Oerlikon Leybold Vacuum COOLPOWER 5/100 User manual

Part Numbers
893 04
893 05
129 78
842 040
842 030
842050V000X
COOLPOWER
5/100, 5/100 T, 7/25, 140 T, 50
Cold Heads
Installation and Operating Instructions GA12119_002_A3

GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
0 Important Safety Information 4
0.1 Mechanical hazards 4
0.2 Electrical hazards 5
0.3 Thermal hazards 5
0.4 Hazards caused by materials and substances 6
0.5 Danger of ignition 6
0.6 Dangers in connection with safety-related measures and
precautions 6
0.7 Risk of damagie to the cold head 6
1 Description 7
1.1 Design and Function 7
1.2 StandardSpecification 7
1.3 Technical Data 9
1.4 Ordering Data 11
2 Transportation and Storing 15
3Installation 16
3.1 Conforming Utilization 16
3.1.1 Non-conforming utilization 16
3.2 Unpacking and Checking the Delivery 17
3.3 Connecting the cold head 18
3.4 Electrical Connection 19
3.5 Installing the Flexible Pressure Lines 20
4 Operation 23
4.1 Removing from Service 24
5Maintenance 25
5.1 Oerlikon Leybold Vacuum Service 25
6 Troubleshooting 26
7Waste Disposal 27
EC Incorporation Declaration 28
EC Declaration of Conformity 29
Declaration of Contamination 30
Contents
2
Page
This is the original installation and operating instructions.

3GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
Obligation to Provide Information
Before installing and commissioning the COOLPOWER, carefully read
these Operating Instructions and follow the information so as to ensure
optimum and safe working right from the start.
The Oerlikon Leybold Vacuum COOLPOWER has been designed for safe
and efficient operation when used properly and in accordance with these
Operating Instructions. It is the responsibility of the user to carefully read and
strictly observe all safety precautions described in this section and through-
out the Operating Instructions. The pump must only be operated in the
proper condition and under the conditions described in the Operating
Instructions.It must be operated and maintained by trained personnel only.
Consult local, state, and national agencies regarding specific requirements
and regulations. Address any further safety, operation and/or maintenance
questions to our nearest office.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury.
NOTICE is used to notify users of installation, operation, programming or
maintenance information that is important, but not hazard related.
We reserve the right to alter the design or any data given in these Operating
Instructions. The illustrations are not binding.
Retain the Operating Instructions for further use.
Safety information
DANGER
WARNING
CAUTION
NOTICE
NOTICE

0 Important Safety Information
0.1 Mechanical hazards
1. The cold head and the pressure lines are pressurised to a helium filling
pressure of up to 16 bar during standstill and up to 28 bar during
operation.
2. Even after switching off, cold head and pressure lines remain
pressurised up to a filling pressure of 16 bar.
3. Fit or disassemble the pressure lines only after having switched off the
compressor unit first.
4. Releasing the pressure lines while the cold head is cold may, when
warmed, cause a pressure rise which may exceed the permissible
operating pressure of 28 bar.
5. The cold head must only be operated with the specified compressors,
pressure lines and electrical connecting lines.
6. For its conforming utilisation the cold head must be installed within an
insulating vacuum. The operator is responsible for properly designing
the vacuum vessel.
7. All lines which are used (electric lines and pressure lines) must be
undamaged.
8. Do not lay flexible pressure lines along passageways – risk of damage
and corrosion!
9. Always maintain a bending radius of at least 20 cm – risk of pinching!
10. Do not damage the pressure lines with pointed or sharp items!
11. Do not repair pressure lines!
12. Do not install any damaged pressure lines!
13. After disassembly, provide the self-sealing fittings with protection caps.
14. Pressurised parts of the cold head must not be processed
mechanically or thermally.
Safety information
4GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
WARNING

