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

Trillium US Inc. Model 125 Cryogenic Helium Compressor User`s
Trillium US Inc.
Model 600 / Model 400 Cryogenic Helium Compressor
User’s Manual
Rev A / November 2015
97-00046-000
User's Manual
Rev A / November 2015 / M600/M400 Helium Compressor
For information about Trillium US Inc., visit the Trillium US Inc. Web site at:
http://www.trilliumus.com
How to Contact Trillium US Inc. Support:
support@trilliumus.com
For contact information and a complete listing of Direct Sales, Distributor, and Sales Representative contacts, visit the
Trillium US Inc. Web site at:
http://www.trilliumus.com
Trillium US Inc. has made its best effort to ensure that the information contained in this document is accurate and reliable.
However, the information is subject to change without notice and is provided “AS IS” without warranty of any kind (express
or implied). Before placing orders, customers are advised to obtain the latest version of relevant information to verify that
information being relied upon is current and complete. All products are sold subject to the terms and conditions of sale
supplied at the time of order acknowledgment, including those pertaining to warranty, patent infringement, and limitation
of liability. No responsibility is assumed by Trillium US Inc. for the use of this information, including use of this information
as the basis for manufacture or sale of any items, nor for infringements of patents or other rights of third parties. This
document is the property of Trillium US Inc. and by furnishing this information, Trillium US Inc. grants no license, expressed
or implied, under any patents, copyrights, trademarks, trade secrets, or other intellectual property rights of Trillium US Inc.
Trillium US Inc., copyright owner of the information contained herein, gives consent for copies to be made of the
information only for use within the customer’s organization as related to the use of Trillium US Inc. products. The same
consent is given for similar information contained on any Trillium US Inc. Web site or disk used to distribute information to
a customer. Trillium US Inc. does give consent to the copying or reproduction by any means of the information contained
herein for general distribution, advertising or promotional purposes, or for creating any work for resale. The names of
products of Trillium US Inc. or other vendors and suppliers appearing in this document may be trademarks or service marks
of their respective owners that may be registered in some jurisdictions. A list of Trillium US Inc. trademarks and service
marks can be found at:
http://www.trilliumus.com/
Trillium US Inc.
1340 Airport Commerce Dr.
Bldg. 1 Suite 175
Austin, Texas 78741 USA
TEL. +1 512 441 6893
FAX +1 512 443 6665
Email: cryo-sales@trilliumus.com
Copyright (©) 2015 by Trillium US Inc., All rights reserved.
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Table of Contents
1.
REVISION HISTORY .................................................................................................................................................... V
2.
PREFACE .................................................................................................................................................................... 1
2.1.
2.2.
2.3.
2.4.
3.
ABOUT TRILLIUM US INC. INC. ........................................................................................................................................ 1
OTHER SERVICES FROM TRILLIUM US INC. ......................................................................................................................... 1
ABOUT THIS MANUAL.................................................................................................................................................... 1
COMPATIBILITY............................................................................................................................................................. 2
SAFETY WARNINGS.................................................................................................................................................... 3
3.1.
STANDARDS FOR USE OF WARNINGS AND CAUTIONS ........................................................................................................... 3
3.2.
WARNINGS APPLICABLE TO ALL ASPECTS OF M600 / M400 OPERATION ............................................................................... 3
3.2.1. High Voltage and Electrical Shock Warnings ...................................................................................................... 3
3.2.2. High Pressure Related Warnings ......................................................................................................................... 3
3.2.3. Helium Gas-Related Warnings ............................................................................................................................ 3
3.2.4. Heat-Related Warnings ....................................................................................................................................... 4
3.3.
OPERATOR INSTRUCTIONS .............................................................................................................................................. 4
4.
INTRODUCTION ......................................................................................................................................................... 4
4.1.
GENERAL INFORMATION ABOUT THE MODEL 600 / MODEL 400 COMPRESSOR ....................................................................... 4
4.1.1. Model 600 / Model 400 Features ........................................................................................................................ 4
4.1.2. Overview of Model 600 / Model 400 Compressor Design and Operation........................................................... 4
4.1.3. Description of Subsystems .................................................................................................................................. 5
4.1.4. Operational Flow................................................................................................................................................. 6
4.2.
SPECIFICATIONS ............................................................................................................................................................ 6
4.3.
CONFIGURATIONS ......................................................................................................................................................... 8
4.4.
ORDERING INFORMATION............................................................................................................................................. 11
5.
INSTALLATION ......................................................................................................................................................... 12
5.1.
SAFETY WARNINGS ..................................................................................................................................................... 12
5.2.
INSTALLATION STEPS ................................................................................................................................................... 12
5.2.1. Unpacking and Inspection ................................................................................................................................. 12
5.2.2. Mounting the Compressor ................................................................................................................................ 13
5.2.3. Preparing the Compressor for Operation .......................................................................................................... 13
5.2.4. Installation ........................................................................................................................................................ 13
5.2.4.1.
Ambient Conditions and Coolant Connection............................................................................................... 13
5.2.4.2.
Verifying and/or Refilling Compressor with Helium Gas .............................................................................. 14
5.2.4.3.
Connecting the Helium Flex Lines ................................................................................................................. 15
5.2.5. Electrical Connection ......................................................................................................................................... 15
6.
OPERATION ............................................................................................................................................................. 18
6.1.
BEFORE SWITCHING ON THE SYSTEM .............................................................................................................................. 18
6.2.
NORMAL OPERATION .................................................................................................................................................. 18
6.2.1. Cycle Times ........................................................................................................................................................ 18
6.3.
ELECTRONICS INTERFACE CONNECTIONS .......................................................................................................................... 18
6.3.1. Remote Interface............................................................................................................................................... 18
6.3.2. D-Sub User Controls .......................................................................................................................................... 20
6.3.3. D-Sub User Status.............................................................................................................................................. 21
6.3.4. Compressor Front Panel User Interface ............................................................................................................ 21
6.3.4.1.
Compressor Front Panel User Interface Revised........................................................................................... 22
6.3.5. Compressor Operational Checks ....................................................................................................................... 22
6.3.5.1.
Compressor Front Panel Fault Errors ............................................................................................................ 23
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6.3.6.
6.3.7.
6.3.7.1.
6.3.7.2.
6.3.8.
6.3.8.1.
6.3.9.
6.3.9.1.
7.
Compressor System Shut Down......................................................................................................................... 23
Compressor Interfaces ...................................................................................................................................... 23
Serial Port Interface (J2-RS232) .................................................................................................................... 23
USB Interface (J1-Maintenance)................................................................................................................... 24
Serial Communications via RS232 ..................................................................................................................... 24
Serial Port Commands .................................................................................................................................. 24
Communications via USB .................................................................................................................................. 26
USB Payload Formats ................................................................................................................................... 27
TROUBLESHOOTING ................................................................................................................................................ 31
7.1.
8.
Rev A / November 2015 / M600/M400 Helium Compressor
TROUBLESHOOTING ACTIVITIES...................................................................................................................................... 31
MAINTENANCE ........................................................................................................................................................ 33
8.1.
MAINTENANCE PERSONNEL REQUIREMENTS .................................................................................................................... 33
8.2.
REMOVING THE COMPRESSOR FROM SERVICE: REMOVAL, TRANSPORT AND STORAGE.............................................................. 33
8.3.
SCHEDULED PREVENTATIVE MAINTENANCE ACTIVITY ......................................................................................................... 33
8.3.1. Remove the Compressor Adsorber .................................................................................................................... 34
8.3.2. Install Replacement Adsorber ........................................................................................................................... 38
8.4.
UNSCHEDULED CORRECTIVE MAINTENANCE..................................................................................................................... 38
8.4.1. Removing Helium Contamination ..................................................................................................................... 38
8.5.
CLEANING EQUIPMENT ................................................................................................................................................ 39
8.6.
