Trillium US Inc. Model 125 Cryogenic Helium Compressor User`s

Trillium US Inc. Model 125 Cryogenic Helium Compressor User`s
Trillium US Inc.
Model 125 Cryogenic Helium Compressor
User’s Manual
Rev A / November 2015
97-00020-000
User's Manual
Rev A / November 2015 / M125 Helium Compressor
For information about Trillium US Inc., visit the Trillium US Inc. Web site at:
http://www.trilliumus.com
How to Contact Trillium US Inc. Support:
support@trilliumus.com
For contact information and a complete listing of Direct Sales, Distributor, and Sales Representative contacts, visit the Trillium US Inc.
Web site at:
http://www.trilliumus.com
Trillium US Inc. has made its best effort to ensure that the information contained in this document is accurate and reliable. However, the
information is subject to change without notice and is provided “AS IS” without warranty of any kind (express or implied). Before placing
orders, customers are advised to obtain the latest version of relevant information to verify that information being relied upon is current
and complete. All products are sold subject to the terms and conditions of sale supplied at the time of order acknowledgment, including
those pertaining to warranty, patent infringement, and limitation of liability. No responsibility is assumed by Trillium US Inc. for the use
of this information, including use of this information as the basis for manufacture or sale of any items, nor for infringements of patents or
other rights of third parties. This document is the property of Trillium US Inc. and by furnishing this information, Trillium US Inc. grants no
license, expressed or implied, under any patents, copyrights, trademarks, trade secrets, or other intellectual property rights of Trillium US
Inc. Trillium US Inc., copyright owner of the information contained herein, gives consent for copies to be made of the information only
for use within the customer’s organization as related to the use of Trillium US Inc. products. The same consent is given for similar
information contained on any Trillium US Inc. Web site or disk used to distribute information to a customer. Trillium US Inc. does give
consent to the copying or reproduction by any means of the information contained herein for general distribution, advertising or
promotional purposes, or for creating any work for resale. The names of products of Trillium US Inc. or other vendors and suppliers
appearing in this document may be trademarks or service marks of their respective owners that may be registered in some jurisdictions.
A list of Trillium US Inc. trademarks and service marks can be found at:
http://www.trilliumus.com/
Trillium US Inc.
1340 Airport Commerce Dr.
Bldg. 1 Suite 175
Austin, Texas 78741 USA
TEL. +1 512 441 6893
FAX +1 512 443 6665
Email: cryo-sales@trilliumus.com
Copyright (©) 2015 by Trillium US Inc., All rights reserved.
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Table of Contents
1
Revision History .......................................................................................................................................................... iv
2
Preface .........................................................................................................................................................................1
3
2.1
About Trillium US Inc. ..........................................................................................................................................1
2.2
Other Services from Trillium US Inc. ...................................................................................................................1
2.3
About this Manual ...............................................................................................................................................1
2.4
Compatibility .......................................................................................................................................................1
Safety Warnings ...........................................................................................................................................................2
3.1
Standards for the Use of Warnings and Cautions ...............................................................................................2
3.2
Warnings Applicable to All Aspects of M125 Operation .....................................................................................2
3.2.1
High Voltage and Electrical Shock Warnings ..............................................................................................2
3.2.2
High Pressure Related Warnings ................................................................................................................2
3.2.3
Helium Gas-Related Warnings ....................................................................................................................2
3.2.4
Heat-Related Warnings ..............................................................................................................................2
3.3
4
Introduction ................................................................................................................................................................3
4.1
5
6
Operator Instructions ..........................................................................................................................................3
General Information about the Model 125 Compressor ....................................................................................3
4.1.1
Model 125 Features ....................................................................................................................................3
4.1.2
Overview of Model 125 Compressor Design & Operation .........................................................................3
4.1.3
Description of Subsystems ......................................................................................................................... 4
4.1.4
Operational Flow ........................................................................................................................................4
4.2
Specifications ......................................................................................................................................................7
4.3
Ordering Information ..........................................................................................................................................9
Installation...................................................................................................................................................................9
5.1
Safety Warnings ..................................................................................................................................................9
5.2
Installation Steps .................................................................................................................................................9
5.2.1
Unpacking and Inspection .......................................................................................................................... 9
5.2.2
Mounting the Compressor .........................................................................................................................9
5.2.3
Preparing the Compressor for Operation .................................................................................................10
5.2.4
Ambient Conditions and Coolant Connection ..........................................................................................10
5.2.5
Connecting the Helium Flex lines .............................................................................................................10
5.2.6
Filling the Compressor with Helium Gas...................................................................................................11
5.2.7
Adjusting Helium Gas Pressure.................................................................................................................11
5.2.8
Electrical Connection ................................................................................................................................11
