LEYBOLD RW 6000-1 User manual

RW 6000-1
Compressor Unit and
Accessories for Cryogenic
Refrigerator Units
Cat.-No.
891 44
Operating Instructions
GA 12.107/5.02
Vacuum Solutions Application Support Service LEYBOLD VACUUM

GA 12.107/5.02 - 12/97
Description
Contents
Page
1Description . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Design and Function . . . . . . . . . . . . . . . . . . . 3
1.2 Standard Equipment . . . . . . . . . . . . . . . . . . . 5
1.3 Technical Specifications . . . . . . . . . . . . . . . . . 6
1.4 Order Information . . . . . . . . . . . . . . . . . . . . . 6
2Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Safety Information . . . . . . . . . . . . . . . . . . . . . 7
2.2 Unpacking and Inspecting . . . . . . . . . . . . . . . 9
2.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Coolant Connection . . . . . . . . . . . . . . . . . . . 10
2.5 Electrical Connection . . . . . . . . . . . . . . . . . . 11
2.6 Mounting the Flexlines . . . . . . . . . . . . . . . . . 12
2.7 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Normal Operation . . . . . . . . . . . . . . . . . . . . 16
3.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Topping up Helium Gas . . . . . . . . . . . . . . . . 18
4.2 Replacing the Adsorber . . . . . . . . . . . . . . . . 20
5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 22
6Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24
7Appendix:
Conformance Declaration / Certifications . . . 26
Service personnel shall without fail read the
instructions provided for their guidance
(ISO 7000-0419).
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
Fig. 1 Simplified schematic for the helium circuit
Key to Fig. 1
1Helium compressor
2Heat exchanger
3Oil separator
4Oil adsorber
5Flexlines
6Self-sealing couplings
7Cold head or cryo pump

LEYBOLD POWER MODULE
FAILURE RESET
COLD HEAD CONTROL
Description
1Description
Cryogenic refrigeration units comprise:
–the compressor unit,
–the cold head, and
–flexlines.
These operating instructions describe the design and
operation of the compressor units and the associated
flexlines.
The compressor units 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 ap-
plication is permissible.
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 have been inspected by the
TÜV technical inspectorate for Rhineland and have been
awarded GS certification; they comply with all the
requirements set forth in the European guidelines for
awarding the CE seal of approval. In addition, they satis-
fy 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 is then vaporized in the cold head to produce low
temperatures.
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 12.107/5.02 - 12/97
Fig. 2 RW 6000-1 compressor unit; front side

GA 12.107/5.02 - 12/97
Description
4
Fig. 3 Flow chart for the RW 6000-1 compressor unit
1,5±0,5 bar
Pressure switch
0 – 40 bar/0 – 600 psig
Pressure gauge
38 °C (100 °F)
Thermal switch
150 °C (302 °F)
Thermal switch
Self-sealing
coupling
Oil flow glass
Helium recharging
Coolant
ph= High pressure
pl= Low pressure
DN = Nominal diameter
Figure 3 shows the flow diagram for a compressor unit.
The oil-lubricated, hermetically sealed helium compres-
sor reduces the volume of the helium gas, which be-
comes very hot in the process. For this reason it is
passed through a helium/water counterflow heat ex-
changer located immediately downstream from the com-
pressor;here the gas temperature is lowered to about
the temperature of the coolant. A part of the oil fog swept
out of the compressor along with the helium is con-
densed to droplets here.
Downstream from the heat exchanger the helium is
passed through two oil separators connected in series, in
which additional oil condensate is removed from the
stream of gas.The condensate from the heat exchanger
and the oil separators 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 mainten-
ance schedule.
In the interest of cooling the compressor itself, the oil is
pumped through an oil/water counterflow heat ex-
changer. The oil pump required for this purpose is integ-
rated into the compressor.
Safety equipment is installed in the compressor units;
details will be found in the table on the next page.