RETURNING EQUIPMENT .............................................................................................................................................. 39
List of Figures
Figure 1 – M600 / M400 Digital Standard Drive ............................................................................................. 8
Figure 2 – M600 / M400 Digital On-Board Drive ............................................................................................ 9
Figure 3 – M600 / M400 Low Volt Digital Multi-Drive ................................................................................... 9
Figure 4 – M600 / M400 High Volt Digital Multi-Drive ................................................................................. 10
Figure 5– M600 / M400 Analog Standard-Drive ........................................................................................... 10
Figure 6– M600 / M400 Analog On-Board -Drive ......................................................................................... 10
Figure 7– M600 / M400 Compressor Internal Tip & Tells ............................................................................ 13
Figure 8– M600 / M400 Packaging Tip & Tells ............................................................................................. 13
Figure 9– M600 / M400 Helium Compressor Control Voltage Transformer Tap Settings ............................ 17
Figure 10– User Control Signal Interface ...................................................................................................... 20
Figure 11– User Status Signal Interface ........................................................................................................ 21
Figure 12 – Removal of Helium Supply Line Aeroquip at Access Panel ........................................................ 35
Figure 13 - Adsorber Aeroquip Nut and Access Panel Removal ................................................................... 36
Figure 14 - Adsorber Screw Removal ............................................................................................................ 36
Figure 15 - Adsorber Aeroquip OMS Supply Line Removal........................................................................... 37
Figure 16 - Adsorber Removal ...................................................................................................................... 37
Figure 17 – Self sealing Connector................................................................................................................ 38
Figure 18 – M600 Water Piping and Instrumentation Diagram ................................................................... 40
Figure 19 – M600 Air Piping and Instrumentation Diagram ......................................................................... 41
Figure 20 – M400 Water Piping and Instrumentation Diagram ................................................................... 42
Figure 21 – M400 Air Piping and Instrumentation Diagram ......................................................................... 43
Figure 22 – M600 / M400 Water Cooled General Dimensions..................................................................... 44
Figure 23 – M600 / M400 Air Cooled General Dimensions .......................................................................... 45
Figure 24 – M600 / M400 Low Volt Standard Drive Schematic .................................................................... 46
Figure 25 – M600 / M400 Low Volt On-Board Drive Schematic ................................................................... 47
Figure 26 – M600 / M400 High Volt Standard Drive Schematic ................................................................... 48
Figure 27 – M600 / M400 Low Volt Multi-Drive Schematic ......................................................................... 49
Figure 28 – M600 / M400 High Volt Multi-Drive Schematic ......................................................................... 50
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Figure 29 – M600 / M400 Low Volt Analog Standard Drive Schematic ........................................................ 51
Figure 30 – M600 / M400 High Volt Analog Standard Drive Schematic ....................................................... 52
Figure 31 – M600 / M400 Low Volt Analog On-Board Drive Schematic ....................................................... 53
Figure 32 – M600 / M400 Fault Tree: Compressor will Not Start / Adsorber Replacement ........................ 54
Figure 33 – M600 / M400 Fault Tree: Compressor Starts but Shuts Off ...................................................... 55
Figure 34 – M600 / M400 Fuse Configurations Digital ................................................................................. 56
Figure 35 – M600 / M400 Fuse Configurations Multi-Drive ......................................................................... 57
Figure 35 – 99-00074-000 Tool Kit Contents ................................................................................................ 58
Figure 36 – 99-00074-001 Tool Kit Contents ................................................................................................ 59
List of Tables
Table 2-1: Model 600 Helium Compressor Coldhead Compatibility .............................................................. 2
Table 2-2: Model 600 Helium Compressor Cryopump Compatibility ............................................................. 2
Table 2-3: Model 400 Helium Compressor Coldhead Compatibility .............................................................. 2
Table 2-4: Model 400 Helium Compressor Cryopump Compatibility ............................................................. 2
Table 4-1 - Description of Model 600/ Model 400 Helium Compressor Subsystems. .................................... 5
Table 4-2 - Power Requirements for Model 600 / Model 400 Helium Compressor. ...................................... 7
Table 4-3 - Model 600 / Model 400 Helium Compressor Specifications. ....................................................... 7
Table 4-4 - Model 600 /Model 400 Helium Compressor Pressure Requirements. ......................................... 8
Table 4-5 - Model 600 /Model 400 Helium Compressor Ordering Information ........................................... 11
Table 4-6 - Model 600 /Model 400 Optional Accessories and Replacement Parts ...................................... 11
Table 6-1 – J1 or J3 Remote Connector (25-Pin D-Sub) ................................................................................ 19
Table 6-2 – Analog Remote Connector ......................................................................................................... 19
Table 6-3 – Remote Interface Inputs for Electrical Boxes Shown in Figure 3 and Figure 4 .......................... 20
Table 6-4 – Remote Interface Outputs for Electrical Boxes Shown in Figure 3 and Figure 4 ....................... 21
Table 6-5 – Operational Checks .................................................................................................................... 22
Table 6-6 – Serial Port Interface Pin Assignments ........................................................................................ 23
Table 6-7 – Serial Port Cable ......................................................................................................................... 24
Table 6-8 – Serial Port Commands................................................................................................................ 24
Table 6-9 – Data Message ............................................................................................................................. 24
Table 6-10 – Command/Data........................................................................................................................ 25
Table 6-11 – Error Codes .............................................................................................................................. 25
Table 6-12 – USB Packet Format................................................................................................................... 26
Table 6-13 – USB Maintenance Interface Command ID's ............................................................................. 26
Table 6-14 – ACK Payload Format................................................................................................................. 27
Table 6-15 – NACK Payload Format .............................................................................................................. 27
Table 6-16 – NACK Reason Codes ................................................................................................................. 27
Table 6-17 – Get Status Payload Format ...................................................................................................... 28
Table 6-18 –Status Response Payload Format.............................................................................................. 28
Table 6-19 – Get Fault History Payload Format ............................................................................................ 29
Table 6-20 –Fault History Response Payload Format ................................................................................... 29
Table 6-21 – Fault Codes............................................................................................................................... 29
Table 6-22 – Set Compressor Payload Format.............................................................................................. 29
Table 6-23 – Set Coldhead Payload Format .................................................................................................. 30
Table 6-24 – Reset Payload Format .............................................................................................................. 30
Table 6-25 – Get Version Payload Format .................................................................................................... 30
Table 6-26 –Version Response Payload Format ........................................................................................... 30
Table 7-1 – Troubleshooting Procedures ...................................................................................................... 31
Table 7-2 – Fuse Listing for Digital Electronics Boxes in Figure 1and Figure 2 ............................................. 32
Table 7-3 – Fuse Listing for Digital Electronics Box in Figure 3 and Figure 4 ................................................ 33
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1. Revision History
Date
Revision
ECR #
June 2009
1.0.1
Combine M600 and M400 manuals. Add new electrical box
configuration information. Change document part number.
March 2010
1.0.2
Make correction to low voltage tap setting description on
Figure 4-1.
December 2013
1.0.3
Change company address and name
November 2015
A
2534
Description of Change
Rebranding, major formatting changes
Content changes all pages
Document Part Number: 97-00046-000
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2. Preface
2.1.
About Trillium US Inc. Inc.
Trillium US Inc. Inc., a wholly-owned subsidiary of Trillium US Inc., specializes in the manufacture and repair of cryogenic
cryopumps, cryocoolers (refrigerators) and helium compressors for semiconductor, optical coating, linear accelerators,
medical equipment, and R&D applications.
You can find just what you need from our range of products and support services:
•
New equipment – cryopumps, compressors, cryocoolers, and cryopump controllers such as the Model 600 / Model
400 Helium Compressor described in this manual.
•
Comprehensive range of accessories for the installation of a whole system and a complete range of spare parts to
repair cryopumps and compressors.
2.2.
Other Services from Trillium US Inc.
Trillium US Inc. Inc. offers comprehensive refurbishment services for its own equipment as well as for that of most of our
competitors. Our products and services are available through our global network of agents and dealers.
•
Repair and refurbishment services – We offer our own quality products, and well as most models from other
manufacturers, often with off-the-shelf availability.
•
Exchanges – We offer our own quality products, as well as most makes of cryopumps and helium compressors,
which are refurbished and fully warranted.
•
Technical support – Our support engineers will help determine if your cryopump system is operating correctly so
that you can get your system back to optimum efficiency as soon as possible.
o
To contact Trillium US Inc. Inc. Technical Support:
Email: cryo-support@trilliumus.com
Telephone: 1-512-441-9258 or Toll Free: 1-800-404-1055
•
Installation – On-site installation services are available to guarantee performance.
•
Training – We offer on-site training to help you and your staff to know more about your cryopump and
compressor systems. Our training will give you confidence and the ability to maintain a highest possible uptime
for your system.
2.3.
About this Manual
The purpose of this manual is to provide our customers using the Model 600/ Model 400 Helium Compressor with the
information needed to safely and efficiently operate the compressor when operating as part of a cryogenic refrigeration
system. Such a system is often comprised of the following equipment:
•
Model M600 / Model 400 Helium Compressor
•
Coldhead(s) or Cryopumps
•
Connecting Helium Lines
•
Connecting Water Lines
This manual describes the design, operation and maintenance of the Model M600 / Model 400 Helium Compressor units.
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2.4.
Rev A / November 2015 / M600/M400 Helium Compressor
Compatibility
The Trillium US Inc. Model 600 / Model 400 Helium Compressors are compatible with various cold heads and cryopumps
described in the following tables. Each Model 600 / Model 400 compressor unit can be used to run one or more such
cryopumps or cold heads. For other combinations than listed below, please contact Trillium US Inc. Technical Support using
the contact information found in Section 2.2.
Table 2-1: Model 600 Helium Compressor Coldhead Compatibility
Model 600 Drive Unit Electrical
Cold Head Model
Number of Multiple Cold Heads
Circuit Configuration
(Manufacturer)
Allowed
350CS (OIA)
3
1020CS (OIA)
2
1050CS (OIA)
1
Scott "T"
350CP (CTI)
3
1020CP (CTI)
2
1050CP (CTI)
1*
*Number of single stage coldheads can be increased to 2
Table 2-2: Model 600 Helium Compressor Cryopump Compatibility
Model 600 Drive Unit Electrical
Cryopump Model
Number of Multiple Cryopumps
Circuit Configuration
(Manufacturer)
Allowed
CP8/CP8LP (OIA)
3
CP10 (OIA)
2
CP16 (OIA)
1
Scott "T"
CT8/CT8F (CTI)
3
CT10 (CTI)
2
CT400
1
CT500
1
OB-8/OB-8F (CTI)
3
OB-10 (CTI)
2
On-Board
OB-400 (CTI)
1
OB-500 (CTI)
1
Table 2-3: Model 400 Helium Compressor Coldhead Compatibility
Model 400 Drive Unit Electrical
Coldhead Model
Number of Multiple Coldheads
Circuit Configuration
(Manufacturer)
Allowed
350CS (OIA)
2
1020CS (OIA)
1
Scott "T"
350CP (CTI)
2
1020CP (CTI)
1
Table 2-4: Model 400 Helium Compressor Cryopump Compatibility
Model 600 Drive Unit Electrical
Cryopump Model
Number of Multiple Cryopumps
Circuit Configuration
(Manufacturer)
Allowed
CP8/CP8LP (OIA)
3
CP10 (OIA)
2
Scott "T"
CT8/CT8F (CTI)
3
CT10 (CTI)
2
OB-8/OB-8F (CTI)
3
On-Board
OB-10 (CTI)
2
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Additional accessories will be needed to operate multiple cryopumps or cold heads. Refer to Section 4.4 for the part
numbers and ordering information.
3. Safety Warnings
3.1.
Standards for Use of Warnings and Cautions
Warnings are noted when there is a possibility of injury or death to persons operating the equipment or performing specific
tasks or procedures noted in this manual. Cautions are noted when there is a possibility of damage to equipment if the
caution is ignored.
3.2.
Warnings Applicable to All Aspects of M600 / M400 Operation
3.2.1. High Voltage and Electrical Shock Warnings
Warning:
This unit can start automatically, and via remote control. Potentially fatal voltages are present
in the compressor unit. The compressor should be switched off and disconnected from its
power supply before carrying out any troubleshooting or maintenance activities on the unit.
Warning:
Connect or disconnect the flex lines joining the compressor and its load (cryopump, coldhead,
etc) only after the compressor and its load are switched off and separated from the power
source. Otherwise, electrical shock hazards may exist, potentially causing damage to the
compressor unit, its load, or the operator.
Warning:
Always provide proper grounding to the compressor unit and its load. All electrical power
connection and disconnection of the unit should be done by a qualified electrician.
Warning:
High voltage is present within the compressor unit and can cause severe injury from electrical
shock. Permit only qualified electrical technicians to open the compressor enclosure to
perform electrical troubleshooting.
Warning:
The main power plug is used as the overall disconnect device. Ensure that access to the
disconnect device is made available at all times.
3.2.2. High Pressure Related Warnings
Warning:
High gas pressure is present within the system and may cause severe injury if a safe pressure
level is exceeded.
