Polycold Closed Loop Gas Chiller (825131)

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 # _____________
825131-00 REV A
Page 1
TABLE OF CONTENTS
1.0 INTRODUCTION..................................................................................................................................... 4
1.1
FOREWORD....................................................................................................................... 4
1.2
SERVICE ............................................................................................................................ 5
1.3
BEFORE YOU START ....................................................................................................... 5
1.4
HAZARD ALERTS INFORMATION ................................................................................... 6
1.5
USER PRECAUTIONS..................................................................................................... 14
1.6
SAFETY INFORMATION ................................................................................................. 16
1.7
SAFETY TRAINING GUIDELINES .................................................................................. 18
1.8
LOCK-OUT, TAG-OUT PROCEDURE............................................................................. 19
2.0 INSTALLATION................................................................................................................................... 20
2.1
SYSTEM DIAGRAMS....................................................................................................... 20
Figure 1: Electrical Distribution Diagram ................................................................................. 21
Figure 2: System Block Diagram............................................................................................... 22
Figure 3: Dimensions, Front (version -06)................................................................................. 23
2.2 ABOUT THE 2XCL ................................................................................................................. 27
.1
3. Unit Features: ............................................................................................................. 28
2.3
INSPECT AND INSTALL THE 2XCL ............................................................................... 30
2.4 CONNECT THE COOLING WATER ...................................................................................... 39
2.5 INSTALL THE EXTERNAL GAS CIRCUIT AND GAS FILL LINE ........................................ 40
2.6 EMERGENCY OFF CIRCUIT ................................................................................................. 42
3.0 OPERATION ........................................................................................................................................ 42
3.1 INITIAL START-UP ................................................................................................................ 42
3.2 BAKE-OUT AND POST BAKE COOLING ............................................................................ 43
3.3 RESETTING SAFETY INTERLOCKS AFTER FAULT.......................................................... 43
4.0 INSPECTION & MAINTENANCE ........................................................................................................ 44
5.0 DISCONNECTION, STORAGE, AND RESHIPMENT......................................................................... 46
6.0 TROUBLESHOOTING ......................................................................................................................... 48
6.1 GENERAL TROUBLESHOOTING MATRIX.......................................................................... 49
6.2 REFRIGERATION COMPRESSOR FAULT MODES ............................................................ 51
Indicator Lamps Based Troubleshooting Matrix (Normal Modes).......................................... 51
Indicator Lamps Based Troubleshooting Matrix (Fault Modes).............................................. 52
6.3 GAS COMPRESSOR UNIT (HC-10) FAULT MODES........................................................... 56
6.4 AUTOFILL TROUBLESHOOTING BASICS.......................................................................... 62
6.5 AUTOFILL TROUBLESHOOTING MATRIX.......................................................................... 63
6.6 AUTOFILL STATUS TABLES ............................................................................................... 64
6.7 AUTOFILL RELAYS AND SOLENOID VALVE..................................................................... 65
6.8 ADJUSTING AUTOFILL CONTROL SETTINGS .................................................................. 66
7.0 APPENDIX ........................................................................................................................................... 67
7.1 BRAZING SPECIFICATION................................................................................................... 67
7.2 THERMOCOUPLE ATTACHMENT SPECIFICATION .......................................................... 68
7.3 SPECIFICATIONS .................................................................................................................. 69
7.4 DESIGN DATA ....................................................................................................................... 69
7.5 INSTRUCTIONS FOR INSTALLATION OF SEISMIC ANCHOR/JACK SCREWS .............. 70
8.0 GLOSSARY ......................................................................................................................................... 75
9.0 PROCESS & INSTRUMENTATION AND ELECTRICAL SCHEMATICS............................................ 77
825131-00 REV A
Page 2
Polycold® Systems Cooling Products, CryoTiger®,AquaTrap®, Polycold Compact Cooler, Repair Services and Certified
Refurbished Products
Polycold® Systems cryogenic cooling products, including water vapor cryopumps (PFC, PCT, FLC, FI), chillers (PGC, PGCL),
cryocoolers (P), CryoTiger, AquaTrap, Polycold Compact Cooler (PCC) and accessories, Certified Refurbished products (the
“Products”) and Repair Service (i.e.- repairs other than warranty repairs) are warranted to be free from defects in materials and/or
workmanship under normal service for the time period as set forth in Table A below from date of shipment from Brooks Automation,
Inc. (“Brooks”). The warranty for Repair Service and Products is limited to the component parts replaced or repair performed by
Brooks at Brooks’ facility. Customer is responsible for all charges and expenses for Brooks Services provided at Customer’s location
by Brooks technicians as set forth in a quotation. Certified Refurbished Products and warranty exchange Products are
remanufactured to like-new condition and contain used parts and materials.
Table A
Product
New Product
Warranty
Repair Service
Warranty
Certified Refurbished
Cryogenic Cooling Products Warranty
Cryotiger® Products and Systems
AquaTrap® Products and Systems
Polycold® Compact Cooler (PCC)
15 Months
12 Months
N/A
Cryogenic cooling products, including:
Water vapor cryopumps (PFC, PCT, FLC,
FI), chillers (PGC, PGCL), cryocoolers (P),
and accessories
24 Months
12 Months
12 months
BROOKS MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO PRODUCTS OR
SERVICES. UNLESS EXPRESSLY IDENTIFIED AS A WARRANTY, SPECIFICATIONS IN ANY PRODUCT DATASHEET CONSTITUTE
PERFORMANCE GOALS ONLY, AND NOT WARRANTIES. BROOKS MAKES NO WARRANTY RESPECTING THE MERCHANTABILITY
OF PRODUCTS OR THEIR SUITABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR RESPECTING INFRINGEMENT
OF INTELLECTUAL PROPERTY RIGHTS. BROOKS DISCLAIMS ANY WARRANTY WITH RESPECT TO PRODUCTS MODIFIED
WITHOUT BROOKS’ WRITTEN CONSENT, REPAIRS MADE OUTSIDE OF OUR FACTORY, PRODUCTS RENDERED DEFECTIVE BY
CUSTOMER MISUSE, NEGLIGENCE, CORROSIVE ATMOSPHERES, ATTACK BY FREE CHEMICALS WITHIN THE SYSTEM,
ACCIDENT, DAMAGE BY CUSTOMER OR CUSTOMER’S AGENT, OPERATION CONTRARY TO OUR RECOMMENDATION, IF THE
SERIAL NUMBER HAS BEEN ALTERED, DEFACED OR REMOVED, THE USE OF SERVICE REPLACEMENT REFRIGERANTS FROM
ANY THIRD PARTY NOT LICENSED BY BROOKS, OR THE PRODUCT IS OTHERWISE COMPROMISED BY USE OF UNAUTHORIZED
PARTS OR SERVICE, ALL AS DETERMINED BY BROOKS IN ITS SOLE DISCRETION.
IN NO EVENT WILL CUSTOMER BE ENTITLED TO, NOR WILL BROOKS BE LIABLE FOR INDIRECT, SPECIAL, INCIDENTAL,
PUNITIVE OR CONSEQUENTIAL DAMAGES OF ANY NATURE, INCLUDING WITHOUT LIMITATION NEGLIGENCE, STRICT LIABILITY,
OR OTHERWISE, ARISING AT ANY TIME, FROM ANY CAUSE WHATSOEVER, INCLUDING, WITHOUT LIMITATION, DOWN-TIME
COSTS, DATA LOSS, DAMAGE TO ASSOCIATED EQUIPMENT, REMOVAL AND/OR REINSTALLATION COSTS, REPROCUREMENT
COSTS, OR LOST PROFITS, EVEN IF BROOKS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, AND EVEN IF THE
LIMITED REMEDIES OF REPAIR OR REPLACEMENT FAIL OF THEIR ESSENTIAL PURPOSE. THIS WAIVER OF LIABILITY DOES NOT
APPLY TO EITHER BROOKS’ LIABILITY UNDER A STATUTE, ACT OR LAW PERTAINING TO BODILY INJURY, OR TO ANY LIABILITY
INCURING OUT OF DAMAGE TO THE BODY, HEALTH OR LIFE OF A PERSON.
The exclusive remedies for breach of warranty will be either repair or replacement of the nonconforming parts or Products during the
warranty period at the sole discretion of Brooks, shipped ExWorks (Incoterms 2000) Brooks factory. Customer’s recovery from
Brooks for any claim shall not exceed the amount paid by customer to Brooks for the Product or Service giving rise to such claim,
irrespective of the nature of the claim, whether in contract, tort, warranty, or otherwise. Customer must inspect the Products within a
reasonable time upon receipt, and must notify Brooks within 30 days of discovering a defect. Every claim on account of defective
material or workmanship shall be deemed waived unless made in writing within the warranty period specified above. Brooks does
not assume, or authorize any other person to assume, any other obligations or liabilities in connection with the sale of the Products.
All Polycold Products are also subject to the Brooks Automation, Inc. General Terms and Conditions, Polycold® Products,
an excerpt of which is set forth above.
®
Polycold is a registered trademark of Brooks Automation, Inc.
Doc# PS-02 Rev D / January 26, 2006
3800 Lakeville Hwy • Petaluma, California 94954 U.S.A. • 707.769.7000 • Toll Free: 888.4.Polycold • Fax 707.769.1380
E-mail petaluma.sales@brooks.com • www.brooks.com
825131-00 REV A
Page 3
1.0 INTRODUCTION
1.1
FOREWORD
Polycold’s Cool Solutions® low temperature gas chillers are used to allow low temperature vacuum
processing of semiconductor device wafers as well as other applications. Vacuum processing systems
use recirculating fluids to keep the wafer at controlled temperature. The wafer sits on a pedestal or table
in vacuum and is processed, typically in a vacuum with specific gases and metallic vapors to create a
uniform coating on the wafer.
Gas circulating in the secondary loop of the 2XCL closed loop gas chiller is cooled in the gas chiller. The
temperature of the gas leaving the gas chiller can reach temperatures of –100oC. The chilled gas is
recirculated by a secondary gas compressor. The customer-installed lines connecting the gas chiller and
the pedestal are vacuum jacketed to minimize the heat leaks from the ambient to the chilled gas.
The system consists of a refrigeration system, which chills the secondary gas, a secondary gas
recirculating compressor, interconnecting gas lines, and the table in the vacuum system. The
refrigeration system uses a propriety and patented blend of refrigerants. The secondary loop compressor
uses an inert gas whose dew point is below –80oC. The refrigeration system as well as the secondary
gas loop requires cooling water. There is no co-mixing of the refrigerant and the secondary gas. The
equipment is designed for continuous operation. Electricity, cooling water, and pressurized dry nitrogen
are the only required utilities.
Pressures are stated as gauge, not absolute.
Kilopascals-gauge.
Psig is pounds per square-inch-gauge and kPa is
kPa = 6.895 x Psig
bar = Psig  14.5
This technical manual contains Safety, Service, Introduction, Specifications, Installation, Operation,
Maintenance, and Parts information for all the equipment in the system.
Notes:
ATTENTION!
REVIEW THE INSTRUCTION MANUAL BEFORE OPERATING THIS EQUIPMENT!
Upon arrival of the equipment and prior to starting its installation or operation confirm that
the balance pressure (BP) shown on the suction pressure gauge is between 165 – 190 psi.
Refer to section 2.3, Item 1.
825131-00 REV A
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1.2
SERVICE
Information provided within this document is subject to change without notice, and although believed to be accurate,
Brooks Automation assumes no responsibility for any errors, omissions, or inaccuracies.
AcuLigner, AcuLine, AcuTran, AcuTrav, AeroLoader IV, AeroTrak, ARV 2000, AquaTran, Atmospheric Express, BALI
400 Indexer, BiSymmetrik, ExpressLock, FabExpress, FixLoad, FrogLeg, Gemini, Gemini Express, Gemini Express Tandem,
Guardian Bare Reticle Stocker, Hercules, Hercules Express, InCooler, InLigner, InLine Express, Leapfrog, Linear
eXchange, MagnaTran 7, MagnaTran 70, MagnaTran 8, MagnaTran X, Marathon, Marathon Express, Marathon Express
Tandem, MicroTool, MultiTran, OneFab AMHS, OpenMTS, PASIV, PF-100, PowerPak, Reliance ATR, Reliance DFR,
Reliance WCR, SENTRY, TCM, Time Optimal Trajectory, TopCooler, TurboStocker, TurboStocker XT, Ultrasort, VacuTran,
VCD, VCE, VPE, WAVE, WAVE II, Zaris, Z-Bot, Aquatrap, Conductron, Convectron, Cool Solutions, Cryodyne,
Cryogem, Cryogenerator, CryoTiger, Cryo-Torr, CTI-Cryogenics, FastRegen™, GOLDLink, Granville-Phillips, GUTS,
Helix, Micro-Ion, Mini-Convectron, Mini-Ion™, On-Board, Polycold, RetroEase, RetroFast, Stabil-Ion, ThinLine™, TrueBlueSM, TurboPlus, and Vacuum AssuranceSM are trademarks of Brooks Automation Hardware.
All other trademarks are properties of their respective owners.
© Brooks Automation 2006, All Rights Reserved. The information included in this manual is Brooks Proprietary Information