GA 12.107/5.02 - 12/97
Description
5
Safety equipment Indication at the compressor unit
1Pressure switch (PSL1): Pressure differential between low- LOW PRESSURE LED lights
pressure helium and atmospheric pressure < 1,5±0,5 bar (22 psi)
2Thermal switch (TSH1): helium temperature following TEMPERATURE LED lights
the heat exchanger > 38 °C (100 °F)
3Thermal switch (TSH 2): helium temperature before the TEMPERATURE LED lights
heat exchanger > 150 °C (302 °F)
4Thermal switch (Klixon) inside the compressor capsule No indication
5Thermal switch in the power module: power module temperature > 65 °C (149 °F) No indication
6Motor protection switch (master switch) Switch is tripped
72 circuit breakers for the cold head (240 V AC) Circuit breaker tripped
8Circuit breaker for control voltage (24 V DC). Circuit breaker tripped
9Bypass valve: opens a shunt between the high- and low-pressure No indication
helium circuits if the pressure differential exceeds 19+1,5 bar (276 psi)
10 Safety valve: opens the helium circuit to the atmosphere if the No indication
high-pressure segment exceeds 31±1,5 bar (435 psig)
11 Check valve in the low-pressure helium line: keeps oil from No indication
flowing back to the cold head
If any of the safety features from 1 through 8 opens, this will cause the compressor unit to shut down.
Safety Equipment
1.2 Standard Equipment
The compressor units are shipped from the factory filled
with helium and oil and ready for immediate operation.
They are equipped with
–mains power cord (2.2 m long), and
–a master switch.
The self-sealing couplings are closed off with protective
caps.
Also supplied with the unit are:
–1 electrical wiring diagram,
–3 certificates of compliance with section 9 of the
pressurized vessels code,
–1 adapter (6 mm Swagelock 1/4”self-sealing
coupling),
–2 clamping rings (spare parts for water connection).
–1 open-end wrench 1”,
–1 open-end wrench 1 3/16”.

GA 12.107/5.02 - 12/97
Description
6
1.3 Technical Specifications
Helium filling pressure at room temp.
Operation at 50 Hz bar 16-1
psig218 to 232
Operation at 60 Hz bar 14-1
psig189 to 203
Operating pressure in the high-pressure
circuit at 50 Hz bar 22±1
psig305 to 334
and with connection of an RGD 5/100-1
Permissible ambient temperature2) °C5 – 40
°F40 to 105
Permissible relative humidity, max. %90
Coolant inlet temperature2) °C5 – 25
°F40 to 80
Permissible coolant connection bar 8
pressure psig 116
Coolant connection, hose nipples Nom.diam 12
Coolant consumption at 25°C
(approx. 80°F) inlet temperature l/min 5
gal/min 1.3
Max. coolant flow rate l/min 10
gal/min 2.6
Mains power supply, 50Hz, 3-ph.,
each±5% V400, 415
Mains power supply, 60Hz, 3-ph,
each±5% V460, 480
Delivered from the factory wired for V415
Electrical power drawn at 50 Hz kW 6.1 – 6.9
Electrical power drawn at 60 Hz kW 6.5 – 7.2
Operating current at 50 Hz A9.8 – 11.1
Operating current at 60 Hz A8.6 – 10.2
Mains cord connection plug3) Type 4
Control voltage for the remote control V DC 24
Connection voltage for the cold head V AC240
Helium connectors: self-sealing couplings4) 1/2“ m
Noise level5), at a distance of 1 m dB(A) 78 - 80
Dimensions (W x H x D) mm 450x445x445
Weight kg 105
lbs 232
1) --
2) Operation at lower temperatures is possible if the appropriate
measures are taken. Please consult the manufacturer for details.
3) Type 4: four conductor ferrules 4,0 mm2x 18 mm long (0.7 inch)
with designations L1/L2/L3/PE
4) f=female / inside threads; m=male / outside threads „Aeroquip
series 5400“ or compatible designs.
5) As per DIN 45 635, Part 1, corresponding to ISO 6081-1986
1.4 Order Information
Cat.-No.
Compressor unit, RW 6000-1 891 44
Adsorber, ARW 2 891 84
Flexlines
One pair each with self-sealing couplings
at both ends
FL 4.5 (1/2“ f4),1/2“ f), 4.5 m long (15 feet) 892 87
FL 9.0 (1/2“ f,1/2“ f), 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
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