Warning:
Do not charge the compressor without using a pressure regulator. Do not charge the
compressor to a pressure level that exceeds limit set by the manufacturer.
Warning:
The static pressure of a compressor is predetermined by the manufacturer based on
operational safety and performance considerations. Do not exceed this level when charging a
compressor.
3.2.3. Helium Gas-Related Warnings
Warning:
Helium gas can cause rapid asphyxiation and death if released in a confined and un-ventilated
area.
Warning:
Use a pressure reducing regulator when withdrawing helium gas from a high-pressure gas
cylinder.
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Warning:
Rev A / November 2015 / M600/M400 Helium Compressor
Detaching the helium flex lines when the compressor load is at low temperature may cause
the pressure to rise in the system beyond the permissible level therefore creating a safety
hazard.
3.2.4. Heat-Related Warnings
Warning:
3.3.
The compressor motor may become hot during operation. Wait for the motor to cool down
before working inside the compressor.
Operator Instructions
Follow standard Model 600/ Model 400 Helium Compressor operating procedures as described in this manual. If you still
have questions regarding the safe operation of the Model 600/ Model 400 Helium Compressor, please contact Trillium US
Inc. Inc. Technical Support using the contact information found in Section 2.2.
Warning:
If the equipment is used in any manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Warning:
Maintenance personnel must verify safe state of equipment after all repairs.
4. Introduction
4.1.
General Information about the Model 600 / Model 400 Compressor
Trillium US Inc. Inc. offers industry-proven compressors such as the Model 600 / Model 400 Helium Compressor described
in this manual, at highly competitive prices and with flexible configurations. Model 600 / Model 400 compressors are
available in high- and low-voltage configurations and in either air or water-cooled models.
4.1.1. Model 600 / Model 400 Features
The Model 600 / Model 400 Helium Compressors are designed for tens of thousands of hours of continuous operation. The
main features of the Model 600 / Model 400 Helium Compressors are:
•
Minimal maintenance requirements
•
Removable adsorber panel for easy maintenance
•
Integrated water flow meter
•
Rack mounting option, which is ideal for vacuum coating/ion implanters, semiconductor vacuum systems, CAT
scanners, MRI systems and sputtering system applications.
•
Reliable helium and oil filtration system
•
Front-mounted high and low pressure gauges
4.1.2. Overview of Model 600 / Model 400 Compressor Design and Operation
Model 600 / Model 400 Helium Compressor is designed to run different cryopump or coldhead models from different
manufacturers (see Table 2-1 thru Table 2-4 for compatibility information), for either high voltage or low-voltage and 60/50
Hz three-phase operations.
The compressor itself consists of five main mechanical components:
•
Compressor Capsule (motor)
•
Heat Exchanger with water ports or dual fans
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•
Oil Mist (Vapor) Separator
•
Bulk Oil Separator
•
Adsorber
Rev A / November 2015 / M600/M400 Helium Compressor
The compressor unit and the coldhead are connected by way of helium gas flex lines. The compressor unit, coldhead, and
helium lines are fitted with self-sealing couplings, and are charged with ultra high-purity (99.999%) helium gas (He 5.0 UH).
Helium gas is pumped through the compressor motor and after being compressed to a higher pressure, the oil is mixed
with the helium. The oil acts (in addition to the primary function as a lubricator) as the medium to remove heat created by
compressing the helium gas from the compressor motor. Once exiting the compressor motor, the hot oil/hot helium
mixture is pumped via differential pressure out of the capsule through the water-cooler or air-cooled heat exchanger. The
cooled oil than enters the oil mist separator, the vast majority of cool oil and cool helium are separated, such that each
medium (helium and oil) enters leaves the oil mist separator through different parallel paths.
The heat exchanger removes the heat generated from the process of compressing helium in the capsule. The cooled oil
returns to the capsule to lubricate and cool the capsule.
The volume tank is an empty tank that provides additional helium gas volume on the low pressure side of the compressor
system. This prevents the low-side pressure from going too low when the compressor is running.
The helium gas purifying occurs after the heat removal and cooling process. Helium gas purification must occur because
the helium out of the heat exchanger still has a small amount of oil vapor mixed with it. If this helium gas gets to the
cryopump with oil vapor in it, the oil will freeze and contaminate the cryopump. The function of the oil mist (vapor)
separator is to rid the helium gas stream of this oil vapor. Any oil condensate is then returned to the capsule.
Typically, the helium gas still contains a trace amount of oil vapor at this point. The adsorber then filters out the remaining
oil vapor from the helium gas stream. Over time, the adsorber will become saturated with the oil vapor. Thus, it is
important that the adsorber be replaced according to the recommended replacement interval found in Section 8.3.
4.1.3. Description of Subsystems
Along with the five main components, Table 4-1 describes the subsystems that serve to monitor the operating condition of
the compressor unit and ensure its safe operation.
Table 4-1 - Description of Model 600/ Model 400 Helium Compressor Subsystems
Subsystem Name
Function
Phase rotation monitor
Purpose: Monitors the phase of the input power. Will not
allow operation if the phase is incorrect.
Internal line break motor protector
An internal line break motor protector, located in the center
of the Y of the motor windings, disconnects all three phases
in case of an overload condition. The internal protector
protects against single phasing
Overload relay
Purpose: Monitors system current. Will turn off the
compressor if the current level exceeds the pre-set value.
Thermal switch (TS1)
Purpose: Monitors helium temperature upstream of the heat
exchanger.
Safety Function: Will turn off the compressor if the helium
temperature gets above 210°F (99°C)
Thermal Switch (TS2)
Purpose: Monitors oil temperature downstream of the heat
exchanger.
Safety Function: Will turn off the compressor if the oil
temperature gets above 122°F (50°C)
Unloading valve
Purpose and Safety Function: Equalizes pressure within the
compressor unit upon power interruption
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Subsystem Name
Function
Oil check valve
Purpose and Safety Function: Prevents oil migration when
power is off
Cooling water flow meter (watercooled model only)
Purpose: Allows a visual reference as to the current flow rate
of the cooling water.
Fuses:
Fuses for the coldhead drive circuit
Fuses for the main input power
Fuses for the control voltage
Fuses for the fan motors
Fuses for the main contactor coil
Safety Function: Over-current protection
See Table 7-2and Table 7-3 for fuse details
Internal relief valve
Purpose and Safety Function: Opens a shunt between the
high and low-pressure helium gas circuits. Sets the proper
operating pressure for the system regardless of the load.
Safety Function: If the differential pressure exceeds a preset
value, this valve opens to allow safe operation.
External relief valve
Purpose and Safety Function: Opens the helium gas circuit to
atmosphere if the helium gas pressure exceeds 430 PSIG
(29.6 Bar)
4.1.4. Operational Flow
The flow diagrams for the Model 600 and Model 400 Helium Compressors are illustrated in Figure 18 thru Figure 21.
The work flow of helium gas within the compressor follows these steps:
1. High-pressure helium gas is delivered from the compressor to the coldhead through the "Supply" helium flex line
at:
a. M600: 260 - 280 PSI (18 - 19.3 Bar)
b. M400: 200 - 260 PSI (13.8 - 18 Bar)
2. The helium gas is then compressed during the compression stroke of the scroll motor.
3. The cryopump then expands the helium gas to expand during its expansion stroke. During this cycle of
compression at the scroll motor and expansion in the cryopump, the helium gas is forced through regeneration
materials to increase the thermodynamic efficiency of the cycle.
4. With each successive cycle, the regeneration material becomes colder and colder. Eventually, the cryopump
temperatures come down to cryogenic range.
5. After expansion, the helium gas returns to the compressor through the "Return" helium flex line at the pressure
specified below to begin the cycle again:
a. M600: 50 - 100 PSI (3.4 - 6.9 Bar)
b. M400 : 0 - 100 PSI ( 0 - 6.9 Bar)
4.2.
Specifications
The Model 600 / Model 400 Helium Compressor specifications are listed in Table 4-2 thru Table 4-4.
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Table 4-2 - Power Requirements for Model 600 / Model 400 Helium Compressor
Working
Max
Rated Operating
Voltage
Frequency
Phase
Current
Voltage (VAC)
Range
(Hz)
Factory Default Setting
Draw (A)
(VAC)
Max
Power
(kW)
200
180-220
50
3
25
7.8
200-230
180-253
60
3
25
7.8
M600 High Voltage
(all models)
380-420
342-457
50
3
13
7.8
440-480
396-528
60
3
13
7.8
M400 Low Voltage
(all models)
200
180-220
50
3
21
7.0
200-230
180-253
60
3
21
7.0
380-420
342-457
50
3
9
7.0
440-480
396-528
60
3
9
7.0
M600 Low Voltage
(all models)
M400 High Voltage
(all models)
Table 4-3 - Model 600 / Model 400 Helium Compressor Specifications.
Feature/Component
Specification Description
Physical Dimensions
See Figure 22 and Figure 23
Weight
water-cooled: 260 lbs (118 Kg)
air-cooled: 300 lbs (136 Kg)
Helium Pressure
See Table 4-4
Interface
Cold Head Power: MS3102A14S-6S or MS3102A18-19S
(dependent on version)
Remote Connector: TE 3-1634224-2
Helium connections: 1/2 inch male Aeroquip couplings
Electrical Service Breaker
20 Amp (HV) minimum
Adsorber Replacement Schedule
15,000 Hours (per elapsed time meter on the
compressor) or 2 years, whichever comes first (see
Section 8.3)
Cooling Water (for water-cooled models)
1.4 -1.8 GPM (5.3 - 6.8 liters/min) minimum flow rate
65°F - 80°F (18.3 - 26.7°C) maximum inlet water
temperature
Recommended chiller capacity:
M600 – 2.5 ton/per unit
M400 – 2.0 ton/per unit
Water line connector: 3/8 inch Swagelok Tube Fittings
(adapters available)
Ambient Air
Air-cooled units must maintain a minimum clearance
of at least 250mm (9.85”) on all sides and 400mm
(15.75”) at top for proper functionality. Adequate airflow is also required.
Maximum ambient temperature should not exceed
104°F (40°C).
Minimum ambient temperature should not fall below
23° F (-5°C).
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4.3.
Rev A / November 2015 / M600/M400 Helium Compressor
Table 4-4 - Model 600 /Model 400 Helium Compressor Pressure Requirements.