Operations .................................................................................................................................................................13
6.1
Before Switching ON the System ...................................................................................................................... 13
6.2
Normal Operation .............................................................................................................................................14
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Troubleshooting ........................................................................................................................................................14
7.1
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Troubleshooting Activities.................................................................................................................................14
Maintenance .............................................................................................................................................................15
8.1
Maintenance Personnel Requirements .............................................................................................................15
8.2
Removing the Compressor from Service: Removal, Transport and Storage .....................................................15
8.3
Scheduled Preventative Maintenance Activity .................................................................................................16
8.3.1
Remove the Compressor Adsorber ..........................................................................................................16
8.3.2
Install Replacement Adsorber ..................................................................................................................16
8.4
Unscheduled Maintenance ...............................................................................................................................18
8.4.1
Adding Helium Gas ...................................................................................................................................18
8.4.2
Removing Helium Gas............................................................................................................................... 18
8.5
Cleaning Equipment ..........................................................................................................................................19
8.6
Returning Equipment ........................................................................................................................................19
List of Figures
Figure 1 – Flow Diagram for Water-Cooled Model 125 compressor ....................................................................................5
Figure 2 – Flow Diagram for Air-Cooled Model 125 compressor..........................................................................................6
Figure 3 – Model 125 Dimensions ........................................................................................................................................8
Figure 4 – Model 125 Electrical Schematic .........................................................................................................................12
Figure 5 – Model 125 Electrical Chassis Components (Inside View) ...................................................................................13
Figure 6 – Location of Adsorber in Model 125 Air-Cooled Compressor .............................................................................17
Figure 7 – Location of Adsorber in Model 125 Water-Cooled Compressor ........................................................................17
Figure 8 – Self Sealing Coupling in Closed Position .............................................................................................................18
List of Tables
Table 2-1: Compatible Configurations ..................................................................................................................................2
Table 4-1: Model M125 Helium Compressor Subsystems ....................................................................................................4
Table 4-2: Power Requirements for Model 125 Compressor ...............................................................................................7
Table 4-3: Model 125 Compressor Specifications ................................................................................................................7
Table 4-4: Model 125 Compressor Unit Ordering Information ............................................................................................9
Table 4-5: Optional Accessories and Replacement Parts .....................................................................................................9
Table 5-1: Figure 5 Legend ..................................................................................................................................................13
Table 7-1: Trouble Shooting Procedures ............................................................................................................................14
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1 Revision History
Date
August 2006
December 2007
Revision
1.0.1
1.0.2
September 2010
1.1
June 2011
1.2
ECR #
August 2012
1.3
November 2015
A
2794
Document Part Number: 97-00020-000
97-00020-000
Description of Change
Conversion to new format
Remove caution on 5.2. Review and revise document
Conversion to new format. Update figures. Change adsorber
change interval.
Correct minor typographical errors. Add maximum inlet water
pressure specification.
Update format
Rebranding, amperage changed Table 4-2
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2 Preface
2.1 About Trillium US Inc.
Trillium US Inc., a wholly-owned subsidiary of Trillium US Inc., specializes in the manufacture and repair of cryogenic
vacuum pumps, cryocoolers (refrigerators) and helium compressors for semiconductor, optical coating, linear accelerators,
medical equipment, and R&D applications.
You can find just what you need from our range of products and support services:
•
•
New Equipment - cryopumps, compressors, cryocoolers, and cryopump controllers such as the Model 125 Helium
Compressor described in this manual.
Comprehensive range of accessories for the installation of whole systems and a complete range of spare parts to repair
cryopumps and compressors.
2.2 Other Services from Trillium US Inc.
Trillium US Inc. offers comprehensive refurbishment services for its own equipment as well as for that of most of our
competitors. Our products and services are available through our global network of agents and dealers.
•
•
•
Repair and refurbishment services - We offer our own quality products, as well as most other manufactures models,
often with off-the-shelf availability.
Exchanges - We offer our own quality products, as well as most makes of cryopumps and helium compressors, which
are refurbished and fully warranted.
Technical Support - Our support engineers will help determine if your cryopump system is operating correctly so that
you can get your system back to optimum efficiency as soon as possible.
o
o
o
•
•
To contact Trillium US Inc. Technical Support:
E-mail: support@trilliumus.com
Telephone: 1-512-441-9258 or Toll Free: 1-800-404-1055
Installation - On-site installation services are available to guarantee performance and save you time.
Training - We offer on-site training to help you and your staff to know more about your cryopump and compressor
systems. Our training will give you confidence and the ability to maintain a highest possible uptime for your system.
2.3 About this Manual
The purpose of this manual is to provide our customers using the Model 125 Helium Compressor with the information
needed to safely and efficiently operate the compressor when operating as part of a cryogenic refrigeration system. Such a
system is often comprised of the following equipment:
•
•
•
Model 125 helium compressor unit
Coldhead(s) or cryopump(s)
Connecting helium lines
This manual describes the design, operation and maintenance of the Model 125 helium compressor unit.
