Sumitomo HC-4E1 User manual

HC-4E1 and HC-4E2 Helium
Compressors
Technical Manual
Sumitomo (SHI) Cryogenics of America, Inc.
1833 Vultee Street
Allentown, PA 18103-4783
U.S.A.
Revision C: August 2012 267318A

TABLE OF CONTENTS
i
Page
SAFETY......................................................................................................................... .1
SERVICE ....................................................................................................................... 5
INTRODUCTION .......................................................................................................... 7
Helium Compressor, Models HC-4E1 and HC-4E2.............................................. 7
PRINCIPLES OF OPERATION .................................................................................... 9
DESCRIPTION ........................................................................................................... 11
Components .................................................................................................... 11
SPECIFICATIONS ...................................................................................................... 17
Electrical Characteristics ................................................................................. 17
Cooling Requirements ..................................................................................... 18
Refrigerant Quality ........................................................................................... 18
Helium Gas Pressures ..................................................................................... 18
Compressor Lubricant ..................................................................................... 19
Compressor Weight ......................................................................................... 19
Compressor Dimensions ................................................................................... 19
Space Requirements......................................................................................... 19
Mounting Position ............................................................................................ 19
Environmental Requirements .......................................................................... 19
Protective Earth Terminal ................................................................................ 19
Maintenance Intervals ....................................................................................... 19
Installation Kit .................................................................................................. 20
Adapter Fittings (Optional Accessory)............................................................... 20
Remote On/Off Cable (Optional Accessory) ...................................................... 20
Supplier Name and Address ............................................................................ 20
Regulatory Compliance ................................................................................... 21
INSTALLATION .......................................................................................................... 23
Introduction ....................................................................................................... 23
Receipt Inspection Instructions ........................................................................ 23
Compressor Position ........................................................................................ 25
Mains Power Supply Connection ..................................................................... 26
Field Wire the Compressor .............................................................................. 28
Compressor Checkout ..................................................................................... 29
Interconnections .............................................................................................. 30
Remote On/Off Cable (Optional Accessory) .................................................... 31
Compressor Shipping Preparation..................................................................... 32
OPERATION ............................................................................................................. 33
Prestart Check ................................................................................................. 33
Starting ............................................................................................................ 33
Stopping .......................................................................................................... 33
Restarting after a Power Failure ...................................................................... 33

TABLE OF CONTENTS
(continued)
ii
Page
MAINTENANCE ......................................................................................................... 35
Adsorber Replacement .................................................................................... 36
Adsorber Removal ..................................................................................... 36
Adsorber Installation .................................................................................. 37
Used Adsorber Venting and Disposal ........................................................ 37
Charging and Venting ...................................................................................... 38
Charging Procedure.................................................................................... 38
Venting Procedure to Adjust the Equalization Pressure ............................. 39
Venting Procedure to Vent to Atmospheric Pressure ................................. 39
Gas Cleanup ................................................................................................... 40
Leak Check ...................................................................................................... 42
Leak Repair ..................................................................................................... 42
Replace the Compressor Shell High Temperature Switch ................................. 43
TROUBLESHOOTING ................................................................................................ 45
Automatic Shutdown ........................................................................................ 45
Troubleshooting Guide .................................................................................... 46
Compressor Capsule ....................................................................................... 48
Winding Continuity, Grounding and Resistance Checks ............................. 48
Current Measurement ................................................................................ 49
PARTS ....... ............................................................................................................... 55
Ordering .......................................................................................................... 55
Compressor Parts Identification and Numbers ................................................. 55
Adapter Fittings ............................................................................................... 59
Cables ............................................................................................................. 60
ILLUSTRATIONS LIST
Figure 1HC-4E Flow Diagram ....................................................................... 9
Figure 2HC-4E1 Outline Dimensions and Parts Identification ..................... 14
Figure 3HC-4E2 Outline Dimensions and Parts Identification ..................... 15
Figure 4Connections for Mains Power Supply ............................................ 27
Figure 5Connect and Remove the Water Lines ........................................... 29
Figure 6Connect Gas Line to Compressor or Manifold ................................ 31
Figure 7 Compressor Shell High Temperature Switch ................................... 44
Figure 8 Compressor Terminals ................................................................... 49
Figure 9HC-4E1 Wiring Diagram ................................................................ 51
Figure 10 HC-4E2 Wiring Diagram ................................................................ 52
Figure 11 HC-4E1 Electrical Schematic ......................................................... 53
Figure 12 HC-4E2 Electrical Schematic ......................................................... 54
Figure 13 Parts Identification .......................................................................... 56
Figure 14 Parts Identification for HC-4E1 ....................................................... 57
Figure 15 Parts Identification for HC-4E2 ....................................................... 57
Figure 16 Adapter Fitting, 8F and 8M, with Valve ........................................... 59
Figure 17 Adapter Fitting, 8F, with Valve ......................................................... 59
TABLES
Table 1 Terminal Position for Mains Power Supply .......................................... 27
SJM P/N 267318A