Static Charge
Operating Pressure
Operating Pressure
Static Charge (PSIG)
(Bar)
Differential (PSIG)
Differential (Bar)
M600
240 ± 5
16.5±.34
250 ± 10
17.23 ± 0.69
M400
240 ± 5
16.5±.34
270 ± 10
18.61 ± 0.69
Configurations
Due to its length of time on the market the Model 600 / Model 400 Compressors have multiple configurations of its
electronics module available and in use by customers. The following figures will help the user identify their
configuration and thus which electrical interfaces, schematics and trouble-shooting areas to refer to when needed.
Figure 1 – M600 / M400 Digital Standard Drive
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Figure 2 – M600 / M400 Digital On-Board Drive
Figure 3 – M600 / M400 Low Volt Digital Multi-Drive
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Figure 4 – M600 / M400 High Volt Digital Multi-Drive
Figure 5– M600 / M400 Analog Standard-Drive
PIC NEEDED
Figure 6– M600 / M400 Analog On-Board -Drive
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4.4.
Rev A / November 2015 / M600/M400 Helium Compressor
Ordering Information
Table 4-5 and Table 4-6 contains ordering information for the Model 600 / Model 400 compressor units and optional
accessories.
Table 4-5 - Model 600 /Model 400 Helium Compressor Ordering Information
Compressor Configuration
Part Number
M600 air-cooled, high voltage, standard drive circuit
91-00019-000
M600 air-cooled, low voltage, standard drive circuit
91-00019-001
M600 air-cooled, low voltage, Onboard drive circuit
91-00019-002
M600 water-cooled, high voltage, standard drive circuit
91-00014-002
M600 water-cooled, low voltage, standard drive circuit
91-00014-003
M600 water-cooled, low voltage, Onboard drive circuit
91-00015-000
M600 water-cooled, high voltage, Multi- drive circuit
91-00060-000
M400 air-cooled, high voltage, standard drive circuit
91-00018-000
M400 air-cooled, low voltage, standard drive circuit
91-00018-001
M400 air-cooled, low voltage, Onboard drive circuit
91-00018-002
M400 water-cooled, high voltage, standard drive circuit
91-00016-002
M400 water-cooled, low voltage, standard drive circuit
91-00016-003
M400 water-cooled, low voltage, Onboard drive circuit
91-00016-004
Table 4-6 - Model 600 /Model 400 Optional Accessories and Replacement Parts
Accessories/Replacement Parts
Part Number
Adsorber
80-00005-000
Helium charge line (10ft.*), adapter 1/4" female Aeroquip to 1/4" flare
10346
Helium regulator
HR-580
Helium lines (10ft.*)
10418-10
Helium tee, for connecting two cryopumps
T-MMF
Three-port manifold, for connecting three cryopumps
80075
Splitter box, supplies power to up to three cryopumps
10359
Onboard splitter box, supplies power to up to three Onboard cryopumps
10366
Maintenance manifold, for helium clean-up process on compressors and cryopumps
10134
Cryopump drive cable (10ft.*), sends power to the cryopump motor from the compressor
10144-10
Tool Kit, Running Purge Decontamination, Swagelok Ends (see Figure 36)
99-00074-000
Tool Kit, Running Purge Decontamination, 1/4" Male Aeroquip Ends (see Figure 37)
99-00074-001
Shipping Platform and Crate: Water
47-00099-000
47-00100-001
Shipping Platform and Crate: Air
47-00099-000
47-00100-002
Cable Assy, Remote Patch, 25 Pin Male D-Sub to 14 Pos Female Mil
81-00600-060
*Custom Lengths Available
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5. Installation
5.1.
Safety Warnings
Review the safety warnings in Section 3 before beginning any installation activities.
5.2.
Installation Steps
5.2.1. Unpacking and Inspection
Once the equipment is received, inspect the exterior of the shipping carton for any signs of damage. Report any damage
and file a claim with the shipping company immediately.
In addition, at least two “Tip-n-Tell” or “TiltWatch” labels are mounted on the exterior of the shipping carton. Inspect
these labels carefully before accepting the shipment. Any sign that the package has been mishandled during transit may
indicate that the compressor may be damaged due to oil migration within the system. This could cause the unit to
overheat and ultimately fail after a short period of operation. The compressor must be returned to the factory for service.
Report the mishandling of the package and file a damage claim with the shipping company immediately. Failure to do so
will void the warranty on the compressor. Please also contact Trillium US Inc. Inc. Technical Support using the contact
information found in Section 2.2.
Remove the straps and packaging materials from the compressor container, then lift or roll the unit out of the container
carefully. Inspect the exterior, if any damage is observed, inform the shipping company and Trillium US Inc. Inc. Keep the
original packaging materials in case the unit needs to be returned to the factory for service.
Most shipping companies have a certain grace period for reporting damages due to shipping in order to process the
insurance information in a timely manner. Therefore it is highly recommended that the shipping container be opened and
the unit inspected immediately whether or not it will be put into operation right away. Tip and Tells are present on the
external packaging as well on the compressor interior as shown in Figure 7 and Figure 8.
Caution:
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When transporting or storing the compressor unit, make certain it is not tilted by more than 45
degrees from horizontal level to avoid potential oil migration damage to the compressor.
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Figure 7– M600 / M400 Compressor Internal Tip & Tells
Figure 8– M600 / M400 Packaging Tip & Tells
5.2.2. Mounting the Compressor
It is highly recommended that the compressor unit be installed on a level and steady surface.
If the unit must be installed in a tilted manner, the maximum tilting angle is 10 degrees. Tilting the unit more than this
maximum allowable angle could result in damage and contamination in the system, and may void the warranty of the unit.
5.2.3. Preparing the Compressor for Operation
1.
2.
3.
4.
5.
6.
Check the voltage of the power source before connecting the main power cable to a suitable connector or
disconnect box, making sure that the compressor switch is off.
a. If the voltage of the power source is different from the factory default setting (see Table 4-2) and it may
be necessary to change the tap settings on the 24VAC control transformer located inside the electrical
box of the compressor for all configurations of the electrical box with the exception of that shown in
Figure 3 and Figure 4. Follow the steps described in Section 5.2.5 to make the change
For water-cooled Model 600 / Model 400 units, connect the cooling water:
a. Typical municipal drinking water is acceptable, however, a closed loop chilled water source is
recommended.
b. Minimum water flow rate of 1.4 - 1.8 GPM (5.3 - 6.8 liters/min) is required to achieve a maximum
discharge temperature of 100°F (38°C); with 80°F (26.7°C) considered ideal.
For air-cooled Model 600 / Model 400 units, make sure the front and rear grills have at least 24 inches of
clearance from the nearest objects at all sides.
Verify that helium pressure is between 240± 5 PSIG (16.5 ± .35 Bar). If the pressure is low, refer to Section 5.2.4.2
for charging procedures.
Start the compressor and run for about 15 minutes to stabilize the compressor oil inventory.
The compressor is now ready to be connected to the cryopump(s) or coldhead(s).
5.2.4. Installation
5.2.4.1.
Ambient Conditions and Coolant Connection
Ambient Conditions:
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When the compressor is in operation, the ambient temperature should be between 40°F - 104°F (5°C - 40°C). The
compressor unit should be set up in a non-condensing environment. An optimal location would be in a well ventilated (or
temperature controlled) location.
Coolant Connection:
Caution:
Caution:
For water-cooled compressor models, the water used in the unit operation must meet the
specifications indicated in Table 4-3.
Failure to comply with the coolant specifications may result in serious damage to the compressor
and may void the warranty on the unit.
Identify the inlet and outlet connection ports first before connecting the hoses. The water supply line should be connected
to the inlet port on the compressor.
An in-line water particulate filter is recommended to prevent heat exchanger fouling.
Periodically check the coolant flow rate and temperature to ensure the proper operation of the compressor unit.
5.2.4.2.
Caution:
Verifying and/or Refilling Compressor with Helium Gas
All safety regulations related to handling pressurized gas cylinders must be observed. Only use
helium with 99.999% or better purity (He 5.0 UH) when performing refill operation.
The compressor should already be pressurized to 240 ± 5 PSIG (16.5 ± .35 Bar) upon arrival. However, in the event that the
static pressure is too low or too high, steps shall be taken to restore the compressor to the proper helium pressure levels.
Examples of situations when the compressor may have lost some pressure include lost pressure due to
connecting/disconnecting helium flex lines, or after certain maintenance/clean-up procedure.
Therefore, prior to each operation of the compressor, verify that the helium pressure inside the compressor is at the
proper levels as stated in Table 4-3. If the pressure is outside of the required limits, follow the appropriate steps below:
Pressure should also be checked after the compressor has been connected to the overall system (as instructed in Section
5.2.4.3), as the static pressure may change based on the overall system pressure after connection.
If the helium pressure is too high:
1. Remove the protective cap from the “Fill/Vent” fitting.
2. Slowly connect the female charge fitting. As the connector is tightened, helium pressure will bleed out of the
compressor.
3. Continue to bleed out helium gas until the pressure reaches the desired limits defined in Table 4-3. Once the
pressure is reached, disconnect the Aeroquip.
4. Re-install the protective cap.
If the helium pressure is too low:
1. Connect a pressure regulator rated at 400 PSIG (27.6 Bar) delivery pressure and a helium charge line to a usersupplied helium supply gas cylinder. Terminate the charge line with the female charge fitting.
2. Set the helium pressure regulator to 10-25 PSIG (.69 - 1.7 Bar). Loosen the ¼” flare connector (part of the female
charge fitting, in between the helium charge line and the ¼” female Aeroquip adaptor).
3. Allow helium gas to flow though the flex line for a minimum 30 seconds to purge the charge line of air. Tighten
the flare connector while venting. After tightening, close the valve on the pressure regulator.
4. Remove the Aeroquip cap of the helium fill/vent fitting on the front of the compressor.
5. Tighten female charge fitting on the end of the helium charge line to the gas fill/vent Aeroquip fitting of the
compressor.
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7.
8.
Rev A / November 2015 / M600/M400 Helium Compressor
Set the pressure regulator to approximately 270 PSIG (18.6 Bar) and slowly open the valve on the pressure
regulator. When the helium supply pressure gauge reaches the specified limits found in 5, tightly close the
regulator valve.
Ensure the regulator valve is tightly closed. Shut off the helium pressure regulator on the helium bottle.
Remove the female charge fitting and reinstall the Aeroquip cap onto the compressor.