GA 12.107/5.02 - 12/97
Installation
7
2Installation
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.
Warning The compressor unit and the flexlines are
filled with helium at pressures of up to 16
bar (232 psig) when stopped and of up to
22 bar (319 psig) 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 shall not
be worked either mechanically or thermally.
The safety pressure relief, bypass and non-
return valves in the compressor unit shall
not be blocked or modified.
The maximum permissible operating pressure for the
flexlines and the helium filling adapter when the self-
sealing couplings are coupled is 28 bar (406 psig).
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.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).
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.
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 if off and allow it
to cool down.

GA 12.107/5.02 - 12/97
Installation
8
Key to Fig. 4
1Master switch
2Electrical connection for the cold
head
3Pressure gauge
4 Power cord
5 Fastening boreholes
6 Low-pressure helium connection
7High-pressure helium connection
8Coolant outlet
9Coolant inlet
Fig. 4 Connection elements
1
2
3
4
5
6
7
8
9
5
LEYBOLD POWER MODULE
FAILURE RESET
COLD HEAD CONTROL
OUTLET
INLET
COOLING
WATER
LOW PRESSURE
HIGH PRESSURE
LEYBOLD

GA 12.107/5.02 - 12/97
Installation
9
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 and lift off the packaging.
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.
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 a suitable device to lift the compressor unit out of the
base section of the packaging. Fasten this lifting device
at the M8 boreholes in the base plate; see Fig. 4.
The lifting equipment is not included with the compressor
unit. Use a lifting device with sufficient carrying capacity
(the unit weighs 105 kg (232 lbs) or more).
Caution Do not use the piping or other components
to grasp 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 15°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 pressure gauge
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.
2.3 Mounting
The compressor unit can be set up for operation at a tilt
of up to a maximum of 15°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.
At the edges of the baseplate there are four mounting
holes. For the purpose of damping vibrations we recom-
mend the use of vibration-damping elements.
The installation location should be dry (max. relative
humidity of 90%) and free of dust.
The ambient temperature must lie between 5°C and
40°C (40°F and 105°F). Operation at lower temperatu-
res is possible if appropriate measures are taken;
please inquire of the manufacturer for details.
Protect the compressor unit against intense, direct sun-
light.
Warning The RW 6000-1 is not equipped with a
safety guard (type of protection IP 21); it
must therefore be installed in a location
where it is protected against contact and
water.
max. 15°
max. 45°
Shipping Operation
OUTLET
INLET
COOLING
WATER
LOWPRESSURE
HIGHPRESSURE
LEYBOLD
OUTLET
INLET
COOLING
WATER
LOWPRESSURE
HIGHPRESSURE
LEYBOLD

GA 12.107/5.02 - 12/97
Installation
10
2.4 Coolant Connection
The compressor units are fitted with nipples to connect
the coolant circuit.
Do not confuse the inlet and outlet ports!
Remove the caps from the hose nipples.
Use hose clamps to attach the water hoses.
Use only hoses of sufficient pressure strength (at least
10 bar at 70°C/145 psig at 165 °F).
Water quality
The compressor units are served by counterflow heat
exchangers.
To prevent calcium deposits in the heat exchanger, the
total of the alkaline earths (water hardness) should be
1.25 to 1.8 mmol/l.
1 mmol/l =5.5°d (German hardness scale)
=7.02°e (English hardness scale)
=10.0°f (French hardness scale)
=5.85°a (American hardness scale)
The pH value of the cooling water should be between 6
and 8.
The water should be as free of suspended matter as
possible.
If there are suspended matter present in the coolant, we
recommend installing a water filter with a mesh size of
from 100 to 150 micrometers.The quantity of matter in
suspension downline from the filter shall be less than 10
mg/l.
In case of doubt, contact your water utility company or
Leybold for advice.
Obtain full information on the water quality before
connecting the compressor unit to a central recirculating
cooling water supply.
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.
Check the cooling water flow rate regularly.
Have the heat exchanger de-limed at regular intervals by
the Leybold Service Department.
To protect the heat exchanger against chemical attack,
fully demineralized or very soft water may be used only
with the addition of suitable inhibitors.
Add anti-freeze to the water if ambient and water tem-
peratures are below 5°C (40°F). If you use anti-freeze,
please consult Leybold as to the proper choice of agent.
The specific thermal capacity, viscosity, and the corros-
ive properties of coolant containing additives will differ
considerably from those for normal cooling water.
Coolant consumption
Note the values for coolant temperature, pressure and
flow rate given in Section 1.3 of the technical specifica-
tions and in Figure 5.
Check the coolant flow rate and temperature at regular
intervals.