0.2 Electrical hazards
1. The electrical connections must only be provided by a trained
electrician in accordance with VDE 0105 according to the guidelines of
VDE 0100 (or corresponding to the harmonised national standards and
guidelines which apply in the country where the equipment is being
operated).
2. The electrical connecting line between the compressor unit and the
cold head must only be connected or disconnected provided the
compressor unit was switched off first and reliably disconnected from
the mains power. Risk of suffering an electric shock. Moreover,
compressor unit and cold head may suffer damage.
3. Un-authorised conversions and modifications to the equipment are
prohibited for safety reasons.
Hazardous voltages are present inside the cold head. In case of
contact, death or severe injury can result.
4. After all servicing work, running of an electrical safety test is
mandatory.
5. Do not expose the cold head to splash or drip water.
6. Lay the connecting lines so that they cannot be damaged. Protect the
lines against humidity and contact with water.
7. When storing the cold head and the connecting cables in a humid
atmosphere then these components may corrode. Corrosion forms
conductive deposits which can result in short-circuits or reduced
insulation of voltage carrying parts.
0.3 Thermal hazards
1. During operation the cold stages become very cold, touching will
cause skin injury. Never operate the cold head without insulating
vacuum.
2. The cold head motor or the low pressure helium connection can get
hot (50 to 60 °C approx.). Protect parts from being touched
inadvertently and leave these to cool down before beginning any
maintenance work on the instrumentation.
Safety information
5GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
WARNING
CAUTION

0.4 Hazards caused by materials and substances
1. When draining out helium do not direct the gas in the direction of
persons or components. Compressed gas at high concentrations can
have a suffocating effect. Do not breathe in helium at high con-
centrations!
2. The cold head may suffer contamination from the process or due to
environmental influences. Contaminated parts can cause health
impairments and environmental damage.
Before beginning with the work inform yourself about any possible
contamination. When handling contaminated components, observe the
pertinent regulations and comply with the protective measures.
3. When using the regeneration heaters from Oerlikon Leybold Vacuum,
note the safety precautions detailed in the enclosed Operating
Instructions.
0.5 Danger of ignition
1. Risk of explosion!
The cold head in its standard version is not suited for operation in
explosion hazardareas. Please consult us if planning such a use.
0.6 Dangers in connection with safety-related measures and
precautions
1. The insulating vacuum must be provided with a safety valve which
opens
-when a leak occurs between the high-pressure helium and the
insulating vacuum
-when frozen gases which collect because of leaks in the insulating
vacuum are released when shutting down and warming the cold head.
2. The safety valve present at the cold head must not be blocked or
modified.
3. The cold head is operated through the connected compressor. In the
event of a brief mains power failure the compressor will automatically
revert to its previous operating status.
0.7 Risk of damagie to the cold head
1. Only very high purity helium (with a purity of 99.999% or higher) must
be used.
2. Operate the cold heads with the permissible settings at the com-
pressor only. The cold heads described operate off three-phase mains
power. For this refer to the notes in the Operating Instructions for the
compressor.
3. Operating the cold head motor without connected helium circuit will
cause a thermal overload of the cold head motor and damage to the
cold head.
4. Do not confuse high-pressureand low-pressure connections.
Confusing these can cause damage in the cold head.
Safety information
6GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
DANGER
CAUTION
CAUTION
NOTICE