Caution:
If the compressor pressure drops over a period of time, either when not in operation or without the
lines being connected/disconnected, this may be an indication that there is a leak along the helium
circuit (compressor, lines, coldhead/cryopump). If that is the case, do not just keep refilling the system
with helium gas. Such leaks will introduce ambient air/moisture and cause contamination in the
helium stream. This will result in catastrophic failure of the whole cryogenic system if not properly
addressed. Contact and report the leak to Trillium US Inc. Inc. immediately using the contact
information found in Section 2.2.
5.2.4.3.
Connecting the Helium Flex Lines
Caution:
Connect or disconnect the helium flex lines only when the power to the compressor unit is switched
off. Never twist or kink the helium flex lines during the installation process.
Before connecting the helium flex lines, follow these steps:
1. Identify the helium “Return” (low pressure) and “Supply” (high pressure) ports on the compressor front panel.
2. Clearly mark the helium flex line that will be used to connect to the corresponding “Supply” and “Return” port on
the cryopump or coldhead.
Note:
The helium flex lines are equipped with self-sealing couplings which can be connected or disconnected
without helium escaping.
Follow these steps to connect the helium flex lines:
1. Unscrew the protective caps from the couplings and keep the caps for future use.
2. Check the couplings for cleanness. When necessary, use lint-free clean cloth or soft brush to clean the couplings.
3. Check the self-sealing connector flat rubber gasket to make sure that it is clean and properly positioned. Replace
any missing or defective seals.
4. Use only the open-wrenches supplied with the installation kit or equivalent wrenches. For a ½” coupling, tighten
with a 1-3/16” wrench and stabilize with a 1” wrench.
5. Make the initial turns by hand and then use the wrenches until the fittings bottom out. This is critical, improper or
loose connections will affect compressor function.
-5
a. Effective connections can be validated by confirming the leak rate is less than 1 x 10 mBar -l/sec)
If the flex lines need to be bent to a radius less than 8” (20 cm), then a 90° helium elbow needs to be installed. Contact
Trillium US Inc. Inc. using the contact information found in Section 2.2.
Some installations may require different accessories to be installed in line with the helium flex lines. To connect these
accessories, follow the instructions listed above and any other applicable user manual associated with the accessory.
5.2.5. Electrical Connection
Caution:
Before connecting power to the compressor unit, make sure the factory setting of the operating
voltage matches that of the power supply where the unit is being installed. Failure to do so will result
in performance degradation of the system.
If the voltage of the power source is different from the factory default setting (see Table 4-2), it may be necessary to
change the tap settings on the 24VAC control transformer located inside the electrical box of the compressor for all
configurations of the electrical box with the exception of that shown in Figure 3 and Figure 4. Follow the steps described
below to make the change:
1. Unscrew the two side panels of the compressor
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2.
3.
4.
5.
6.
Rev A / November 2015 / M600/M400 Helium Compressor
Unscrew the top (wrap-around) cover of the unit
Unscrew the electrical box cover
Change taps on the 24VAC control transformer to the setting that is closest to that of the power source (illustrated
in Figure 9)
Put back and screw down the electrical box cover
Put back and screw down the panels and top cover of the compressor
Electrical connections are to be made in accordance with the schematics shown in Figure 24 thru Figure 26 for digital
configurations shown in Figure 1 and Figure 2; and in accordance with the schematics shown in
Figure 29 thru Figure 31 for analog configurations shown in Figure 5 and Figure 6.
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Figure 9– M600 / M400 Helium Compressor Control Voltage Transformer Tap Settings
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6. Operation
6.1.
Before Switching On the System
After the compressor unit and its load (cryopump, coldhead, etc) are installed and connected, check the helium gas
pressure as indicated by the pressure gauges mounted on the front panel of the compressor unit. Refer to Section 4.2 for
the proper static pressure readings for the compressor.
If the helium pressure needs to be adjusted, refer to Section 5.2.4.2 for procedures to adjust the helium pressure inside of
the compressor.
6.2.
Normal Operation
The load of the compressor can be powered through the power connectors located on the front panel of the compressor.
To start operation of the compressor, do the following:
1. Open the coolant supply (water-cooled compressor model only)
2. Switch on the main power source.
a. For analog electrical boxes this will start the compressor and the load simultaneously
3. For digital versions of the electrical box, press the green ON button to start the compressor. Both the compressor
and its load should start simultaneously
Note:
During initial start-up, the compressor internal relief valve may begin to “Chatter”. This is a normal occurrence
and should subside within a few minutes.
During operation, check the operating pressure frequently. Refer to Table 4-3 for required operating pressures. If
necessary, stop the compressor and adjust the helium pressure (see Section 5.2.4.2). If pressure drop-off occurs
frequently, a substantial leak may be in the helium circuit. In this case, stop operation and contact Trillium US Inc. Inc.
customer service immediately (see Section 2.2).
Note:
4.
During shut down, the compressor motor may reverse rotate as the pressures equalize internally through the
scroll members of the motor. This will cause the compressor to emit a “shuttering” sound. This reversal of
direction has no effect on the compressor durability and is entirely normal.
To shut down the compressor unit, press the red OFF button on the front panel for digital electrical boxes or the
main power switch for analog electrical boxes. For water cooled units, allow coolant to continue to circulate for at
least 10 more minutes before shutting off flow.
6.2.1. Cycle Times
There is no set answer to how often the cryogenic compressor can be started and stopped in an hour. Trillium US Inc. Inc.
recommends a maximum of twelve cycles per hour. One critical consideration is a minimum run time required to return oil
to the compressor after start up. To assure proper oil return, one minute is the minimum run time for all cryogenic
compressors. A second consideration is a four minute minimum off cycle time once the compressor cycles off.
6.3.
Electronics Interface Connections
The Model 600 / Model 400 helium compressors are provided with a pig tail for connecting to the installation location.
Electrical box interfaces are described below.
6.3.1. Remote Interface
The electrical box can be controlled through a remote interface. This allows a PLC or other hardware device to control and
monitor certain functions of the compressor and cold-head.
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Digital configurations of the electrical box as shown in Figure 1 thru Figure 4 provide a D-sub 25 pin connector for remote
interface control and status collection; the pin-out is shown in Table 6-1.
Table 6-1 – J1 or J3 Remote Connector (25-Pin D-Sub)
PIN #
SIGNAL DESCRIPTION
1
N/C
2
N/C
3
Reset
4
Cold Head ON/OFF
5
N/C
6
Compressor ON/OFF
7
N/C
8
N/C
9
N/C
10
N/C
11
N/C
12
N/C
13
N/C
14
N/C
15
N/C
16
Pressure Alarm
17
Phase Error
18
Temperature Alarm
19
Run Status
20
N/C
21
N/C
22
N/C
23
N/C
24
Ground
25
+24V Output
For analog configurations of the electrical box as shown in Figure 5 and Figure 6 a two pin MS3102A14S-9S connector is
provided; the pin-out is shown in Table 6-2 .
Table 6-2 – Analog Remote Connector
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PIN
SIGNAL DESCRIPTION
A and B
Compressor Remote Control
Make-ON, Break = OFF
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6.3.2. D-Sub User Controls
For the Model 600/ Model 400 compressors that have electrical box configurations as shown in Figure 1 and Figure 2 input
control signals (pins 3, 4, 6) require a user slide switch or opto-coupler as shown in Figure 10. Independent control of the
compressor and cold head / cryo pump is not possible with this configuration of electrical box. The compressor is shipped
with a mating plug which when left installed will cause the compressor to return to powered on state in the event of a
power failure.
Example: To start the compressor connect pin 6 to pin 24. To start the coldhead, connect pin 4 to pin 24.
Figure 10– User Control Signal Interface
For the Model 600/ Model 400 compressors that have electrical box configurations as shown in Figure 3 and Figure 4
remote interface inputs are shown Table 6-3. The inputs require a dry-contact switch or an opto-coupler as shown in the
diagram below. Short each input (pin 3, 4, or 6) to the Input Return (pin 24) to assert the signal. Open the circuit to deassert the signal.
Since there are up to three ways to issue commands in the Figure 3 and Figure 4 electrical boxes; front panel buttons, USB
interface, and the DB25 interface, the control logic uses a “last command” approach based on state transitions. The
transition of shorting an input to pin 24 signals the controller to turn on the corresponding subsystem. The transition of
removing the short to pin 24 signals the controller to turn off the subsystem. If the remote system intends to turn on a
subsystem and the input is already shorted to pin 24, then the short must be removed for 100ms or more and then the
short reapplied. If the remote system wants to turn off a subsystem and the input is already open, the pin must be shorted
to pin 24 for 100ms or more and then opened again.
Table 6-3 – Remote Interface Inputs for Electrical Boxes Shown in Figure 3 and Figure 4
SIGNAL
SIGNAL DESCRIPTION
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Reset
Short pin 3 to pin 24 for 3 seconds or longer to reset the control
board processor. Leave pin 3 open-circuit (floating) for normal
operation.
Coldhead Enable
Short pin 4 to pin 24 to turn on the coldhead.
Open-circuit pin 4 to turn off the coldhead.
Compressor Enable
Short pin 6 to pin 24 to turn on the compressor.
Open-circuit pin 6 to turn off the compressor.
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6.3.3. D-Sub User Status
For the Model 600/ Model 400 compressors that have electrical box configurations as shown in Figure 1 and Figure 2
output status signals (pins 16-19) are designed to drive a user side opto-coupler as shown in Figure 11.
Example: Use the output voltage from pin 19 & 25 to monitor the run status of the compressor, this output can be used to
drive a LED or used as an input to a PLC.
Figure 11– User Status Signal Interface
For the Model 600/ Model 400 compressors that have electrical box configurations as shown in Figure 3 and Figure 4
remote interface outputs are shown Table 6-4. The output signals are designed to drive a user-side opto-coupler as shown
in the figure above. Each output is shorted to ground by the controller when the output is asserted and is open-circuit
otherwise. Connect a 24VDC load between each output pin and the Output Source (+24V power) at pin 25. Each output
should draw a maximum of 5 milliamps. The outputs can be used to drive LEDs or opto-couplers.
Table 6-4 – Remote Interface Outputs for Electrical Boxes Shown in Figure 3 and Figure 4
SIGNAL
SIGNAL DESCRIPTION
Pressure Alarm
When the compressor pressure is too low, pin 16 is shorted to
ground. Pin 16 is left floating when the pressure is normal or the
system is off.
Phase Error
When there is input power phase error, pin 17 is shorted to
ground. Pin 17 is left floating when there is not a phase error.
Temperature Alarm
When the compressor is too hot, pin 18 is shorted to ground. Pin
18 is left floating when the compressor temperature is normal.
