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

GA 12.137/2.02 - 05/2002
Installation
11
Item in Description
Fig 6 Description Remark in Section
1 High-pressure helium connection marked with red dot 2.6
2 Low-pressure helium connection marked with green dot 2.6
3 Helium refilling connection used for releasing and topping up helium 4.1
4 Sub-D connector, 9 pole 3.5
RS 232/485 interface
5 Sub-D connector, 25 pole See Fig. 12 2.5
for remote control
6 Display 16 characters 1.1, 3, 5
7 OFF button Red; used to stop operation of the compressor unit 3
8 ON button White or black; used to start operation
of the compressor unit 3
9 SELECT button Gray; used to display the hours meter or
failure messages 3
10 Cover plate Terminals for setting the compressor unit to the 2.5
line voltage and for setting the cold head motor type
are located behind the cover plate; see Fig. 11.
11 Crane eyelets Detachable 2.2
12 Fuses Safeguard the input current (primary circuit) of the 1.3
transformer for the cold head motor and the
control voltage
13 Electrical connection for cold head bended 2.5
14 Main switch Connects the power module to the mains supply
or disconnects it from the mains supply; 2.5, 3
simultaneously acts as motor protection switch
15 Socket for mains power cord, type HAN3HvE 2.5
16 Pressure gauge Displays the pressure on the high-pressure 1.1, 3
helium side of the compressor unit
17 Coolant inlet Do not throttle throughput in the inlet line. 2.4
18 Coolant outlet To set the flowrate use a throttle here 2.4
19 Handle Do not use for crane 2.2
Connections and controls

GA 12.137/2.02 - 05/2002
Installation
12
2.2 Unpacking and
inspecting
Unpack the equipment immediately after receipt, even if
it is not to be put into operation until later.
Examine shipping cartons and packaging for signs of
external damage.
Remove the straps, open the packaging, and lift the
compressor unit by the crane eyelets.
Warning When lifting and setting down the compres-
sor unit do not reach under the edges of
the frame; the hands and feet could be
pinched. Do not stand under the suspend-
ed compressor unit while it is being moved.
Use only the crane eyelets for crane transport. Use the
handles for manoevering the unit in the rack.
Caution Do not use the piping or other components
to lift or move the compressor unit.
When the compressor unit is being transported or is in
storage, it should be tilted by no more than 45°(danger
of tipping over) and a maximum of 10°during operation.
More severe angles could result in damage to the com-
pressor capsule or oil contamination in the helium circuit.
Check the pressure level indicated at the manometer
attached to the compressor; see Section 4.1 for details.
If the pressure indicated is too low, top up with helium or
notify the Leybold Service Department.
Keep the packaging for re-use in case it should become
necessary to return equipment to the factory.
Check the delivery for completeness (see Section 1.2)
and make a careful visual check.
If damage is detected, submit damage reports to the car-
rier and the insurer at once. If it is necessary to replace
damaged components, please contact Leybold for
instructions.
2.3 Mounting
The compressor unit can be set up for operation at a tilt
of up to a maximum of 10°in any direction.
At severe angles block the compressor unit to keep it
from sliding. In areas subject to earthquake hazard,
fasten the compressor unit to the building. The fastening
should be able to withstand acceleration of 0.5 g in the
horizontal plane and 0.33 g in the vertical plane.
In the baseplate there are mounting holes. For the pur-
pose of damping vibrations we recommend the use of
vibration-damping elements.
The unit is prepared for installation in a 19“ rack.
The installation site should be dust-free. Protect the
compressor unit against strong sunlight.
The crane eyelets can be unscrewed. Remove the eye
screws at the front and replace with the M8x10 counter-
sunk screws provided. Retain the eye screws for future
use.
max. 10°
max. 45°
Transport Operation
Fig. 7: Maximum inclination

