Olicom 9600 Users Manual 8040540.bk

2015-02-05

• Table of Contents
• Table of Contents (continued)
• Table of Contents (continued)
  • Figures
• Table of Contents (continued)
  • Tables
  • Section 1 - 9600 Compressor Description
    • General
    • Benefits
    • CAUTION
      • Compressor Configurations
      • System Documentation
      • CTI-CRYOGENICS Helium Refrigeration System
        • Figure 1-1: 9600 Compressor
      • Specifications
        • Dimensions
      • 19.52 in.
      • (496 mm)
        • Figure 1-2: 9600 Compressor Dimensions
    • CAUTION
      • Weight
        • Table 1-1: Compressor Weight
      • 200lbs./91kg
        • Electrical
          • Table 1-2: Electrical Input Specifications
      • Operating Voltage Range
      • 180 - 253 VAC
      • Line Frequency
      • 50/60 Hz
      • Phase
      • 3
      • Nominal Input Power
      • 5.5 KW
      • Nominal Power Factor
      • 0.85
      • Rated FL/LR* Current
      • 16.2/80
      • Minimum Electrical Service
      • 30 Amps
        • Cooling Water
          • Table 1-3: Cooling Water Specifications
      • Maximum Inlet Temperature
      • 90˚F (32˚C)
      • Minimum Inlet Temperature
      • 50˚F (10˚C)
      • Flow Rate
      • 2.75 ±1.25 gpm (10.4 ± 4.7 lpm)
      • Pressure Drop (inlet-to-outlet)
      • See Figure 1-3
      • Maximum Inlet Pressure
      • 100 psi (6.9 bars)
      • Alkalinity
      • 6.0 - 8.0 pH
      • Calcium Carbonate
      • < 75 ppm
        • Figure 1-3: Water Flow Rate versus Pressure Drop
          • General
            • Table 1-4: General Compressor Operating Specifications 
      • Part Numbers
      • Input Power Cable
      • (Customer Supplied)
      • 600 VAC
      • 10 Gauge, 3 conductor wire with ground
      • Must conform to local electrical codes
      • Nominal Helium Pressure
      • Refer to Table 4-1
      • Ambient Operating Temperature Range
      • 50 - 100º F (10 - 38º C)
      • Interface
      • Gas Supply Connector
      • Gas Return Connector
      • Remote Control Receptacle
      • Cryopump Power Receptacles: mates with the
      • CTI-CRYOGENICS supplied cryopump power cable for single pump use.
      • Mates with remote junction box power cable for multiple cryopump use.
      • 1/2 in. Aeroquip self-sealing coupling
      • 1/2 in. Aeroquip self-sealing coupling
      • 24VAC, 2.7A inductive mates with P5 connector P/N MS3106A*
      • Adsorber Service Schedule
      • 3 Years
      • * Supplied by CTI-CRYOGENICS
        • Component Description
        • Control Circuit
        • Breaker
          • Figure 1-4: 9600 Compressor Rear View Component Locations
            • System Circuit Breaker
            • Control Circuit Breaker
            • Power ON Indicator
            • Gas Charge Flared Fitting
            • Helium Pressure Gauge
            • Power Inlet
            • Return Gas Coupling
            • Cooling Water IN
            • Cooling Water OUT
            • Cryopump Electrical Outlet
              • Table 1-5: Cryopump Electrical Outlet Pin Assignments
      • A and B
      • Heater Power - 208 VAC nominal
      • C
      • Center tap for D and E
      • D and E
      • 24 VCT @ 4.6 Amps
      • F-G and G-H
      • Cold Head Voltage Output 130-160 VAC @ 4.5 Amps
      • J
      • Chassis Ground
      • K
      • Not Used
        • Cryopump Power Phase Switch
        • Compressor Remote Connector
          • Table 1-6: Compressor Remote Connector Pin Assignments
      • A and B
      • Compressor Remote Control - Make = ON, Break = OFF
        • Supply Gas Coupling
        • Multiple On-Board Cryopump Connections
          • Figure 1-5: 9600 Compressor Connected to Multiple On-Board Cryopumps
        • HELIUM SUPPLY
          • Multiple Cryo-Torr Cryopump Connections
        • CRYOPUMP POWER CABLE
          • Figure 1-6: 9600 Compressor Connected to Multiple Cryo-Torr Cryopumps
  • Section 2 - Unpacking and Inspection
    • Introduction
    • Shipping Carton Inspection
    • Removal from Shipping Carton
      • 1. Cut the two straps on the exterior of the shipping pallet.
      • 2. Lift the cardboard carton straight up and remove it from the pallet.