GA 12.107/5.02 - 12/97
Installation
11
Fig. 5 Charts: Coolant criteria
0 1 2 3 bar
0 15 30 45 psi
Pressure differential between water inlet and outlet
10
l/min
8
6
4
2
0
5 10 20 30 °C
40 60 80 °F
Coolant inlet temperature
10
l/min
6
5
4
3
2
0
New heat exchanger
Calcium-clogged heat exchanger
Permissible
range
Maximum
2.6
Gal/min
2.1
1.6
1.1
0.5
0
Coolant flow rate
2.6
Gal/min
1.6
1.1
0.5
0
Coolant consumption
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 iso-
late it from the power supply network (lock-
out and tag power).
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 li-
censed electrician in accordance with VDE
standard 0105, in compliance with the
guidelines set forth in VDE 0100, and
observing local codes.
Set the compressor unit to match the mains
voltage
The compressor unit can be adjusted to operate on any
of a number of line voltages;the factory setting is indicat-
ed in Section 1.3. Observe the specifications shown on
the tag attached to the power cord.
Caution Where the local power supply differs from
this value, it is absolutely necessary to
reconnect the terminals at the power
module.
To do so, loosen the screws which hold the power mo-
dule on the base plate and pull out the power module.
Take out the 2 screws at the upper edge of the power
module and fold the frontplate forward and down.
Remove 4 screws and take off the left side-panel of the
power module.
A terminal plan is affixed to the side-panel. Compare the
terminal assignment at the transformers with the termi-
nal plan and change as necessary.
Reinstall the left side-panel, fold up the frontplate and
secure it with the screws.
Reconnect the protective earth conductor if it was
removed.
Connect the compressor unit to the mains.
Connect the cold head
Attach the electrical cord from the cold head at the
socket (4/2).
An adapter must be used with cold heads which were
manufactured prior to 1990.

GA 12.107/5.02 - 12/97
Installation
12
Fig. 6 Mounting the self-sealing couplings
Stabilizing wrench
Wrench for tightening
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 at-
tached and detached without helium escaping.
Unscrew the protective caps from the couplings.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 fittings
shall never be greased or oiled.
Use only the supplied open-end wrenches, or open-end
wrenches approved by Leybold, to mount flexlines.
Attach or detach flexlines only when the pressure unit is
switched off.
Never twist flexlines.
Use one wrench to screw down the coupling and a
second to stabilize the connector nipple; see figures 8
and 9.
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, (8/1) to (8/4), corre-
sponding to the direction in which the helium flows.
Caution Do not mix up the high- and low-pressure
connections.
Interchanging these connections can cause
damage inside the cold head.
After installation, check the helium filling pressure at the
pressure gauge.
Detach the flexlines by unscrewing the couplings in
reverse order.
Once they have been detached, fit protective caps on the
couplings.