Description
7GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
1 Description
Gifford-McMahon cryogenerators consist of:
■the cold head,
■the compressor unit,
■and flexlines.
1.1 Design and Function
The cold heads COOLPOWER 5/100 (T), COOLPOWER 7/25, COOLPOWER
140 T and COOLPOWER 50 generate in connection with a compressor unit
“cryogenic” temperatures, i.e. temperatures below 120 K (K = Kelvin).
The COOLPOWER 5/100 (T) and 7/25 units are of a two-stage design, the
COOLPOWER 140 T and 50 are of a single-stage design.
Acold head is utilized e.g. to refrigerate samples or to cool shielding plates
or cryoanels.
Apair of flexlines connect it to a compressor unit. Cold head, flexlines and
compressor unit are equipped with self-sealing fittings and are filled with
high-purity,high-pressurehelium gas.
Oerlikon Leybold Vacuum cryogenerators operate in a closed helium gas
cycle according to the Gifford-McMahon principle. In this process, helium gas
is compressed in a compressor. The pressure is then decreased in the cold
head to generate low temperatures.
A rotating control valve (1/8) controls the movement of the displacer, the
expansion of the helium gas in the cold head, and the pneumatic drive of the
displacement piston. The control valve is mounted on the shaft of a
synchronous motor (1/9) which is supplied with electric power from the
compressor unit.
The frequency of the compressor piston movement is 2 Hz at a line
frequency of 50 Hz, 2.4 Hz at a line frequency of 60 Hz.
For the two-stage cold heads, the displacer pistons of the 1st (1/3) and 2nd
stage (1/6) are mechanically interconnected.
Asafety valve (1/11) protects the cold head against excessively high helium
pressure.
The cold head has a weld-on pipe (1/7) or a flange for mounting on the
system.
The refrigerating capacity of the refrigeration stages depends on the
temperature. Fig. 4 shows the characteristic curves for refrigerating capacity.
1.2 Standard Specification
Gifford-McMahon cold head with copper flanges, safety valve and power
cord with plug for connection to the compressor unit.
The cold head is filled with 16 bars of ultra-pure helium (99.999 % purity or
higher).
The COOLPOWER 5/100 (T) and 140 T have a mounted electrical cable with
plug for connection to the compressor unit.
Gifford-McMahon principle
Control valve
Safety valve

Description
8GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
Fig. 1 Two-stage Gifford-McMahon cold head COOLPOWER 5/100 (Part No. 893 05; schematic diagram)
10
11
12
12nd (refrigeration) stage, copper flange
2 Expansion volume, 2nd stage
3Displacer piston, 2nd stage
41st (refrigeration) stage, copper flange
5 Expansion volume, 1st stage
6 Displacer piston, 1st stage
7Weld-on pipe
(Flange for Part Nos. 893 04 and 842 030)
8 Control valve
9Synchronous motor
10 Helium high-pressure connection
11 Safety valve
12 Helium low-pressure connection
9
8
7
6
5
4
3
2
1

Description
9GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
1.3 Technical Data
Cold head COOLPOWER 5/100 5/100 5/100 T 140 T
Part No. 893 04 893 05 129 78 842 030
Compressor unit COOLPAK 6000, 6200 6000, 6200 6000, 6200 6000, 6200
Refrigerating capacity at 50/60 Hz
1st stage at 80 K, approx. 100 W 100 W 100 W 140 W
1st stage at 20 K, approx. – – – 20 W
2nd stage at 20 K, approx. 6 W 6 W 7 W –
2nd stage at 10 K, approx. – – 3 W –
Lowest achievable
temperature, approx.
1st stage #35 K #35 K #35 K #15 K
2nd stage #10 K #10 K 6 K –
Cooldown time
of 2nd stage to 20 K, approx. 20 min 20 min 20 min –
to 20 K, approx. – – - 55 min
Permissible ambient temperature 10-40 °C
He filling pressure
at room temperature 1) 16(-1) bar
Opening pressure
of safety valve 28 bar
He connections:
Self-sealing fittings 1/2“, m 2)
Weight excluding power cord, approx. 8 kg
Connection for mounting
on the system Flange Weld-on pipe Weld-on pipe Flange
DN 160 ISO-K [130 mm [130 mm DN 160
ISO-K
Holes with a thread M4
at the copper flanges
1st stage 16 16 16 8
2nd stage 6 6 6 –
Length of power cord
to the compressor unit 4.5 m
Type of protection
provided by the housing
DIN/VDE Standard 0470-1 IP 52
1) State of delivery; for filling pressure during operation refer to the Operating Instructions for the compressor unit.
2) f=female coupling, m = male coupling; T
ype „Aeroquip series 5400“ or compatible types