and is provided for the use of Brooks customers only and cannot be used for distribution, reproduction, or sale without
the expressed written permission of Brooks Automation. This information may be incorporated into the user’s
documentation, however any changes made by the user to this information is the responsibility of the user.
Brooks Automation
15 Elizabeth Drive
Chelmsford, MA 01824
Phone +1 (978) 262-2400
Fax +1 (978) 262-2500
For emergencies, contact Technical Support +1 (978) 262-2900
www.brooks.com
This manual is available in the following languages: English.
This technology is subject to United States export Administration Regulations and authorized to the destination
only;
diversion contrary to U.S. law is prohibited.
Printed in the U.S.A.
© 2006 by Brooks Polycold Systems Inc.
All rights reserved.
Printed in the United States of America.
Trademark Recognition:Armaflex® is a registered trademark of Armstrong World Industries, Inc.
CPI UltraSeal™ is a trademark of Parker Hannifin Corporation.
Phillips® is a registered trademark of Phillips Screw Company.
Polycold® is a registered trademark of Brooks Technology Corporation.
VCR® is a registered trademark of Cajon Company.
is a registered trademark of Brooks Technology Corporation.
1.3
BEFORE YOU START
Please have the following information available to help us assist you:
Polycold Model: __________________________
Polycold Serial No: ________________________
Date Manufactured: ________________________
The above information is on the nameplate of your 2XCL. You may wish to enter this information now
(before the 2XCL is installed).
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1.4
HAZARD ALERTS INFORMATION
VISUAL HAZARD ALERTS USED IN THIS MANUAL AND AS LABELS ON THE EQUIPMENT SHOULD
BE REVIEWED AND UNDERSTOOD BY 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 alert icons and text for information on icons, which identify potentially hazardous
situations/consequences of not avoiding the hazard. Hazard alerts used in the manual and on the
equipment follow ANSI Z535 and use the signal words DANGER, WARNING or CAUTION.
The signal words have the following meanings:
Pictogram (icon) depicting nature of hazard
Hazard Keyword Level
WARNING
ELECTRICAL HAZARD
High Voltage can cause severe injury or death.
Disconnect power before removing access panels
Text describing how to avoid the hazard
Text describing hazard and what
might/could happen
HAZARD KEYWORD LEVELS
DANGER
An imminently hazardous situation that, if not avoided, will result in
serious injury or death.
WARNING
A potentially hazardous situation that, if not avoided, could result in
severe injury or death.
CAUTION
A potentially hazardous situation that, if not avoided, could result in
moderate or minor injury or property or equipment damage.
Hazard Warning Labels Identified by Number
1. CAUTION
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2. WARNING
3. CAUTION
4. ATTENTION
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5. CAUTION
6. ATTENTION
7. WARNING
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8. CAUTION
9. SEISMIC ANCHOR P0INT
10.
P/N 407145-00
11.
P/N 407149-00
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12.
13.
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2
2
2
2
4
8
5
2
5
2
9 (version -07)
9 (version -07)
9 (version -06)
9 (version -06),
13 (version -07)
Right Side View
Front View
Interior Label Placement
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Page 11
7
9 (version -07)
9 (version -07)
7
9 (version -06)
9 (version -06),
13 (version -07)
Left Side View
Rear View
Interior Label Placement, Continued
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10
10
12
12
2, 1, 3
10
10
10
12
2, 1, 3
2, 1, 3
2, 1, 3
6, 11
Exterior, Left Front Oblique
Exterior, Right Rear Oblique
2, 1, 3
Top View
Exterior Label Placement
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1.5
USER PRECAUTIONS
CAUTION!
REVIEW THE INSTRUCTION MANUAL BEFORE PERFORMING ANY PROCEDURE
OTHER THAN THE ROUTINE OPERATION OF THE 2XCL.
Performance of procedures other than those specified herein may result in hazardous
exposures to electrical, ultra-low temperature, or moving parts hazards. Additional
precautions are located in the appropriate section of this manual.
CAUTION!
THE 2XCL CONTAINS PRESSURIZED GAS. DO NOT OPEN THE REFRIGERANT
CIRCUIT TO THE ATMOSPHERE. All refrigeration work must be performed by qualified,
Type 2, High Pressure refrigeration technicians. Do not loosen any valve packing or fittings
unless you are specifically following the instructions in the recharge procedure. Discharge
of refrigerant may cause personal injury due to high pressures or ultra-low temperatures. In
addition, if refrigerant is lost, the 2XCL may need to be re-charged before it can be used.
WARNING!
HAZARDOUS VOLTAGE EXISTS AT ALL TIMES AFTER THE POWER IS CONNECTED.
Only qualified electricians should perform electrical work. Power should be removed at the
point of electrical connection, and locked-out following standard lock-out tag-out
procedures. A lock-out device may be placed on the supply power circuit breaker (provided
by others) or on the supplied electrical power plug.
DANGER! DO NOT REACH INSIDE THE 2XCL WHEN IT IS OPERATING.
The unit contains hazardous voltages and extreme temperatures.
DANGER! DO 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 risk of frostbite.
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WARNING!
LIFTING HAZARD (900 pounds (400 kg))
Failure to properly lift this device may result in severe injury or death.
Read the manual before lifting this equipment using the lifting eyes. Assure that the eyes
are fully engaged in the frame with no exposed threads. Use all four lifting eyes with an
adequate lifting harness and mechanism. Lifting harness must be centered between the
lifting eyes. Lift vertically only with no horizontal component.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or death.
The equipment should be removed from its shipping pallet by using the top installed lifting
eyes.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or death.
Read the manual before moving this equipment using the casters. Move the equipment on
level floors only. Move it slowly and avoid rapid acceleration and deceleration. Apply force
to move the system below the equipment center of gravity. Do not place yourself between
the moving equipment and fixed obstructions.
CAUTION! THIS SYSTEM PRODUCES AND CIRCULATES COLD GAS AT
TEMPERATURES AS LOW AS - 110º C. Assure that integrating systems and components
are suitable for rapid exposure to these low temperatures.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Maintain weight on casters at all times.
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1.6
SAFETY INFORMATION
Safety Hazards and Safeguards
NOTE: The user is advised to retain current copies of material safety data sheets (MSDS) for
refrigerants and cleaning agents used in the operation and maintenance of this equipment. One copy of
the MSDS for the system refrigerant has been attached to this user’s manual.
Safety Devices incorporated in the 2XCL and their function is described below:
REFRIGERATION COMPRESSOR UNIT
Descriptor
PS1
Name
High Pressure Switch
Function
A high-pressure switch is incorporated in the discharge side of the
compressor. The switch opens contacts if the refrigerant pressure
exceeds normal operating pressure, interrupting power to the
compressor and turning it off. This switch requires manual reset.
The user should not adjust it.
FP1
Fusible Plug
(located on expansion tank)
A fusible plug is installed in the discharge plumbing of the
compressor and serves as the controlled release point for refrigerant
should a fire occur in the area of the 2XCL. The fusible plug
provides a means to reduce high pressures caused by excessive
ambient temperatures in a manner that does not result in an
explosion.
TS1
High Temperature Switch
A high temperature switch is coupled to the condenser refrigerant
side. In the event that the condenser is obstructed or flow is
otherwise interrupted, the refrigerant temperature will rise, opening
the contacts on the high temperature switch. This removes power
from the compressor and turns it off. This switch requires manual
reset. The user should not adjust it.
PS4
Refrigerant Low Pressure
Temperature Switch
A low-pressure switch is incorporated on the suction side of the
compressor. The switch opens contacts if the refrigerant suction
pressure drops below normal operating pressure, interrupting power
to the compressor and turning it off. This switch will auto-reset once
the refrigerant pressure reaches the reset point. The user should
not adjust it.
Schematic representations of safety device locations may be found in the Process and Instrumentation Diagram
and on the Electrical Diagrams.
GAS COMPRESSOR UNIT
PS2
Low Pressure Switch
A low-pressure switch is incorporated in the suction side of the gas
compressor. The switch opens contacts if the gas pressure drops
below normal operating pressure, interrupting power to the
compressor and turning it off. This switch is auto-reset. The user
should not adjust it.
PS3
High Pressure Switch
A high-pressure switch is incorporated in the discharge side of the
gas compressor. The switch opens contacts if the gas pressure
exceeds normal operating pressure, interrupting power to the
compressor and turning it off. This switch requires venting of
nitrogen to 0 psi and manual reset. The user should not adjust it.
TS2
Oil High Temp Pressure
Switch
A high temperature switch shuts off the gas compressor when
excessive oil temperature causes it to function. The compressor
automatically restarts after the temperature cools and the switch
resets.
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TS3
Compressor Shell High
Temperature Switch
TS4
Gas High Temperature Switch
TS5
Refrigerant High Discharge
Switch
A high temperature switch shuts off the gas compressor when
excessive shell temperature causes it to function. The compressor
automatically restarts after the temperature cools and the switch
resets.
A high temperature switch shuts off the gas compressor when
excessive gas temperature causes it to function. The compressor
automatically restarts after the temperature cools and the switch
resets.
A high temperature switch shuts off the refrigerant compressor when
excessive refrigerant temperature causes it to function. The
compressor automatically restarts after the temperature cools and
the switch resets.
CAUTION! Safety devices are installed on the 2XCL to help protect it from
permanent damage. Some of the protective devices are self-resetting, with a system status
output to the integrating equipment. When the system status indicates that a safety
component has functioned, the integrating equipment should not enable operation until the
cause of the fault is corrected.
If a protective device is triggered, the cause of the problem must be corrected before
continuing to use the 2XCL. Please see Section 6.0 “Trouble-Shooting” or call the Polycold
Service Department for assistance. Bypassing or repeated resetting of a protective device
may expose personnel and or the facility to hazards, permanently damage the equipment,
and may void your warranty.
TABLE A
CIRCUIT BREAKER AND FUSE PROTECTION
Reference
Designation
CB1
Protection Provided
Overcurrent
Rated Voltage
And Amperage
460V / 16A
Amperage Interrupting
Capacity
6,000 (See Note)
CB2
Overcurrent
CB3
Overcurrent
460V / .5A
24VAC / A
1,000
CB4
Overcurrent
460V / 16A
6,000
FU1
Overcurrent
230V / 2AT
FU2
Overcurrent
230V / 2AT
FU3
Overcurrent
230V / 0.4AT
FU4
Overcurrent
230V / 0.4AT
FU5
Overcurrent
230V / 0.4AT
FU6
Overcurrent
230V / 0.4AT
FU7
Overcurrent
230V / 0.4AT
6,000
Note: Your electrical supply must also have enough capacity to handle the Rated Load Amps and should be
provided through a circuit breaker rated with at least 10,000 AIC.
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1.7
SAFETY TRAINING GUIDELINES
This chapter provides a summary of the safety information that is to be successfully conveyed to service
personnel as part of their training on the POLYCOLD GAS CHILLER 2XCL. The training program is
intended to ensure that any person who undertakes the service of the 2XCL can demonstrate
competence to perform the required tasks safely. Accordingly, training required for each task includes,
but is not limited to, the following:
1. A review of applicable safety standards and procedures as well as those presented in this
chapter.
2. A review of maintenance and safety recommendations applicable to vendor supplied
equipment.
3. An explanation of the purpose of subsystems and their operation.
4. An explanation of the specific tasks and responsibilities of each person (operator, service
personnel, etc.) assigned to the Polycold GAS Chiller 2XCL equipment.
5. The person(s) (identified by name, location, and telephone number) to be contacted when
required actions are beyond the training and responsibility of the person being trained.
6. Identification of the recognized hazards associated with each task.
7. Identification of, and appropriate responses to, unusual operating conditions.
8. Explanation of the functions and limitations of all safeguards, and their design characteristics.
9. Instructions for the functional testing (or other means of assurance) for proper operation of
safeguarding devices.
10. Service personnel should understand the operation of process-related hardware interlocks,
and the sequences of hardware operation that are executed automatically, as explained in
this chapter.
11. The equipment should not be used without assuring correct operation of all connected
facilities, especially fugitive emissions exhaust.
12. Service personnel should always assume that high voltage is present unless they have
personally turned it off and locked it out.
13. The equipment should not be operated without all guards and safety devices in place.
14. The equipment should be shut down, locked-out, and should not operated while it is being
maintained.
15. Users should not attempt to defeat, modify, or disable any of the equipment’s safety interlock
switches.