Run Status
When the compressor, the coldhead, or both are running, pin 19
is shorted to ground. When the compressor and coldhead are
both off, pin 19 is left floating.
6.3.4. Compressor Front Panel User Interface
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 1 and Figure
2, on start-up, the front panel LCD will display the title screen and revision information. Once initialization is complete, the
main screen is displayed.
Note:
If the phases are not connected properly, a "Phase Error" will be displayed. The compressor cannot be started
until the unit is powered down and the phase error is corrected.
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These configurations of the compressor provide 3 buttons and a 2-line display for easy operation:
• Off
• On
• Menu
Pressing the “Off” button from any screen results in powering the compressor off. The unit can only be turned on if all
operational checks are passed. If a system error occurs, pressing the “Menu” button displays the status of each system
check. If all operational checks are successful, pressing the “Menu” button displays the operating hours on the
compressor.
The “On” button powers the compressor if all system checks are successful. If a system check is in the failed state, the
“On” button is ignored.
6.3.4.1.
Compressor Front Panel User Interface Revised
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 3 and Figure
4, on start-up, the front panel LCD will display it's initialization sequence and once complete the system status screen will
be displayed showing the current state of the compressor and cold head as well as the current accumulated compressor
run time.
Note:
If the phases are not connected properly, a "AC Power Phase Error" will be displayed. The compressor cannot be
started until the unit is powered down and the phase error is corrected.
These configurations of the compressor provide 4 buttons and a 2-line display for easy operation:
• Off: Pressing this button will turn the Cold Head, Compressor, and Solenoid Valves off. Pressing the Off button will
always override the signals on the Remote Interface allowing the user to turn off the system.
• On: Pressing this button will turn the Solenoid Valves, Compressor, and Cold Head on unless prohibited by one or
more fault interlocks.
• Menu: Pressing this button will cycle between the Status Screen and the Active Faults Screen. Pressing this button
when the Fault History screen is displayed will move to the Status Screen. If more than one fault is active, the
Menu button is used to cycle through each of the active faults before going back to the Status Screen.
• History: From either the Status Screen or Active Faults Screen, pressing this button take will take the user to the
Fault History screen where the most recent fault will be displayed. Pressing the History button will cycle through
each of the logged faults in reverse-chronological order until the last logged fault is displayed. Then the fault
history will wrap around to the most recent fault again.
6.3.5. Compressor Operational Checks
The following table lists all of the compressor operational checks and the cause of a failed operational check.
Table 6-5 – Operational Checks
Fault
System Interlock
Helium Pressure Alarm*
Pressure alarm contact is not OPEN. Verify pressure
contact and helium pressure.
Helium Temperature Alarm
Temperature alarm contact is not CLOSED. Verify
temperature contact and helium temperature.
Oil Return Temperature Alarm
Temperature alarm contact is not CLOSED. Verify
temperature contact and oil temperature.
Overload Alarm
Contactor overload tripped. Reset overload on contactor.
*Pressure switch does not come with standard models.
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6.3.5.1.
Rev A / November 2015 / M600/M400 Helium Compressor
Compressor Front Panel Fault Errors
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 3 and Figure 4
the following errors can be displayed:
• System Error
• Compressor Overload
• Low Pressure
• High Temperature
• AC Power Phase Error
• F13-F15 Fuse Blown
• F16-F18 Fuse Blown
• 3PH Detected in 1PH Mode
• 1PH Detected in 3PH Mode
6.3.6. Compressor System Shut Down
Manual shut-down
Push the OFF button or the Main Power Switch
Automatic shut-down
The following system indication will cause the compressor to automatically shut down:
1. Low Helium pressure (not standard)
2. High Helium pressure (not standard)
3. High Helium temperature
4. High Oil Return temperature
5. Contactor Overload
6. Loss of Power
If an automatic shut down occurs, refer to Table 6-5 to identify and remove the fault. Once the fault has been corrected,
the user can restart the system by pressing the “ON” button.
6.3.7. Compressor Interfaces
For the Model 600 / Model 400 compressors that have digital electrical box configurations shown in Figure 1 and Figure 2 a
connector is provided for serial communication.
6.3.7.1.
Serial Port Interface (J2-RS232)
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 1 and Figure
2, a DB9 Male connector is provided for serial port communications. A “straight through” serial cable, as shown in Table
6-6 and Table 6-7, is necessary for interfacing to the serial port. Only pins 2, 3, and 5 are required.
Table 6-6 – Serial Port Interface Pin Assignments
DB9 Female (to Compressor)
DB9 (to Controller)
97-00046-000
1
-------------
1
2(TxD)
-------------
2(TxD)
3(RxD)
-------------
3(RxD)
4
-------------
4
5(Gnd)
-------------
5(Gnd)
6
-------------
6
7
-------------
7
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Rev A / November 2015 / M600/M400 Helium Compressor
DB9 Female (to Compressor)
DB9 (to Controller)
8
-------------
8
9
-------------
9
Table 6-7 – Serial Port Cable
Serial Port Settings
6.3.7.2.
Baud Rate
4800
Data Bits
8
Parity
NONE
Start Bits
1
Stop Bits
NONE
USB Interface (J1-Maintenance)
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 3 and Figure 4
a USB type B connector is provided. This connector provides control input and status output using USB protocol. The
underlying protocol of the USB link is HID. The data is streamed as raw bytes.
6.3.8. Serial Communications via RS232
•
•
•
•
•
•
•
•
•
•
No handshaking
PC is always the host.
Commands and data requests from host.
Message Format:
o Byte 1: STX (02h = control-B)
o Bytes 2..4 Command or data request
o Bytes 5..X Command or requested data
o Byte X+1 (Carriage Return = 0Dh)
All bytes are ASCII type (20h..7Fh)
Maximum value for X is 126.
Individual data values are separated by a forward slash
Used letters are ASCII capitals.
Used numbers are ASCII decimals.
Incorrect formats are ignored
6.3.8.1.
Serial Port Commands
The following serial port commands are provided:
Command
Description
Send: STX SYS1 CR
1+4+1
Turn System On
Receive: STX SYS2 CR
1+4+1
System Error
Command
Send: STX DAT CR
97-00046-000
Table 6-8 – Serial Port Commands
No. of Bytes
Table 6-9 – Data Message
No. of Bytes
Description
1+3+1
Data request
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No. of Bytes
Command
Receive:
STX DAT
0.00
000000
12345
000000000000000
003
1
1+3
4+1
6+1
5+1
15
3+1
1+1
1
1+1
0000
00
1000000000000000
4
2+1
16 + 1
4
CR
Description
SW Version
Reserved
Hours Counter
Reserved
On Timer(seconds)
Status:
0 = Off
1 = On
2 = System Error
Compressor Status:
0 = Off
1
1 = On
Reserved
Number of active errors
1 = active error
0 = error inactive
Number of errors logged (≤
8)
End of message
Table 6-10 – Command/Data
Send
Compressor
Description
STX SYS x CR
STX SYS y CR
X = Y = 0 Off
X = Y = 1 On
Y = 2 System Error
STX SC x y CR
STX SC x y CR
X = 1 Cold Head
Y = 1 On
Y= 0 Off
STX DAT CR
As described in previous table
Data Requested
STX ERR xx hhhhh / xx hhhhh / xx hhhhh CR
xx = error code
(Will display last 8 error codes)
hhhhh = hours counter
* Example:
STX SYS1 CR Turns the compressor on, the system will respond with SYS1
STX SYS0 turns the compressor off
STX ERR CR
STX 11 CR = Coldhead On the compressor will return SC11
Note the compressor must be running to turn the Coldhead on.
Table 6-11 – Error Codes
97-00046-000
Error Code
Display
1
System Error
Description
Error has occurred
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2-3
Reserved
4
Contactor Error
5
Phase/Fuse Error
6
Pressure Alarm
Low pressure switch tripped
7
Temperature Fail
Thermal Switch has tripped
Coolant Supply Failure
Lack of cooling
8 - 16
Compressor overload relay has tripped off.
Line voltage out of Phase.
Fuses blown
Reserved
6.3.9. Communications via USB
Communication via USB can be achieved via PC integration. The format for the packet is shown in Table 6-12.
Table 6-12 – USB Packet Format
Range
Field
Bytes
Notes
Header #1
1
0x55
Header #2
1
0xAA
Packet Length
2
Command
1
Payload Data
[0:102]
Number of bytes in:
• Source
• Destination
• Command
• Payload Data
Field is transmitted in little endian.
[0:255]
See Table 6-13
Various
See Table 6-14 thru
Table 6-26
Payload fields that are native types (e.g. integers) and
have more than one byte are sent in little endian.
[0:255]
The packet’s CRC is calculated by:
• Seed value = 0
• Polynomial = x8 + x2 + x1 + 1
• Includes the following fields:
o Payload Data Length
o Source
o Destination
o Command
o Payload Data
Various
CRC
1
Table 6-13 – USB Maintenance Interface Command ID's
97-00046-000
Name
Packet ID
Description
Get Status
229
Requests the system status
Status Response
10
Packet contains system status information
Get Fault History
53
Requests the set of historic faults
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6.3.9.1.
Rev A / November 2015 / M600/M400 Helium Compressor
Name
Packet ID
Description
Fault History Response
54
List of either current or historic faults
Set Compressor
57
Commands the compressor to be on/off
Set Coldhead
58
Commands the cold/head to be on/off
Reset
224
Forces the control board processor to reset
Get Version
226
Request for the firmware version information
Version Response
225
Packet contains the version, build date, and part
number
ACK
254
Response to indicate a command was executed
successfully
NACK
255
Response to indicate a command failed to execute
successfully
USB Payload Formats
Table 6-14 thru Table 6-26 define the payload formats for all commands listed in Table 6-13.
Table 6-14 – ACK Payload Format
Response to: Any command that successfully executes and does not have a specific response.
Field
Bytes
Range/Units
Response to Command ID
1
See Table 6-13
Payload Length
1
Table 6-15 – NACK Payload Format
Response to: Any command that fails to execute correctly or whose format is incorrect.
Field
Bytes
Range/Units
Command ID
1
See Table 6-13
Reason Code
1
See Table 6-16
Payload Length
2
Table 6-16 – NACK Reason Codes
97-00046-000
Value
Description
0
Unspecified/Other
1
Unrecognized/unsupported command
2
CRC error
3
Parameter out of range or other invalid data
4
Not ready for command
5
Packet length error
6
Timeout
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Table 6-17 – Get Status Payload Format
Response Expected: Status Response
Action: Queries the Pump Controller for its current status.