Description
10 GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
Cold head COOLPOWER 7/25 50
Part No. 842 040 842050V0000
Compressor unit COOLPAK 2000, 2200 2000, 2200
Refrigerating capacity at 50/60 Hz
1st stage at 80 K, approx. 25 W 50 W
1st stage at 20 K, approx. – –
2nd stage at 20 K, approx. 7 W –
2nd stage at 10 K, approx. – –
Lowest achievable
temperature, approx.
1st stage #35 K #25 K
2nd stage #10 K –
Cooldown time
of 1st stage to 20 K, approx. 20 min
of 2nd stage to 20 K, approx. 20 min
Permissible ambient temperature 10-40 °C
He filling pressure
at room temperature 1)
Opening pressure
of safety valve 28 bar
He connections:
Self-sealing fittings 1/2“, m 2)
Weight excluding power cord, approx. 8 kg
Connection for mounting
on the system Weld-on pipe Weld-on pipe
[130 mm [130 mm
Holes with a thread M4
at the copper flanges
1st stage 88
2nd stage 6 –
Length of power cord
to the compressor unit – –
Type of protection provided
by the housing
DIN/VDE Standard 0470-1 IP 52
1) State of delivery; for filling pressure during operation refer to the Operating Instructions for the com-
pressor unit.
2) f=female coupling, m = male coupling; T
ype „Aeroquip series 5400“ or compatible types

Description
11GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
1.4 Ordering Data
Part No.
Cold head COOLPOWER 5/100
with flange DN 160 ISO-K 893 04
with weld-on pipe 893 05
Cold head COOLPOWER 5/100 T 129 78
Cold head COOLPOWER 7/25 842 040
Cold head COOLPOWER 50
with flange DN 100 CF-R 842050V0001
with weld-on pipe 842050V0000
Cold head COOLPOWER 140 T 842 030
Other flanges upon request
Compressor units for COOLPOWER 5/100 T and 140 T
COOLPAK 6000-H 400 V, 50 Hz, 3ph,
470 V, 60 Hz, 3ph 840000V6001
COOLPAK 6200-H 200 V 1),50 Hz, 3ph,
200/230 V, 60 Hz, 3ph 840000V6201
Compressor units for COOLPOWER 7/25
Water cooling
COOLPAK 2000 230 V, 50 Hz, 1ph 840000V2000
COOLPAK 2200 208 V, 60 Hz, 1ph 840000V2200
Air cooling
COOLPAK 2000 A 230 V, 50 Hz, 1ph 840000V2010
COOLPAK 2200 A 208 V, 60 Hz, 1ph 840000V2210
Mains power cord for COOLPAK 6000
3.5 m long, 4x4mm2,with CE plug (32 A/6h, 3+N+PE) 893 95
3.5 m long, 4xAWG 12, with NEMA plug
(L16-20P, 20 A/480 V) 893 96
Mains power cord for COOLPAK 6200
(also suitable for COOLPAK 6000
with conductor ferrules (4xAWG 10)
10 m long 840 111
20 m long 840 112
COOLPAK: water-cooled compressor unit. The helium
connections of the compressor units listed here are m 2)
1/2“, 1/2“self-sealing fittings.
Flexlines, in each case, 1 pair with f 2) Aeroquip fittings
FL 4.5 (1/2“, 1/2“), 4.5 m long 892 87
FL 9.0 (1/2“, 1/2“), 9 m long 892 88
Electrical connection cable for COOLPOWER 7/25, 4.5 m long 400 000 323
Electric extension cable for the
cold-head power cord, 4.5 m long 893 74
Further accessories for the connection and operation of cold heads: See the
Operating Instructions for the compressor unit.
1) Operation at 230 V, 50 Hz is possible with additional measures.
2) f=female coupling, m = male coupling; T
ype „Aeroquip series 5400“ or compatible types