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Installation
13
Fig. 7 Attaching and detaching self-sealing couplings
Attaching coupling to the compressor unit Attaching coupling to the cold head
Unscrewing coupling from the compressor unit Unscrewing coupling from the cold head
turn
hold
break
Cold head
Compressor unit Cold head
Compressor unit Cold head
Compressor unit
turn
turn
turnhold
hold
hold
hold hold break
11/16“ 1“ 13/16“13/16“
(27) 11/16“ 1“ 13/16“ 11/8“
(27)

GA 12.107/5.02 - 12/97
14
Installation
OUTLET
INLET
COOLING
WATER
LOW PRESSURE
HIGH PRESSURE
LEYBOLD
1
2
3
4
Attached to
Flexline Color connection Color
————————————————————————
1. High-pressure red Compressor
high-pressure red
2. High-pressure red Cold head-
high-pressure red
3. Low-pressure green Low-pressure
cold head green
4. Low-pressure green Low-pressure
compressor green
Fig. 8 Connecting the compressor unit and cold head
Low-pressure
flexline (green)
High pressure
flexline (red)

GA 12.107/5.02 - 12/97 15
Installation
2.7 Start-up
Check the phase sequence
Check the mains connection for correct phase sequence
each time the unit is connected to the power supply and
following every modification of the electrical connections.
The cable ends are marked with L1, L2, L3 and PE.
When connected this way, the clockwise phase se-
quence remains.
If the phase sequence is incorrect, the compressor unit
will be shut down after about 5 minutes in operation and
the “TEMPERATURE”error message will appear (thermal
switch TSH 2).
Since malfunctions in the coolant supply can trigger the
same error message, check for correct coolant connec-
tion, flow rate and temperature.If the coolant delivery
volume and temperature are sufficient, then the difficulty
is probably due to inverted polarity.Isolate the mains
cable from the power supply and interchange two pha-
ses at the mains connection.
Helium filling pressure
Caution If the RW 6000-1 is connected to 60 Hz line
voltage, the helium filling pressure may not
exceed 14-1 bar at room temperature.
Release helium, if necessary. A helium filling adapter is
provided for this purpose with the compressor unit.
Unscrew the protective cap from the drain connection
(11/2).
Slowly and carefully screw the self-sealing couplings of
the adapter onto the drain connection.
Warning Do not screw the adaptor on too quickly as
there is otherwise the danger that too much
helium will escape or that oil will be swept
along with the helium out of the compres-
sor.
Keep the face and bodily openings away
from the adapter discharge orifice.
Compressed gas can induce asphyxiation
effects at high concentration. Do not inhale
helium or use it to create a “squeaky voice”
effect.
Once the correct helium filling pressure has been
reached, remove the adapter once again. Replace the
protective cap on the drain connector.

GA 12.107/5.02 - 12/97
16
Operation
3Operation
3.1 Switching on
Open the coolant inlet.
Switch on the compressor unit at the master switch.Volt-
age will be supplied to the connector circuit for the cold
head at the same time and the cold head connected here
will be started.
After a longer period in service, operating pressure
should stabilize at approx. 22 bar (319 psig), read at the
compressor gauge on the compressor. During the start-
ing phase, pressure will temporarily be higher.
3.2 Normal Operation
During operation, check the operating pressure and the
coolant flow rate at regular intervals (at least every 6
months).
Refer to Section 1.3 for nominal values.
If the helium pressure is too low during operation, switch
off the compressor unit and find the cause; refer to Sec-
tion “Troubleshooting”.
If the coolant flow rate is insufficient, eliminate potential
malfunctions in the water supply or at the water outlet. If
deposits of calcium or grime have collected in the heat
exchanger, switch off the compressor unit and inform the
Leybold Service Department.
Safety devices are integrated into the compressor unit to
protect the device during operation; refer to the table in
Section 1 for details.
3.3 Switching off
Manual shut-down
Turn off the compressor unit at the master switch.
Allow the coolant to circulate for 10 minutes following
shutdown and then close off the circuit.
Automatic shut-down
The compressor unit will be shut down automatically if
insufficient helium pressure or excessive helium temper-
ature is detected.
The malfunction message will remain visible in the dis-
play even after the effects have diminished; the com-
pressor unit will not restart automatically.
The malfunction indication will remain stored in memory
even in case of a power failure.
Find and rectify the cause of the malfunction. Then
press the RESET button. The compressor unit will then
restart.
If a circuit breaker is tripped, the compressor unit will
automatically be switched off.
Find and eliminate the cause of the malfunction. The
compressor will restart when the button on the circuit
breaker is pressed.
The compressor unit will be switched off in case of
excessive motor current. In this case the master switch
will be at its “0” position.
Locate and eliminate the cause of the malfunction and
switch the compressor unit back on at the master switch.
If the temperature of the compressor motor is too high,
the compressor unit will be switched off without indica-
tion of the malfunction.
Warning The compressor unit will switch back on
automatically once the compressor motor
has cooled down (approx. 1 to 2 hours).
If the power module gets too hot, the compressor unit will
be switched off without indication of the malfunction.
Actions following a power failure
When power is restored after a temporary failure of the
line voltage, the compressor unit will automatically return
to its previous operating status.