16. Only Brooks Automation trained service personnel should perform assembly, operation,
disassembly, service, or maintenance of the Polycold GAS Chiller 2XCL equipment. A
certified refrigeration technician must perform any work performed on the refrigeration portion
of the system.
17. All safety related incidents or near misses should be reported to a supervisor or Brooks
Automation Customer Service.
18. The user should carefully review and understand manufacturer provided material safety data
sheets (MSDS) for materials used by this equipment.
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1.8
LOCK-OUT, TAG-OUT PROCEDURE
LOCK-OUT TAG-OUT PROCEDURE, ELECTRICAL
1. Notify personnel you are performing a Lock-Out Tag-Out (LOTO).
2. Shut down the system following normal procedure: Remove power to the 2XCL.
Verify that the compressor is off.
3. Isolate the system from the electrical supply by locking-out the breaker in the “OFF”
position and notifying others with an identification tag.
4. Use a voltmeter to observe “0” volts in the area you will be working. Service can
now be performed.
5. To re-energize, reverse these steps.
LOCK-OUT TAG-OUT PROCEDURE, GAS SUPPLY
1. Notify personnel you are performing a Lock-Out Tag Out (LOTO).
2. Isolate the system from the gas supply by closing the customer supplied gas
connectors.
3. Verify the system is locked-out by slowly opening the gas inlet fitting on the 2XCL
unit and allow the pressure to bleed down for 2 minutes—the flow should gradually
slow to a stop.
4. Add lock and notification Tag to supply source shutoff.
5. To reestablish gas supply, reverse these steps.
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2.0
2.1
INSTALLATION
SYSTEM DIAGRAMS
See Section 9 for Process & Instrumentation Diagram and Electrical
Schematics
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Figure 1: Electrical Distribution Diagram
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Figure 2: System Block Diagram
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Figure 3: Dimensions, Front (version -06)
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Figure 4: Dimensions, Rear (version -06)
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Figure 5: Dimensions, Front (version -07)
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Figure 6: Dimensions, Rear (version -07)
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2.2 ABOUT THE 2XCL
1. What it is and what it does
Polycold’s Cool Solutions® 2XCL is a refrigeration unit that cools a stream of gas to ultra-low
temperatures. It consists of two separate subsystems, the upper portion known as the Refrigeration Unit,
which provides the cooling of the gas stream and the lower portion, which provides the secondary loop
circulation of the gas stream. The Refrigeration Unit has a refrigerant circuit and a gas circuit.
The refrigerant circuit is located entirely within the 2XCL. The 2XCL‘s compressor circulates refrigerant in
a continuous loop through the Polycold stack. The water-cooled condenser removes the heat of
compression from the refrigerant by circulating cooling water through a coaxial coil, and the Polycold
stack cools the refrigerant to ultra-low temperatures. (The refrigerant is a proprietary mixture of
refrigerants provided by Brooks Automation.) The gas circuit consists of a continuous copper tube that
runs through the refrigerant circuit. The gas is cooled as it runs through the Polycold stack.
The gas compressor compresses customer supplied nitrogen or helium gas and uses a heat exchanger
to cool it to room temperature. Oil separators and an oil adsorber reduce levels of oil and moisture in the
gas stream to very low levels. A regenerative heat exchanger is used to assure that low pressure gas
entering the compressor is within design limits of the gas compressor.
High pressure gas exiting the regenerative heat exchanger enters the Polycold stack. When the Polycold
stack is cold, it chills the high pressure gas being supplied to the customer process. Low pressure gas
returning from the process passes through the regenerative heat exchanger before entering the gas
compressor.
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2. The 2XCL features (refer to the figures below)
11
11
6 4
32
9
8
25
7
23
24
31
See Detail Below
5 2
30
3
33
1
28
12
12
29
27
26
10
FRONT VIEW
REAR VIEW
16
19
20
21
15
22
13
14
17
18
REAR VIEW DETAIL
.1
3. Unit Features:
1
CONTROL VOLTAGE CIRCUIT BREAKER CB-1 (HC-10): This switch protects a control
voltage source. It must be closed to allow the unit to start. After initial start-up, switch must
remain in the ON position if unit functions are to be accessed remotely.
2
CB-4 REFRIGERATION UNIT: This switch starts the Refrigeration unit. After initial start-up,
ON/OFF functions of the unit may be accessed remotely.
3
RUN INDICATOR HC-10: Will be illuminated when gas compressor (HC-10) is running (and CB1
& CB2 are closed).
4
RUN INDICATOR, REFRIGERATION UNIT: Will be illuminated when power is applied, the CB4
switch is in the on position, and all systems are operating normally, indicating that the compressor
contactor is closed (green LED).
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5
FAULT INDICATOR, REFRIGERATION UNIT: Will illuminate if a problem such as overpressure(s) or high temperature(s) should occur (red LED).
6
LINE INDICATOR, REFRIGERATION UNIT AND GAS COMPRESSOR UNIT (HC-10):
Illuminates when line voltage is present and Gas Compressor circuit breaker (CB1 & CB2 are
closed) (yellow LED).
7
EMO (emergency machine off) BUTTON: Used to power-down the unit(s) in the event an
emergency situation should occur. This circuit is wired to a dedicated safe voltage supply and if
activated all unit functions will cease and cause power contactors to open with the exception of
power to this circuit. This button latches in the off position and must be rotated clockwise to
disengage. Hazardous voltages remain in the unit from the point of electrical connection to the
line side of the compressor contactors. The customer is responsible for removing power from the
Polycold unit supply when the EMO circuit is activated.
8
RECIRCULATING GAS SUPPLY GAUGE: This dial represents supply pressure from the Gas
Compressor Unit (HC-10) portion of the cooling unit to the host equipment. During normal
operation, the dial typically reads 85 - 115 PSI.
9
REFRIGERANT SUCTION GAUGE: This dial represents internal Refrigeration Unit pressure
(suction). During normal operation, the dial typically reads 25-35 PSI.
10 SEISMIC ATTACHMENT POINTS: These (4) 3/8-16 NC or ½ -13 NC threaded barrels are
provided for seismic anchoring and can be used to install seismic anchor/jack screws.
11 LIFTING EYES: These lifting eyes (4) are provided as an accessory to safely lift the unit into
place. These eyes are mounted in 3/8-16 NC threaded barrels.
WARNING!
LIFTING HAZARD (900 pounds (400 kg))
Failure to properly lift this device may result in severe injury or death.
Read the manual before lifting this equipment using the lifting eyes. Assure that the eyes
are fully engaged in the frame with no exposed threads. Use all four lifting eyes with an
adequate lifting harness and mechanism. Lifting harness must be centered between the
lifting eyes. Lift vertically only with no horizontal component.
12 CASTERS: Enable the unit to be rolled into place for installation and for maintenance, etc….
13 WATER IN CONNECTION: ½ FNPT connection
14 WATER OUT CONNECTION: ½ FNPT connection
15 EMO LOOP J1 CONNECTOR: This is the FEMALE connector that allows access to the
dedicated emergency machine off circuitry. It is wired in SERIES with the EMO button.
16 EMO LOOP J2 CONNECTOR: This is the MALE connector that allows access to the dedicated
emergency machine off circuitry. It is wired in SERIES with the EMO button.
17 VENT VALVE (V5): 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 units.
19 THERMOCOUPLE CONNECTOR: Miniature Type K, Supply temperature
20 THERMOCOUPLE CONNECTOR: Miniature Type K, Return Temperature
21 THERMOCOUPLE CONNECTOR: Spare
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22 GAS FILL PORT: This is a ¼” compression fitting, used for charging the coolant loop. It is
connected to a check valve to prevent pressurized gas from releasing through this fitting when it
is open. It is piped to the suction side of the compressor. See fill procedures.
23 GAS SUPPLY: Bayonet adapter fits here, ½ Parker Ultraseal x Linde ½
24 GAS RETURN: Bayonet adapter fits here, ½ Parker Ultraseal x Linde ½
25 POWER INLET: Liquid tight conduit fitting, diam.: 1”, 2.45” (L), 1.88” (W)
26 CB 2 (MAIN CIRCUIT BREAKER): This is the main circuit breaker for the gas compressor. After
initial start-up, switch must remain in the “ON” position if unit functions are to 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
(V5).
29 REMOTE JUMPER: The jumper is used to simulate the remote interface “GO” signals for the
refrigeration chiller and the gas compressor unit. This jumper allows the 2XCL to be operated
without being connected to the tool’s remote user interface.
30 FLOW INDICATING METER: Provides indication of gas flow rate. This is not calibrated and is
for indication only.
31 AUTOFILL CONTROL (PS 5): This display shows the gas suction pressure. It also is used to
adjust settings for the autofill controller.
32 FILL POWER SWITCH: This switch is used to enable or disable the autofill controller.
33 GAS COMPRESSOR UNIT (HC-10): Fault Mode LCD Display.
2.3 INSPECT AND INSTALL THE 2XCL
CAUTION!
No operator serviced parts within. Access restricted to trained service personnel only.
Review specifications table (7.3) for facility requirements prior to installation.
Tools and materials needed:
1. Forklift (for overhead lift only), pallet truck, or overhead crane
2. Power cable from voltage source, suitably sized for this equipment
3. Wire strippers
4. #2 Phillips head screwdriver
1. Inspect and document any visible damage on the 2XCL crate.
2. Open the crate and inspect the 2XCL.
Notify the carrier immediately if you suspect the 2XCL was damaged during shipping.
Read the dial of the RECIRCULATING GAS SUPPLY GAUGE and record the pressure:
________ psig.
Read the dial of the REFRIGERANT SUCTION GAUGE and record the pressure: ____
psig.
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3. Determine if the seismic anchor/jack screws are installed. If not, install the seismic anchor/jack
screws per the procedure shown in 7.5.
4. Remove the 2XCL from the crate using the top mounted lifting eyes.
WARNING!
LIFTING HAZARD (900 pounds (400 kg))
Failure to properly lift this device may result in severe injury or death.
Read the manual before lifting this equipment using the lifting eyes. Assure that the eyes
are fully engaged in the frame with no exposed threads. Use all four lifting eyes with an
adequate lifting harness and mechanism. Lifting harness must be centered between the
lifting eyes. Lift vertically only with no horizontal component.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or death.
The equipment should be removed from its shipping pallet by using the lifting eyes installed
on top of the unit.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or
death. Read the manual before moving this equipment using the casters. Move the
equipment slowly and avoid rapid acceleration and deceleration. Apply force to move the
system below the equipment center of gravity. Do not place yourself between the moving
equipment and fixed obstructions.
WARNING!
Due to its weight, a lift truck or overhead crane is required to place and remove the
2XCL from the transport unit.
WARNING!
Due to its high center of gravity, care must be taken to avoid tipping the unit. 1) While
transporting the pallet to which the unit is strapped and 2) While positioning the unit on
its casters. (See illustration figures 3 & 4). The 2XCL should only be lifted from above,
using its lifting eyes and a sling system.
5. Install 2XCL seismic anchor/jack screws. (See Appendix 7.5).
Place the 2XCL as close as possible to the desired location of your cold GAS stream. The
2XCL must remain vertical during transport and installation. The base frame of the 2XCL can
be secured to the floor at the four locations labeled “Seismic Anchor Point”. (See section 7
for installation instructions.)
6. Move the 2XCL unit to its installation location
The 2XCL unit should be lifted, using the lifting eyes mounted on top of the unit and a sling system;
then moved to an area near its installation location. The 2XCL unit may be transported on its casters
short distances on level floors within the installation location. DO NOT MOVE THE UNIT UP OR
DOWN RAMPS ON ITS CASTERS!
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or
death. Read the manual before moving this equipment using the casters. Move the
equipment on level floors only. Move it slowly and avoid rapid acceleration and
deceleration. Apply force to move the system below the equipment center of gravity. Do
not place yourself between the moving equipment and fixed obstructions.
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WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Maintain weight on casters at all times.
2XCL
2XCL
2XCL
2XCL
2XCL
2XCL
Figure 7: 2XCL “Footprint”
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FIGURE 8: 2XCL(version -06) 440V Weight Distribution
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FIGURE 9: 2XCL(version -07) 440V Weight Distribution
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7. Connect the electrical power.
WARNING!
HAZARDOUS VOLTAGES
Electrical power to the 2XCL must be connected by qualified personnel, according to local
codes.
WARNING!
HAZARDOUS VOLTAGE EXISTS AT ALL TIMES AFTER THE POWER IS CONNECTED.
Only qualified electricians should perform electrical work. Power should be removed at the
point of electrical connection, and locked-out following standard lock-out tag-out
procedures. A lock-out 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
over-current protection for the electrical supply circuit.
Before connecting the 2XCL to your power source, verify the following:

The disconnect device is readily accessible to the operator; located in sight and within 25’ of the
2XCL; and clearly marked to indicate the equipment that it protects.

The disconnect device locks in the de-energized position only; complies with IEC 947-1 and 9473 standards; and meets the requirements of SEMI S2 section 17.

Your actual voltage falls within the acceptable range listed in Table B.

Your electrical supply has enough capacity to handle the Rated Load Amps and is provided
through a circuit breaker rated with at least 10,000 AIC.

The circuit protection must be adequately sized to operate with the 10 AWG internal wiring of the
circuit.

The supply power wiring must be sized in accordance with NFPA 79.

The 2XCL is grounded according to SEMI S2 and CE requirements.
Note: The 2XCL is intended to be a subsystem of equipment and requires incorporation and protection by
the host equipment Emergency Off (EMO) circuit. Refer to Electrical Schematic.
TABLE B
Nominal Voltage
Voltage/Phase/
Cycles
Acceptable Voltage
Range
FLA
Fuse
Size
440V
440/3Ø/60
396V- 484V
13.2A
16A
480V
480/3Ø/50/60
432V- 528V
12A
16A
CAUTION!
Phase sensitive equipment. Clockwise rotation required. Incorrect rotation will prevent
equipment operation.
The 2XCL is phase-sensitive and will not function if wired incorrectly. If the phase
rotation of your power source is incorrect, an error will be displayed on the LCD (see
section 6.6).
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CAUTION!
Status 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 of electrical power, the
2XCL system will restart when provided an enable signal. Placing the equipment in a
safe shut-down condition requires removing the 2XCL Main Power cord connector.
Power Cord Installation
1. Remove top panel of the 2XCL unit.
2. Using a 5/16” nut driver or socket drive, remove the nuts from the plastic guard on the terminal block.
3. Remove the plastic guard from the terminal block (see photo below).
Terminal Block with Plastic Guard
Note: Use 10 AWG wire for your power cord.
4. Insert power cord through the liquid tight fitting located on the back-side of the 2XCL unit (see label 1
in “Power Inlet” photo below).
1
Power Inlet
Terminal Block with Power Cord Connected
5. Connect power cord to terminal block using the #10-32 screws provided.
6. Tighten screws on the terminal block using a torque wrench set to 20 IN-LBS.
7. Connect ground wire to terminal lug labeled “PE” (potential earth)/ “GND” and tighten screws securely
(see photo labeled “Terminal Block with Power Cord Connected” above).
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8. Reinstall plastic guard (see photo below).
Terminal Block with Power Cord Connected and Plastic Guard Installed
8. Installation of seismic anchorage brackets
Make sure seismic anchor/jack screws are installed (See Appendix 7.5 for more information). Install
SEMI S2 approved seismic anchorage brackets. Install seismic anchorage brackets that secure the
seismic anchor/jack screws firmly to the facility floor. Seismic anchorage brackets must be suitable to
withstand a seismic load of 1400 lbs. per SEMI S2 requirements. (See semi.org for more information on
S2 requirements.)
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Maintain weight on casters at all times.
9. 2XCL Safety Circuit Connector
WARNING!
THIS UNIT MUST BE WIRED INTO THE CUSTOMER’S SAFETY CHAIN.
HAZARDOUS VOLTAGE EXISTS AT ALL TIMES AFTER THE POWER IS CONNECTED.
Only qualified electricians should perform electrical work. Power should be removed at the
point of electrical connection, and locked-out following standard lock-out tag-out
procedures. A lock-out device may be placed on the supply power circuit breaker (provided
by others) or on the supplied electrical power plug.
The safety circuit connector provides the two following distinct functions: 1) Pressure switch fault status,
either high (discharge side) or low (suction side) pressure; 2) Remote monitoring of the thermostat
switches coupled to the discharge and liquid line temperatures.
10. 2XCL Thermocouple Connectors
The type k thermocouple connector provides remote temperature monitoring of the refrigerant
temperature as it leaves the evaporator and the discharge temperature of the compressor.
RETURN - Measures the nitrogen temperature returning to the 2XCL from the customer process
SUPPLY - Measures the temperature of the nitrogen supplied by the 2XCL
SPARE – (optional) Customer supplied
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11. Machine Remote Connector
The Machine Remote Connector is used for the remote (User) operation of the 2XCL. This connection
enables User controlled start-up and provides the remote system with 2XCL contactor status signals.
The 2XCL may be tested without connection to the User system by use of a jumper. Under normal
operation the 2XCL should be under the control of the user remote system.
CAUTION! Safety devices are installed on the 2XCL to help protect it from
permanent damage. Some of the protective devices are self-resetting, with a system status
output to the integrating equipment. When the system status indicates that a safety
component has functioned, the integrating equipment should not enable operation until the
cause of the fault is corrected.
If a protective device is triggered, the cause of the problem must be corrected before
continuing to use the 2XCL. Please see Section 6.0 “Trouble-Shooting” or call the Polycold
Service Department for assistance. Bypassing or repeated resetting of a protective device
may expose personnel and/or the facility to hazards, may permanently damage the
equipment, and may void your warranty.
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2.4 CONNECT THE COOLING WATER
Tools and materials needed:
1/2-inch (15 mm) standard pipe size wrench
Adjustable or open-ended wrench for fittings supplied by customer
1. Make certain your cooling water is adequate.
Measure the inlet water temperature. It must be 55-85° F (13-29° C). Make certain you have at
least the minimum flow rate required for your water’s temperature. See Table C “Cooling Water
Flow Requirements”.
Your cooling water may be warmer in the summer than in the winter. Cooling water lines within the 2XCL
are not insulated. To prevent condensation inside the system enclosure, assure that the cooling water
temperature is warmer than the dew point of the room in which the 2XCL is installed. Maximum working
pressure of the cooling water circuit is 200 psig (1380 kPa).
Your cooling water should be clean and suitable for use in copper based heat exchangers. We
recommend that you filter your cooling water if it is very dirty or has abrasives in it. Any chemical
impurities in your cooling water must be compatible with copper.
2. Connect a supply and a drain line to the refrigeration unit.
Make certain you use the correct size pipe—see “Tools & Materials Needed” at the beginning of
this section. For the 2XCL, the “COOLING WATER” connections have 1/2-inch female NPT
fittings. Connect your supply line to the port labeled “IN”. Connect your drain line to the port
labeled “OUT”. The cooling water must flow in this direction to properly cool the unit.
TABLE C
Refrigeration
Unit
Water Inlet
Temperature
° F (° C)
Minimum Flow Rate
Gpm (L/min)
Pressure Drop
Inside the Unit
Psi (kPa)
Heat Rejection
Btu/hour
(kW)
2XCL
59 (15)
75 (24)
87 (30)
3 (5.4)
6 (10.8)
10 (36)
1.8 (13)
6.4 (44)
16.7 (115)
29,000 (8.5)
3. Verify that the water plumbing has no leaks.
CAUTION!
EQUIPMENT DAMAGE
Do not turn on the unit until the cooling water has been connected and turned on.
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2.5 INSTALL THE EXTERNAL GAS CIRCUIT AND GAS FILL LINE
Tools and materials needed:
1. Tubing or hoses with 3/8” I.D. or Vacuum Jacketed Lines (recommended)
2. Clean room compatible tubing insulation that is rated for extreme temperatures
3. Adhesive tape for fiberglass tubing insulation or equivalent
4. 1-1/2 inch channel lock pliers
1. Verify that the GAS source from the host equipment is adequate.
CAUTION! If your GAS contains moisture, the water will condense and freeze in
the GAS circuit, and the 2XCL’s performance will degrade as the GAS circuit becomes
blocked. The 2XCL system is designed for use with inert Gases, having a dew point of
lower than -80ºC (He or N2) only. Contact Brooks Automation prior to introduction of a GAS
other than those specified.
CAUTION!
Do not exceed 90 PSI max supply pressure to the 2XCL! If this pressure is exceeded, the
discharge pressure switch (PS3) may activate and cause a fault condition.
2. Install the external gas circuit.
Prior to installation, the lines and chuck need to have been conditioned to remove any moisture and
contaminants. Evacuating these components via vacuum pump for a minimum of two hours is
recommended. After conditioning, they need to be kept dry by back filling with nitrogen and sealing
until they are ready for use.
Note: When attaching vacuum jacketed lines or Linde Male and Female bayonet adapters, special
adjustments may be needed for rigid support of the lines. Both the supporting brackets are adjustable
via the use of slotted holes. Difficulty may be experienced when fitting the Female line unless the
outermost hanger clamp is removed completely and the inner clamp is loosened. After the knurled
nut has been tightened (taking care not to put undue stress on the copper line), the hanger brackets
can be tightened safely.
1. Assemble vacuum jacketed lines to the Polycold unit and the System Integrator making sure all
connections are leak-tight,
Note: It is recommended to leak check using a pressure decay method:
a. Connect a source of dry nitrogen (dew point < -80° C) to the gas fill port.
b. Verify that unit has power and that the autofill control is on. This can be confirmed by
observing that PS5 is illuminated. If not, verify that the unit has power and that the
autofill switch is in the “ON” position.
c. Pressurize the unit (vacuum jacketed lines and chuck assembly to 85 psig through gas fill
port). The autofill control will automatically pressurize the unit. This process takes 10
minutes or less.
d. Observe/record reading on PS5. Switch the autofill switch to the “OFF” position.
e. Test for 30 minutes: there should be no detectable leak.
Notes: Small leaks (up to 20 psi loss per 24 hours, or 0.83 psi/hr, from 2XCL + lines) can
be compensated for by using the autofill control. Leaks in excess of this must be
eliminated.
f. Switch autofill switch back to the on position.
g. Do not use tracer gas (i.e., refrigerant) for leak detection due to possible damage to
adsorber.
2. Purge the lines and chuck with nitrogen:
a. Disconnect the return port bayonet connector at the Polycold unit.
b. Purge the lines and chuck with nitrogen by turning on the nitrogen source and flowing
approximately 5 to 10 SCFM for 30 minutes.
c. Turn off nitrogen and reconnect the coolant gas outlet bayonet connector.
d. Fill unit with nitrogen to 70 - 90 psig.
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e. Verify that the return joint is leak-tight (pressure degrade or soap test, etc….)
3. Turn on refrigeration compressor and wait at least 30 minutes to allow refrigerant to achieve
equilibration inside the Polycold unit.
4. After the refrigeration compressor has run for at least 30 minutes turn on recirculation compressor
and wait at least 30 more minutes to allow the recirculating nitrogen to cool the chuck and the
vacuum jacketed lines.
5. Observe/record recirculation compressor pressure. It must be: 85 – 115 psig.
6. If the pressure is not as described in step above, then allow nitrogen to fill via the autofill control
until target pressure is achieved.
Required Tools and Recommended Accessories:

Nitrogen (dew point < -80° C, 70 - 90 psig)
PS1
Reset
Button
PS3
Reset
Button
Model 2XCL: Back of unit, cover removed
If the Chuck table does not achieve cold enough temperatures: Check the thermocouples with a Ktype thermocouple read-out meter. The temperatures during normal operation are:

Thermocouple connector at left-hand side, Chuck inlet (Polycold outlet temperature):
Temperature should be colder than –65º C.
Note: If the temperature is warmer than this, check the following specifications:

Refrigeration gauge during operation (suction pressure): 20 – 40 psig

Recirculating compressor gauge (discharge pressure): 85 – 115 psig
If the above readings are within specification tolerances, turn off the refrigeration compressor and
leave the N2 recirculating compressor on.
Turn off the refrigeration compressor and run the gas compressor for one hour. Alternately,
power-off the unit for at least 18 hours.

Refrigeration gauge when off and at ambient temperature (refrigerant “balance” pressure):
165 – 190 psi