GA 12.137/2.02 - 05/2002
Installation
13
2.4 Ambient conditions and
coolant connection
Ambient temperature
The ambient temperature must be between 5 °C and 40
°C (40 °F to 104 °F) when the compressor unit is in ope-
ration.
Ambient air pressure
The minimum ambient air pressure is 700 mbar (700
hPA, 10 psi).
Coolant data
Coolant inlet temperature 5 to 25 °C
Permissible connected
coolant pressure < 8 bar (116 psig; 0.8 MPa)
Min. inlet pressure 2 bar (abs)
Min. absolute pressure at coolant outlet 1 bar
(atmospheric pressure)
Coolant port, hose nipples DN 12
for hoses with an inner diameter 1/2“ (12 mm)
Hose clamp range 1/2 to 11/8“ (12 to 28 mm)
Alternative coolant port:
outside threads G 1/2“
Coolant consumption
at 25 °C inlet temperature 5 l/min
Max. coolant throughput 10 l/min
Pressure drop ∆p between coolant inlet
and outlet depending on the throughput 0.2 to 0.6 bar
Water quality
Appearance Colorless, clear, free of oils and greases
Suspended matter < 250 mg/l
Particle size < 150 µm
Electrical conductivity < 500 µS/cm
pH value 7 to 8.5
Total hardness (total alkaline earths) < 20 °dH
Acid capacity up to pH 4.3 2.5 to 3.5 mmol/l
Carbonate hardness 7 to 10 °dH
Aggressive carbon dioxide None, not detectable
Oxygen 4 to 5 mg/l
Chloride < 100 mg/l
Sulfate < 70 mg/l
Iron < 0.2 mg/l
Manganese < 0.1 mg/l
Ammonium < 10 mg/l
Free chlorine < 0.2 mg/l
20 °dH (degrees German hardness) = 3.5 mmol/l
= 25 °e (degrees English hardness)
= 36 °f (degrees French hardness)
= 21 °a (degrees American hardness)
Caution Failure to comply with the coolant data may
lead to internal corrosion. This will result in
destroying the compressor unit.

Installation
Relative air humidity
Only set up the compressor units in a non-condensing
atmosphere. See Fig. 8 in this context.
Coolant connection
Remove the end caps from the hose nipples. Secure the
water hoses with hose clamps. Do not confuse the inlet
and outlet ports!
To set the flow rate, the coolant flow must be thrott-
led in the outlet.
Caution If the coolant flow is throttled in the inlet or
if the pressure difference falls below the
specified limit, this may lead to insufficient
cooling of the oil circuit and compressor fai-
lure or damage.
Only use hoses with sufficient pressure resistance (min.
10 bar (1 MPa) at 70 °C, 145 psig at 160 °F).
Pay attention to the coolant data.
If water with properties deviating from specified values is
used, calcium deposits in the heat exchanger could
restrict the flow of water and adversely impact heat
removal.
Have the heat exchanger de-limed at regular intervals by
the Leybold Service Department.
If required install a fine filter of 100 µm. Replace it in
regular intervals.
To protect the heat exchanger against chemical attack,
fully demineralized or very soft water may be used only
with the addition of suitable inhibitors.
Permanent operation at ambient and water temperatures
below 5°C (40°F) is only possible with additional safety
measures. Even if you use anti-freeze the coolant inlet
temperature must have the permitted temperature,
except from a warm-up time of approx. 15 minutes. If
you use anti-freeze, please consult Leybold.
The specific thermal capacity, viscosity, and the corro-
sive properties of coolant containing additives will differ
considerably from those for normal cooling water.
Check the coolant flow rate and temperature at regular
intervals.
14 GA 12.137/2.02 - 05/2002
5 10 15 20 25 30
°C
45
40
35
30
25
20
°C
20 %
50 %
100 %
90 %
70 %
80 %
60 %
30 % 40 %
Fig. 8: Dewpoint diagram
Minimum coolant inlet temperature at which
condensation does not yet occur,
as a function of maximum room temperature
and maximum relative humidity.
Example:Max. ambient temperature 25 °C
Min. coolant inlet temperature 17 °C
⇒Max. relative humidity 60%
Maximum relative humidity
Maximum ambient temperature
Minimum coolant inlet temperature

Installation
15
GA 12.137/2.02 - 05/2002
Coolant
IN OUT
Fig. 9: Coolant connection Fig. 10: Coolant consumption
510 20 30 °C
40 60 80 °F
Coolant inlet temperature
10
l·min-1
6
5
4
3
2
0
Permissible
range
Maximum
2.6
Gal/min
1.6
1.1
0.5
0
Coolant consumption