Field
Bytes
Range/Units
Payload Length
0
No payload data
Table 6-18 –Status Response Payload Format
In Response To: Get Status
Action: Payload contains the Pump Controller status..
Field
Bytes
Range/Units
Compressor Run Time
4
Seconds
PCB Temperature
2
0.1 C
24V Input Voltage
2
mV
Digital Output States
Digital Input States
Button States
Fault States
97-00046-000
2
Bit Set:
Bit 0 – Compressor Pressure Fault
Bit 1 – Compressor Temperature Fault
Bit 2 – Phase Error Fault
Bit 3 – System Running
Bit 4 – Fan/Heater On
Bit 5 – Compressor/Solenoid On
Bit 6 – Coldhead On
Bit 7 – Spare Output #1 On
Bit 8 – Spare Output #2 On
Bit 9-15 - Reserved
2
Bit Set:
Bit 0 – Coldhead Enable
Bit 1 – Compressor/Solenoid Enable
Bit 2- System Reset
Bit 3 – Compressor Pressure Fault
Bit 4 – Compressor Temperature Fault
Bit 5 – Compressor Overload Fault
Bit 6 – Spare Remote Input #1
Bit 7 – Spare Remote Input #2
Bit 8 – Spare Chassis Input #1
Bit 9-15 - Reserved
2
Bit Set:
Bit 0 – On Button Pressed
Bit 1 – Off Button Pressed
Bit 2 – Menu Button Pressed
Bit 3 – History Button Pressed
Bit 4-15 – Reserved
2
Bit Set:
Bit 0 – System Fault
Bit 1 – AC 220V Fuse Blown
Bit 2 – AC 24V Fuse Blown
Bit 3 – Compressor Overload Fault
Bit 4 – AC Phase Fault
Bit 5 – Compressor Pressure Fault
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In Response To: Get Status
Action: Payload contains the Pump Controller status..
Field
Bytes
Range/Units
Bit 6 – Compressor Temperature Fault
Bit 7 – 3 Phases Detected; 1 Phase Expected
Bit 8 – 1 Phase Detected; 3 Phases Expected
Bit 9-15 - Reserved
Payload Length
16
Table 6-19 – Get Fault History Payload Format
Response Expected: Fault History Response
Action: Queries the Pump Controller for the list of historic faults.
Field
Bytes
Range/Units
Payload Length
0
No payload data
Table 6-20 –Fault History Response Payload Format
In Response To: Get Fault History
Action: Payload contains the list of historic faults.
Field
Bytes
Range/Units
Number of Faults
1
[0..25]
Reserved
1
N/A
The remaining payload is a sequence of Number of Fault entries:
See
Fault Identifier
1
Timestamp
4
Payload Length
[2..102]
Table 6-21
Running time, in seconds, of the compressor at
which the fault occurred.
Table 6-21 – Fault Codes
Value
Description
0
System Fault
1
AC 220V Fuse Blown
2
AC 24V Fuse Blown
3
Compressor Overload
4
AC Phase Fault
5
Compressor Pressure Fault
6
Compressor Temperature Fault
7
3 Phases detected; 1 Phase expected
8
1 Phase detected; 3 Phases expected
Table 6-22 – Set Compressor Payload Format
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Response Expected: ACK/NACK
Action: Powers the Compressor/Solenoid on or off.
Field
Bytes
Range/Units
Power State
1
0 – Off
1 - On
Payload Length
1
No payload data
Table 6-23 – Set Coldhead Payload Format
Response Expected: ACK/NACK
Action: Powers the Coldhead on or off.
Field
Bytes
Range/Units
Power State
1
0 – Off
1 - On
Payload Length
1
No payload data
Table 6-24 – Reset Payload Format
Response Expected: ACK/NACK
Action: Performs a reset on the control board processor.
Field
Bytes
Range/Units
Payload Length
1
No payload data
Table 6-25 – Get Version Payload Format
Response Expected: Version Response
Action: Queries the control board for the set of firmware version numbers.
Field
Bytes
Range/Units
Payload Length
0
No payload data
Table 6-26 –Version Response Payload Format
In Response To: Get Version
Action: Payload contains the list of firmware version numbers.
Field
Bytes
Range/Units
Communication Protocol Version
2
[1..255]; currently set to 1
Year code was compiled
2
Full year (yyyy)
Month code was compiled
1
Month (1=Jan; 12=Dec)
Day code was compiled
1
Day of Month
Firmware Part Number
2
Will be 437.
Firmware Version Number
2
Bootloader Part Number
2
Bootloader Version Number
2
Hardware Part Number
2
97-00046-000
Will be 436.
Will be 401.
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In Response To: Get Version
Action: Payload contains the list of firmware version numbers.
Field
Bytes
Range/Units
Calculated Checksum
2
Should be equivalent to Stored Checksum
Stored Checksum
2
Should be equivalent to Calculated Checksum
Reserved
5
Payload Length
25
7. Troubleshooting
7.1.
Troubleshooting Activities
Table 7-1 describes some problems that users might encounter while operating the Model 600 / Model 400 Helium
Compressor and provides potential solutions to those problems. Additional Fault trees are presented in Figure 32 and
Figure 33.
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 1 and Figure
2, Table 7-2 lists the fuse function and amperage rating. See Figure 34 for PCBA fuse locations.
For the Model 600/ Model 400 compressors that have digital electrical box configurations as shown in Figure 3 and Figure
4, Table 7-3 lists the fuse function and amperage rating. See Figure 35 for PCBA fuse locations.
If a compressor problem still persists after performing the corrective actions described in this section, please contact
Trillium US Inc. Inc. Technical Support for further assistance (see Section 2.2).
Problem
Table 7-1 – Troubleshooting Procedures
Possible Cause
Corrective Action
1.
2.
The compressor On/Off switch
(SW1) is in the On position but will
not start.
3.
4.
5.
No power is coming from
the power source.
Incorrect or disconnected
wiring within the
compressor
Thermal protection switch
(TS1 and/or TS2) is open.
Pressure protection switch
(PS1 or PS 2) is open*
High current has tripped
the current overload relay.
1.
2.
3.
4.
5.
97-00046-000
Check service fuses, circuit
breakers, and wiring
associated with the power
source. Repair as needed.
Check the compressor
wiring against the wiring
schematic.
Confirm that switch TS1
and/or TS2 is open.
Add Helium if the pressure
is low, remove Helium if
the pressure is high
Reset the current overload
relay.
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Problem
Possible Cause
Corrective Action
1.
High temperature of the
1.
compressor caused by
insufficient cooling (most
likely due to the ambient
temperature being too
high, resulting in the
opening of thermal
2.
Compressor stops after several
protection switches (TS1
minutes of operation and remains
and/or TS2).
off.
2. Insufficient helium static
3.
pressure.
3. High temperature helium
4.
gas tripped the thermal
protection switch (TS1).
5.
4. Low power source voltage.
5. Mechanical seizure.
6.
6. High Pressure in the system
*Pressure switch does not come with standard models.
Confirm that sufficient
cooling air is flowing to the
compressor. If possible,
provide additional cooling
to the surrounding
environment.
Add helium, using the
procedures described in
Section 5.2.4.2.
Check for proper cooling of
the compressor unit.
Confirm that power source
voltage is correct.
Contact Trillium US Inc. for
assistance.
Check for proper pressure
in Table 5.
Table 7-2 – Fuse Listing for Digital Electronics Boxes in Figure 1and Figure 2
OI Part Number
Fuse Designator
Function
Amperage
PCBA: F12
Fan
3
31-00012-010
PCBA: F11
Fan
3
31-00012-010
PCBA: F5
Contactor
1.5
31-00012-007
PCBA: F1
Solenoids
2
31-00012-009
PCBA: F2
Solenoids
2
31-00012-009
PCBA: F3
Cold head
4
31-00012-013
PCBA: F9
Cold head
4
31-00012-013
PCBA: F4
Cold head
4
31-00012-013
PCBA: F10
PCBA Protection
0.8
31-00012-012
Fuse Box: F6
Scott-T Protection
4
31-00152-009
Fuse Box: F7
Scott-T Protection
4
31-00152-009
Fuse Box: F8
Scott-T Protection
4
31-00152-009
Transformer Mounted: F10*
Control Transformer
5.6
50173-2
Fuse Box: F13**
Control Transformer
0.4
31-00152-001
Fuse Box: F14**
Control Transformer
0.4
31-00152-001
Fuse Box: F15**
Heater
10
31-00152-004
Fuse Box: F16**
Heater
10
31-00152-004
Fuse Box: F17**
Control Transformer
3
31-00152-003
*Standard Unit Only
**On-Board Unit Only
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Table 7-3 – Fuse Listing for Digital Electronics Box in Figure 3 and Figure 4
OI Part Number
Fuse Designator
Function
Amperage
PCBA: F13
Main Power
15
31-00012-014
PCBA: F14
Main Power
15
31-00012-014
PCBA: F15
Main Power
15
31-00012-014
PCBA: F16
24VAC
3
31-00012-015
PCBA: F18
24VAC
3
31-00012-015
High Volt Fuse Block: F1
Heater Power
5
31-00152-011
High Volt Fuse Block: F2
Heater Power
5
31-00152-011
8. Maintenance
8.1.
Maintenance Personnel Requirements
Only trained and qualified personnel should perform the maintenance procedures described in this chapter. All other
maintenance work must be performed by Trillium US Inc. Inc. personnel in the factory. Please contact Trillium US Inc. Inc.
to make arrangements for maintenance work (see Section 2.2).
8.2.
Removing the Compressor from Service: Removal, Transport and Storage
It is recommended that the Model 600 / Model 400 Helium Compressor be removed from service when carrying out the
maintenance duties described in Section 8.3.
To remove the compressor unit from service, do the following:
1. Turn off the compressor unit by pressing the OFF button.
2. Switch off the main power supply to the compressor.
3. Separate the compressor unit from the main power source.
4. Allow coolant to continue circulate for at least 10 more minutes (for water-cooled model)
5. Allow the compressor load (cryopump, coldhead, etc) to warm up to room temperature before detaching the
helium flex lines from the compressor.
Caution:
Loosening or detaching helium flex lines with the compressor load at low temperature without
proper warming-up can result in loss of helium and/or pressure rise in the cryopump or
coldhead unit beyond its designed maximum pressure level.
