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Model LNP-40

Liquid Nitrogen Plant

INSTALLATION, OPERATION and

ROUTINE MAINTENANCE MANUAL

Summary of Contents for LNP-40

Page 1: ...Model LNP 40 Liquid Nitrogen Plant INSTALLATION OPERATION and ROUTINE MAINTENANCE MANUAL...

Page 2: ...rer Cryomech Inc reserves the right to add change modify or delete any or all information contained herein without prior written notice Revisions to this document may be issued at the time such change...

Page 3: ...1 Overview Section 2 Warranty Section 3 Safety Section 4 Inspection and Unpacking Section 5 Specifications Section 6 Installation Section 7 Operation Section 8 Routine Maintenance Appendix Spray Lubri...

Page 4: ...1 1 N Section 1 Overview...

Page 5: ...A complete system consists of two major components one is the helium compressor package which compresses refrigerant and removes heat from the system the other is the cold head which takes refrigerant...

Page 6: ...in the appendix Numbered lists labeled with 1 2 etc and lettered lists labeled with a b etc are used for sequential actions that must be performed in the order listed Lists for which order is not imp...

Page 7: ...d Loop System This refers to a cryogenic system that has no helium loss because the helium is cycled through a closed loop The advantage of such a system is that there is no need to add helium Cold He...

Page 8: ...essure helium to the necessary high pressure Helium Compressor Package The helium compressor package houses the helium compressor module and all other components that cool and purify helium and that p...

Page 9: ...es an N2 generator filter bank panel a nitrogen flex line and an air compressor 1 3 2 Acronyms The following acronyms are used in the text and provided here for convenient lookup FPT Female Pipe Threa...

Page 10: ...2 1 N Section 2 Warranty...

Page 11: ...ion that does not meet the specifications in this section will void the warranty If you plan to operate the system outside any of the specified conditions contact Cryomech See Section 5 Failure to fol...

Page 12: ...any significant length of time will void the warranty If the power cord is not wired properly the compressor will run in reverse and there will be no pressure differential on the pressure gauges Turn...

Page 13: ...3 2 N Section 3 Safety...

Page 14: ...h Read the manual or handbook sign When this symbol is found on a piece of equipment the user should read the whole manual before starting installation or use This symbol is found on the compressor pa...

Page 15: ...stem installation CAUTION Failure to follow these installation guidelines could result in voiding the warranty WARNING Do not allow the released oxygen which enhances flammability to accumulate in an...

Page 16: ...uced into the system even for cleaning purposes it will void the warranty CAUTION Do not apply heat to the cooling water inlet and outlet connectors located on the front panel of the compressor Sectio...

Page 17: ...ip couplings from the helium flex lines without first relieving the helium charge in the line to acceptable levels The pressure in the hose can blow off the coupling with sufficient force to cause inj...

Page 18: ...lation CAUTION The air compressor must be installed and operated according to the manufacturer s specifications included in the air compressor s instruction manual Failure to follow the manufacturer s...

Page 19: ...anel is 125 F 52 C Temperatures above 125 F 52 C will damage the filter bank components This type of damage is not covered under the warranty CAUTION The filter bank s ability to remove water from the...

Page 20: ...mpressor must be bolted to the floor please pay special attention to the mounting instructions included in Section 3 of the air compressor s instruction manual Failure to mount the air compressor acco...

Page 21: ...ogen WARNING Before extracting liquid nitrogen from the dewar carefully read the following safety precautions Improper handling of liquid nitrogen may result in serious injury or death WARNING If a la...

Page 22: ...ion 8 4 Helium compressor adsorber replacement CAUTION At no time should the Aeroquip couplings be removed from the adsorber when replacing the adsorber Replacement can be completed without relieving...

Page 23: ...h contamination occurs factory service will be required Section 8 8 Filter element replacement WARNING Failure to replace the filter bowl in the locked position could result in catastrophic failure an...

Page 24: ...Safety 3 11 WARNING Failure to disconnect the power to the electrical protection device before attempting to replace the fuses may result in serious injury or death 26Apr07...

Page 25: ...4 1 N Section 4 Inspection and Unpacking...

Page 26: ...to the sides or cutting the steel banding 2 Check for tip indicators on the inside of the packing crate and notify Cryomech if interior tip indicators have been activated even though tip indicators on...

Page 27: ...age Inspect the helium compressor package for any signs of damage such as dents scratches or any signs of oil leaks There should be a tag on the front of the helium compressor package that states the...

Page 28: ...mpressor package to the pallet making certain that there is sufficient insulating material between the compressor and the straps so the straps will not scrape any paint off the compressor package o Us...

Page 29: ...5 3 N Section 5 Specifications...

