconds the display wl reum to the rst ine ET Elapsed time in hours to one decimal place Helium Water Temp OK water Flow OK Motor Temp OK Phase Seq sequence OK Motor Amps Locked Rotor OK Error conditions system error occurs that causes alarm or shutdown condition the monitor point as sted above wil change from OK to ERR and that monitor point wil be scrolled to ne fr display When the operator manually scrolls the display any point that has not failed wil continue display OK t addtional points fail before operator resets the first error s the latest point to fail wil change from OK to and wil be scrolled to the for display In tus way the operator see the most recent faul displayed on the LCD and by manual scroling the display
60. separators and an adsorber reduce levels of ol and moisture in ie ias stream to very low levels regenerative haat exchanger is used to assure tha ow pressure gas tering the compressor within design mit of the gas compressor High pressure gas exiting the regenerative heat exchanger enters the Polycld stack When the Polyeold tack is cod chils high pressure gas being supplied customer process Low pressure gas retuming from the process passes through the regenerative heat exchanger before entering the gas compressor 825131 00 REV A Page 27 2 The 2XCL features reer to the figures below See Detail Below 12 FRONT VIEW REAR VIEW 2 m 15 1 m REAR VIEW DETAIL Unit Features 1 CONTROL VOLTAGE CIRCUIT BREAKER HC 10 This switch protects control voltage source must be closed to alow tna unt to start After initial start up switch must remain in the ON postion unt functions are to be accessed remotely 2 REFRIGERATION UNIT This switch starts the Refrigeration unit Afarinial startup ONIOFF functions of he unit may be accessed remotely RUN INDICATOR HC 10 Will be sluminated when gas compressor 10 is running and CBT CB are closed 4 RUN INDICATOR REFRIGERATION UNIT Wil be iluminated when power is applied the sich is in the on postion and all systems
61. the unit Purge and chuck with nitrogen tuning on the nitrogen source and flowing approximately 5 to 10 SCFM fr 30 minutes Tum off nitrogen and reconnect the coolant gas outlet bayonet connector Fil unit with nirogen to 70 90 psig 82813100 REV A Page 40 3 Verify that the retum joint is leak ight pressure degrade or soap lest ec 3 Tumonrefrgeraton compressor and wal atleast 30 minutes 1 alow refrigerant io achieve equilibration mida tna er ihe refigeration compressor has run for at least 20 minutes tum on recirculation compressor and wat at east 20 more minutes to alow the recirculating nitrogen to the chuck and Vacuum jacketed ines Observerecord recireulalian compressor pressure It must be 85 115 psig Ifthe pressure is as described in step above then allow nitrogen fll via he control target pressure is achieved Required Tools and Recommended Accessories Nirogen dew point lt 80 C 70 90 psig Model 2XCL Back of unit cover removed Itthe Chuck table does not achieve cold enough temperatures Check tne thermocouples witha pe thermocouple read out meter The temperatures during normal operation are Thermocouple connector at lef nand side Chuck inlet outlet temperature Temperature should be colder Ian 65 C Note Ifthe temperature is warmer than this check the folowing specications Re
62. tion and telephone number to be contacted when requted actions are beyond the training and responsibility of the person being trained Identification of the recognized hazards associated with each task identification of and appropriate responses to unusual operating condiions Explanation of the functions and imitations of all safeguards and their design characteristics Instructions for the functional testing or other means of assurance for proper operation of safeguarding devices Service personnel should understand the operation of process 1elated hardware interlocks andthe sequences of hardware operation that are execulsd automatically as explained in his chapter The equipment should not be used without assuring correct operation of all connected facies especialy fugitive emissions exhaust Service personnel should always assume that high voltage is present unless they have personaly fumed t off and locked it out The equipment should not be operated without all guards and safety devices in place The equipment should be shut down locked out and should not operated while itis being maintained Users should not attempt to defeat modify disable any of the equipments safely interlock switches Only Brooks Automation trained service personnel should perform assembly operation disassembly service of maintenance of the Polycod GAS Chiler 2XCL equipment A refrigeration technician must perform any wor
63. torch or a actylene torch propane is not hot enough For copperto coppe joints Haris or Handy amp Harman Si Fos or equivalent alloy For capper to stainless steel or copperto brass joints Harris Safety Sv 66 or Handy amp Harman Braze 560 or equivalent siver alloy Harris Stay Siv black lux or Handy Flux type B 1 or equivalent Note Brazing operations must be performed by quaifed technicians 1 Thoroughly clean mating surfaces to bare met 2 Purge the tubes with dry nitrogen GAS while brazing and unti tubes and joints have cooled to below 190 C This prevents intemal scale formation or oxidation 3 Remove excess fux from the brazed joints Use a wet rag while the brazed joint is stil hot 4 Dispose ofthe contaminated waste in a manner approved by the location 5 Carefully inspect each joint for the proper of the brazing alloy both surfaces should be wetted by the aly 6 Carefully check all joints for leaks 825131 00 REV A Page 67 7 2 THERMOCOUPLE ATTACHMENT SPECIFICATION Tools and materials needed Type Thermocouple wire Thermal wire sippers Tools and materials needed for soldering Sand paper Propane torch Rosin ux Harris Brigit or equivalent solder Neutralizing agent lo remove the fux Note Brazing operations should be performed by qualified technicians 1 Thoroughly clean all mating surfaces to bare metal 2 Purge the t