When transporting the compressor unit, follow these guidelines:
1. Make sure the appropriate protective caps are properly secured before shipping.
2. Always store the compressor unit in a dry place.
3. If a freezing temperature environment is anticipated whether during shipping or under storage, make certain the
coolant in the compressor circuit is properly drained.
Caution:
8.3.
The compressor unit should never be tilted more than 10 degrees either during shipping or in
storage.
Scheduled Preventative Maintenance Activity
The only scheduled field service maintenance required on the Model 600 / Model 400 Helium Compressor is replacement
of the compressor adsorber after every 15,000 hours of operation (as shown on the Elapsed Time Meter) or 2 years,
whichever comes first. While in many cases an adsorber can last longer, Trillium US Inc. experience dictates that from a
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cost-value perspective it is better to swap the adsorber out after 2 years to protect the integrity of the overall integrated
solution with the compressor load.
The adsorber is used as the final filter to keep the oil vapor out of the helium gas just before the gas is pumped into the
compressor load (cryopump, coldhead, etc.). After about 15,000 hours of operation or 2 years, the effectiveness of the
adsorber will decrease and need to be replaced. If not replaced, the oil particles could accumulate on the cold surface of
the compressor load, reducing the cooling performance of the overall system. In severe cases of such oil contamination,
the load could cease to function completely.
To remove and replace the compressor adsorber, follow the steps described in Section 8.3.1 and Section 8.3.2.
8.3.1. Remove the Compressor Adsorber
To remove the compressor adsorber:
1. Turn off the compressor and disconnect it from the main power supply.
2. Allow sufficient time for the load of the compressor (cryopump or coldhead) to warm up before detaching the
helium flex lines from the compressor. Refer to Section 5.2.4.3 for proper procedures to detach helium flex lines.
Caution:
3.
4.
5.
6.
Detaching helium flex lines with the compressor load at low temperature could result in loss of helium
gas. It may also cause the pressure rise in the system beyond the permissible level therefore creating a
safety hazard.
Use the two wrenches supplied with the (optional) Installation Kit to avoid loosening the body of the coupling
from its adapter. Hold one wrench tight on the coupling half attached to the rear side of the compressor. Use the
other wrench to loosen the coupling to the helium supply line. Unscrew the two-self sealing coupling halves
quickly to minimize minor gas leakage. Figure 17 contains an illustration of the self-sealing couplings.
After detaching the helium flex line from the helium supply connection located on the adsorber panel on the front
panel, unscrew and remove the nut and washer of the helium supply connector. See Figure 12.
Unscrew the six screws holding the adsorber panel on the front panel. See Figure 13.
Once the adsorber panel is removed, the adsorber should be in full view. There is a short section of helium flex
line that connects the adsorber with the oil-mist separator of the compressor.
To detach the helium flex lines, perform the following:
1. Use two wrenches sized 1-1/8" and 1-3/16" to avoid loosening the body of the coupling from its adapter
during removal (if optional installation kit purchased, utilize the two wrenches from the kit).
2. Hold 1-1-8" wrench tight on the coupling half attached to the adsorber.
3. Use the 1-3/16" wrench to loosen and disconnect the coupling to the helium supply and OMS line.
Caution:
Detaching helium flex lines with the compressor load at low temperature (i.e. without proper
warming-up) can result in loss of helium and/or pressure rise in the compressor unit beyond
its designed maximum pressure level.
Note:
Unscrew the two-self sealing coupling halves quickly to minimize minor gas leakage. See
Figure 17 for an illustration of the self-sealing couplings.
Remove the two screws that hold the adsorber to the bottom of the compressor chassis, see Figure 14.
Slightly pull the adsorber assembly towards the front. Then tilt the assembly to remove it from the chassis, see
Figure 16.
9. Remove the adsorber and save all nuts, bolts, and washers for installing the replacement adsorber.
10. The removed adsorber can be returned to Trillium US Inc. for credit. Section 2.2 provides the contact information.
7.
8.
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Figure 12 – Removal of Helium Supply Line Aeroquip at Access Panel
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Figure 13 - Adsorber Aeroquip Nut and Access Panel Removal
Figure 14 - Adsorber Screw Removal
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Figure 15 - Adsorber Aeroquip OMS Supply Line Removal
Figure 16 - Adsorber Removal
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1
1-3/16" Wrench
1-1/8" Wrench
Figure 17 – Self sealing Connector
Note:
Image from Aeroquip Catalog.
8.3.2. Install Replacement Adsorber
To install the replacement adsorber:
1. Remove the dust caps from the self
self-sealing
sealing coupling halves at each end of the replacement adsorber.
2. Check the self-sealing
sealing connector flat rubber gasket to make sure that it is clean and properly positioned.
3. Place the adsorber back in the compressor using the nuts, bolts and washers set aside during the removal process
described in Section 8.3.1.
self sealing coupling halves quickly tto minimize minor gas leakage.
4. Install the two-self
5. Use the 1-1/8" and 1-3/16" wrenches
wrenches, holding the 1-1/8" wrench tight on the coupling half attached to the
adsorber. Use the 1-3/16" wrench to tighten the coupling to the helium supply
supply/OMS line.
6. Make the initial turns by hand and then use the wrenches until the fittings bottom out. This is critical, improper or
loose connections will affect compressor function.
-5
a. Effective connections can be validated by confirming the leak rate is less than 1 x 10 mBar -l/sec)
7. Make sure the supply pressure is in accordance to the pressures found in Table 4-4.. If the pressure is either too
high or too low, follow the instructions in Section 5.2.4.2 to add helium gas to the compressor.
8. Write the installation date and number of running hours (if known) on the decal provided with the replacement
adsorber.
9. Re-install the adsorber access panel that was removed in Section 8.3.1.
10. Restart the compressor.
8.4.
Unscheduled Corrective Maintenance
The following corrective maintenance activities may be necessary should the helium gas circuit of the Model 600 / Model
400 Helium Compressor becomes contaminated.
8.4.1. Removing Helium Contaminatio
Contamination
Helium contamination is usually indicated by irregular, noisy, or intermittent operation (ratcheting), and sometimes the
seizure of the coldhead or cryopump drive mechanism. This is caused by the accumulation of frozen contaminants within
the compressor load and resulting in interference. The source of the helium contamination is due to either:
•
Inadvertent introduction of ambient air into the system
o Use of helium with purity of less than 99.999% (He 5.0 UH),, such as helium gas used for leak detection
and welding.
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•
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Minor contamination can usually be removed by running the coldhead or cryopump for several hours to trap the
contaminants in the coldhead/cryopump, then shutting down the compressor and immediately removing the
helium lines at the compressor. Then allow for the coldhead/cryopump to warm thoroughly and perform the
helium cleanup procedures as outlined in the coldhead/cryopump manual.
Stubborn contamination involving water vapor requires decontamination of the compressor. One effective
method involves supplying clean helium to the return side of the compressor at appropriate pressures while
venting a small amount of gas from the supply side while the compressor is running. This is referred to as a
“running purge.” Contact Trillium US Inc. Inc. if such a procedure is needed.
The steps to remove compressor decontamination: (with the compressor running)
1. Set the helium regulator to whatever the compressor return pressure gauge reads (i.e. 50 PSIG)
2. Attach the helium charge line to the running purge fill fitting
3. Attach the running purge fill fitting to the return Aeroquip
4. Loosely attach the running purge vent fitting to the supply Aeroquip
5. Slowly tighten the running purge vent tool until helium is venting from the vent tool
6. Open the regulator valve and watch the compressor pressure gauge. The pressure should be stable at the
pressure set in step 1. The adjustment of the regulator or the amount of helium venting from the compressor may
need to be performed in order to maintain stability.
7. Once the pressure is stabilized, allow the running purge to continue for a minimum of 15 minutes.
8. After a minimum of 15 minutes, stop the running purge by first removing the running purge vent tool. Next, close
the regulator valve and remove the helium charge line from the compressor.
9. Turn off the compressor.
10. Remove the running purge tools from the compressor.
11. Check the static pressure and readjust the pressure to the proper limits (see Table 4-3) in accordance with Section
5.2.4.2.
8.5.
Cleaning Equipment
The Model 600 / Model 400 Helium Compressor also will allow for the coldhead drive circuit to be operated independent of
the compressor motor. Such an operation would be utilized if minor contamination would need to be removed from the
coldhead unit. The following steps shall be taken:
1. Connect pin 24 to pin 4 on J1. The coldhead will operate for up to 10 minutes. The timer will be displayed on the
LCD screen at this point.
2. To stop the coldhead, remove the connection between pin 24 and pin 4.
3. If the jumper is not removed, the coldhead drive will automatically stop after 10 minutes.
Caution:
8.6.
Do not use solvents to clean the Aeroquip fittings. The fittings come pre-lubricated from the factory
and should never be greased or oiled. Failure to comply could result in a contaminated helium circuit.
Returning Equipment
Before returning any equipment, contact Trillium US Inc. Inc. to receive special instructions and to obtain a return
authorization (RMA) number. See contact information found in Section 2.2.
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Figure 18 – M600 Water Piping and Instrumentation Diagram
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Figure 19 – M600 Air Piping and Instrumentation Diagram
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Figure 20 – M400 Water Piping and Instrumentation Diagram
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Figure 21 – M400 Air Piping and Instrumentation Diagram
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Figure 22 – M600 / M400 Water Cooled General Dimensions
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Figure 23 – M600 / M400 Air Cooled General Dimensions
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Figure 24 – M600 / M400 Low Volt Standard Drive Schematic
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Figure 25 – M600 / M400 Low Volt On-Board Drive Schematic
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Figure 26 – M600 / M400 High Volt Standard Drive Schematic
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Figure 27 – M600 / M400 Low Volt Multi-Drive Schematic
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Figure 28 – M600 / M400 High Volt Multi-Drive Schematic
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Figure 29 – M600 / M400 Low Volt Analog Standard Drive Schematic
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Figure 30 – M600 / M400 High Volt Analog Standard Drive Schematic
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Figure 31 – M600 / M400 Low Volt Analog On-Board Drive Schematic
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Figure 32 – M600 / M400 Fault Tree: Compressor will Not Start / Adsorber Replacement
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Figure 33 – M600 / M400 Fault Tree: Compressor Starts but Shuts Off
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F1
F5
F12
F11
F3
F2
F9
F4
F10
Figure 34 – M600 / M400 Fuse Configurations Digital
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Figure 35 – M600 / M400 Fuse Configurations Multi-Drive
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Figure 36 – 99-00074-000 Tool Kit Contents
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Figure 37 – 99-00074-001 Tool Kit Contents
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