GA 12.107/5.02 - 12/97
LEYBOLD POWER MODULE
FAILURE RESET
COLD HEAD CONTROL
17
Operation
3.4 Shut-down
Switch off the compressor unit at the master switch.
Allow the coolant circulate for a further 10 minutes after
shutting down the unit and then close the circuit.
Allow the cold head being served to warm-up before
detaching the flexlines.
Loosening the flexlines with the cold head at low temper-
atures can result in a loss of helium.
Warning Detaching the flexlines with the cold head at
low temperature can, when they heat up,
result in a rise in pressure beyond the per-
missible 28 bar (406 psig) operating pres-
sure for the disconnected flexline.All the
self-sealing couplings which are not in use
shall be provided with protective caps.
Unscrew the flexlines in a sequence reverse to that
described in Section 2.6. Screw protective caps on to
the self-sealing couplings.
Store the compressor unit in a dry place.
Warning Even after the unit is switched off, the com-
pressor unit, the cold head and the flexlines
will be under pressure of up to 16 bar (232
psig).
Observe the appropriate safety regulations.
If there is danger of freezing temperatures, drain the
coolant prior to storing or shipping the compressor unit.
The compressor unit may be tilted by a maximum of 45°
during shipment and storage, to a maximum of 15°
during operation.
Key to Fig. 9
1Master switch
2Indicator:Helium too warm
3Reset button
4Indicator:Insufficient pressure
5Operating hours meter
6Circuit breaker for control voltage
7Circuit breaker for cold head
8Pressure gauge
Fig. 9 Control elements
1
2
3
4
5
6
7
8

GA 12.107/5.02 - 12/97
18
Maintenance
4. Maintenance
Warning Separate the compressor unit from mains
power supply before beginning any work.
After making repairs to the electrical equipment, the
compressor unit may not be returned to service without
conducting an electrical safety test. It is for this reason
that work of this type may be carried out only by trained
and qualified personnel or by the Leybold Service
Department.
Maintenance work carried out improperly will jeopardize
the safety, longevity and availability of the equipment and
will void the warranty.
Any work which is not described in these operating
instructions may be carried out only by the Leybold Ser-
vice Department or by personnel specially trained by
Leybold for this purpose.
4.1 Topping up Helium Gas
Warning Observe all safety regulations when work-
ing with pressurized gas cylinders.
If the helium pressure in the compressor unit has fallen
below the minimum level, it will be necessary to recharge
with helium.
Helium filling pressure
Operation at line frequency
————————————————————————
Minimum values
50 Hz 15 bar
60 Hz 13 bar
Nominal values
50 Hz 16 bar
60 Hz 14 bar
When making measurements at the compressor unit,
switch the unit off and allow it to cool down to room tem-
perature and the cold heads being served to warm up.
Detaching the flexlines when the cold head is at low tem-
perature can result in a loss of helium.
Warning Detaching the flexlines with the cold head at
low temperature can, when they heat up,
result in a rise in pressure beyond the per-
missible 28 bar (406 psig) operating pres-
sure for the disconnected flexline.All the
self-sealing couplings which are not in use
shall be provided with protective caps.
Caution Only helium of the highest purity (99.999%
or better) shall be used.
Warning The maximum permissible operating pres-
sure for the helium filling adapter when the
self-sealing couplings are detached is 28
bar (406 psig). Do not exceed this pres-
sure level when setting the pressure redu-
cer.
Use the pressure reducer and a suitable high-flexline to
connect the helium cylinder to the helium filling adapter
supplied with the unit; do not yet tighten the Swagelock
connector.
Open the valve at the cylinder.
Open the pressure reducer and the shut-off valve slightly
so that the high flexline and the filling adapter are purged
with helium.
Tighten down the Swagelock connector after purging the
configuration several times.
Set the pressure in the supply line to correspond to the
set-point value of the compressor unit. If there is insuf-
ficient pressure in the supply line, oil can pass from the
compressor unit into the supply line.
Observe the instructions given in Section 2.6.
Use a 19 mm open-end wrench to tighten the couplings.
Connect the coupling at the helium filling adapter to the