      • 3. Cut the tape which holds the ramp in the vertical position.
      • 4. Swing the ramp down until the end touches the floor as shown in Figure 2-1.
      • 5. Remove any excess shipping material from around the Compressor.
    • WARNING
      • CAUTION
        • 6. Unlock the swivel casters as shown in Figure 2-1.
        • 7. Carefully roll the Compressor down the ramp and onto the floor as shown in Figure 2-1.
        • Figure 2-1: Using the Shipping Carton Ramp
        • Compressor Inspection
          • Compressor
          • Helium Static Pressure Verification
          • Shipping Carton Contents
  • Section 3 - Installation
    • Introduction
      • Figure 3-1: 9600 Compressor Installation Flowchart
    • Supply and Return Water Line Connections
    • (refer to page 3-3)
      • Supply and Return Water Line Connections
        • Hard Water Lines
          • 1. Apply a light coating of standard plumbing thread sealant to the hard line pipe threads.
          • 2. Install the Supply hard line into the INPUT connection on the rear panel of the Compressor. Ti...
          • 3. Install the Return hard line into the OUTPUT connection on the rear panel of the Compressor. T...
    • CAUTION
      • 4. Using a wrench, tighten the fittings.
      • 5. Allow water to flow and check for leaks at the rear of the Compressor.
      • Flexible Water Lines
        • 1. Apply a light coating of standard plumbing thread sealant to the barbed fitting threads.
        • 2. Install the barbed fittings into the INPUT and OUTPUT connections on the rear panel of the Com...
    • CAUTION
      • 3. Using a wrench, tighten the barbed fittings.
      • 4. Connect the Supply flexible water line to the INPUT barbed fitting and secure with a hose clamp.
      • 5. Connect the Return flexible water line to the OUTPUT barbed fitting and secure with a hose clamp.
      • 6. Allow water to flow and check for leaks at the rear of the Compressor.
      • Electrical Connections
        • Power Cable Preparation
    • WARNING
      • CAUTION
        • 1. Cut a 10 AWG (6.00 mm2), 3 conductor cable with ground to an appropriate length.
        • 2. Strip the cable jacket back 4 in. (101.6 mm).
        • 3. Strip the insulation back 3/8 in. (9.3 mm) on each individual conductor.
        • 4. Install a #10 ring tongue terminal on the end of each conductor using the appropriate size dou...
        • 5. Remove the rear panel as shown in Figure 3-2.
        • 6. Remove the circuit breaker terminal cover as shown in Figure 3-2.
        • 7. Install the cable into the Compressor through the cable strain relief.
        • 8. Remove the 10-32 nut and install the grounding wire on the ground stud. Install the nut and ti...
        • 9. Remove the screws from the Compressor circuit breaker terminals X, Y, and Z as shown in Figure...
        • Figure 3-2: 9600 Compressor Circuit Breaker Terminals (Cover Removed)
          • 10. Install the conductor terminal lugs to the circuit breaker terminals X, Y, and Z as shown in ...
          • 11. Torque the screws to 12 in.-lbs (0.14m-kg).
          • 12. Allow enough cable to stay in the electrical enclosure to prevent strain on the electrical co...
          • 13. Install the power source end of the power cable according to the local electrical codes.
          • 14. Install the circuit breaker terminal cover.
          • 15. Proceed with Phase Check.
          • Phase Check
    • WARNING
      • 1. Make sure power is applied to compressor circuit as described in Table 1-2.
      • 2. Turn the Compressor circuit breaker to the ON position. If the circuit breaker trips, refer to...
      • 3. If the circuit breaker trips, perform the following steps:
        • a. Turn the Compressor circuit breaker to the OFF position.
        • b. Disconnect the power cord from the power source.
        • c. Remove the circuit breaker terminal cover.
        • d. Reverse the wiring order of Compressor circuit breaker terminals X and Y.
        • e. Torque the circuit breaker terminal screws to 12 in.-lbs.
        • f. Install the circuit breaker terminal cover.
        • g. Repeat steps 1- 2 of this procedure.
      • 4. Install the rear panel.
      • 5. Proceed with Cryopump Power Phase Switch Setting.
      • Cryopump Power Phase Switch Setting
        • 1. Inspect the On-Board Cryopump(s) being installed for the presence of a THREE-PHASE label by th...
        • 2. If a three-phase label is present, set the cryopump power phase switch, shown in Figure 3-2, t...
        • 3. If a three-phase label is not present, or Cryo-Torr Cryopumps are being installed, set the cry...
      • Connecting/Disconnecting Helium Flex Lines
      • CAUTION
        • Connecting
          • 1. Remove all dust plugs and caps from the Gas Supply and Return lines, and the Compressor and cr...