GA 12.137/2.02 - 05/2002
Installation
16
2.5 Electrical connection
Warning Potentially fatal voltages are present in the
compressor unit. Before beginning any
work on the compressor unit, switch it off
and isolate it from the power supply network
(lock out and tag power).
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, always connect
the equipment to a low impedance ground.
The electrical connection/disconnection
shall be made only by a qualified and licen-
sed electrician in accordance with VDE
standard 0105, in compliance with the gui-
delines set forth in VDE 0100, and obser-
ving local codes.
Setting the compressor unit to the line voltage
The compressor unit can be adjusted to operate on
various line voltages. Refer to Section 1.3 for the per-
missible values for the compressor unit and the factory
setting. Observe the information on the tag attached to
the compressor unit.
Caution If the line voltage differs from the value sta-
ted on the tag, it is essential to reconnect
the terminals on the Power Module.
Do not use the terminals for 230 V. Using
these terminals may damage the power
module and the cold head.
To make the setting, first remove the cover plate; see
Fig. 11 left. Then the terminals for mains voltage and
coldhead motor type are visible. Do not use the 2.0 mm
screwdriver delivered with the compressor unit. Use a
Phillips screwdriver instead. The 2.0 mm screwdriver
shall exclusively be used on the mains voltage and the
motor type selector terminal slits; see below.
Caution Connect all three phase leads - L1, L2 and
L3 - to the correct voltage value on the ter-
minal strips CM2 and CM3; see Fig.11
middle. Using the wrong terminals may
damage the power supply and the cold
head.
To detach the leads from the terminal strips, insert the
screwdriver (2 mm width) into the slits, press on the ter-
minals and pull out the lead with a pair of pliers. Hold the
screwdriver horizontally and do not jam it.
Insert the leads as far as possible without using the
screwdriver. By pulling the leads verify that they are
safely fixed. If not repeat the procedure.
Changing the setting of the cold head motor
All Leybold cold heads can be operated in the setting for
2-phase alternating current.
All Leybold cold heads with a type designation beginning
with “RGD 5/100“or “COOLPOWER 5/100“ can also be
operated on 3-phase (rotary) current. The compressor is
set this way at the factory.
Caution For all cold heads except RGD 5/100 .. or
COOLPOWER 5/100 .. the setting must be
2-phase alternating current.
For changing the setting of the cold head motor type
reconnect all three terminals CM6 to CM8; see Fig. 11
middle and right.
Screw the cover plate back in place after altering the set-
ting. You are strongly advised to make a note of all chan-
ges made, both on the compressor unit and in the Ope-
rating Instructions.
Connecting the cold head and power supply
Plug the electrical connecting lead of the cold head into
the socket COLD HEAD.
Connect the power cord to the compressor unit’s socket
and the power cord’s terminals to the mains.

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CM 10
Installation
17
GA 12.137/2.02 - 05/2002
1 2 3
CM8
1 2 3
CM6
1 2 3
CM7
1
2
3
CM3
4
5
6
7
8
L3
470 V
400 V
230 V
200 V
200 V
230 V
400 V
470 V
L2
L3
L2
1
2
3
CM2
4
L1
200 V
230 V
400 V
470 V
L1
MAIN
VOLTAGE
SELECT
RETURN 2 PHASE 3 PHASE
RETURN 2 PHASE 3 PHASE
RETURN 2 PHASE 3 PHASE
COLDHEAD
MOTORTYPE
SELECT
Terminals for 2-phase cold head motor
and for setting the line voltage (400 V setting shown)
1 2 3
1 2 3
1 2 3
CM8
CM6
CM7
RETURN 2 PHASE 3 PHASE
RETURN 2 PHASE 3 PHASE
RETURN 2 PHASE 3 PHASE
COLDHEAD
MOTORTYPE
SELECT
Terminals for 3-phase
cold head motor
Only permissible for cold
heads RGD or
COOLPOWER 5/100 .. .
Fig. 11: Power supply connection
Cover plate
Cold head
Socket for the
mains power
cord
380 V
400 V
480 V
480 V
400 V
380 V
380 V
400 V
480 V
Checking the direction of the rotating field
Check the correct direction of the rotating field of the
power supply when first making the connection and after
any changes to the electrical connection.
The connector is wired for a clockwise rotating field
when shipped.
While pressing the OFF button switch on the master
switch. If correctly wired, the display reads
VERSION: Vx.xx
and then
SYSTEM OFF
If the wiring is incorrect, the message
SYSTEM ERROR
is displayed. After pressing the SELECT button the mes-
sage
Phase/Fuse ERROR
is displayed. As this error message also appears if one
of the fuses (6/12) has blown, first check the fuses. If
they are OK, disconnect the power from the power leads
and reverse two phases on the power supply connec-
tion.
Switch off the main switch.