SAFETY
1
GENERAL
The HC-4E1 Helium Compressor is designed to operate safely when the installation, operation
and servicing are performed in accordance with the instructions in this technical manual.
Consult the nearest SCAI Service Center with any questions you may have concerning the use
or maintenance of these compressors. For Service Center locations, see the Service section of
this manual.
SPECIAL NOTICES
Three types of special notices - WARNINGS, CAUTIONS and NOTES are used in this technical
manual. They appear as follows and serve the purposes stated.
WARNINGS call attention to actions or conditions that can result in serious injury or death to
personnel.
CAUTIONS call attention to actions or conditions that can result in damage to the equipment or
in abnormal performance.
NOTE
NOTES give important, additional information, explanations or recommendations related to the
procedure or discussion presented.
WARNINGS and CAUTIONS, like other safety instructions, appear within rectangles in the text
where they are especially applicable. Because of their importance, they are summarized in this
section and in the General Technical Manual, and should be read first.

Safety
2
WARNINGS
AVOID ELECTRIC SHOCK. All electrical supply equipment must meet applicable codes and
be installed by qualified personnel. Permit only qualified electrical technicians to open electrical
enclosures, to perform electrical checks or to perform tests with the power supply connected
and wiring exposed. Failure to observe this warning can result in serious injury or death.
Disconnect the power to the compressor before troubleshooting the electrical components.
AVOID INJURY. Never use compressed helium gas from a cylinder without a proper regulator.
Overpressure can cause serious injury if the system equipment ruptures.
During operation, some surfaces under the compressor’s cover become hot. Allow the
compressor to cool for 1/2 hour after shutdown before removing the cover for maintenance.
Always wear eye protection when handling pressurized gas lines and other pressurized
equipment. Never apply heat to a pressurized gas line or other pressurized components.
Disconnect gas lines only when the compressor is stopped. Disconnecting the cold head while
it is cold can create excessively high internal pressure as the gas warms. Material failure and
uncontrolled pressure release can cause injury.
Use two wrenches when disconnecting a gas line coupling to avoid loosening the cold head or
compressor coupling. Gas pressure can project the coupling with enough force to cause
serious injury.
The compressor is charged with helium gas. Vent both supply and return Aeroquip couplings to
atmospheric pressure before disassembly, except when disconnecting the adsorber or the gas
lines. Uncontrolled pressure release can cause serious injury.
Always vent a gas-charged component before beginning to disassemble its couplings. Gas
pressure can launch a loose coupling with enough force to cause serious injury.
The adsorber is charged with helium gas. Follow the used adsorber venting procedure for safe
disposal of the used adsorber.
CAUTIONS
PRESERVE YOUR WARRANTY. Modification to equipment without the consent of the
manufacturer will void the warranty.
Specifications require the use of 99.995% pure helium gas. Using a lesser quality of helium can
damage the system and void the warranty.
AVOID GAS LEAKS. Check the condition of the gasket face seal on the male half of each
Aeroquip coupling. Be sure the gasket face seal is in place and the sealing surfaces on both
the male and female halves are clean before connecting. Replace the gasket face seal if it is
damaged or missing.
Keep the gas line couplings aligned when making or breaking a coupling connection. Leaks can
occur due to the weight of the gas line or due to a sharp bend near the connection.