          • 2. Connect the Gas Return line to the GAS RETURN connector on the rear of the Compressor and then...
          • 3. Connect the Gas Supply line to the GAS SUPPLY connector on the rear of the Compressor and then...
          • 4. Attach the Supply and Return line identification labels to each end of the appropriate lines.
        • Disconnecting
          • 1. Using two wrenches as shown in Figure 3-3, disconnect the two self sealing coupling connectors...
        • Figure 3-3: Connecting/Disconnecting Helium Flex Line Self Sealing Couplings
        • Single On-Board Cryopump Connections
      • CAUTION
        • 1. Connect the Supply and Return lines to the 9600 Compressor as described in Connecting/Disconne...
        • 2. Connect one end of the Cryopump cold head cable to the CRYOPUMP ELECTRICAL OUTLET on the rear ...
        • 3. Connect the opposite end of the cold head cable to the cryopump cold head cable connector.
        • HELIUM SUPPLY
          • Figure 3-4: Single On-Board Cryopump Connections
            • Single Cryo-Torr Cryopump Connections
      • CAUTION
        • 1. Connect the Supply and Return lines to the 9600 Compressor as described in Connecting/Disconne...
        • 2. Connect one end of the Cryopump cold head cable to the CRYOPUMP ELECTRICAL OUTLET on the rear ...
        • HELIUM SUPPLY
          • Figure 3-5: Single Cryo-Torr Cryopump Installation
          • Multiple On-Board Cryopump Connections
      • CAUTION
        • Helium Line Connections
      • CAUTION
        • 1. Connect the Supply and Return lines to the 9600 Compressor as described in Connecting/Disconne...
        • 2. Connect the Gas Return Line to the customer supplied helium manifold and then to the GAS RETUR...
        • 3. Connect the Gas Supply Line to the customer supplied helium manifold and then to the GAS SUPPL...
        • Power Cable Connections
          • 1. Connect the On-Board Splitter Box power cable between the CRYOPUMP ELECTRICAL OUTLET on the re...
          • 2. Connect the On-Board Cryopump or Waterpump power cables to the CRYOPUMP 1, 2, or 3 connectors ...
        • HELIUM SUPPLY
          • Figure 3-6: Recommended Multiple On-Board Cryopump or Waterpump Installation (Splitter Box locate...
          • Figure 3-7: Alternative Multiple On-Board Cryopump or Waterpump Installation (Splitter Box locate...
        • HELIUM SUPPLY
          • Multiple Cryo-Torr Cryopump Connections
      • CAUTION
        • Helium Line Connections
      • CAUTION
        • 1. Connect the Supply and Return lines to the 9600 Compressor as described in Connecting/Disconne...
        • 2. Connect the Gas Return Line to the customer supplied helium manifold and then to the Gas Retur...
        • 3. Connect the Gas Supply Line to the customer supplied helium manifold and then to the Gas Suppl...
        • Power Cable Connections
          • 1. Connect the Cryo-Torr power cable between the CRYOPUMP ELECTRICAL OUTLET on the rear panel of ...
          • 2. Connect the Cryo-Torr Power Cables between the CRYOPUMP 1, 2, or 3 connectors on the Cryo-Torr...
          • 3. Connect the User Remote cable to the Cryo-Torr Interface as shown in Figures 3-8 or 3-9.
          • 4. Connect the Remote cable between the Cryo-Torr Interface and the Compressor as shown in Figure...
        • CRYOPUMP POWER CABLE
          • Figure 3-8: Recommended Multiple Cryo-Torr Cryopump Installation
          • Figure 3-9: Alternative Multiple Cryo-Torr Cryopump Installation
        • CRYOPUMP POWER CABLES
  • Section 4 - Operation
    • Adjusting System Helium Pressure
    • Static Helium System Pressure Verification
      • 1. Make sure the Compressor and Cryopump(s) are OFF.
      • 2. Make sure all system components are connected together as described in Section 3 - Installation.
      • 3. Allow all system components to acclimate to a temperature between 60º F and 80º F (15.5º C - 2...
      • 4. Read the compressor helium pressure gauge located on the compressor rear panel as shown in Fig...
      • Table 4-1: 9600 Compressor Helium Static Charge
    • 60 Hz
    • 240 - 250 psig (16.5 - 17.2 bars )
    • 50 Hz
    • 255 - 265 psig ( 17.6 -18.3 bars )
      • CAUTION
        • 5. If the static helium charge pressure is not within the ranges as indicated in Table 4-1, then ...
      • Compressor Operation
        • 1. Set the System Circuit Breaker to the ON (UP) position.