2.4 Compatibility
The Model 125 Helium Compressor is compatible with the cryopumps and coldheads described in Table 1-1. Each Model
125 Helium Compressor can be used to run one such cryopump or coldhead.
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Table 2-1: Compatible Configurations
Compressor Drive Circuit Configuration
Coldheads
Cryopumps
RC
350CS
CTI 350 CP
Cryo-Plex 8
Cryo-Plex 8LP
CT-8
CT-8F
3 Safety Warnings
3.1 Standards for the Use of Warnings and Cautions
Warnings are noted when there is a possibility of injury or death to persons operating the equipment or performing specific
tasks or procedures noted in this manual. Cautions are noted when there is a possibility of damage to equipment if the
caution is ignored.
3.2 Warnings Applicable to All Aspects of M125 Operation
3.2.1 High Voltage and Electrical Shock Warnings
Warning:
Potentially fatal voltages are present in the compressor unit. Before beginning any work on the
compressor unit, the compressor needs to be switched off then isolated from the power supply.
Warning:
Connect or disconnect the flex lines joining the compressor and its load (cryopump, coldhead, etc.) only
after the compressor is switched off and separated from the power source. Otherwise, an electrical
shock hazard may exist, causing the compressor unit and its load damage.
Warning:
Always provide proper grounding to the compressor unit. All electrical connection and disconnection of
the unit should be done by a qualified and licensed electrician.
Warning:
High voltage is present within the system and can cause severe injury from electrical shock. Permit only
qualified electrical technicians to open any electrical enclosure to perform electrical troubleshooting.
Warning:
Disconnect the compressor from its power source before carrying out any troubleshooting or
maintenance activities.
3.2.2 High Pressure Related Warnings
Warning:
High gas pressure is present within the system and can cause severe injury from propelled particles or
parts.
Warning:
Do not recharge the system without using a pressure regulator.
3.2.3 Helium Gas-Related Warnings
Warning:
Helium gas can cause rapid asphyxiation and death if released in a confined and un-ventilated area.
Warning:
Use a pressure reducing regulator when withdrawing helium gas from a high pressure cylinder.
3.2.4 Heat-Related Warnings
Warning:
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The compressor motor may become hot during operation. Wait for the motor to cool down before
working inside the compressor.
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3.3 Operator Instructions
Follow standard Model 125 operating procedures as described in this manual. If after reading this manual and you still have
questions regarding the safe operation of the Model 125 Helium Compressor, please contact Trillium US Inc. Technical
Support using the contact information found in Section 2.
4 Introduction
4.1 General Information about the Model 125 Compressor
Trillium US Inc. offers industry-proven compressors such as the Model 125 Compressor described in this manual, at highly
competitive prices, and with flexible configurations. Model 125 compressors are available in low-voltage and in either air or
water-cooled model.
4.1.1 Model 125 Features
The Model 125 compressor is designed for tens of thousands of hours of continuous operation. The main features of the
Model 125 compressor are:
•
•
•
•
Minimal maintenance requirements
Removable top cover for easy maintenance
No front or rear panels with which to struggle
Rack mounting available, which is ideal for ion implanters, cat scanners, and sputtering system applications.
4.1.2 Overview of Model 125 Compressor Design & Operation
Model 125 Helium Compressor is specifically designed to run a single CP-8 or CP-8LP (low profile) cryopump for 208/230
VAC and 60/50 Hz single phase operation.
The compressor itself consists of four main components:
• Compressor capsule
• Heat exchanger
• Oil mist (vapor) separator
• Adsorber
The compressor unit and the coldhead are connected by way of helium gas flex lines. The compressor unit, coldhead and
helium lines are fitted with self-sealing couplings, and are charged with ultra high-purity (99.999%) helium gas.
The heat exchanger removes the heat generated from the process of compressing helium in the capsule. The heat
generated by the capsule must be removed from the oil and the helium gas.
To remove heat from the compressor capsule, oil is used as lubrication and cooling medium. The helium gas as well as oil is
then pumped by way of differential pressure, out of the capsule through the water-cooled or air-cooled heat exchanger.
The cooled oil returns to the capsule to lubricate and cool the capsule.
The helium gas purifying occurs after the heat removal and cooling process. Helium gas purification must occur because the
heat exchanger still has a small amount of oil vapor mixed with it. If this helium gas gets to the cryopump with oil vapor in
it, the oil will freeze and foul the cryopump. The function of the oil mist (vapor) separator is to rid the helium gas stream of
this oil vapor. The condensate from the oil is then returned to the capsule. The helium gas still contains a small quantity of
oil vapor at this point.
The adsorber then filters out the remaining oil vapor from the helium gas stream. Overtime, the adsorber may become
saturated from the oil vapor. Thus, it is important the adsorber be replaced according to the recommended replacement
interval.
