LEYBOLD COOLPAK 6000-1 User manual

COOLPAK
6000-1
Compressor unit and
accessories for cryogenic
refrigerator units
Cat.-No. 892 35
Operating instructions
Vacuum Solutions Application Support Service LEYBOLD VACUUM
GA 12.137/2.02

GA 12.137/2.02 - 05/2002
Description
Contents
Page
1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Design and function . . . . . . . . . . . . . . . . . . . 3
1.2 Standard equipment . . . . . . . . . . . . . . . . . . . 5
1.3 Technical specifications . . . . . . . . . . . . . . . . . 7
1.4 Order information . . . . . . . . . . . . . . . . . . . . . 8
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Safety information . . . . . . . . . . . . . . . . . . . . . 9
2.2 Unpacking and inspecting . . . . . . . . . . . . . . 12
2.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Ambient conditions and coolant connection . 13
2.5 Electrical connection . . . . . . . . . . . . . . . . . . 16
2.6 Mounting the flexlines . . . . . . . . . . . . . . . . . 20
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Normal operation . . . . . . . . . . . . . . . . . . . . . 23
3.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4 Removing from service . . . . . . . . . . . . . . . . 24
3.4.1 Transport and storage . . . . . . . . . . . . . . . . . 25
3.5 Interface description . . . . . . . . . . . . . . . . . . 26
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Helium gas pressure adjustment . . . . . . . . . 30
4.2 Replacing the adsorber . . . . . . . . . . . . . . . . 31
4.3 Changing the fuses for the control voltage . . 33
4.4 Leybold service . . . . . . . . . . . . . . . . . . . . . . 33
5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 35
6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Appendix: Conformance statement /
Electrical Schematic / Certifications . . . . . . . 39
Service personnel shall without fail read the
instructions provided for their guidance
(ISO 7000-0419).
Precautionary notes used in these instructions:
Warning
This indicates procedures and operations which must be
strictly observed to prevent hazards to persons.
Caution
This indicates procedures and operations which must be
strictly observed to prevent damage to or destruction of
the unit.
Illustrations
In the references to illustrations, such as (1/2), the first
number is the figure number, while the second digit iden-
tifies the item in the illustration.
We reserve the right to adopt modifications in the
engineering design and the specifications indicated
here.
The illustrations are not binding.
2
Legend for Fig. 1
1 Helium compressor
2 Heat exchanger
3 Oil separator
4 Oil adsorber
5 flexlines
6 Self-sealing couplings
7 Cold head or cryo pump
Fig. 1 Simplified schematic for the helium circuit

Description
1 Description
Cryogenic refrigeration units comprise:
– the compressor unit,
– the cold head, and
– flexlines.
These operating instructions describe the design and
operation of the compressor unit and the associated
flexlines.
The compressor unit shall be used only to operate cold
heads and other units in which cold heads are installed,
e.g. refrigerator cryopumps or cryostats. No other appli-
cation is permissible.
This compressor unit, COOLPAK 6000-1, is for use with
the following cold heads or cryo pumps only:
Cold heads: RGD, RGS, or COOLPOWER
580, 5/100 (..), 120, 120 T.
Cryo pumps: COOLVAC or RPK 5000 and larger.
For multi-unit operation contact Leybold.
Only components manufactured by Leybold may be
attached to the compressor units. The installation of
other components is permissible only after consultation
with Leybold.
These compressor units comply with all the require-
ments set forth in the European guidelines for awarding
the CE seal of approval. In addition, they satisfy the
requirements of Underwriters Laboratories (UL) and the
Canadian Standards Association (CSA); please refer to
the appendix for details.
1.1 Design and function
Compressor units are used to compress helium gas
which then expands in the cold head to produce low tem-
peratures.
Every compressor unit comprises the following func-
tional modules:
– helium compressor (1/1),
– heat exchanger (1/2),
– gas purifiers (1/3) and (1/4),
– power module (electrical supply unit).
The compressor unit and the cold head (1/7) are joined
by way of flexlines (1/5). The compressor unit, cold head
and pressure lines are fitted with self-sealing couplings
(1/6) and are charged with high-purity helium gas.
The helium compressor is sealed, lubricated and cooled
with oil. The oil is cooled with water in a heat exchanger.
After compression the helium gas is cooled in the heat
exchanger (1/2); oil is then removed from the gas at the
oil separators (1/3) and in the adsorber (1/4).
3
GA 12.137/2.02 - 05/2002
Fig.2 COOLPAK 6000-1 compressor unit