        • 2. Set the Control Circuit Breaker to the ON (UP) position.
        • 3. Close all Cryopump gate valves.
        • 4. Refer to the On-Board Module Programming and Operation manual or Cryo-Torr Cryopump Installati...
        • 5. Once the second stage temperature for all cryopumps is below 17K, record the compressor pressu...
        • 6. Affix a copy of the data next to the compressor gauge on each compressor. This data is to be v...
      • Replacement of Helium Circuit Components
        • CAUTION
    • Section 5 - Maintenance
      • Scheduled Maintenance
  • Suggested Maintenance Equipment
    • Table 5-1: Suggested Maintenance Equipment
    • Helium, 99.999% pure
    • -
    • Pressure regulator (0-3000/0-400 psi) Assy.
    • 8031403
    • Helium charging line terminating in a 1/4-inch female flare fitting
    • 7021002P001
    • Lint-free gloves and cloth
    • -
    • Oakite or equivalent detergent soap
    • -
    • Denatured alcohol
    • -
  • Adsorber Replacement
    • 1. Set the System Circuit Breaker, on the rear of the 9600 Compressor, to the OFF position.
    • 2. Remove the 4 screws which secure the rear panel to the Compressor and remove the rear panel.
    • 3. Using a 1-3/16 in. wrench, and a 1-1/8 in. wrench, as shown in Figure 5-1, disconnect the two ...
    • Figure 5-1: Disconnecting Self Sealing Couplings
      • 4. Using a 7/16 in. (11mm) wrench, remove the adsorber mounting bolt as shown in Figure 5-2.
      • 5. Move the adsorber from under the mounting tabs in the base as shown in Figure 5-2 and remove t...
      • 6. Install the replacement adsorber under the mounting tabs and secure it into place with the bol...
      • 7. Using two wrenches as shown in Figure 5-1, connect the two self sealing couplings quickly to m...
      • 8. Install the Compressor rear panel.
      • 9. Ensure that the pressure gauge reads the proper value as shown in Table 4-1. If additional gas...
      • 10. Record the adsorber replacement date on the label as shown in Figure 5-2, and also note that ...
    • Adsorber
    • Mounting
    • Bolt
      • Figure 5-2: Adsorber Location within the 9600 Compressor (Rear Panel Removed)
      • Adjusting System Helium Pressure
  • Reducing Helium Pressure
    • 1. Remove the flare cap from the gas charge fitting as shown in Figure 5-3.
    • GAS CHARGE FLARED FITTING
      • Figure 5-3: 9600 Compressor Helium Pressure Control Components
        • 2. Open the gas charge control valve very slowly to allow a slight amount of helium to escape. Le...
        • 3. Close the gas charge control valve and install the flare cap.
  • Increasing Helium Pressure
    • CAUTION
    • CAUTION
      • 1. Attach a regulator (0-3000/0-400 psig) and charging line to a helium bottle (99.999% pure).
      • 2. Purge the regulator and charging lines as follows:
        • a. Open the regulator a small amount by turning the adjusting knob clockwise until it contacts th...
        • b. Loosely connect the charge line to the helium pressure regulator.
        • c. Slowly open the bottle valve, and purge the regulator and line for 10 to 15 seconds. Turn the ...
      • 3. Remove the flare cap of the gas charge flared fitting on the rear of the Compressor.
      • 4. Loosely connect the charging line from the helium pressure regulator to the 1/4-inch male flar...
      • 5. Set the helium pressure regulator to 300 psig (20.7 bars). If the compressor is ON, proceed wi...
        • a. Obtain the previously recorded normal system operating pressure from the Compressor Operation ...
        • b. Obtain the appropriate (50 or 60 Hz) static system operating pressure from Table 4-1. Open the...
      • 6. Ensure that the helium charge valve on the Compressor is tightly closed. Shut off the helium p...
• Appendix A - Customer Support Information
  • Customer Support Center Locations
  • Guaranteed Up-Time Support (GUTS®)
    • Product Information
  • E-mail
    • Appendix B - Flow Diagram
      • Figure B-1: 9600 Compressor Flow Diagram
• Appendix C - Troubleshooting Procedures
  • Troubleshooting the Compressor
  • The compressor troubleshooting procedures are summarized in Table C-1.
    • Technical Inquiries
  • Please refer to Appendix A of this manual for a complete list of the
  • CTI-CRYOGENICS’ world wide customer support centers.
    • WARNING
      • Table C-1: Compressor Troubleshooting Procedures
    • Appendix D - Schematic
      • Figure D-1: 9600 Motor Drive Compressor Schematic