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4.1.3
Description of Subsystems
Along with the four main components, Table 3-1 describes the subsystems that serve to monitor the operating condition of
the compressor unit and to ensure its safe operation.
Table 4-1: Model M125 Helium Compressor Subsystems
Subsystem Name
Thermal switch(TS1)
Thermal switch (TS2)
Bypass valve
Fuses:
• Fuse for coldhead drive circuit
• Fuses for the main input power
• Fuses for the fan motors
Internal relief valve
External relief valve
Function
Purpose: Monitors helium temperature upstream of the
heat exchanger
Safety Function: Will turn OFF the compressor if the
temperature get too high
Purpose: Monitors helium temperature downstream of
the heat exchanger
Safety Function: Will turn OFF the compressor if the
temperature get too high
Purpose and Safety Function: Equalizes pressure within
the compressor upon power interruption
Safety Function: Over current protection
Purpose: Opens a shunt between the high and lowpressure helium gas circuits
Safety Function: If the differential pressure exceeds a
preset value, this valve opens to allow safe operation
Purpose and Safety Function: Opens the helium gas circuit
to atmosphere if the helium gas pressure exceeds 350 PSI
4.1.4 Operational Flow
The work flow of helium gas within the compressor follows these steps:
1.
2.
3.
4.
5.
6.
High-pressure helium gas is delivered from the compressor to the coldhead through the "Supply" helium flex
line at 250-260 PSI.
The helium gas is then compressed during the compression stroke of the cryopump.
The cryopump then expands the helium gas to expand during its expansion stroke. During this cycle of
compression and expansion of the cryopump, the helium gas is forced through regeneration materials to
increase the thermodynamic efficiency of the cycle.
With each successive cycle, the regeneration material becomes colder and colder.
Eventually, the cryopump temperatures come down to cryogenic range.
After expansion, the helium gas returns to the compressor through the "Return" helium flex line at 50-100 PSI
to begin the cycle again.
The helium flow between the Model 125 compressor’s components are illustrated in Figure 1 and Figure 2, for the watercooled and air-cooled version of the Model 125 compressor, respectively.
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Figure 1 – Flow Diagram for Water-Cooled Model 125 compressor
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Figure 2 – Flow Diagram for Air-Cooled Model 125 compressor
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4.2 Specifications
The Model 125 Helium Compressor specifications are listed in Table 4-2 and Table 4-3. Figure 3 shows the Model 125
compressor dimensions.
Table 4-2: Power Requirements for Model 125 Compressor
P/N
Model
Voltage (AC)
Hz
Phase
91-00003-0LW
91-00003-1LA
Model 125 Water
Water-cooled
Model 125 Air--cooled
208/230
208/230
50/60
50/60
1
1
Avg.
AMPs
5-9
6-10
Recommended
Circuit Breaker
15
15
Table 4-3: Model 125 Compressor Specifications
Feature/Component
Physical Dimensions
Weight
Helium Pressure
Interface
Adsorber Replacement Schedule
Cooling Water
Air Cooling
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Specification Description
• Length 19.00 inches (183 mm)
• Height 16.00 inches (406 mm)
• Width 19.50 inches (495mm)
150 lb. (68 kg)
• Static: 190 ± 5 psig
• Operating: 250 ± 10 psig (supply)
• Cold head power connector mates with ASC and CTI drive
cables
• Compressor power cord is equipped with a Hubbell No.
5G66C plug
• Helium connections: 1/2 inch Male Aeroquip couplings
15,000 Hours (per elapsed time meter on the compressor) or 3
years, whichever comes first
• 0.4 GPM minimum flow rate
• 80°F maximum inlet water temperature
• 100°F maximum outlet temperature
• Recommended chiller capacity: 1 ton/per unit
• Water line connector: 3/8” Swagelok
• Air-cooled
cooled units must maintain a minimum clearance of at
least 12 Inches at both the front and rear grills
• Maximum ambient temperature should not exceed 104°F
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Figure 3 – Model 125 Dimensions
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4.3 Ordering Information
Table 4-4 contains the ordering
ing information for the Model 125 compressor unit. Customers can also order the optional
accessories and replacement parts listed in Table 4-5
Table 4-4:: Model 125 Co
Compressor Unit Ordering Information
Compressor Unit
M125 Water-cooled,
cooled, Low Voltage, Standard Drive Circuit
M125 Air-cooled,
cooled, Low Voltage, Standard Drive Circuit
Part Number
91-00003--0LW
91-00003--1LA
Customers can also order the optional accessories and rreplacement parts listed in Table 3-5.