Safety
3
CAUTIONS (continued)
AVOID CONTAMINATION. When checking the compressor for shipping damage, do not
connect gas lines and cold head. The components may become contaminated with
compressor oil.
Follow the charging or venting procedures to prevent reversed flow of system gas. Do not
charge through the supply coupling. Do not vent through the return coupling. Reversed flow
can contaminate the system with compressor oil.
A leaking coupling on an adsorber should not be repaired in the field. Consult a Service Center.
Venting the adsorber will introduce contaminants to the system, which cannot be removed in the
field.
PREVENT EQUIPMENT DAMAGE. Damage to gas lines can result from crimping by repeated
bending and repositioning.
Always thoroughly drain the coolant from the cooling circuit if the compressor is to be shipped or
stored.
If the compressor starts but runs roughly and the supply pressure does not increase, turn it off
immediately. This is an indication that the power supply leads are connected in the wrong
phase sequence and the compressor is operating in the reverse direction. The compressor’s
circuit breaker may also trip. Disconnect the power to the compressor. Interchange any two
incoming power leads (except ground) at the compressor’s power cord plug or at the customer’s
disconnect switch. Reconnect the power and restart the compressor.
Never pull a vacuum on the compressor or on the cold head. The motors will short circuit if
started.
After starting the system for the first time, to be certain that the water lines are properly
connected, check that the outlet water temperature is warmer than the inlet water.
For an installation using a water chiller or other circulating cooling system:
Use pure ethylene glycol with water for the coolant antifreeze solution. Do not use commercial
ethylene glycol sold for automotive cooling systems, which usually contains a fine grit material
that can damage the cooling system.
AVOID A MALFUNCTION. Repeatedly charging the system with helium gas rather than
locating and repairing gas leaks can cause a malfunction. Impurities are introduced at an
abnormal rate and can freeze in the cold head.
Do not allow air to get into the helium gas refrigerant of the system. Moisture from the
atmosphere can seriously degrade cold head performance.
AVOID EQUIPMENT FAILURE, CONTAMINATION OR A NUISANCE SHUTDOWN. Do not
tip the compressor greater than 5 degrees from horizontal, to avoid flowing oil into unwanted
places.

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SERVICE
5
HEADQUARTERS
Sumitomo (SHI) Cryogenics of America, Inc.
1833 Vultee Street
Allentown, PA 18103-4783
Sales and Parts
TEL: [phone]
or
[phone]
FAX: [phone]
Service
TEL: [phone]
or
TEL: [phone]
SERVICE CENTERS
Eastern
U.S.A
Sumitomo (SHI) Cryogenics of America, Inc.
1833 Vultee Street
Allentown, PA 18103-4783
TEL: [phone]
or
[phone]
FAX: [phone]
Western
U.S.A.
Sumitomo (SHI) Cryogenics of America, Inc.
1700 Wyatt Dr.
Suite 8
Santa Clara, CA 95054
TEL: [phone]
FAX: [phone]
Europe
Sumitomo (SHI) Cryogenics of Europe, Ltd.
3 Hamilton Close
Houndmills Industrial Estate
Basingstoke
Hampshire RG21 6YT
United Kingdom
TEL: [phone]
FAX: [phone]
Sumitomo (SHI) Cryogenics of Europe, GmbH
Daimlerweg 5a
D-64293 Darmstadt
Germany
TEL: [phone]
FAX: [phone]
Asia
Sumitomo Heavy Industries, Ltd.
Service Section
Cryogenics Division
2-1-1 Yato-Cho Nishitokyo-City
Tokyo 188-8585
Japan
TEL: [phone]
FAX: [phone]
Sumitomo (SHI) Cryogenics Korea, Co., Ltd.
Room 619-620, Venture Valley
#958 Goseck-Dong, Kwonsun-Gu
Suwon-City, Gyeonggi-Do
South Korea
TEL: [phone]
FAX: [phone]
Sumitomo Heavy Industries (Shanghai)
Management, Ltd.
Room 107-110, Building 5
No. 100, Zixiu Road
Shanghai 201103
People’s Republic of China
TEL: [phone]
FAX: [phone]
Sumitomo (SHI) Cryogenics Taiwan Co., Ltd.
4th Floor, No.3
Lane 216, Gongyuan Rd.
Hsinchu City 300
Taiwan ROC
Phone: [phone]
Fax: [phone]

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INTRODUCTION
7
Helium Compressor Models HC-4E1 and HC-4E2
The Compressors are single-stage, water-cooled, rotary, and designed to deliver high-pressure,
oil-free helium gas to cryogenic refrigerators. Cold head cables are used to supply electrical
power to cold heads. Self-sealing couplings allow for easy connection to and disconnection
from the rest of the closed-cycle cryogenic refrigeration system.
The information in this manual pertains only to the HC-4E Series Compressors. Other
components used to form an operating system are described in separate technical manuals.
Pressures are stated as gauge, not absolute. Psig is pounds per square inch gauge and kPa is
Kilopascals gauge,
kPa = 6.895 x Psig.
Definition of Symbols used in this manual and on equipment:


Power Switch On
Protective Earth (Ground) Terminal
O Power Switch Off
WARNING Risk of Electric Shock
CAUTION Refer to Manual V ~ Volts, AC, 1 Phase

8
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PRINCIPLES OF OPERATION
9
The compressor continuously draws low-pressure helium from the system return line.
It compresses, cools and cleans the gas, then delivers it through the system gas supply line
to the cold head. See Figure 1.
1.
Oil Injection Filter
11.
Gas Supply Pressure Gauge
2.
Oil Injection Orifice
12.
Gas Equalization Solenoid Valve
3.
Heat Exchanger
13.
Gas Supply Coupling
4.
Compressor Capsule
14.
Gas Return Coupling
5.
Oil Separator
15.
Water Supply Fitting
6.
Oil Capillary Filter
16.
Water Return Fitting
7.
Oil Capillary
17.
Pressure Relief Valve
8.
9.
Adsorber
Internal By-pass Orifice
18.
Temperature Switches (water, oil,
gas and compressor shell)
10.
Surge Bottle
19.
Internal Relief Valve
Figure 1 HC-4E Flow Diagram

Principles of Operation
10
When gas leaves the compressor, the gas contains heat and compressor lubricant. Both must
be removed. From the compressor, the hot gas with its entrained oil flows over the motor
winding, where the gas loses some of its suspended oil, then out of the shell and through one
circuit of a three-circuit heat exchanger, where it is cooled. Next, the gas passes through the oil
separator and the adsorber for oil and moisture removal. From the adsorber, the high-pressure
gas is supplied to the cold head through gas lines.
Through the system gas return line, low-pressure gas from the cold head flows into the
compressor.
A gas line containing an internal by-pass solenoid valve connects the high-pressure line to the
low-pressure line. The by-pass valve will open to prevent overloading the motor when the
system gas lines are not connected to the compressor.
Oil is separated from the gas in three stages. The first stage is by precipitation when the gas
passes over the motor windings. The second stage is in the oil separator whose element
collects oil mist from the gas; oil is agglomerated and returned to the compressor. The third
stage is the adsorber that removes any remaining oil the gas is carrying.
Oil collected in the separator flows back to the compressor through a capillary tube. The
differential gas pressure across the system is the moving force, and the capillary size limits the
amount of gas bypassed. The small amount of oil collected in the adsorber remains there and
is removed only by replacing the adsorber.
Oil in the compressor capsule also collects heat. The shell-wrapped heat exchanger removes
heat from the compressor motor and from the warm oil by direct conduction through the
compressor shell. Gas pressure pushes oil through the heat exchanger’s outer tubes that cool
the warm oil from the compressor. This cooled oil is then reinjected into the gas return line,
which returns the oil to the compressor to reabsorb heat and lubricate the compressor.

DESCRIPTION
11
The components of the HC-4E Series Compressors are identified schematically in Figure 1.
Figures 2 and 3 identify front panel components. Features and functions of individual
components are described in the following paragraphs.
Components (See Figures 2 and 3)
50/60 Hz Toggle Switch (HC-4E2 only): This switch is used to select different phasing circuits
for cold head operation at 50 Hz or 60 Hz.
Accessory Receptacle and Optional Remote On/Off Cable: The accessory receptacle
mounted on the front panel is a 14-socket connector for supplying remote on/off capability. The
remote on/off cable is available as an option.
Adsorber: The adsorber removes any oil and moisture the gas is carrying which did not drop
out in the separator. This vessel contains activated charcoal for oil adsorption. The adsorber
has a finite life and must be replaced every 30,000 operating hours.
Circuit Breaker: A panel-mounted, 20 ampere, circuit breaker in the main power supply
protects the compressor from electrical overload.
Cold Head Receptacle and Optional Cables - A 28-socket receptacle mounted on the front
panel and a cold head cable supply electrical power from the compressor to the cold head. The
compressor can be supplied with cables for operating a DE-202, DE-204SL, M204S or CH204S
Cold Head.
Compressor Capsule: The rotary, positive displacement compressor capsule is hermetically
sealed. Electrical connections to the motor are made at terminals under a protective cover on
top of the housing.
If oil needs to be added to the compressor, an oil charging vessel (with oil), P/N 263775A3 is
available as an accessory from SCAI.
Compressor Power Cord: Terminating with a 3-prong, NEMA L6-20P plug, the power cord
supplies electrical power to the compressor.
Elapsed Time Meter: The battery-operated LCD digital display, elapsed time meter shows the
compressor’s cumulative running time in hours up to a total of 99,999 hours.
AVOID INJURY. The compressor’s elapsed time meter contains a lithium
battery. Do not remove the battery. Do not recharge, disassemble, mutilate, wet
or dispose of the meter in fire. Contact local environmental authorities for proper
disposal of the lithium battery.
Electrical Chassis: The electrical chassis contains electrical components and connections and
distributes power to all system circuits. The wire terminals are accessible by removing a cover
from the front panel of the compressor. Components are accessible by removing the right side
cover from the compressor capsule.