12 GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
Description
Fig. 2a Dimensional Drawing , dimensions in mm
COOLPOWER 5/100, Part No. 893 05
COOLPOWER 5/100 T, Part No. 129 78
135
108,5
80
110
19
47,5
6
27
92,2
115
6
32,2
129
474,5
149
117,5
105
40 60 105
M4
13,5°
13,5°
128,7
127
47,5
130
129
COOLPOWER 5/100, Part No. 893 04
135
108,5
80
277,5
19
47,5
6
27
92,2
115
6
32,2
129
474,5
149
117,5
105
40 60 105
M4
13,5°
13,5°
128,7
127
47,5
DN 160 ISO-K

13GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
Description
Fig. 2b Dimensional Drawing , dimensions in mm
A
B
Ansicht A
Ansicht B
30°
6x60
°
45°
8x45°
47,5
125,5
69
87 490
M4
40
60
M4x7
82,1
18
3
ca. 120
ca. 120
6
135
COOLPOWER 7/25
Ø 105
Ø 115
Ø 105
6
DN 160 ISO-K
12
148.5
346
ca. 121
M4
10∞
Mid of clamp
Ø 60
Heli-Coil M4, 7 deep
22.5°
45°
Length
4.5 m
COOLPOWER 140 T
View B
View A

Description
14 GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
Fig. 2c Dimensional Drawing , dimensions in mm
ø69
149.5±0.3
A-A
364.75
31.5
117.5
8x45
16x22.5
22.5
11.3
A
Gewinde M2
thread M2
M4
ø69±0.3
13.5
27
A
400000867 (1x)
Flansch DN100 CF: drehbar
COOLPOWER 50, Cat. No. 842050V0000
365
ø 69
117.75 31.5 11.8
ø 87
13.5
°
27°
°
22.5
°
60
COOLPOWER 50, Cat. No. 842050V0001

Transportation and Storing
15GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
2 Transportation and Storing
Storing and transporting the cold head
Store the cold head in a dry place at temperatures between –20 °C and
+50 °C; during transportation avoid exposure to shock and vibration.
Due to the limited stability of the cold head, always use suitable props or
supports (such as the original packaging) for storage and shipment.
The cold head must not be picked up by the second cooling stage for
shipment. It can be handled at the motor and the connection flange.
Fig. 3 Cold Head COOLPOWER 5/100
12nd (refrigeration) stage, copper flange
2 1st (refrigeration) stage, copper flange
3 Weld-on pipe or flange
4 Electrical connection cable to compressor unit
(Separate cable for COOLPOWER 7/25;
must be plugged in at the cold head motor)
5 Helium low-pressure connection
6 Safety valve
7 Helium high-pressure connection
1
2
3
4
5
6
7

Installation
16 GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
3 Installation
3.1 Conforming Utilization
1. The cold head generates in connection with a compressor unit “cryo-
genic” temperatures, i.e. temperatures below 120 K (K = Kelvin).
2. The cold head has been designed for operation with a very high purity
helium (purity 99.999% or higher). Compressors and connected cold
heads have been designed to be operated in indoor rooms.
3. The cold head must, when being operated, be firmly installed to the
insulating vacuum, respectively welded to it.
4. The cold head must only be operated with the compressors, pressure
lines and electric connecting lines specified for it. Connecting other
components requires prior approval by Oerlikon Leybold Vacuum.
3.1.1 Non-conforming utilization
Non-conforming utilizations for the cold head are among others:
1. Safety devices must not be disabled.
2. Use of helium which is not pure(a purity of 99.999 % or higher is
required) or other gases.
3. Operation at helium pressures higher than those specified.
4. Use of the cold head in environments which demand a type of pro-
tection in excess of IP 54 and altitude above 1000 m.
5. Operation without connected helium pressure lines and compressor.
6. Removal, covering or obstructing warning information.
7. Standstill or storing the cold head without having sealed it off suitably
and dried it. When stored in a humid atmosphere there is the risk of
corrosion.
8. Cold head, cables and pressure lines must not be used to climb onto
the system.
9. The use of compressors, cables, helium pressure lines and other
accessories not approved as original accessories from Oerlikon
Leybold Vacuum.
10. Conversions, modifications and maintenance work by personnel not
authorised by Oerlikon Leybold Vacuum.
Any non-conforming utilisation of coldhead, cryo pumps and accessories
can result in severeinjury and may cause damage to components.
CAUTION