Table 4-55: Optional Accessories and Replacement Parts
Accessories/Replacement Parts
Adsorber (Water-cooled model)
Adsorber (Air-cooled model)
Helium Lines (10ft.*)
Helium Regulator
Maintenance Manifold, for helium clean
clean-up process on compressors and
cryopumps
Cryopump Drive Cable (10ft.*), sends power to the cryopump motor from
the compressor
*Custom length available.
Part Number
80034
80111
10418-10
10418
HR-580
HR
10134
10144-10
10144
5 Installation
5.1 Safety Warnings
Review the safety warnings in Section 3 before beginning any installation activities.
5.2 Installation Steps
5.2.1 Unpacking and Inspection
Once the equipment is received, inspect the eexterior
xterior of the shipping carton for any signs of damage. Report any damage to
the shipping company immediately.
Remove the straps and packaging materials on the compressor unit, then lift or roll the unit out of the carton carefully.
Inspect the exterior off the unit. If any damage is observed, inform the shipping company. Keep the original packaging
materials in case the unit needs to be returned to the factory for service or other reasons.
Most shipping companies have a certain grace period for reporting damages due to shipping in order to process the
insurance information in a timely manner. Therefore it is highly recommended that shipping carton be opened and the unit
inspected whether or not it will be put into operation right away.
Caution:
When transporting
sporting or storing the compressor unit, make certain it is not tilted by more than 45 degrees
to avoid the unit been tipped over.
5.2.2 Mounting the Compressor
It is highly recommended that the compressor unit be installed on a level and steady surface.
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If the unit must be installed in a tilted manner, the maximum tilting angle is 10 degrees. Tilting the unit more than this
maximum allowable angle could result in damage and contamination in the system, and may void the warranty on the unit.
5.2.3 Preparing the Compressor
ssor for Operation
1.
2.
3.
4.
5.
6.
Connect the main power cable to a suitable connector or disconnect box, making sure that the compressor switch
is off.
For water-cooled
cooled Model 125 units, connect the cooling water:
a. Typical municipal drinking water is recommended.
b. 0.4 to 0.5 GPM is required to achieve a maxim
maximum discharge temperature of 100°FF (with 80°F considered
ideal)
c. Maximum inlet water pressure should not exceed 150 PSIG (with less than 100 PSIG considered ideal).
For air-cooled
cooled Model 125 units, make sure the front and rear grills have at least 12 inches of clearance from the
nearest objects.
Verify that helium pressure is between 190 ± 5 psig. If pressure is low, refer to Section 8.4.1 for charging
procedures.
Start the compressor
pressor and run for about 15 minutes to stabilize the compressor oil inventory.
The compressor is now ready to be connected to the cryopump.
5.2.4 Ambient Conditions and Coolant Connection
Ambient Conditions:
When the compressor is in operation, the ambient te
temperature should be between 5°C to 40°C (40°°F to 104°F). The
compressor unit should be set up in a non-condensing
condensing environment.
Coolant Connection:
Caution:
For water-cooled
cooled compressor models, the water used in the unit operation must meet the
specifications
ions indicated in Section 4.2.
Caution:
Failure to comply with the coolant specifications may result in serious damage to the compressor and
may void the warranty on the unit.
nnection ports first before connecting the hoses. The water supply line should be connected
Identify the inlet and outlet connection
to the inlet port on the compressor.
Periodically check the coolant flow rate and temperature to ensure the proper operation of the compressor unit.
5.2.5 Connecting the Helium Flex lines
Caution:
Attach or detach the helium flex lines only when the power to the compressor unit is switched off.
Never twist the helium flex lines during the installation process.
Before connecting the helium flex lines,, follow these steps:
1. Identify the helium “Return” (low pressure) and “Supply” (high pressure) ports on the compressor front panel.
2. Clearly mark the helium flex line that will be used to connect to the corresponding “Supply” and “Return” port on
the cryopump or coldhead,
Note:
The helium flex lines are equipped with self
self-sealing
sealing couplings which can be attached and detached without helium
escaping.
Follow these steps to connect the helium flex lines
lines:
1.
2.
Unscrew the protective caps from the couplings and keep the caps for future u
use.
Check the connectors for cleanness. When necessary, use lint
lint-free clean cloth or soft brush to clean the
connectors.
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4.
5.
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Check the flat seals on the male couplings and make sure they are properly placed. Replace any missing or
defective seals.
Use only the open-wrenches
wrenches supplied with the installation kit. For a ½" coupling, tighten with a 1-3/16"
1
wrench
and stabilize with a 1" wrench.
Tighten down all couplings as far as possible and then back off by one quarter turn to relieve strain.
If the flex lines need
ed to be bent to a radii of less than 8" (20 cm), then a 90 degree helium elbow needs to be installed (see
Section 3.3 for the part number).
5.2.6 Filling the Compressor with Helium Gas
Caution:
All safety regulations related to handling pressurized gas cylinde
cylinders must be observed. Only use helium
with 99.999% or better purity when performing refill operation.