64. ubes with ery nitrogen gas while brazing and unt the tubes and joints have cooled ta below 190 C 3 Remove an inch 13 mm of insulation from one end of the thermocouple wire and tist the two wires together 4 Apply flux and pre in the twisted wires 5 Use sand paper to remove oxidation from the copper tube 6 Apply Rux and pre tin the tube 7 Apply flux to the preinnad vires and the pre nnod copper tube Position the thermocouple wire so that the first twist of wire nearest the insulation is against he tube Note Make certain the wire twist closest to the insulation is in contact with the copper tube 1 the frst twist of wire closest to the insulation senses and determines the temperature reading 9 Solder he wire twist othe copper tube Do overheat the flux Do not melt or cut he plastic insulation on the thermocouple wire may create false readings 10 Remove the flux residue using a wet cloth 11 Dispose of the contaminated waste in a manner approved by the location 12 Wrap the thermocouple wire tightly around the tube 3 4 times 13 Secure the wire with ie wrap s or tape suitable for temperatures Allow enough thermocouple wre to reach your temperature meter 14 Apply insulation Section 25 Install the Extemal GAS Circuit 825131 00 REV A Page 68 7 3 SPECIFICATIONS Ses Figure 3 and Figure 4 Shipping Weight ente salt Weight ETT
65. ugh capacity to handle the Rated Load Amps and is provided through a circuit breaker rated with at 10 000 The circuit protection must be adequately sized to operate with the 10 AWG intemal wiring of the supply power wing must be sized in accordance with 79 The 2XCL is grounded according to SEMI S2 and CE requirements Note The ZXCL is intended to be a subsystom of equipment and requires incorporation and protection the host equipment Emergency Of EMO crcuit Refer to Electrical Schematic A CAUTION Phase sensitive equipment Clockwise rotation required Incorrect rotation wil prevent equipment operation The 2XCL is phase sensive and wil not function f wired incorrectly f the phase rotation of your power source is incorrect an error wil be displayed on the LCD see Section 68 82813100 REV A Page 35 us on Power interruption Restoration The 2XCL system is not configured with onboard main circuit breaker In the event of power interruption the 2XCL ceases operation On restoration power the EXCL system wil restart when provided an enable signal Placing te equipment safe shut down condition requires removing the 2XCL Main Power cord connector Power Cord installation 1 Remove lop panel of the ZXCL unit 2 Using nut driver or socket drive remove the nus from the plastic gus 3 Remove the plastic guard from the
66. uring intial nitrogen i Toone NZ i pressum There may be lose wiring somewhere sore 70 00 psi suppbed Open the E box and check to see rely 6 is lighted Iis check he auth solenoid valve io ecl whether colis warm fine colis warm and there is no nitrogen filing replace the solenoid valve ifthe calis not warm check is voltage It is 24V replace the ftis zero check to see there wing somewhere If relay 6 is dim check the green indicator on SMC ON check the votage between the Black and Brown lead of the SMC voltage is zero the SMC is bad LELE LCD reads OVER RESET VALUE luring inital EST En vae Check te status of relay 6 dim check solenoid valve feel its coll to see it ie warm Ifthe calis cad but unit continues filing replace the solenoid valve If relay 6 is lighted check the green indicator of SMC fitis OFF bul the volage between the Black and Brown lead is 24VDC the SMC is bac during a run En vale Loose wiring in the system Check WWE the auto solenoid valve to fee whether is warm Ifthe coll is warm but no nitrogen filing occurs replace the solenoid valve Ifthe not warm check ts voltage I itis ZAV replace the fiis zero check to see if hore l
67. water condensation can be avoided while not in use by plugging tne open of the GAS crcui small amount about 5 SCFH of nitrogen to purge the GAS cii ATTENTION The refigeration compressor control circuit features ime delay to remote signals sending remote signal on off the refrigeration compressor wait two minutes for this action lo take place 3 1 INITIAL START UP 1 Very that tho unit is hardwired or plugged in and that ine votage is present LINE ight on the font of the unit wil lamina when the Main ONIOFF Racker Soren Ram 1 in Unt Features is in the on postion 2 Verify that the remote cable is connected to the remoto connector onthe back of the unit and thatthe EMO loop connections are connected 3 Verily that GAS and COOLING WATER connections have been established and are loak free Verily that Fil Power such is in the ON position 5 Switch the CB CB2 amp CB switch to the ON poston 6 The unit should be operational Functions can be monitored through the remote connector T on the refrigeration compressor via the remote Observe the upper Refrigeration Gas Pressure gauge tem 9 in Un Features should show a drop in pressure Initial pressure should be between 165 and 190 psi Note pressure osi Wait approximately 30 minutes for the Unit portion of he unit t

Polycold Closed Loop Gas Chiller (825131)

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