Installation
17GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
3.2 Unpacking and Checking the Delivery
Unpack the equipment immediately after delivery, even if it is to be put into
operation at a later date.
Before doing so, examine the shipping container for any external damage.
Then completely remove the packaging materials. The shipping container and
packaging materials must be kept in the case of return shipments becoming
necessary.
Check that the equipment is complete and carefully examine it visually.
If any damage is discovered, report it immediately to the forwarding agent
and insurer. If the damaged part has to be replaced, please get in touch with
Oerlikon Leybold Vacuum.
In order to prevent the formation of condensate, leave the cold head to warm
up to room temperature before installing it.

3.3 Connecting the cold head
Insulation vacuum
The cold head can be installed in any position. The cold head is delivered
complete with a weld-on pipe or with a flange for installation in a system.
The copper flanges have holes with an M4 thread. They are used to fasten
parts to be cooled.
Connect the cold head to the compressor unit. Refer to the Operating
Instructions for the compressor unit.
The refrigerating stages have to be thermally vacuum insulated from the
environment (p#5·10-2 mbar)to be able to cool the cold heads. Wewill
gladly be of assistance in selecting a suitable vacuum pump.
Do not interchange the high-pressure- with the low-pressure connections.
Wrong connection may damage the cold head.
Installation
18 GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
NOTICE

Installation
19GA12119_00_A3 - 01/2012 - © Oerlikon Leybold Vacuum
3.4 Electrical Connection
Please note the safety information given in Section 0.2.
Before connecting the electrical connection cable, check to ensure that the
compressor unit is set for the correct line voltage. Refer to the compressor
unit operating instructions for details.
CAUTION
200
150
100
50
0
W
Q1
3000 50 100 150 200 250 K
T1
5/100
140 T
7/25
50
30
20
10
5
0
W
Q2
3000 50 100 150 200 250 K
T2
25
15 5/100
7/25
Refrigerating capacity 1of the 1st stage as a function of
temperature T1of the 1st stage (2nd stage: 2=0).
Q
.
Q
.
Refrigerating capacity 2of the 2nd stage as a function of tem-
perature T2of the 2nd stage (1st stage: T1=80 K = constant)
Q
.
Operation with the recommended compressor unit at 50 Hz; measured under standard acceptance conditions:
(Cold head in vacuum, 2nd cold stage thermally shielded by a high gloss nickel-plated radiation shield on the 1st refrigerating stage.
Load simulated by electrical heater.)
Q
.
Fig. 4 Refrigerating capacities as a function of the temperature

3.5 Installing the Flexible PressureLines
Use flexlines from Oerlikon Leybold Vacuum only.
Replace any damaged flexlines.
Working instructions for self-sealing screw fittings
The interconnecting cables and elements possess self-sealing screw fittings.
The connections can be opened and closed without helium escaping.
Remove the protective caps from the screw fittings.
Keep the protective caps in a safe place.
Check all connections for dust and dirt particles and clean them as
necessary using a clean, lint-free cloth or a soft, clean brush.
Do not use solvents to clean the connections! The connections must not be
greased or oiled.
Check the correct fit of the flat gaskets in the screwed fittings with external
thread. Replace missing or damaged gaskets.
Tomount the pressurelines, only use the supplied fork wrenches or fork
wrenches approved by Oerlikon Leybold Vacuum.
Only connect or disconnect pressure lines if the compressor unit is turned off
and the pressureis below 28 bar.
Do not twist the pressure lines.
When fixing the screw fittings, use one wrench for tightening and a second
wrench for countering; see Figs. 5 and 6.
Installation
20 GA12119_002_A3 - 01/2012 - © Oerlikon Leybold Vacuum
CAUTION
Stabilizing wrench
Wrench for tightening
Fig. 5 Mounting the self-sealing couplings