Follow these steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Connect a pressure reducer and a helium flex line to a helium supply gas cylinder
Connect the open end of the helium flex line to the helium gas charge/vent valve on the rear panel of the unit; do
not tighten the 1/4” flare connector on the end of the flex line
Open the valve at the cylinder
Set the pressure of the helium supply cylinder to the value specified in Table 4-3. Tighten the 1/4” flare connector
on the end of the helium flex line to the gas charge/vent valve of the compressor
Open the pressure regulator valve slightly so that the helium flex lines are purged with helium gas for at least
leas 15
seconds.
Open the helium gas charge/vent valve and fill the compressor unit to the desired pressure value
Detach the coupling of the helium flex line from the helium charge/vent valve
Close the helium gas regulator on the supply cylinder
Seal the helium
um gas charge/vent valve on the compressor unit by properly securing with a protective cap.
5.2.7 Adjusting Helium Gas Pressure
Refer to Table 4-3 for the required pressure specification of the compressor unit. If the pressure
ressure falls below that level, the
helium gas refill procedure described in Section 5.2.6 needs to be performed. On the other hand, if the pressure is too high,
then the helium gas needs to be released in order to maintain the proper level.
5.2.8 Electrical Connection
Caution:
Before connecting power to the compressor unit, make sure the factory setting of the frequency switch
on the front panel matches the frequency of the power supply where the unit is being installed.
instal
Failure
to do so will result in performance degradation of the system.
Electrical connections are to be made in accordance to the diagram in Figure 4. Figure 5 shows the Electrical Control
Chassis and the components within.
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Figure 4 – Model 125 Electrical Schematic
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Figure 5 – Model 125 Electrical Chassis Components (Inside View)
Table 5-1: Figure 5 Legend
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
6
Description
Capacitor, Run
Capacitor, Start
Capacitor, 60Hz
Fuse, 1 AMP (Not Shown)
Relay, Start
Meter, Elapsed Time
Connector, 15 Pin Chassis
Resistor, 150Ω, 100W
Resistor, 15Ω, 2W
Resistor, 68Ω, 1W
Switch, Compressor "ON-OFF"
Switch, Safety Interlock
Transformer
Terminal Block
Ref. Desig.
C1
C2
C3
F1
K1
M1
P2
R1
R2
R3
SW1
SW2
T1
TB1
P/N
30016
30015
30014
50081
50085
50089
50087
20053
20056
20057
50083
50155
50082
50125
Operations
6.1 Before Switching ON the System
After the compressor unit and its load (cryopump, coldhead, etc.) are installed and connected, check the helium gas
pressure as indicated by the pressure gauge mounted on the rear panel of the compressor unit. Refer to Table 4-3, for the
proper static pressure readings for the compressor.
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If the helium pressure needs to be adjusted, refer to Sections 8.4.1 and 8.4.2 for procedures to release helium gas in order
to reduce the pressure or to fill the compressor with more helium gas to increase the pressure.
Do not remove the top cover of the compressor unit. Doing so will disable the unit due to the built-in safety interlock
mechanism.
6.2 Normal Operation
The load of the compressor can be powered through the power connectors located on the front panel of the compressor.
To start operation of the compressor and its load, do the following:
1.
2.
3.
Open the coolant supply (water-cooled compressor model only)
Switch on the main power source
Press the ON button to start the compressor. Both the compressor and its load should start simultaneously
During operation, check the coolant flow rate (water-cooled compressor) and the operating pressure frequently. Refer to
Table 4-3 for required coolant flow rate. If it is too slow, make sure any problems associated with water supply or water
outlet are resolved. Refer to Table 4-3 for proper helium pressure level for the compressor unit. If the helium pressure is
too low, switch off the compressor unit. It may be necessary to perform a helium "topping-up" maintenance procedure as
described in Section 8.4.1. If pressure drop-off happens frequently, there may be a substantial leak in the helium circuit of
the compressor. In this case, contact Trillium US Inc. customer service immediately.
To shut down the compressor unit, press the OFF button on the front panel. After that, allow coolant to continue to
circulate for at least 10 more minutes before shutting off flow.
7 Troubleshooting
7.1 Troubleshooting Activities
Table 6-1 describes some problems that users might encounter while operating the Model 125 Cryopump Compressor and
provides solutions to those problems.
If a compressor problem still persists after performing the corrective actions described in this section, please contact
Trillium US Inc. Technical Support for further assistance. Refer to Section 2 for contact information.
Table 7-1: Trouble Shooting Procedures
Problem
The compressors On/Off
switch (SW1) remains in
the
On position when switched
on, but the pump does not
run.
Possible Cause
1
2
1
The compressor On/Off
switch
(SW1) will not remain in
the ON position.
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2
3
Corrective Action
No power is coming from the power
source.