Recirculation compressor gauge when off and at ambient temperature (gas circuit “balance”
pressure): 70 – 90 psig
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If the above readings are not within specification tolerances, it is necessary to call for
refrigeration service.
2.6 EMERGENCY OFF CIRCUIT
The EMO button provided on the 2XCL is a dry 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
customer’s system is shutdown.
3.0 OPERATION
CAUTION!
If dry GAS is not being pumped though the GAS circuit, the 2XCL will condense water in the
GAS circuit whenever the Polycold stack is cold. This can occur while waiting for the stack
to cool down (after turning on the 2XCL) and up to four hours after turning off the 2XCL as
well.
If the host equipment is sensitive to water, condensation can be avoided while not in use by
plugging the open end(s) of the GAS circuit, or allowing a small amount (about 5 SCFH) of
dry nitrogen to purge the GAS circuit.
ATTENTION!
The refrigeration compressor control circuit features a time delay to remote signals. After
sending a remote signal (on or off) to the refrigeration compressor, wait two minutes for this
action to take place.
3.1 INITIAL START-UP
1. Verify that the unit is hardwired or plugged in and that line voltage is present. “LINE” light on
the front of the unit will illuminate when the Main “ON/OFF” Rocker Switch (item 1 in “Unit
Features”) is in the on position.
2. Verify that the remote cable is connected to the remote connector on the back of the unit and
that the EMO loop connections are connected.
3. Verify that “GAS” and “COOLING WATER” connections have been established and are leakfree.
4. Verify that the “Fill Power” switch is in the “ON” position.
5. Switch the CB1, CB2, & CB4 switch to the “ON” position.
6. The unit should be operational. Functions can be monitored through the remote connector.
7. Turn on the refrigeration compressor via the remote. Observe the upper Refrigeration Gas
Pressure gauge (item 9 in “Unit Features”). It should show a drop in pressure. Initial pressure
should be between 165 and 190 psi. Note initial pressure ________psi.
8. Wait approximately 30 minutes for the Refrigeration Unit portion of the unit to reach operating
temperature.
9. Turn on the gas compressor via the remote.
10. If the system does not start, see Section 6. “Troubleshooting”.
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3.2 BAKE-OUT AND POST BAKE COOLING
It is the responsibility of the operator/integrator to allow sufficient time after a bake-out cycle to bring the
2XCL down to temperature slowly, without subjecting the components of the integrated unit to thermal
shock or stresses, which can cause premature failure.
After a bake-out cycle, operate the gas compressor only until the return temperature is < 32° C; then turn
on the refrigeration chiller. User must control rate of chuck cooling so that it remains within the
specification limits of the chuck.
3.3 RESETTING SAFETY INTERLOCKS AFTER FAULT
First, try to determine the reason behind the fault condition and affect the proper remedy. In normal
operation the protective devices should not be triggered. However, should the need arise, these devices
can be reset. (See interlock descriptions in Section 1.6). Refer to the following illustrations.
PS1 Reset
Switch
Reset Switches
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PS3 Reset
Switch
4.0 INSPECTION & MAINTENANCE
Inspect the Cool Solutions® 2XCL every six months or whenever moisture accumulates in the gas circuit,
whichever occurs more often.
1.
Verify 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 29C (85F).
2.
Verify that the insulation on the “GAS-OUT” line is adequate.
The insulation should be airtight. It should not be cracked or holding moisture. If necessary,
disconnect power to the 2XCL and replace the insulation. (See Section 2.4 “Install the External
GAS Circuit.”)
3.
Verify that the refrigerant circuit does not have a leak.
Disconnect power to the 2XCL and wait 24 hours.
The balance pressure should be within 7 psig of the pressure recorded in Section 2.3, “Inspect
and Install the 2XCL,” Step #1. If the pressure is lower, the refrigerant circuit may have a leak.
4.
Remove moisture from the GAS circuit.
Moisture may accumulate in the GAS circuit and will freeze when the 2XCL is operating, which
may restrict GAS flow.
To purge moisture from the gas line, follow the instructions in Section 2.5 of this document. Allow
the GAS supply from the host equipment to flow (at about 50 SCFH) through the GAS circuit until
the exiting GAS is dry. The exiting GAS should be dry in about 10 minutes.
CAUTION!
If the host equipment is sensitive to water, condensation can be avoided while the system is
not in use by plugging the open end(s) of the GAS circuit, or allowing a small amount (about
5 SCFH) of dry nitrogen to purge the GAS circuit.
825131-00 REV A
Page 44
5.
Adsorber (Molecular Sieve) Replacement
The adsorber must be replaced as a part of routine maintenance after every 10,000 hours of operation of
the Gas Compressor.
Replacement part numbers:
Polycold Part No# 840208-00
SHI-APD Part No# 460962
Mol. Sieve
1. Shut down system and allow N2 circuit to reach room temperature.
2. Vent gas using the refrigeration valve (V5) at the rear of the unit.
3. Remove external and internal covers to allow access to molecular sieve.
4. Loosen sieve inlet and outlet fittings.
5. Remove two (2) securing screws.
6. Remove adsorber.
7. Place new adsorber on bottom plate and secure with two (2) screws.
8. Connect inlet and outlet gas lines.
9. Charge with gas and check for leaks.
10. Replace covers and run unit.
825131-00 REV A
Page 45
5.0 DISCONNECTION, STORAGE, AND RESHIPMENT
1. The 2XCL should be transported using its original shipping materials. If these materials are
unavailable, please contact Polycold for support.
2. Shut down power to the 2XCL and allow the system to reach ambient temperature (allow 24 hours to
reach thermal equilibrium); or turn off the refrigeration compressor unit, and run the gas compressor
unit for one (1) hour to warm up the lines and the chuck.
3. Disconnect electrical power from the 2XCL system.
4. Disconnect the gas supply line.
5. Vent gas from the Gas Compressor Unit using the refrigeration valve (V5) at the rear of the unit.
6. After the gas has vented, disconnect the Coolant Gas Bayonet connectors (23, 24).
7. Cap the Bayonet connectors to prevent diffusion of moisture into the system.
8. Turn off the cooling water lines and disconnect.
9. Use compressed air to blow out remaining water from the lines.
10. Remove the insulated interconnection plumbing from the transport path of the 2XCL unit.
11. Verify that the casters are firmly affixed to the base of the 2XCL unit.
12. Raise the seismic anchor/jack screws so that the weight of the unit rests on the casters. Slowly
transport the unit to an area where it can be lifted onto the pallet.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or
death. Read the manual before moving this equipment using the casters. Move the
equipment slowly and avoid rapid acceleration and deceleration. Apply force to move the
system below the equipment center of gravity. Do not place yourself between the moving
equipment and fixed obstructions.
825131-00 REV A
Page 46
13. Using the eyebolts on the top of the 2XCL unit, lift the system, and, depending on the crate design,
remove its seismic anchor/jacks screw.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Over-tipping (leaning) this device may cause it to fall over resulting in severe injury or death.
The equipment should be removed from its shipping pallet by using the top installed lifting
eyes.
WARNING!
LIFTING HAZARD (900 pounds (400 kg))
Failure to properly lift this device may result in severe injury or death.
Read the manual before lifting this equipment using the lifting eyes. Assure that the eyes
are fully engaged in the frame with no exposed threads. Use all four lifting eyes with an
adequate lifting harness and mechanism. Lifting harness must be centered between the
lifting eyes. Lift vertically only with no horizontal component.
14. Lower the 2XCL unit onto its original shipping pallet. Verify that the casters carry no weight when the
unit is in the crate. Failure to do so may cause damage to the casters and void your warranty.
Assemble the crate around the 2XCL unit and transport to its new location.
825131-00 REV A
Page 47
6.0 TROUBLESHOOTING
CAUTION!
If dry GAS is not being pumped though the GAS circuit, the 2XCL will condense water in the
GAS circuit whenever the Polycold stack is cold. This can occur while waiting for the stack
to cool down (after turning on the 2XCL) and up to four hours after turning off the 2XCL as
well.
If the host equipment is sensitive to water, condensation can be avoided while not in use by
plugging the open end(s) of the GAS circuit, or allowing a small amount (about 5 SCFH) of
dry nitrogen to purge the GAS circuit.
ATTENTION!
The refrigeration compressor control circuit features a time delay to remote signals. After
sending a remote signal (on or off) to the refrigeration compressor, wait two minutes for this
action to take place.
Contact your local sales representative or the Brooks Automation Service Department if you
need any assistance troubleshooting or repairing your 2XCL. Be sure to do this if the
compressors have an internal problem, if the refrigerant circuit has a leak, or if the cooling
water circuit is obstructed. Also, see Section 3.3 for resetting safety limit switches.
825131-00 REV A
Page 48
6.1 GENERAL TROUBLESHOOTING MATRIX
Problem
Unit does not start, and there are
no indicating lights illuminated on
the unit.
Possible Cause
EMO tripped on user system or
2XCL
No power to system.
Inadequate power to system.
Compressor(s) do not start (and
make(s) no noise).
No electrical power
If CB4 stays in the “ON” position,
verify the following:
 Refrigeration Unit has power.
 Power supply is adequate.
 CB1 and CB2 are in the “ON”
position, CB3 is not tripped.
Corrective Action
Determine if EMO is tripped, if
this is the reason, make sure it is
safe; then reset and restart the
system.
Confirm that upstream power
source is adequate. Reconnect
the equipment. Apply power.
Correct power problem and
supply adequate power to the
equipment. For power
requirements, see table B in
Polycold’s 825105 Customer
Instruction Manual.
Check that power source is on
and the power cord is connected.



If CB4 has tripped to the “OFF”
position, verify the following:
 Power supply is adequate.


Unit has power and both
Refrigeration and Gas
compressors are not operational.
Customer user interface not
connected properly.
Confirm that the EMO switch
is in the extended (normally
closed) position.
EMO switch on the 2XCL
and the user system is in the
correct (ON) position.
Correct power problem and
supply adequate power to
the equipment. For power
requirements, see table B in
Polycold’s 825105 Customer
Instruction Manual.
Verify transformer is wired to
correct taps. See section
2.2, step 7 in Polycold’s
825105 Customer Instruction
Manual.
If power is within
specification, wired correctly,
and breaker is tripping, call
your certified service agent
or Polycold.
Disconnect user interface and
install remote jumper; if
compressors start, troubleshoot
tool side of user interface. If
either compressor fails, see
section 6.2 or 6.3.
Refrigeration compressor not
operating, Gas compressor is
operating.
See section 6.2.
Gas compressor is operating,
Refrigeration compressor is not
operating.
See Section 6.3.
825131-00 REV A
Page 49
Problem
Refrigeration and Gas
compressor both operating but
cooling is inadequate.
Possible Cause
Line obstruction or Autofill not
working (See section 6.5).
Corrective Action
Verify nitrogen source is dry (dew
point of –80° C or less.
Verify nitrogen suction pressure
is greater than 12 (i.e., red
Autofill led reads 12 or minimum
Autofill setting. See section 3.4)
and nitrogen discharge pressure
is less than 140. Check
evidence of flow via mechanical
flow meter on front panel of unit.
(AND) Nitrogen flow has been
checked and is OK.
Incorrect vacuum jacked lines.
Gas supply temperature
incorrect.