Installation
18 GA 12.137/2.02 - 05/2002
Connecting the Sub-D connectors (option)*
Refer to Section 3.5 for the RS 232 interface.
Warning For protection against thermal cut-outs, if
this compressor unit as part of a refrigerati-
on system is used in a medical electrical
system (e.g. a MRI system), the compres-
sor unit’s operation must be monitored by
the higher level control of the medical
system, e.g. via the compressor’s built-in
remote and/or RS 232 interface.
If required, connect the REMOTE connector.
Maximum contact load 30 mA total on signal lines.
Do not apply 24 V DC permanently to pin 3 (Reset).
(Recommendation for reset: pulse > 100 ms)
Caution Do not connect to “free“ pins as they are
already internally connected.
The compressor unit satisfies EU Directives regulating
electromagnetic compatibility (EMC). To ensure that
compatibility is maintained, adhere to the following
installation instructions:
•Use the prescribed Leybold connector lines to
connect the cold head.
•Use shielded cables to connect the Sub-D connec-
tors and attach the shielding to the metal housings of
the Sub-D plugs.
Operation via the interfaces
The interfaces can be used to run the compressor unit in
parallel to the control buttons for ON, OFF and SELECT.
The control lines for the REMOTE interface respond to
the rising or falling flank of a +24 V DC signal.
Example:
0 V ⇒+24 V at pins 4 and 6: Compressor ON
+24 V ⇒0 V at pins 4 and 6: Compressor OFF
Before changing the operating mode, it is necessary to
first switch off the compressor unit and the cold head
while in the "old” operating mode and then to switch on
again in the "new” operating mode.
Failure to observe this rule may result in undefined ope-
rating states, for example:
The compressor unit is running in the REMOTE mode;
24 V is present at pins 4 and 6. The compressor unit is
(contrary to the rule) switched off with the OFF button.
Then it is off although the 24 V signal is present at pins
4 and 6.
* The required counter plug is available e.g. from
Framatome Connectors International:
REMOTE:
25-pole, solder version, male DB25P064TX
Metallized housing, straight exit 8655 2181

Installation
19
GA 12.137/2.02 - 05/2002
13 12 11 10 9 8 7 6 5 4 3 2 1
25 24 23 22 21 20 19 18 17 16 15 14
Reset →
Cold head ON/OFF →
Compressor ON/OFF →
Ground
PE
→Pressure Alarm
→Phase/Fuse Error
→Temp Alarm
→Operation
→Compressor Fail.
(Klixon Error)
0 V
+ 24 V
REMOTE
Fig. 12: Pin assignments on the Sub-D connectors
+ 24 V
status
signals
+ 24 V DC required
for remote operation
Pin +24 V is present 0 V is present
3 Reset –
4 Cold head on Cold head off
6 Compressor on Compressor off
16 Pressure alarm No pressure alarm
17 Phase/fuse error No phase/fuse error
18 Temp. alarm No temp. alarm
19 Compressor in Compressor not in
operation operation
20 Compressor failure No compressor failure

Installation
2.6 Mounting the flexlines
Information for working with self-sealing couplings
The connector lines and elements are equipped with
self-sealing couplings. These connectors can be atta-
ched and detached without helium escaping.
Unscrew the protective caps from the couplings. Keep
the protective caps for further use.
Check all connectors for evidence of dust and grime and,
if necessary, use a clean and lint-free cloth or a soft,
clean brush (e.g. toothbrush) to clean the fittings.
Never use solvents to clean the connections! The fit-
tings shall never be greased or oiled.
Check that the flat seals are in place on male couplings.
Replace missing or defective flat seals.
Use only the supplied open-end wrenches, or open-end
wrenches approved by Leybold, to mount flexlines.
Attach or detach flexlines only when the compressor unit
is switched off and when the pressure is below 28 bar
(406 psig; 2.8 MPa).
Never twist flexlines.
Use one wrench to screw down the coupling and a
second to stabilize the connector nipple; see figures 13
and 14.
1/2” coupling:
tighten with 1 3/16” wrench,
stabilize with 1” wrench.
Tighten down all couplings as far as possible and then
back them off by 1/4 turn to relieve strain.
If the flexlines are to be laid in such a way that radii of
less than 20 cm (8“) are required, it will be necessary to
install 90°elbows; see Section 1.4.
Use insulating adapters for electrical installation; see
Section 1.4.
Use hose couplers to extend the flexlines; see Section
1.4 for details.
Connect compressor unit and cold head
Follow the instructions for the work.
Connect the flexlines in sequence, (15/1) to (15/4), cor-
responding to the direction in which the helium flows.
Caution Do not mix up the high- and low-pressure
connections. Interchanging these connec-
tions can cause damage inside the cold
head.
Do not use a flexline on the high-pressure
side which was ever used on the low-pres-
sure side.
Do not connect the high-pressure connec-
tion directly to the low-pressure connection
(short-circuit). Operation with directly
connected high- and low-pressure can
damage the compressor unit.
Checking the helium filling pressure
After installation, check the helium filling pressure at
the pressure gauge and correct it if required; see
Section 4.1 for the correct data and the filling or
reducing procedure.
Detach flexlines only with the compressor unit switched
off, the cold head warmed up, and when the pressure is
below 28 bar (406 psig; 2.8 MPa). See Section 3.4
“Removing from service“ for details. Detach the flexlines
by unscrewing the couplings in reverse order.
Once they have been detached, fit protective caps on
the couplings.
20 GA 12.137/2.02 - 05/2002
Fig. 13 Mounting the self-sealing couplings
Stabilizing wrench
Wrench for tightening