Description
12
Fuses:
#
Electrical Rating
(250 VAC) Circuit Location
HC
-
4E1
HC
-
4E2
FU1 0.63 AT 1.0 AT Cold head Front panel
FU2 0.63 AT 1.0 AT Cold head Front panel
FU3 5.0 AT 5.0 AT Cold head Front panel
FU4 5.0 AT 5.0 AT Cold head Front panel
FU5 0.4 AT 0.4 AT Control Inside Electrical Chassis
FU6 0.4 AT 0.4 AT Control Inside Electrical Chassis
Gas Equalization Solenoid Valve: This solenoid valve opens when the compressor is stopped.
The valve allows the helium gas pressure across the compressor to equalize, to prevent oil from
being blown out of the compressor into the low-pressure (return) gas line.
Gas High Temperature Switch: Located on the supply gas line near the top of the compressor,
the switch opens at 93ºC (200ºF) and stops the compressor if the gas temperature is too high.
Gas Supply and Return Couplings: Both are self-sealing, size 8, male, Aeroquip, bulkhead
couplings and are the points of connection on the front panel for the rest of the system.
Heat Exchanger: The heat exchanger consists of three coils wrapped around the compressor
capsule. One cools helium, another cools the compressor shell and another cools oil in the oil
injection circuit. This circuit cools oil that has absorbed heat from the compressor and reinjects
the cooled oil, which continues to absorb heat from the compressor.
Internal Relief Valve: The internal by-pass valve opens to allow the compressor to be run when
the system gas lines are disconnected, to avoid overloading the compressor capsule.
Oil Capillary: The capillary returns oil collected in the oil separator sump to the low-pressure
side of the compressor for recycling.
Oil Filters: There are two oil filters. One filter in the oil separator drain line protects the return
oil capillary. The other filter in the oil injection circuit protects the compressor.
Oil High Temperature Switch: Located on the oil return line, the switch opens at 60ºC (140ºF)
and stops the compressor if the oil temperature is too high.
Oil Injection Orifice: This orifice is installed downstream of the oil filter in the oil injection line
and controls the flow rate of oil into the compressor’s gas return line.
Oil Separator: The bottom of the oil separator serves as a sump. A cartridge above the sump
contains fibrous material that acts as the separating agent. Entrained oil coalesces on it,
forming large droplets that drain into the sump. This unit needs no servicing or replacement.
Power On/Off Switch: This on/off rocker switch starts and stops the compressor. The switch
lights to indicate that power is on to the compressor.
Pressure Gauge: A pressure gauge indicates gas pressure in the supply line. When the
compressor is not running, the gauge shows the equalization pressure.

Description
13
Pressure Relief Valve: The relief valve prevents the compressor from operating at an unsafe
pressure.
Shell High Temperature Switch: Located on top of the compressor next to the compressor
motor terminals, the switch opens at 80º C (176º F) and stops the compressor if the shell
temperature is too high. The switch resets automatically after it cools.
Surge Bottle: The surge bottle located in the return gas line dampens the pressure pulsations.
Water High Temperature Switch: Located in the water return line, it shuts down the
compressor if the outlet water temperature is too high. The switch opens at 52º C (125º F) and
resets automatically after cooldown.
Water Supply and Return Fittings: Both fittings are compression-type bulkhead fittings
mounted on the front panel.

Description
14
Figure 2 HC-4E1 Outline Dimensions and Parts Identification
(Dimensions in mm)
NOTE
Three (3) 8 mm holes at the bottom of the front panel may be used for bolts to
prevent movement of the compressor.

Description
15
Figure 3 HC-4E2 Outline Dimensions and Parts Identification
(Dimensions in mm)
NOTE
Three (3) 8 mm holes at the bottom of the front panel may be used for bolts to
prevent movement of the compressor.

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