Compressor hums or starts, and
then stops.
2XCL makes unusual noises.
825131-00 REV A
Inlet gas flow is not within
specification.
Gas circuit has a leak.
Water circulation through
the condenser is
inadequate.
The refrigerant circuit has a
leak.
Electrical connections may be
out of phase.
The circuit breaker may have
been triggered, or the thermal
overload protector on the
compressor may be cycling the
compressor on and off.
Verify the following:
 The compressor(s) are not
overheating.
 The power supply (voltage) is
adequate.
Verify the following:
 There are no loose parts.
 A tube is not rubbing or
rattling against another
surface.
Page 50
Check against tool OEM
specifications.
 Check gas supply
temperature; if colder than
–70°, check Chuck heater
control.
 If warmer than –70° and
refrigeration compressor has
been in operation for greater
than one hour, record
refrigeration suction pressure
and call your certified service
agent or Polycold.
See Polycold manual 825105
section 4.0 Inspection &
Maintenance.
Check for phase error signal on
LCD display.
Verify the supply voltage meets
specification (see Table B) and
that the transformer taps are
properly configured (see section
2.2 step 7).
Look for loose parts and / or
other conspicuous tubes or
rattling components.
6.2 REFRIGERATION COMPRESSOR FAULT MODES
Indicator Lamps Based Troubleshooting Matrix (Normal Modes)
REFRIGERATION UNIT
STATIC MODE 1 (UNIT NOT RUNNING
- NO LINE POWER PRESENT)
INDICATOR
COLOR
STATUS
LINE
YELLOW
OFF
RUN
GREEN
OFF
FAULT
RED
OFF
POWER
OFF
CB4 = NA, CB1 & CB2 = ON
REFRIGERATION UNIT
STATIC MODE 2 (UNIT NOT RUNNING – LINE POWER PRESENT AND MAIN ON/OFF
SWITCH FOR GAS COMPRESSOR IS IN ON POSITION – REFRIGERANT COMPRESSOR
REQUIRES USER REMOTE SIGNAL TO START)
INDICATOR
COLOR
STATUS
LINE
YELLOW
ON
RUN
GREEN
OFF
FAULT
RED
OFF
POWER
OFF
CB4 = ON, CB1 & CB2 = ON
REFRIGERATION UNIT
RUN MODE (UNIT RUNNING - SYSTEM OK)
INDICATOR
COLOR
STATUS
LINE
YELLOW
ON
RUN
GREEN
ON
FAULT
RED
OFF
POWER
ON
CB4 = OFF, CB1 & CB2 = ON
825131-00 REV A
Page 51
Indicator Lamps Based Troubleshooting Matrix (Fault Modes)
REFRIGERATION UNIT
FAULT MODE 1 (NOT RUNNING – PRESS/TEMP TRIP OCCURRED)
INDICATOR
COLOR
STATUS
LINE
YELLOW
ON
RUN
GREEN
OFF
FAULT
RED
OFF
POWER
OFF
CB4 = ON, CB1, CB2 & CB3 = ON
REFRIGERATION UNIT
FAULT MODE 2 (NOT RUNNING - CIRCUIT BREAKER CB4
TRIPPED)
INDICATOR
COLOR
STATUS
LINE
YELLOW
ON
RUN
GREEN
OFF
FAULT
RED
OFF
POWER
OFF
CB4 = OFF, CB1, CB2 and CB3 = ON
REFRIGERATION UNIT
FAULT MODE 3 (NOT RUNNING - COMPRESSOR OVERLOAD TRIPPED)
INDICATOR
COLOR
STATUS
LINE
YELLOW
ON
RUN
GREEN
OFF
FAULT
RED
OFF
POWER
OFF
CB4 = ON, CB1, CB2 and CB3 = ON
825131-00 REV A
Page 52
REFRIGERATION UNIT
FAULT MODE 4 (UNIT NOT RUNNING – LINE POWER PRESENT AND MAIN ON/OFF
SWITCH FOR GAS COMPRESSOR IS IN ON POSITION – CIRCUIT BREAKER CB3 IS
TRIPPED
INDICATOR
COLOR
STATUS
LINE
YELLOW
ON
RUN
GREEN
OFF
FAULT
RED
OFF
POWER
OFF
CB4 = ON, CB1 & CB2 = ON CB3= OFF
6.2.1 REFRIGERATION UNIT INDICATOR LAMP FAULT CONDITIONS EXPLAINED
Problem
STATIC MODE 2
Refrigeration compressor is not
working AND CB4 is ON and
Line light is ON.
Possible Cause
Timer delay relay is still active.
Corrective Action
Wait two minutes for timer to
time-out.
Check timer relay settings if on
delay is in excess of 2 minutes.
User remote signal not provided.
Verify user remote signal is
provided on pins 1 and 2.
If user remote fails to start
compressor but the remote
jumper does, inspect condition
of pins 1 and 2 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 function of the
integrating equipment (in the
event of unit fault resulting in
control-interrupt latching).
825131-00 REV A
Page 53
Problem
FAULT MODE 1: Refrigeration
compressor not working, CB4 is
ON AND fault light is ON.
Possible Cause
Refrigerant Pressure Switch (High Side)
(PS1) is tripped due to:
 Excess load
Corrective Action
PS1 is a latching switch –
Manual reset required.
Excess load:
Verify nitrogen compressor
pressures (typically 19 – 23 psi
during operation – lower values
used with long lines) are within
control parameters of autofill
control (see sections 6.4 to
6.8). If not, troubleshoot autofill
control.
Verify gas return temperature is
below 32° C. During post bakeout, the gas compressor can be
used, but the refrigeration
compressor must remain off
until the return temperature is
below 32° C).
 Cooling water flow or temperature
out of specification
Verify cooling water flow and
temperatures are within
specifications of Table C.
 Problem with refrigerant charge
Verify condenser has not
accumulated excessive scale.
Call your certified service agent
or Polycold.
Refrigerant Pressure Switch (Low Side)
(PS4) is tripped due to:
 Loss of refrigerant charge
PS4 is a non-latching switch.
Call your certified service agent
or Polycold.
Before calling, turn on the gas
compressor for 30 minutes to
warm the refrigerant system.
Record the refrigerant suction
pressure and check against
installation records.
Temperature switch trip (TS1)
 Cooling water flow or temperature
out of specification
TS1 is a non-latching switch
Verify cooling water flow and
temperatures are within
specifications of Table C.
Verify condenser has not
accumulated excessive scale.
825131-00 REV A
Page 54
Problem
FAULT MODE 2:
Refrigeration compressor not
working AND CB4 is OFF.
FAULT MODE 3:
Refrigeration compressor not
working AND CB4 is ON AND
the Fault light is not lit, AND
CB1, CB2 and CB3 are on.
Possible Cause
Incorrect voltage or transformer tap
configuration.
Corrective Action
Verify the supply voltage meets
specification (see Table B) and
that the transformer taps are
properly configured (see
section 2.2, step 7).
Internal short in high voltage wiring.
Call your certified service agent
or Polycold.
Locked rotor condition.
Call your certified service agent
or Polycold.
Incorrect voltage or transformer tap
configuration.
Verify the supply voltage meets
specification (see Table B) and
that the transformer taps are
properly configured (see
section 2.2, step 7).
Internal motor failure.
The internal overload is a
non-latching switch.
Call your certified service agent
or Polycold.
FAULT MODE 4:
Refrigeration compressor not
working AND CB4 is ON AND
the Fault light is not lit AND
CB3 is Off.
825131-00 REV A
Electrical short in the safety circuit.
Page 55
Call your certified service agent
or Polycold.
6.3 GAS COMPRESSOR UNIT (HC-10) FAULT MODES
Circuit breakers and LCD Display:
LCD Display
CB1
CB2
CB3
CB4
Gas compressor cycling: If the gas compressor cycles on and off without any indicated fault, reset
circuit breaker 2 (“CB2”).
825131-00 REV A
Page 56
6.3.1
GAS COMPRESSOR UNIT TROUBLESHOOTING MATRIX
Problem
Gas compressor
not working AND
CB1 AND/OR CB2
are OFF.
Possible Cause
Overcurrent in control
circuit or compressor
current.
Corrective Action
Verify the supply voltage meets specification (see
Table B) and that the transformer taps are properly
configured (see section 2.2, step 7).
Call your certified service agent or Polycold.
Verify the supply voltage meets specification (see
Table B) and that the transformer taps are properly
configured (see section 2.2, step 7).
Gas compressor
not working (Run
light is OFF); CB1,
CB2, and CB3 are
ON; AND there are
no faults codes
displayed on the
LCD.
Gas compressor
runs with remote
jumper but NOT
with tool remote
signal.
Call your certified service agent or Polycold.
Remote/Control Signal not
present.
Verify user remote signal is provided on pins 5 and
6.
Damaged pins on remote
connector.
If user remote fails to start compressor but the
remote jumper does, inspect condition 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 function of the
integrating equipment (in the event of unit fault
resulting in control-interrupt latching).
“PHASE SEQ
ERROR” ON LCD
Display.
Wrong phase for power.
This fault is electronically latched. To reset,
cycle CB1.
Provide clockwise rotation for the supply power.
825131-00 REV A
Page 57
Problem
“MOTOR TEMP
ERROR” ON LCD
DISPLAY
Possible Cause
One of several faults are
possible see below:
“MOTOR TEMP
ERROR” ON LCD
DISPLAY.
Excess gas discharge
pressure due to:
PS3 is latched electronically and mechanically
– Requires manual reset and reset of CB1.
Excessive flow.
Scroll through LCD display – verify that no other
faults are present.
Due to:
Hi Pressure (PS3)
Fault.
Corrective Action
Flow restriction in line.
If no other faults present, follow the steps below:
1. Vent gas to achieve 0 psi using the refrigeration valve (17) at the rear of the unit.
2. Press the green switch on “PS3” to reset it.
RESET SWITCH
for PS3
3. Fill the gas system with a fresh charge of dry gas (70 psig min., 90 psig max.).
4. Restart the system, and if the high pressure switch trips, check for restrictions in the customer
installed lines.
825131-00 REV A
Page 58
6.3.1 GAS COMPRESSOR UNIT TROUBLESHOOTING MATRIX (CONTINUED)
Problem
“MOTOR TEMP
ERROR” ON LCD
DISPLAY.
Possible Cause
Low suction pressure in gas
line due to:
Corrective Action
PS2 is latched electronically – reset “CB1” to
clear fault (after resetting switch).
Scroll through LCD display – verify no other faults
are present.
due to:
Low Pressure
(PS2) Fault.
To reset the switch, the nitrogen pressure must be
raised above 70 psi then cycle CB1 to reset
electronics.
Low nitrogen charge/gas
leaks.
With gas compressor off check the recirculating
gas pressure gauge (item 8) which should show a
minimum pressure of 70 psi. If below 70 psi, check
for:
 Adequate nitrogen fill source (70 psi
minimum)
 Leaks in lines
Mechanical obstruction in
line.
Kinked lines or other obstructions in line.
Verify nitrogen supply meets required dryness (dew
point < -80° C).
(Note: Small leaks can be compensated for with
the internal autofill control switches (33) on and
PS5 (32) set properly (see section 7.6) verify gas is
connected to gas fill port (22) and that its supply
pressure is adequate; verify customer installed
lines are not blocked.
“Water Temp Err”
OR
“Water Flow Err”
Autofill control malfunction.
See autofill troubleshooting section 6.4 and 6.5.
Incorrect water flow or
temperature caused TS3 or
TS4 to trip.
TS3 and TS4 are electronically latched (after
resetting switch).
ON LCD DISPLAY
(and compressor
runs).
Scroll through LCD display to verify that no other
faults are present. If fault(s) present, determine
which one(s) occurred.
To reset, allow 30 minutes for thermostats to cool
and reset. Then cycle CB1 to reset electronics.
Verify water flow and temperature are within
specification (see Table C).
825131-00 REV A
Page 59
Problem
LCD reads “Helium
Temp-ERR”
Possible Cause
Excessive discharge
temperature at gas
compressor.
Corrective Action
This fault is electronically latched. To reset
cycle CB1.
Verify proper operating pressures for gas
compressor (suction pressure of 12 psi to 25 psi,
discharge of 70 psi to 130 psi).
Verify water flow and temperature are within
specification (see Table C).
System shutdown;
LCD reads “Motor
Amps-ERR”.
Oil has been pumped from
the coolant loop to the
compressor’s lower sump.
Try to restart the compressor two times. If it does
not start, check the oil level in the upper sight glass
of the compressor. Oil should be visible after the
compressor has been operating for 15 minutes.
Contact Polycold Service if the oil is not visible.
Compressor motor high
current switch opened.
This fault is electronically latched. To reset
cycle CB1.
If water and power checks indicate utilities are
within specifications, interlocks may be faulty.
Consult Polycold Service.
This fault is electronically latched. To reset,
cycle “CB1” and then press the three round
buttons simultaneously. If more than two resets
are required, contact Polycold Service.
LCD reads “Locked
Rotor-ERR”
Loss of one power phase.
Verify that voltage for each leg meets the Power
requirements indicated in Table B.
Compressor has shutdown
on three (3) Motor AmpsERR.
Do not attempt to restart. Consult Polycold
Service.
LCD reads “MicroERR”
Microprocessor internal
diagnostics as required.
Consult Polycold Service.
Intermittent
operation.
Compressor is cycling on
and off.
Check input power, coolant flow, and temperature.
Compare with Specifications.
Loss of
refrigeration
capacity
Compressor malfunction.
Check input power, coolant flow and temperature.
Compare with Specifications.
Compressor shuts
down, LCD display
is blank, circuit
breaker is closed.
Fu1 or Fu2 fuse is blown.
Contact Polycold Service to have a qualified
electrical technician replace the fuse inside the
electrical enclosure.
System shuts
down, no error
message on LCD.
Fu4, Fu5, or Fu6 fuse is
blown.
Contact Polycold Service to have a qualified
electrical technician replace the fuse inside the
electrical enclosure.
825131-00 REV A
Page 60
6.3.2 ADDITIONAL INFORMATION ON LCD FAULT CONDITIONS
Restarting After a Power Failure
When the power comes on, the microprocessor will determine if the last shutdown was due to a power
outage. If the operator turns off the system by the main breaker, it will be detected as a power outage. If
the compressor power was interrupted by a power outage, the compressor and the shield cooler will
restart automatically after a one (1) second delay.
If the compressor stops for other reasons, compressor troubleshooting is required.
System Status Display
Normal conditions: When all systems are operating normally, with no system errors, the following lines
are displayed on the LCD in the order listed below by scrolling the display. Press the DISPLAY button
to scroll the LCD. Scrolling past the bottom of the display will start back at the top and repeat. If the
DISPLAY button is pressed and not pressed again after 30 seconds, the display will return to the first
line (ET).1
Elapsed time in hours to one decimal place
“Helium Temp-OK”
“Water Temp-OK”
“Water Flow-OK”
“Motor Temp-OK”
“Phase Seq (sequence)-OK”
“Motor Amps-OK”
“Locked Rotor-OK”
“Micro-OK”
Error conditions: If a system error occurs that causes an alarm or shutdown condition, the monitor point
(as listed above) will change from “OK” to “ERR” and that monitor point will be scrolled to the top for
display.
When the operator manually scrolls the display, any point that has not failed will continue to display “OK”.
If additional points fail before the operator resets the first error(s), the latest point to fail will change from
“OK” to “ERR” and will be scrolled to the top for display. In this way, the operator will see the most recent
fault displayed on the LCD and, by manually scrolling the display, can see other error conditions that lead
up to the latest.
Clearing Error Conditions
The preferred reset method is to cycle “CB1”. Alternatively, the faults can be cleared by pressing the
“ON” and “DISPLAY” buttons simultaneously.
Restarting after an Error Condition
When the shut-down is caused by any of the high-temperature switches, the compressor will restart only
after it has cooled enough for the switch to close. After waiting for the compressor to cool, clear the error
message then push the ON button to restart. Should the compressor fail to start, allow more cooling time.
Repeat the restart procedure. Check cooling water temperature and flow. Compare with Specifications.
The motor high winding temperature relay automatically resets after the compressor shuts down and the
relay cools. This typically takes about 30 minutes. To restart the compressor, clear the error message, and
then push the “ON” button. If the compressor fails to start, allow more cooling time. Repeat the restart
procedure.
1
Note: The display refers to helium. For this system, all messages showing helium refer to the nitrogen
gas being used.
825131-00 REV A
Page 61
6.4 AUTOFILL TROUBLESHOOTING BASICS
1. Verify the nitrogen supply pressure is in the correct range, 70 – 90 psi.
2. Verify that the auto-refill switch is ON and the red display illuminates on the SMC pressure switch.
3. Verify that the SMC pressure switch does not blink. If it does, turn off auto-refilll switch for 1-2 minutes
then turn it back on. If it is still blinking, remove one lead on the coil of the auto-refill solenoid valve.
If it stops blinking, replace the coil.
4. Verify that the SMC pressure switch setting is correct.
a. Push and hold the set button for more than two seconds; then release it. The display should
show “PSI”. Push the set button again. If “PSI” is NOT shown, push the left or right scroll
button until “PSI” is displayed; push the set button again.
b. The display should show “1nC.” If not, push the left or right scroll button until the display
shows “1nC.” Then, push the set button.
c.
The display should show “2nC.” If not, push the left or right scroll button until the display
shows “2nC.” Then push the set button.
d. The display should show “768.” If not, push the left or right scroll button until the display shows
“768”. Then push the set button.
_
e. The display should show “ n A n .” If not, push the left or right scroll button until the display
_
shows “ n A n ”. Then push the set button.
f.
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 > n_2 > n_3 > n_4 > 8. If not, push the left or right
scroll button to desired valve, and then push the set button.
g. See section 7.6 in Polycold’s 825105 Customer Instruction Manual for reprogramming
instructions.
825131-00 REV A
Page 62
6.5 AUTOFILL TROUBLESHOOTING MATRIX
Problem
Unit does not fill
during initial nitrogen
fill.
Possible Cause
Incorrect N2 fill pressure.
There may be loose wiring
somewhere.



Unit continues to fill;
LCD reads “OVER
RESET VALUE”
during initial nitrogen
fill.
Bad solenoid valve or SMC.
Unit does not refill
during a run.
Bad solenoid valve or SMC.
Loose wiring in the system.




Unit continues to fill;
LCD reads “OVER
RESET VALUE”
during a run.
Loose wire, bad solenoid
valve or SMC.



Red LED display is
flashing, Autofill
function not working.