GA 12.137/2.02 - 05/2002
Description
4
TSH 1
PI
29 bar
Ph
Pl
He
TSH 2
PSL
TSH 1
TSH 2
PI
PSL
He
Fig. 3 Flow chart for the COOLPAK compressor units
Figure 3 shows the flow diagram for a compressor unit.
The oil-lubricated, helium scroll compressor reduces the
volume of the helium gas, which becomes very hot in the
process. For this reason it is passed through a heli-
um/water counterflow heat exchanger located immedia-
tely downstream from the compressor; here the gas tem-
perature is lowered to about the temperature of the coo-
lant. A part of the oil fog swept out of the compressor
along with the helium is condensed to droplets here.
Downstream from the heat exchanger the helium is
passed through a two-stage oil separator. The conden-
sate from the oil separator is returned to the compressor
by means of capillary pipes.
The helium gas exiting the second oil separator will still
contain small quantities of oil vapor. To keep this oil from
entering the cold head and freezing there, an adsorber is
provided downstream from the oil separators. This ad-
sorber shall be replaced in accordance with the mainte-
nance schedule.
To cool the compressor, the oil is pumped through an
oil/water counterflow heat exchanger. Oil circulation is
maintained by the pressure difference between low and
high-pressure helium.
Safety equipment is installed in the compressor units;
details will be found in the table on the next page.
38 °C Thermal switch
100 °C Thermal switch
0 - 40 bar/0-600 psig/0 - 4 MPa
Pressure gauge
2.0 bar Pressure switch
Self-sealing
coupling
Helium recharging
Coolant
ph= High pressure
pl= Low pressure

GA 12.137/2.02 - 05/2002
Description
5
Safety equipment Display on the compressor unit
1 Pressure switch (PSL): pressure difference between 1.: SYSTEM ERROR
low-pressure helium and atmospheric pressure < 2.0 bar 2.: Pressure Alarm
2 Thermal switch (TSH1): Helium temperature 1.: SYSTEM ERROR
downstream of heat exchanger > 38 °C (100 °F) 2.: Helium temp.fail
3 Thermal switch (TSH2): Helium temperature 1.: SYSTEM ERROR
upstream of heat exchanger > 100 °C (212 °F) 2.: Oil cct. fail
4 Thermal switch (Klixon) in compressor capsule 1.: SYSTEM ERROR
2.: Compressor fail
5 Motor protection switch (integrated in main switch) Switch set to 0
6 3 fuses for cold head and input voltage of power module No display or
(F1, F2, F3, accessible from outside) 1.: SYSTEM ERROR
2.: Phase/Fuse ERROR
7 2 fuses for control voltage (internal) No display
8 Bypass valve: opens a shunt between the high- and low-pressure No display
helium circuits if the pressure differential exceeds the preset value
9 Safety valve: opens the helium circuit to the atmosphere if the No display
high-pressure segment exceeds 29 bar (406 psig; 2.9 MPa)
10 Microprocessor for checking the phase rotation 1.: SYSTEM ERROR
2.: Phase/Fuse ERROR
If any of the safety features from 1 through 7 or 10 opens, this will cause the compressor unit to shut down.
Press the SELECT button to read messages 2 and 3.
Safety equipment and displays in case of corresponding failure
1.2 Standard equipment
The compressor units are shipped from the factory filled
with helium and oil. They are equipped with
– detachable crane eyelets,
– sliding rails,
–an integrated main switch including the motor protec-
tion switch.
The self-sealing couplings are closed off with protective
caps.
Accessories also supplied with the unit are:
– 2 certificates of compliance with section 9 of the
German pressurized vessels code,
– 1 adapter (6 mm Swagelock — 1/4” self-sealing
coupling),
– 2 clamping rings (spare parts for water connection),
– 6 spare fuses 0.315 A T
– 1 screwdriver 2.0 mm exclusively for mains voltage
and cold head motor type selection,
– 1 open-end wrench 1“,
– 1 open-end wrench 13/16“.