Page 30: ...ull 260 lb 545 lb 118 kg 247 kg Dewar Dimensions Outside Diameter x H 24 x 60 in 61 x 152 cm Dewar Capacity 42 gal 160 liters Helium Compressor Package Weight Air Cooled Water Cooled 387 lb 262 lb 176...

Page 31: ...r Inlet Temperature 0 C Figure 1 Cooling Water Requirements 5 10 15 20 25 30 35 40 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 Water Flow Rate LPM Water Pressure Drop bar 2 1 2 1 CP980 CP950 CP970 Water F...

Page 32: ...W N A kW 5 2 kW 4 4 kW Current 21 A N A A N A A 9 A Air Cooled Input Power Maximum Steady state 6 4 kW 5 9 kW N A kW N A kW 5 0 kW 4 3 kW 5 6 kW 4 7 kW Current 21 A N A A 16 5 A 10 A Dedicated circuit...

Page 33: ...llution Degree 2 Installation Category II Category II Maximum relative humidity 80 for T 88 F Decreasing linearly to 50 at 104 F 80 for T 31 C Decreasing linearly to 50 at 40 C Maximum sound level air...

Page 34: ...rload Switch An internal motor overload switch located inside the compressor module protects the system by sensing excessive current draw and temperature This switch automatically resets itself after...

Page 35: ...ssor package Circuit Breaker High Pressure Aeroquip High Pressure Gauge Low Pressure Aeroquip Service Valve Service Access Pressure Switch Reset Temperature Switch Reset Cooling Water Outlet Connectio...

Page 36: ...essor package Power Switch Hour Meter Dewar Cord Connector Circuit Breaker Service Valve Service Access Pressure Switch Reset Temperature Switch Reset Power Cord High Pressure Aeroquip High Pressure G...

Page 37: ...ure of the compressed helium gas that is transported from the compressor package When the compressor package is off and the complete system is at room temperature the gauge should read the pressure sp...

Page 38: ...compressor package during operation The connector thread size is 1 4 FPT 1 4 Female National Pipe Thread Pressure Switch Reset Low Pressure The compressor package has a low pressure shutdown switch t...

Page 39: ...lange and the cold head seals the nitrogen gas inside the dewar Low Pressure Regulator A low pressure regulator is attached to the top of the dewar The regulator is set to maintain a pressure inside t...

Page 40: ...the dewar and the helium compressor package The liquid nitrogen plant will not operate unless the dewar cord is connected to the dewar and the helium compressor Bleed Valve The bleed valve is used to...

Page 41: ...odel High Pressure Regulator The high pressure regulator is preset and locked at 85 PSIG 5 9 bar This compressed air pressure setting is required for optimal performance of the N2 generator Pressure G...

Page 42: ...The dehumidifier is designed to remove water vapor from the compressed air before it enters the carbon filter The dehumidifier consists of bundles of hollow membrane fibers each permeable only to wate...

Page 43: ...ted out and returned to the atmosphere through the nitrogen generator s vent The nitrogen generator can withstand water vapor in the compressed air supply however liquid water oil and carbon dust will...

Page 44: ...tor Pressure Switch The pressure switch automatically starts and stops the air compressor to maintain the required air pressure supplied to the N2 generator filter bank panel The pressure switch is pr...

Page 45: ...able Receiver Tank Pressure Gauge The receiver tank pressure gauge displays the compressed air outlet pressure Compressed Air Outlet Valve The compressed air outlet valve when open allows the compress...

Page 46: ...matically and requires periodic maintenance The manufacturer s user manual is included with the dryer Figure 5 9 Refrigerated air dryer front view Figure 5 10 Refrigerated air dryer rear view Power Sw...

Page 47: ...air port is a 3 8 compression fitting that is used to connect to the outlet port of the air compressor The connection is made with the copper tubing supplied with the air compressor Outlet Air Port T...

Page 48: ...and 5 pin connector that attaches to a mating receptacle located on the helium compressor Figure 5 11 Electrical protection device Electrical Protection Module The monitoring relay ensures that the v...

Page 49: ...d tested at the factory Cryomech does not recommend changing any of the settings The settings are as follows UNBALANCE 2 8 TRIP DELAY 5 seconds AUTO RESTART DELAY 5 minutes SELECTOR Auto Restart W Del...

Page 50: ...6 1 N Section 6 Installation...

Page 51: ...low from the nitrogen generator s vent To prevent accidental flow blockage do not install a valve in the vent line If the system is installed in an enclosed confined space an oxygen monitor alarm shou...

Page 52: ...compressor package and the N2 generator filter bank panel If greater separation is required longer helium or nitrogen flex lines will be needed Position the dewar so there is sufficient space around i...