Corrective Action
Make sure 70-90 psi is supplied at gas fill line.
Open the E-box and check to see if relay #6 is
lighted. If it is, check the autofill solenoid valve
to feel whether its coil is warm. If the coil is
warm, and there is no nitrogen filling, replace
the solenoid valve. If the coil is not warm,
check its input voltage. If it is 24V, replace the
coil. If it is zero, check to see if there is loose
wiring somewhere.
If relay #6 is dim, check the green indicator on
SMC. If it is ON, check the voltage between
the Black and Brown lead of the SMC. If the
voltage is zero, the SMC is bad.
Check the status of relay #6. If it is dim, check
the autofill solenoid valve; feel its coil to see if it
is warm. If the coil is cold, but unit continues
filling, replace the solenoid valve.
If relay #6 is lighted, check the green indicator
of SMC. If it is OFF but the voltage between
the Black and Brown lead is 24VDC, the SMC
is bad.
Check to see if relay #5 is lighted. If it is, check
the autofill solenoid valve to feel whether its
coil is warm. If the coil is warm, but no nitrogen
filling occurs, replace the solenoid valve. If the
coil is not warm, check its input voltage. If it is
24V, replace the coil. If it is zero, check to see
if there is loose wiring somewhere.
If relay #5 is dim, check the red indicator on
SMC. If it is on, check the voltage between the
White and Brown lead. If the voltage is zero,
the SMC is bad. If it is 24 V, check to see if
there is loose wiring somewhere.
Check whether relay #4 has been energized. If
not, there is a loose wire. If it is energized,
continue to next bullet.
Check the status of relay #5. If it is dim, check
the autofill solenoid valve to feel whether its
coil is warm. If the coil is cold, but nitrogen
filling continues, replace the solenoid valve.
Otherwise, continue to next bullet.
If relay #5 is lighted, check the red indicator of
the SMC. If it is off, but the voltage between
the White and Brown lead is 24 VDC, the SMC
is bad.
Cycle power for Autofill on / off switch. Also
cycle “CB2”.
See section 9.0 for detailed Autofill schematic
825131-00 REV A
Page 63
6.6 AUTOFILL STATUS TABLES
1) Initial Fill
SMC Pressure (p)
Green Indicator on SMC
Red indicator on SMC
Relay #4
Relay #5
Relay #6
Autofill Solenoid Valve
p < n3
On
On
Off
On
On
On
n3 < p < n1
On
Off
Off
Off
On
On
2) Idle (unit has been filled but nitrogen compressor is off)
SMC Pressure (p)
Green Indicator on SMC
Red indicator on SMC
Relay #4
Relay #5
Relay #6
Autofill Solenoid Valve
p < n2
On
Off
Off
Off
On
On
p >= n1
Off
Off
Off
Off
Off
Off
3) Run (unit has been filled and nitrogen compressor is on)
SMC Pressure (p)
Green Indicator on SMC
Red indicator on SMC
Relay #4
Relay #5
Relay #6
Autofill Solenoid Valve
825131-00 REV A
p < n4
On
On
On
On
On
On
p >= n3
On
Off
On
Off
On
Off
Page 64
p >= n1
Off
Off
Off
Off
Off
Off
6.7 AUTOFILL RELAYS AND SOLENOID VALVE
2XCL Autofill Relays and Solenoid Valve
Relay #4
Relay #6
Relay #5
Solenoid Valve
825131-00 REV A
Page 65
6.8 ADJUSTING AUTOFILL CONTROL SETTINGS
This section describes how to adjust the settings of the autofill controller (PS4).
CAUTION!
INCORRECT ADJUSTMENT MAY RESULT IN UNIT FAULTS
Do not adjust these settings unless specifically authorized by the tool manufacturer.
Contact the tool manufacturer before making any control setting adjustments.
The controller has been factory set with the following settings:
Unit of measure = psig
Set-point when gas compressor off (n2): 70 psig.
Reset-point when gas compressor off (n1): 75 psig.
Set-point when gas compressor on (n4): 19 psig.
Set-point when gas compressor on (n3): 23 psig.
Even when not powered, the controller will retain these settings for 5 – 10 years. Readjustment is not
needed under normal circumstances. Do not adjust these settings unless specifically authorized by the
tool manufacturer. Failure to do so may result in tool down-time.
Procedure to verify Pressure Switch Set-up
1. Turn on the auto refill On/Off switch. Red display on SMC should illuminate.
2. Push set button for more than 2 seconds. Display should show “PSI”, push set button. If
not, push the left or right scroll button until display “PSI”, then push set button.
3. Display should show “1nC”. If not, push the left or right scroll button until display “1nC”.
Push set button.
4. Display should show “2nC”. If not, push the left or right scroll button until display “2nC”.
Push set button.
5. Display should show “768”. If not, push the left or right scroll button until display “768”.
Push set button.
_
6. Display should show y “ n A n ”. If not, push the left or right scroll button until display
_
“ n A n ”. Push set button.
7. Push set button for less than 2 seconds. Display should show “n_1” and “75”. If it is not
“75”, push the left or right scroll button until display “75”. Push set button.
8. Display should show “n_2” and “70”. If not “70”, push the left or right scroll button until
display “70”. Push set button.
9. Display should show “n_3” and “23”. If not “23”, push the left or right scroll button until
display “23”. Push set button.
10. Display should show “n_4” and “19”. If not “19”, push the left or right scroll button until
display “19”. Push set button.
825131-00 REV A
Page 66
7.0 APPENDIX
7.1 BRAZING SPECIFICATION
Tools and materials needed:
Tubing cutter
Reamer
Sand paper or wire brush or steel wool
Pressure or flow regulated dry nitrogen GAS
Oxy-acetylene torch or air-acetylene torch (propane is not hot enough)
For copper-to-copper joints:
Harris Dynaflow® or Handy & Harman Sil-Fos 6M® or equivalent alloy
For copper-to-stainless steel or copper-to-brass joints:
Harris Safety-Silv 56® or Handy & Harman Braze 560® or equivalent silver alloy
Harris Stay-Silv® black flux or Handy Flux type B-1 or equivalent
Note: Brazing operations must be performed by qualified technicians.
1. Thoroughly clean all mating surfaces to bare metal.
2. Purge the tubes with dry nitrogen GAS while brazing and until the tubes and joints have
cooled to below 190C. (This prevents internal scale formation or oxidation.)
3. Remove all excess flux from the brazed joints. Use a wet rag while the brazed joint is still
hot.
4. Dispose of the contaminated waste in a manner approved by the location.
5. Carefully inspect each joint for the proper flow of the brazing alloy (both surfaces should be
“wetted” by the alloy).
6. Carefully check all joints for leaks.
825131-00 REV A
Page 67
7.2 THERMOCOUPLE ATTACHMENT SPECIFICATION
Tools and materials needed:
Type K Thermocouple wire
Thermal wire strippers
Tools and materials needed for soldering:
Sand paper
Propane torch
Rosin flux
Harris Bridgit® or equivalent lead-free solder
Neutralizing agent (to remove the flux)
Note: Brazing operations should be performed by qualified technicians only.
1. Thoroughly clean all mating surfaces to bare metal.
2. Purge the tubes with dry nitrogen gas while brazing and until the tubes and joints have cooled
to below 190º C.
3. Remove half an inch (13 mm) of insulation from one end of the thermocouple wire and twist
the two wires together.
4. Apply flux and pre-tin the twisted wires.
5. Use sand paper to remove oxidation from the copper tube.
6. Apply flux and pre-tin the tube.
7. Apply flux to the pre-tinned wires and to the pre-tinned copper tube.
8. Position the thermocouple wire so that the first twist of wire (nearest the insulation) is against
the tube.
Note: Make certain the wire twist closest to the insulation is in contact with the copper tube.
(It is the first twist of wire closest to the insulation that senses and determines the
temperature reading.)
9. Solder the wire twist to the copper tube. Do not overheat the flux. Do not melt or cut the
plastic insulation on the thermocouple wire- it 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 tie wrap(s) or tape suitable for ultra-low temperatures. Allow enough
thermocouple wire to reach your temperature meter.
14. Apply insulation per Section 2.5 “Install the External GAS Circuit”.
825131-00 REV A
Page 68
7.3 SPECIFICATIONS
Dimensions:
See Figure 3 and Figure 4
Shipping Weight:
Based on 200 lb for wooden crate
~ 910 lbs (413 kgs)
Installed Weight :
~ 710 lbs (322 kgs)
(max 230 lbs (104 kgs) / leveling foot)
Electrical Requirements, 5300 W
Required circuit breaker:
Acceptable Voltage Range:
60 Hz:
440V
16 A
480V
16 A
396V -484V
432V -528V
GAS-In & GAS-Out Lines:
½” x 6” Linde Bayonet connectors
Water Temperature:
15C – 30C
Cooling Water Required:
10 gpm @ 25 – 30 C, 6 gpm @ 15 – 25 C
Cooling Capacity:
490W at -40°C Chuck Outlet Temperature and 20 scfm gas
flow
Noise Emissions (SPL):
74.5 dB(A)
Ambient Temperature:
10º C to 35º C
Ambient Humidity:
10 to 85% RH (maximum dew point 27º C)
Altitude:
0 to 3000 m
Voltage Fluctuation:
Complies with Semi F-47, survives 1 second loss of power
without unit tripping circuit breakers (single occurrence)
Over voltage category per EN 61010-1:
Category 2
7.4 DESIGN DATA
Balance Pressure:
175 – 205 psig
GAS Flow Rate Range:
18 – 24 SCFM
Approximate Heat Rejection Rate:
8500 W (29,000 BTUH)
Accessories & Refrigerant
Charges:
The refrigerant charge for your unit is specified on the unit
nameplate. Contact your local sales representative or
Polycold for a current price list.
CONVERSION FACTORS & FORMULAS
F = (9/5 x C) + 32
1 psig = 0.07 bar = 0.07 kg/cm
1 inch = 2.54 centimeters, exactly
C = 5/9 (F  32)
1 pound = 0.45 kilograms
1 standard cubic foot per hour (SCFH) = 0.47 standard liters/minute
825131-00 REV A
Page 69
7.5 INSTRUCTIONS FOR INSTALLATION OF SEISMIC ANCHOR/JACK
SCREWS
This procedure describes installation of the seismic anchor/jack screws on Polycold’s Cool Solutions®
2XCL (PGCL-1) and 2XCL (PGCL-2) models. *Note: Option shown has seismic anchor/jack screws 1 ea
all 4 sides. Some options have 2 ea front and rear.
1. Remove the four panels (front, two sides, and lower back).
825131-00 REV A
Page 70
2. Lift the unit up about 18 inches (0.5 meters) off the ground using a forklift, lifting hooks, and a harness.
WARNING!
LIFTING HAZARD (900 pounds (400 kg))
Failure to properly lift this device may result in severe injury or
death
If lifting using the lifting eyes (shown below):
Assure that the eyes are fully engaged in the frame with no exposed
threads. Use all four lifting eyes with an adequate lifting harness and
mechanism. Lifting harness must be centered between the lifting eyes.
Lift vertically only with no horizontal component.
If lifting from the bottom using a forklift, use only appropriate equipment,
operated by trained employees. Strap the unit to the vertical back