GA 12.137/2.02 - 05/2002
Description
6
Fig. 4: View of the compressor unit without cover and side panels
Pressure switch 2.0 bar
Thermal switch 38 °C
Adsorber
Separator
Power Module
Heat exchanger
Helium compressor
Bypass valve
Thermal switch 100 °C
Safety valve 29 bar

GA 12.137/2.02 - 05/2002
Description
7
1.3 Technical specifications
Compressor unit COOLPAK 6000-1
————————————————————————
Helium fill pressure to be set at the system,
at room temp.
at 50 Hz 15-1 bar
218-15 psig
1.5-0.1 MPa
at 60 Hz 14-1 bar
203-15 psig
1.4-0.1 MPa
Factory set Helium filling pressure 15-1 bar
218-15 psig
1.5-0.1 MPa
Operating pressure in the high-pressure
circuit at 50 and 60 Hz 20±2 bar
and with connection of a RGD 5/100 290±29 psig
2.0±0.2 MPa
Coolant data see Section 2.4
Ambient conditions for transportation
and storage see Section 3.4.1
Mains power supply,
50 Hz, 3-ph, each ± 10 % 380/400 V
60 Hz, 3-ph, each ± 10 % 480 V
Delivered from the factory wired for 400 V
Cold head motor type select (see Section 2.5)
factory set to 3-phase (rotary) current
Motor protection switch factory set to 14 A
Electrical power drawn at operation temperature
at 50 Hz 6.0 - 6.5 kW / 20,500 - 22,200 BTU/h
at 60 Hz 6.5 - 6.9 kW / 22,200 - 23,600 BTU/h
Electrical power drawn at start-up
with warm cold head
at 50 Hz 8.2 kW / 28,000 BTU/h
at 60 Hz 8.7 kW / 29,700 BTU/h
Operating current at operation temperature
at 50 Hz 9.5 - 10.5 A
at 60 Hz 9.0 - 10.0 A
Operating current at start-up
with warm cold head
at 50 Hz 13.7 A
at 60 Hz 12.0 A
Control voltage for the remote control + 24 V DC
Supply voltage for the cold head 240 V AC
Fuses (5x) 0.315 AT (slow blow)
5x20 mm glass tube
DIN 41662, IEC 127-2/III
IEC rating for circuit breaker in the mains supply 20 A
Helium connectors: self-sealing
couplings1) 1/2“ m
Noise level2), at a distance of 1 m 53 dB(A)
Weight 95 kg / 210 lbs
Equipment type Industrial safety standard class I
The safety standard for the device when installed in
accordance with these instructions, with the line power
and cold head connector lines attached IP 30
1.4 Order information
Cat.-No.
Compressor unit COOLPAK 6000-1 892 35
Adsorber CACP 6000 893 52
Mains power cords
4xAWG 12, Plug Han 3 HvE/conductor ferrules
2.5 m long, cable turns to the right at
power module 200 81 194
0.7 m long, cable turns to the left at
power module 200 16 178
Flexlines
One pair each with self-sealing couplings
at both ends f1)
FL 4.5 (1/2“,1/2“), 4,5 m long (15 feet) 892 87
FL 9.0 (1/2“,1/2“), 9 m long (29.5 feet) 892 88
FL 2.0 ELBOW (1/2“ m /1/2“ f), 2 m long 893 66
FL 13.5-SF (1/2“ f,1/2“ f), 13.5 m long (45 feet) 893 67
FL 11.3 (1/2“ f,1/2“ f), 11.3 m long (37 feet) 893 68
FL 15.0 ELB (1/2“ f,1/2“ f), 15 m long (49 feet) 893 69
Installation accessories
with self-sealing couplings, Helium filling
pressure at room temperature (16-1) bar (232 psig)
90°elbows, 1/2“ m /1/2“ f 891 73
Insulating adapter, 1/2“ m / 1/2“ f 891 76
Line coupler, 1/2“ m / 1/2“ m 891 71
CRYO SERVICE SET, case with tools for
maintenance work at all cold heads and
compressor units 890 93
Electric extension cable for the
cold-head power cord, 4.5 m long 893 74
1) f=female / inside threads; m=male / outside threads “Aeroquip
series 5400“ or compatible designs.
2) As per DIN 45 635, Part 1, corresponding to ISO 6081-1986,
ISO 11203