Page 53: ...eat to the cooling water inlet and outlet connectors located on the front panel of the compressor 1 Make sure that the cooling water supply is turned OFF 2 Apply Teflon tape or pipe sealant to the thr...

Page 54: ...ircuit breaker is turned OFF 4 The ground or earth wire in the power cord is either green 60 Hz systems or green yellow stripe 50 Hz systems Connect the ground wire in the power cord to the ground or...

Page 55: ...gh pressure and low pressure helium flex lines are not interchangeable due to the size of the Aeroquip couplings attached to the ends of the flex lines Before connecting the flex lines to the componen...

Page 56: ...sure port on the helium compressor package front panel The high pressure port is marked HIGH Tighten the connector until a positive stop is felt 7 Connect the other end of the helium flex line to the...

Page 57: ...1 below 1 Observe both the low and high pressure gauges located on the front panel of the helium compressor package and determine which gauge has the lower reading If the system helium pressure shown...

Page 58: ...is not covered under the warranty The N2 generator filter bank panel is wall mountable A minimum clearance of 5 inches 13 cm measured from the bottom edge of the panel to the floor is suggested in or...

Page 59: ...t 2 ft 0 6 m of open space around the dryer to provide sufficient air flow for proper cooling and to perform periodic maintenance 6 5 2 Connect the dryer to the main power 1 The dryer comes with a mai...

Page 60: ...so that the oil pressure gauge and receiver tank gauge are visible Allow at least 2 ft 0 6 m of open space behind the belt guard to allow for a sufficient air flow required to cool the air compressor...

Page 61: ...cal electrical codes and guidelines 3 Make sure that the dedicated circuit breaker is turned OFF 4 The ground or earth wire in the power cord is either green 60 Hz systems or green yellow stripe 50 Hz...

Page 62: ...w Yellow Stripe Figure 6 4 Color codes for 60 Hz and 50 Hz models c If your system contains a 60 Hz power cord switch the black and red wires If your system contains a 50 Hz power cord swap any two b...

Page 63: ...st two filters will remove it As a rule the incoming compressed air temperature should be within 10 F 6 C of the ambient temperature for optimal operation of the compressed air filter bank If the inco...

Page 64: ...ely 3 8 in 10 mm Make certain the end of the tube is seated fully in the fitting 6 Tighten the nut by hand until snug 7 With one wrench holding the fitting and another holding the nut tighten the nut...

Page 65: ...e electrical protection device EPD is an optional item If the system was not supplied with an EPD proceed to the next section The EPD is housed in a wall mountable electrical enclosure The enclosure i...

Page 66: ...resentative view 2 Push the plug onto the connector and turn the locking ring clockwise until snug 3 To disconnect the plug reverse the procedure The system will not start if the EPD is not connected...

Page 67: ...7 2 N Section 7 Operation...

Page 68: ...essor Before starting the air compressor the air compressor manufacturer s instruction manual must be completely read and understood The manufacturer s instruction manual is included with this manual...

Page 69: ...and dewar of any contaminants This process will ensure that only nitrogen will be present in the dewar and its interconnecting lines This procedure should be performed only when the dewar is empty 1...

Page 70: ...r and the dewar 3 If applicable make sure the optional electrical protection device s cord is attached to the receptacle on the front panel of the helium compressor 4 Make sure all Aeroquip couplings...

Page 71: ...with the optional electrical protection device proceed with the following steps If the optional electrical protection device is not included with the system skip to step 11 2 Open the door of the EPD...

Page 72: ...ssure differential of at least 200 PSIG 13 76 bar If the system is functioning correctly there will be an immediate increase in the high pressure gauge and an immediate decrease in the low pressure ga...

Page 73: ...of the liquid nitrogen when the system is in standby mode The pressure relief valve on the dewar will open when the internal pressure in the dewar reaches approximately 10 PSIG Frost and condensation...

Page 74: ...alent volumes of gas at room temperature 68 F 20 C When filling a vessel with liquid nitrogen make certain the vessel is adequately vented If a sufficient amount of liquid nitrogen is vaporized in a c...

Page 75: ...l continue to drain CAUTION Damage to the valve stem and seat will occur if the valve is over tightened 7 7 DAILY INSPECTIONS The liquid nitrogen plant has been designed to give continuous trouble fre...

Page 76: ...e compressed air supply the two upstream filters or the automatic drain valve The problem must be diagnosed and corrected immediately See the Troubleshooting Section Open the manual drain located on t...

Page 77: ...shut down the air compressor switch its dedicated circuit breaker off 7 9 Disassembling the system for transport or storage Use the following steps to prepare a Cryomech Liquid Nitrogen Plant for even...