GA 12.107/5.02 - 12/97 19
Maintenance
helium filling nipple (11/1).
Refill the compressor unit up to nominal value.
Detach the coupling from the helium filling nipple.
Close the valve at the supply cylinder.
Seal the helium filling nipple at the front of the compres-
sor unit tightly with a protective cap.
Warning The filling hose at the helium cylinder will
still be under pressure of up to 16 bar (232
psig). Relieve pressure from the line be-
fore detaching the filling connector.
Keep the face and bodily openings away
from the adapter discharge orifice.
Compressed gas can induce asphyxiation
effects at high concentration. Do not inhale
helium or use it to create a “squeaky voice”
effect.
Fig. 10 Topping up the helium filling
Helium supply
cylinder
Pressure reducer
Shut-off valve
Pressure gauge Pressure gauge
Helium filling
connection with self-
sealing coupling
Compressor unit
Helium filling with
Swagelock connector and
self-sealing coupling

GA 12.107/5.02 - 12/97
OUTLET
INLET
COOLING
WATER
LOW PRESSURE
HIGH PRESSURE
LEYBOLD
20
Warning Detaching the flexlines with the cold head at
low temperature can, when they heat up,
result in a rise in pressure beyond the per-
missible 28 bar (406 psig) operating pres-
sure for the disconnected flexline.All the
self-sealing couplings which are not in use
shall be provided with protective caps.
Observe the instructions for the work given in Section
2.6.
Unscrew the high-pressure flexline from the compressor
unit (11/3).
Loosen the nut (11/5) with a 13-mm open-end wrench.
Use the assembly wrench supplied to detach the self-
sealing coupling (11/2).
Remove the adsorber (11/4).
Remove the protective caps from the new adsorber and
install the new adsorber in reverse order.
The new adsorber is filled with helium of highest purity to
a level of 16 bar (232 psig).
Maintenance
Key to Fig. 11
1Helium filling and discharge
connection
2Self-sealing coupling
3High-pressure helium connection
4Adsorber
5Nut (behind the base plate)
Fig. 11 Maintenance
4.2 Replacing the Adsorber
The adsorber is provided to keep the oil vapor out of the
flow of helium gas.It will have to be replaced after about
18,000 hours of operation. Otherwise oil can collect in
the cold head as a result of incomplete adsorption of the
oil vapors.This will cause a reduction in cooling perform-
ance; extreme contamination of the helium gas may
cause the cold head to cease functioning entirely.
Caution When making this replacement use only the
appropriate adsorber supplied by Leybold;
refer to Section 1.4.
Switch off the compressor unit in preparation for re-
placing the adsorber.
Allow the cold head to warm up before disconnecting the
flexlines.
Detaching the flexlines with the cold head at low tempe-
rature can cause a loss of helium.
1
2
3
4
5