GA 12.137/2.02 - 05/2002
Description
8
70
146 261
80
156,5
440
199
55,6
8,5
8,5
16
46,5
70 70
440
7,5
77
47,5
70
43
47,5
70
46,5
16 7,5
571
533
439
444,4
536,5
567,5
Fig. 5 Dimensional drawing, dimensions in mm

GA 12.137/2.02 - 05/2002
Installation
9
2 Installation
2.1 Safety information
The owner/operator shall ensure that the compressor
units are operated only by persons who have been
instructed in their use and that they are serviced only by
qualified technicians; refer also to the Accident Preven-
tion Regulations for compressors (VBG 16), sections 12
rule 17, mounting and operation information or equiva-
lent local codes. Moreover, the owner/operator must pre-
vent the unauthorized use of the compressor units and
the connected equipment.
Warning The compressor unit and the flexlines are
filled with helium at pressures of up to 16
bar (232 psig; 1.6 MPa) when stopped and
of up to 29 bar (420 psig; 2.9 MPa) during
operation.
The components in the compressor units
(e.g. compressor capsule, heat exchanger,
piping, separators and adsorber) are under
pressure, as are the flexlines; they must
not be worked either mechanically or ther-
mally.
All valves or switches in the compressor
unit must not be blocked or modified.
Do not lay flexlines across corridors or passageways –
danger of physical damage and corrosion!
Observe minimum bending radius of 20 cm (8“) – danger
of kinking!
Never damage flexlines with pointed or sharp objects!
Never attempt to make repairs to flexlines!
Never install flexlines which show signs of damage!
When running the compressor unit, provide protective
caps at all self-sealing couplings which are not required
for operation.
Attach or detach flexlines only with the compressor unit
switched off and when the pressure is below 28 bar (406
psig; 2.8 MPa). Once flexlines have been detached,
place protective caps on the self-sealing couplings.
Even when switched off, the compressor unit and the
flexlines will be under pressure of up to 16 bar (232 psig;
1.6 MPa).
Warning These compressor units shall not be used
in an environment subject to explosion
hazard.
Warning Potentially fatal voltages are present in the
compressor unit. Before beginning any
work on the unit, switch it off and isolate it
from the power supply network.
The line joining the compressor unit and the
cold head may be connected or disconnec-
ted only after the compressor unit has been
switched off and separated from the line
supply. Electrical shock hazard! Moreover,
the compressor unit and the cold head
could be damaged.
To avoid electrical shock, be sure to ground
the compressor unit and all attached de-
vices.
The electrical connection shall be made
only by a qualified and licensed electrician
in accordance with VDE standard 0105, in
compliance with the guidelines set forth in
VDE 0100, and observing local codes.
Warning The compressor capsule, heat exchanger
and piping will become so hot during opera-
tion, (> 80°C, 176°F) that there will be a
danger of burns. Before beginning any work
on the compressor, switch it off and allow it
to cool down.

GA 12.137/2.02 - 05/2002
Installation
10
RS 232/485
REMOTE
OFF
ON COLD
HEAD
FUSES COLD HEAD
F1 F2 F3
MAIN SWITCH
OFF/ON
HELIUM
FILLING
HELIUM
LOW
PRESSURE
HELIUM
HIGH
PRESSURE COOLING
WATER
OUTLET
COOLING
WATER
INLET
HELIUM
HIGH
PRESSURE
SELECT
Fig. 6: Connections and controls
See table on right for key
5
4
3
2
1
11
12
13
14
15
16
17
18
19
6 7 8 9 10