support of the forklift to prevent the unit from tipping over when on the
forks.
825131-00 REV A
Page 71
3. Install threaded rod in front of unit. Locate opening on bottom side of frame centered in the front
labeled “Seismic Anchor Point”. Identify end of threaded rod with machined flats. This is the
Insert top of threaded rod from below and thread up through frame until flats are exposed. Install
onto bottom of threaded rod. Use a wrench on the pad and the flats to tighten. Thread leveling
higher up so that the pad will not contact the floor when the machine is lowered to the ground.
and
top.
pad
foot
4. The remaining seismic anchor/jack screws can be installed with the unit on the floor, supported by the
casters. Place the unit on floor and remove forklift or lifting harness.
825131-00 REV A
Page 72
5. Screw in other three seismic anchor/jack screws from top and put the pad from bottom. For these
seismic anchor/jack screws, thread the rod in from the top, keeping machined flats at top. After
threading the rod though the frame and with about two inches of exposed thread below the frame,
install pad. Use a wrench on the pad and the flats to tighten.
825131-00 REV A
Page 73
6. Position the unit where it will be installed. Lower each of the four seismic anchor/jack screws to the
floor. Turn each leveling foot by one turn. DO NOT extend jack screw to point where caster will spin.
Verify that the unit is secure and will not roll. If not, add one more turn to each leveling foot. Repeat
as needed until unit is secure and will not roll.
WARNING!
TIPPING HAZARD, HIGH CENTER OF GRAVITY, LESS THAN 10º MAX TILT ANGLE
Maintain weight on casters at all times.
7. Reinstall panels after installing all seismic anchor/jack screws.
825131-00 REV A
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: portion of the refrigerant circuit, 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 portion of the refrigeration unit that contains the compressor and
condenser
Condenser: component in the refrigeration unit that removes heat from the refrigerant vapor after it exits
the compressor
Cryopump: Polycold’s cryogenic refrigeration system that captures water molecules in a vacuum
chamber. It consists of a refrigeration unit, a refrigerant line, and a cryosurface (with cryogenic
feedthrough).
Cryosurface: the coil or baffle in the vacuum chamber that captures water molecules by freezing them
to its surface
Discharge Line: portion of the refrigerant circuit, containing high-temperature, high-pressure refrigerant
just after it has exited the compressor
EC: European Community
EEC: European Economic Community
EMC: electromagnetic compatibility
EN: European norm (or standard)
Feed Line: the copper tube in the refrigerant line that carries refrigerant from the refrigeration unit to the
cryosurface
Field Replacement Charge: refrigerant mixture that replaces the refrigerant in the cryopump
FNPT: Female national pipe thread
HC-10E1 Compressor -- Located inside the 2XCL, it provides recirculating, inert, high-pressure helium
gas to the host equipment.
IEC: International Electrotechnical Commission
I/O: input / output
Liquid Line: portion of the refrigerant circuit containing high-pressure refrigerant just after the watercooled condenser has cooled it
Manifold: service manifold gauge set
825131-00 REV A
Page 75
NEC: national electrical code
NPT: national pipe thread
OFHC: oxygen free, high capacity
Polycold stack: the upper portion of the refrigeration unit that is insulated with foam
Recharge: procedure for replacing the refrigerant in a cryopump
Refrigerant: a proprietary mixture of refrigerants made by Polycold Systems International
Refrigerant Circuit: the path of the refrigerant, which goes from the refrigeration unit, through the feed
line, through the cryosurface, through the return line, and back to the refrigeration unit
Refrigerant Expansion Tank: tank inside the refrigeration unit that maintains the gaseous refrigerant at
a safe pressure when the unit is not at operating temperature
Refrigerant Line: insulated feed and return lines that carry refrigerant to and from the cryosurface
Refrigeration Unit: the machine containing the compressor, condenser and Polycold stack that cools
the refrigerant mixture to cryogenic temperatures
Return Line: the copper tube in the refrigerant line that carries refrigerant from the cryosurface to the
refrigeration unit
SAE: Society of Automotive Engineers
TC: thermocouple
Top-off Charge: refrigerant mixture that can be added to the refrigerant in the cryopump
TÜV: Technical Supervision Society—organization that verifies compliance with EN and IEC standards
UL: Underwriters Laboratories— organization that verifies compliance with NEC standards
Vacuum Jacketed Gas Lines -- Connect the compressor to the vacuum process system. The supply
gas line carries high-pressure inert gas from the compressor to the host equipment and another gas line
returns low-pressure gas from the host equipment back to the compressor.
825131-00 REV A
Page 76
9.0 PROCESS & INSTRUMENTATION AND ELECTRICAL SCHEMATICS
825131-00 REV A
Page 77
TS 2 G
X
RED
- +
- +
GAS
CPRSR
ON
LEGEND
RED
TERMINAL BUS
CONNECTOR
TERMINAL STRIP
D TS 2
RED
+24 VDC
BLK
6
5 RED / BLK
E-STOP S1
WHT
WHT
WHT
BLK
D
TS 1
TS 1 C
D1
28 V
B
WHT
BLK
ORN
SW 1
"ON / OFF"
BLK
1
BLU
SIG. 2
SMC
PRESS.
(PS5)
SIG. 1
BRN
LO
WHT
HI
BLK
3
2
-1
+3
-13
BLK
K4
+14
K5
SEE SEPARATE PARTS LIST
4
A
TS 1
REV
-4
+2
5
-4
+2
COMMON
K6
+24 VDC
DATE
3800 Lakeville Highway, Petaluma, CA 94954 (707) 769-7000
V6
-1
+3
RED
679188-00
CKT DIAG PGCL2-V3
GAS AUTO FILL CONTROL
WHT
9
REVISIONS
RED
RED
TS 1
APVD/DATE
RED
RED
WHT / RED
BLK
BLK
RED
RED
WHT
Page 78
BLK
RED
WHT / BLK
825131-00 REV A
ECO
Process & Instrumentation Diagram
825131-00 REV A
Page 79
REVISIONS
440 VAC
1
2
1
2
1
2
APVD/DATE
T1
LEAD 1 440V/60 Hz
LEAD 2 460V/60 Hz
REV
DATE
ECO
OVLD2
12 AWG BLK
L1
12 AWG BLK
12 AWG BLK
12 AWG BLK
L2
12 AWG BLK
12 AWG BLK
12 AWG BLK
L3
12 AWG BLK
12 AWG BLK
X
16A
CB4
REFRG.
CPRSR 2
460V 3PH
Y
+A1
18 AWG ORN CONT2
CB4 AUX3
95
(E-STOP)
96
RED
CA18/2
36
SAFETY LOOP
1XCL
BLK
TS1
OPERATE GREEN
CB2
S1-3
35
18 AWG RED
.5A
CB1
ORN
22 AWG/5
-
24VDC RFGT CPRSR ON
STATUS CONT RFGT CPRSR
5
+
6
-
24VDC GAS CPRSR ON
7
WHT
C
STATUS CONT GAS CPRSR
8
RED
9
BLK
+
24VDC
10 -
22 AWG/5
HI PRESS
11 +
18 AWG ORN
18 AWG BLK
12 13
PS5
SW1
22 AWG RED
22 AWG BLU
FU7 .4A
A
FU4 .4A
12 AWG RED
4
"LINE"
AMB
12 AWG RED
12 AWG BLK
220 VAC
220 VAC
FU1 2A
FU2 2A
PWR SPLY 1
24 VDC
PWR SPLY 2
24 VDC
"FAULT"
RED
-
5
+
-
16
FLOW SWITCH
RED
17 +
BLK
S2
24VDC FLOW STATUS
18 19
22 AWG/3C
20
21
RLY2
AUX2
M2
21
FU5 .4A
15
PRES2
12 AWG BLK
220 VAC
14
LO PRESS
18 AWG BLK/WHT
V6
18 AWG RED
24 VAC
18 AWG ORN
18 AWG BLK
FU3 .4A
18 AWG BLK
BLK
DISCH TEMP
1A
CB3
18 AWG BLU
12 AWG BLK
12 AWG BLK
18 AWG ORN
+
2
4
RED
AUX CONT
TS5
1
3
WHT
18 AWG BLU/WHT
CCH1
12 AWG BLK
ORN
LIQ LINE TEMP
18 AWG RED
16A
REMOTE J3
-A2
LC1D18BD
24 VDC
M2
AUX3
12 AWG BLK
GND
12 AWG BLK
12 AWG BLK
Z
+
22 +
-
23 22
RLY2
18 AWG BLK/WHT
+
24 +
25 -
D25 FEMALE
220 VAC
18
15
TDR1
18
A1
A1
TDR2
20W 150
COM
COM
FU6 .4A
15
20W 150
S1-1
EMO
A2
13
TDR1
A2
14
M2 AUX1
18 AWG RED
S1-2
18 AWG RED
COM
ESTOP
S1-2
18 AWG BLK
18 AWG BLU
220 VAC
18 AWG ORN
6
J1
2
AUX CONT
12 AWG BLK
1
M1
L1
18 AWG RED
OVLD1
12 AWG BLK
12 AWG BLK
L2
12 AWG BLK
12 AWG BLK
L3
12 AWG BLK
GAS
CPRSR 1
(HC 10)
460V 3PH
J2
22 AWG/5/C/A
4 5 6
61
62
63
J2 1
2
3
4
5
6
7
8
J6 1
2
3
J8 1
2
1 2 3
J7
PCB
HC-10
J5
1 2 3 4 5 6
18 AWG BLK
18 AWG BLK
18 AWG BLK
18 AWG BLK
PHASE 17
ERROR
SIGNAL 24
J4
T/C1
95
(T/C3)
96
18 AWG BLK
OIL TEMP
SHELL TEMP
+A1
-A2
+
-
GAS TEMP
18 AWG BLK
TS2
TS3
RUN IND
TS4
9
22 AWG/5C/B
13
18 AWG WHT
3800 Lakeville Highway, Petaluma, CA 94954 (707) 769-7000
14
K3 14
K1
1
J9 2
CKT DIAG PGCL2-V3 SE
13
5
THIRD ANGLE PROJECTION
18 AWG RED
18 AWG RED
LO PRESS
HI PRESS
18 AWG BLK
9
SIZE
D
1
DO NOT SCALE DRAWING
Electrical Schematics (440V)
825131-00 REV A
1
2
MPS LOOP
1
2
3
4
5
SAFETY LOOP HC10
LC1D18BD
24 VDC
18 AWG ORN
+
CHUCK IN
+
1
CHUCK OUT
2
T/C2
18 AWG BLK
18 AWG BLK
18 AWG BLK
1
2
1
2
3
4
5
Page 80
SCALE: NONE
DWG NO.
679317-00
SHEET 1 OF 1
REV
00
REVISIONS
480 VAC
1
2
3
1
2 3
1
2 3
APVD/DATE
T1
LEAD 1 480V/60 Hz
LEAD 2 460V/60 Hz
LEAD 3 420V/50Hz
DATE
REV
ECO
OVLD2
12 AWG BLK
L1
12 AWG BLK
12 AWG BLK
12 AWG BLK
L2
12 AWG BLK
12 AWG BLK
12 AWG BLK
L3
12 AWG BLK
12 AWG BLK
X
16A
CB4
REFRG.
CPRSR 2
480V 3PH
Y
+A1
18 AWG ORN CONT2
CB4 AUX3
95
(E-STOP)
96
RED
CA18/2
36
SAFETY LOOP
1XCL
BLK
TS1
OPERATE GREEN
CB2
S1-3
35
18 AWG RED
.5A
CB1
22 AWG/5
22 AWG RED
22 AWG BLU
A
"LINE"
AMB
+
24VDC
220 VAC
FU1 2A
FU2 2A
PWR SPLY 1
24 VDC
PWR SPLY 2
24 VDC
+
-
14
15
S2
+
COM
22 +
-
23 18 AWG BLK/WHT
+
24 +
25 -
15
TDR1
A1
TDR2
COM
21
RLY2
A1
15
20W 150
S1-1
EMO
A2
13
TDR1
A2
14
D25 FEMALE
M2 AUX1
18 AWG RED
S1-2
18 AWG RED
ESTOP
S1-2
18 AWG BLK
18 AWG BLU
18 AWG ORN
6
12 AWG BLK
3
4
J1
2
AUX CONT
M1
L1
18 AWG RED
OVLD1
12 AWG BLK
12 AWG BLK
L2
12 AWG BLK
12 AWG BLK
L3
12 AWG BLK
95
J2
T/C1
-A2
(T/C3)
96
+
CHUCK IN
1
+
2
+
-
1
OIL TEMP
2
-
4
5
CHUCK OUT
GAS TEMP
SAFETY LOOP HC10
LC1D18BD
24 VDC
18 AWG BLK
TS2
TS3
RUN IND
TS4
9
22 AWG/5C/B
18 AWG ORN
1
2
T/C2
SHELL TEMP
+A1
MPS LOOP
2
3
18 AWG BLK
18 AWG BLK
18 AWG BLK
5
1
GAS
CPRSR 1
(HC 10)
480V 3PH
18 AWG BLK
18 AWG BLK
18 AWG BLK
18 AWG BLK
18 AWG BLK
1
2
1
22 AWG/5/C/A
PHASE 17
ERROR
SIGNAL 24
J4
19
22 AWG/3C
22
18
J2 1
2
3
4
5
6
7
8
J6 1
2
3
J8 1
2
24VDC FLOW STATUS
18 -
20
AUX2
M2
FU6 .4A
COM
17 +
RLY2
18
220 VAC
RED
BLK
220 VAC
20W 150
16
FLOW SWITCH
18 AWG BLK
220 VAC
-
5
61
62
63
STATUS CONT GAS CPRSR
9
LO PRESS
18 AWG RED
12 AWG BLK
"FAULT"
RED
21
13
18 AWG WHT
3800 Lakeville Highway, Petaluma, CA 94954 (707) 769-7000
14
K3 14
K1
1
J9 2
CKT DIAG PGCL2-V3
13
5
THIRD ANGLE PROJECTION
18 AWG RED
18 AWG RED
LO PRESS
HI PRESS
18 AWG BLK
9
SIZE
D
1
DO NOT SCALE DRAWING
Electrical Schematics (480V)
825131-00 REV A
24VDC GAS CPRSR ON
10 -
PRES2
12 AWG RED
FU5 .4A
1 2 3 4 5 6
-
12 -
18 AWG BLK/WHT
4
220 VAC
J5
6
22 AWG/5
HI PRESS
SW1
12 AWG BLK
PCB
HC-10
+
8
RED
BLK
18 AWG RED
PS5
18 AWG ORN
V6
12 AWG RED
J7
STATUS CONT RFGT CPRSR
5
13
24 VAC
FU4 .4A
1 2 3
24VDC RFGT CPRSR ON
11 +
FU7 .4A
4 5 6
-
7
WHT
C
18 AWG ORN
18 AWG BLK
18 AWG BLK
18 AWG BLK
FU3 .4A
ORN
DISCH TEMP
1A
CB3
18 AWG BLU
12 AWG BLK
12 AWG BLK
BLK
TS5
18 AWG ORN
+
2
4
RED
AUX CONT
1
3
WHT
18 AWG BLU/WHT
CCH1
12 AWG BLK
ORN
LIQ LINE TEMP
18 AWG RED
16A
REMOTE J3
-A2
LC1D18BD
24 VDC
M2
AUX3
12 AWG BLK
GND
12 AWG BLK
12 AWG BLK
Z
Page 81
SCALE: NONE
DWG NO.
679186-00
SHEET 1 OF 1
REV
03
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