Page 78: ...t the flex line from twisting IMPORTANT When connecting or disconnecting the flex lines Cryomech recommends using a small amount of Teflon spray lubricant A can of lubricant is included with each syst...

Page 79: ...ower cord in preparation for transport or storage 4 Disconnect the drain line from the automatic drain valve 5 If applicable close the filter bank s needle valve 6 Close the compressed air outlet valv...

Page 80: ...storage 3 Disconnect the copper tubing from the inlet and outlet ports 4 If applicable disconnect the drain line from the condensate drain tube 7 9 6 Electrical protection device option Disconnect the...

Page 81: ...on 5 5 Reset the temperature switch located on the bottom of the front panel of the helium compressor package as shown in Section 5 6 Refer to electrical protection troubleshooting section below 7 10...

Page 82: ...in Section 5 If the helium charge is within the specification reset the pressure switch located on the bottom of the front panel of the helium compressor See Section 5 4 Water cooled models Make certa...

Page 83: ...umulated condensate The timer is properly set if nothing but air vents at the end of the open period 3 The filters are not designed to remove vaporous water The incoming air must be cool enough to all...

Page 84: ...e helium compressor If the Phase Loss or Unbalance indicator is lit measure the voltage at each phase to ensure they are balanced 2 If the EPD senses a fault when the LNP is operating the system will...

Page 85: ...lter bank assembly PROCEDURE The best way to fix this is to empty the Dewar completely and warm it up Once the Dewar is warm room temperature The high pressure line can then be flushed with isopropyl...

Page 86: ...formation offered should facilitate set up and operation you may have a special situation that requires further considerations If after reading the Operation Section you still have questions contact C...

Page 87: ...8 1 N Section 8 Routine Maintenance...

Page 88: ...See Section 8 3 8 2 2 Helium compressor Maintenance Frequency Comment Replace adsorber CP900 Series Compressors CP800 Series Compressors Every 20 000 hours Every 15 000 hours See Section 8 4 Vent hel...

Page 89: ...screwdriver For turn cover screws and hose clamp CAUTION At no time should the Aeroquip couplings be removed from the adsorber when replacing the adsorber Replacement can be completed without relievi...

Page 90: ...ng the high pressure Aeroquip coupling to the front panel 7 Loosen and disconnect the hose clamp that attaches the adsorber to the front panel 8 Remove the adsorber from the compressor package 9 Check...

Page 91: ...ng helium the helium must be 99 999 pure Contamination by other gases will result in the freezing of the contaminant gases in the cold head because their freezing temperature is much higher than that...

Page 92: ...o a typical vacuum charging system as shown in Figure 8 3 and Figure 8 4 below Figure 8 3 Vacuum charging system Service Aeroquip Coupling Charging hose Service Valve Helium Tank Valve 3 0 7 0 SCFM Di...

Page 93: ...ed amount of helium pressure 12 Slowly open the service valve to add helium to the system The final helium charge in the system is specified in Section 5 CAUTION No more than 5 PSIG 34 bar of gas shou...

Page 94: ...3 4 wrench 6 Disconnect the compression fitting on the inlet fitting of the automatic drain valve Turn the compression fitting nut with the 11 16 wrench while holding the fitting body with the 5 8 wre...

Page 95: ...icient force to cause injury If operated in a clean environment the only parts of the cryorefrigerator system that are likely to require cleaning are the Aeroquip couplings The mating surfaces of the...

Page 96: ...fuse cover grasp it in the center and pull it straight back 6 Remove the fuse from the fuse holder and replace it with a fuse equivalent in style and amperage rating Spare fuses are shipped with the...

Page 97: ...ust be performed using Cryomech parts and the appropriate work instructions Contact Cryomech if the cold head requires service Main power cord If the power cord becomes damaged a replacement should be...

Page 98: ...Appendix Spray Lubricant Instructions...

Page 99: ...The purpose of this work instruction is to document the proper use of TFL 50 Dry Lube on Cryomech systems with Aeroquip connectors Related documents and work instructions TFL 50 MSDS Connection Insta...

Page 100: ...the open ends of the Aeroquips Doing so will contaminate the system and void the warranty Apply lubricant to the Aeroquips only after they are hand tightened together 3 Before using this product care...

Page 101: ...the female Aeroquip Swivel portion Figure A 5 Apply lubricant to swivel portion 5 Apply a small amount of TFL 50 to the threaded portion of the male Aeroquip Threaded portion Figure A 6 Apply lubrica...

Page 102: ...ix Disassembly 1 Apply a small amount of TFL 50 to the swivel portion of the female Aeroquip as shown in Figure A 5 2 Use wrenches to loosen and remove the Aeroquips see manual for instructions A 4 30...

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