Incorrect or disconnected wiring
within the compressor
1
The safety interlock switch (SW2) is
open. This will happen if the top
cover of the unit is removed.
Thermal protection switch (TS1
and/or TS2) is open.
High current has activated the trip
switch in the compressor’s On/Off
Switch.
1
2
2
Check service fuses, circuit breakers,
and wiring associated with the power
source. Repair as needed.
Check the compressor against the wiring
schematic. See Figure 5.
Securing the compressor cover may
correct the problem. If not, check for
proper operation of safety interlock
switch (SW2) located in the top right
side of the electronic control chassis.
See Figure 5.
Confirm that switch TS1 and/or TS2 is
closed.
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Problem
Possible Cause
3
1
Compressor stops after
several minutes of
operation and remains
OFF.
2
3
4
5
6
High temperature of the compressor
caused by insufficient cooling water
(for water-cooled model), resulting
in the opening of thermal protection
switch TS1 and/or TS2). For aircooled model, the ambient
temperature is too high.
When the compressor is not in
operation, cold cooling water was
left running through the compressor.
Insufficient helium static pressure.
High temperature helium gas tripped
the thermal protection switch (TS1).
Low power source voltage.
Mechanical seizure.
1
2
3
4
5
6
Corrective Action
Contact the Trillium US Inc. service
department for assistance Compressor
stops after several minutes of operation
and remains off.
Confirm that sufficient cooling water
(for water-cooled model) is flowing to
the compressor. For air-cooled model,
provide additional cooling to the
surrounding environment.
Turn the compressor on and off for
several times to allow the oil
temperature to rise.
Add helium, using the procedure
described in Section 8.4.1.
Check for proper cooling of the
compressor unit.
Confirm that power source voltage is
correct.
Contact the Trillium US Inc. service
department.
8 Maintenance
8.1 Maintenance Personnel Requirements
Only trained and qualified personnel should perform the maintenance procedures described in this section. All other
maintenance work must be performed by Trillium US Inc. personnel in the factory. Please contact Trillium US Inc. to make
arrangement for such work. See contact information in Section 2.
8.2 Removing the Compressor from Service: Removal, Transport and Storage
It is recommended that the Model 125 compressor be removed from service when carrying out the maintenance duties
described in Section 8.3.
1.
2.
3.
4.
5.
6.
To remove the compressor unit from service, do the following:
Turn off the compressor unit by pressing the OFF button
Switch off the main power supply to the compressor
Separate the compressor unit from the main power source
Allow coolant to continue circulate for at least 10 more minutes (for water-cooled Model.
Allow the compressor load (cryopump, coldhead, etc.) to warm up before detaching helium flex lines
Caution:
Loosening or detaching helium flex lines with the compressor load at low temperature without proper
warming-up can result in loss of helium and/or pressure rise in the cryopump unit beyond its designed
maximum pressure level.
When transporting the compressor unit, follow these guidelines:
• Make sure the appropriate protective caps are properly secured before shipping.
• Always store the compressor unit in a dry place. Refer to Table 4-3 for proper storage environment.
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• If a freezing temperature environment is anticipated whether during shipping or under storage, make certain the
coolant in the compressor circuit is properly drained.
Caution:
The compressor unit should never be tilted more than 45 degrees either during shipping or in storage.
8.3 Scheduled Preventative Maintenance Activity
The only scheduled maintenance required on the Model 125 compressor is the replacement of compressor adsorber after
every 15,000 hours of operation as indicated on the compressor elapsed time meter or every three years (whichever comes
first). When the compressor is used with 50 Hz power, the actual elapsed time will be 1.2 times of that shown on the
meter.
The adsorber is used to keep the oil vapor out of the helium gas in the flow circuit of compressor unit and its load. After
about 15,000 hours of operation (or every three years, whichever comes first), the effectiveness of the adsorber will
decrease. It will then need to be replaced. Otherwise the oil particles could accumulate on the cold surface of the
compressor load, reducing the cooling performance of the overall system. In severe cases of such oil contamination, the
load (cryopump, coldhead, etc.) could cease to function completely.
To remove and replace the compressor adsorber, follow the steps described in Sections 8.3.1 and 8.3.2
Caution:
Use only Trillium US Inc. supplied adsorber for replacement. Refer to Section 4.3 for part number.
8.3.1 Remove the Compressor Adsorber
To remove the compressor adsorber:
1. Turn off the compressor.
2. Use the two wrenches supplied with the Installation Kit to avoid loosening the body of the coupling from its
adapter. Hold one wrench tight on the coupling half attached to the rear side of the compressor. Use the other
wrench to loosen the coupling to the helium supply line.
3. Unscrew the two-self sealing coupling halves quickly to minimize minor gas leakage.
4. Figure 8 contains an illustration of the self-sealing couplings.
5. Remove the top cover.
6. Remove the adsorber from the compressor as shown in Section 8.3.1. Save all nuts, bolts, and washers for
installing the replacement adsorber.
7. The removed adsorber can be returned to Trillium US Inc. for credit. Section 2 provides the contact information.
8.3.2 Install Replacement Adsorber
To install the replacement adsorber:
1. Remove the dust caps from the self-sealing coupling halves at each end of the replacement adsorber.
2. Check the self-sealing connector flat rubber gasket to make sure that it is clean and properly positioned.
3. Place the adsorber back in the compressor using the nuts, bolts, and washers set aside during the removal process
described in Section 8.3.1.
4. Install the two-self sealing coupling halves quickly to minimize minor gas leakage.
5. Use the two wrenches supplied with the Installation Kit, holding one wrench tight on the coupling half attached to
the rear side of the compressor. Use the other wrench to tighten the coupling to the helium supply line.
6. Make the final turns by hand and then use the wrenches until the fittings bottom out.
7. Replace the cover and the flex lines. Make sure that the cover is installed so that it depresses the safety interlock
switch. The compressor cannot be started until the switch is depressed.
8. Make sure the supply pressure gauge reads 190 ±5 PSI. If the pressure is either too high or too low, follow the
instructions in Section 8.4.1 to fill the helium gas to the proper pressure level.
9. Add 15,000 to the reading of the elapsed time meter and write this number on the decal provided with the
replacement adsorber. This decal can be affixed to the foot of the compressor.
10. Restart the compressor.
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Adsorber
Figure 6 – Location of Adsorber in Model 125 Air-Cooled Compressor
Adsorber
Figure 7 – Location of Adsorber in Model 125 Water-Cooled Compressor
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Figure 8 – Self Sealing Coupling in Closed Position
8.4 Unscheduled Maintenance
The following corrective maintenance activities may be necessary should the helium gas circuit of Model 125 compressor
becomes contaminated.
8.4.1 Adding Helium Gas
If a compressor unit needs to have helium gas added more than once every several months, check for leaks caused by
improperly connected self-sealing connections or incorrectly sealed charge valve. If the compressor unit is connected to its
load (cryopump, coldhead, etc.), check for leaks in the load also.
Use only 99.999% pure helium gas.
To add helium gas:
1.
2.
3.
4.
Remove the flare cap of the gas charge fitting on the rear of the compressor.
Loosely attaching a charging line from the helium pressure regulator on the helium pressure bottle to the 1/4 inch
male flare fitting installed on the helium charge valve. A user-supplied helium charging line terminating in a 1/4
inch female flare fitting and a pressure regulator rated at 400 psig delivery pressure is required.
Set the helium pressure regulator to 10 to 25 PSI. Allow helium gas to flow through the charging flare fitting for 30
seconds to purge the charging line of air. Then tighten the flare nut at the end of the charge line.
a. If the compressor is running under normal operating conditions, set the helium pressure regulator to 325
PSI and slowly open the helium charge valve in the rear of the compressor. When the helium supply
pressure gauge rises to 250 to 260 PSI, tightly close the charger valve.
b. If the compressor is not running, set the helium pressure regulator to 250 psig and slowly open the
helium charge valve. When the helium supply pressure gauge rises to 190 ±5 PSI, tightly close the charge
valve.
Insure that the helium charge valve on the compressor is tightly closed. Then shut off the helium pressure
regulator on the helium bottle. Remove the charging line from the male flare fitting and reinstall the flare cap.
8.4.2 Removing Helium Gas
Helium contamination is usually indicated by irregular, noisy or intermittent operation (ratcheting), and sometimes seizure
of the cryopump drive mechanism. This is caused by accumulation of frozen contaminants within the compressor load and
resulting in interference. The source of the helium contamination is due to either
• Inadvertent introduction of ambient air into the system
• Use of helium with purity of less than 99.999%, such as helium gas used for leak detection and welding.
Steps to decontaminate the helium circuit:
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• Minor contamination can usually be removed by running the cold cryopump for several hours to trap contaminants in
the cryopump, then shut down the compressor and immediately remove the helium lines at the compressor. Allow the
cryopump to warm thoroughly, and then perform the cleanup procedure as outlined in the cryopump manual.
8.5 Cleaning Equipment
Stubborn contamination involving water vapor requires decontamination of the compressor. One effective method
involves supplying clean helium to the return side at appropriate pressure while venting a small amount of gas from the
supply side; while the compressor is running. This is referred to as a "running purge". Contact Trillium US Inc. if such a
procedure is needed.
Caution:
Do not use solvents to clean the connectors. The fittings should never be greased or oiled. Otherwise
the helium circuit could become contaminated.
8.6 Returning Equipment
Before returning any equipment, contact Trillium US Inc. to receive special instructions and to obtain a return authorization
(RMA) number. See contact information in Section 2.
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