LEYBOLD 892 35 Operating Instructions Manual Download Page 1

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COOLPAK

6000-1

Compressor unit and
accessories for cryogenic
refrigerator units

Cat.-No. 892 35

Operating instructions

Vacuum Solutions

Application Support

Service

LEYBOLD VACUUM

GA 12.137/2.02

Summary of Contents for 892 35

Page 1: ...COOLPAK 6000 1 Compressor unit and accessories for cryogenic refrigerator units Cat No 892 35 Operating instructions Vacuum Solutions Application Support Service LEYBOLD VACUUM GA 12 137 2 02...

Page 2: ...ormance statement Electrical Schematic Certifications 39 Service personnel shall without fail read the instructions provided for their guidance ISO 7000 0419 Precautionary notes used in these instruct...

Page 3: ...t forth in the European guidelines for awarding the CE seal of approval In addition they satisfy the requirements of Underwriters Laboratories UL and the Canadian Standards Association CSA please refe...

Page 4: ...wo stage oil separator The conden sate from the oil separator is returned to the compressor by means of capillary pipes The helium gas exiting the second oil separator will still contain small quantit...

Page 5: ...set value 9 Safety valve opens the helium circuit to the atmosphere if the No display high pressure segment exceeds 29 bar 406 psig 2 9 MPa 10 Microprocessor for checking the phase rotation 1 SYSTEM E...

Page 6: ...on 6 Fig 4 View of the compressor unit without cover and side panels Pressure switch 2 0 bar Thermal switch 38 C Adsorber Separator Power Module Heat exchanger Helium compressor Bypass valve Thermal s...

Page 7: ...2 III IEC rating for circuit breaker in the mains supply 20 A Helium connectors self sealing couplings1 1 2 m Noise level2 at a distance of 1 m 53 dB A Weight 95 kg 210 lbs Equipment type Industrial...

Page 8: ...12 137 2 02 05 2002 Description 8 70 146 261 80 156 5 440 199 55 6 8 5 8 5 16 46 5 70 70 440 7 5 77 47 5 70 43 47 5 70 46 5 16 7 5 571 533 439 444 4 536 5 567 5 Fig 5 Dimensional drawing dimensions in...

Page 9: ...en 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 and when...

Page 10: ...FUSES COLD HEAD F1 F2 F3 MAIN SWITCH OFF ON HELIUM FILLING HELIUM LOW PRESSURE HELIUM HIGH PRESSURE COOLING WATER OUTLET COOLING WATER INLET HELIUM HIGH PRESSURE SELECT Fig 6 Connections and controls...

Page 11: ...late Terminals for setting the compressor unit to the 2 5 line voltage and for setting the cold head motor type are located behind the cover plate see Fig 11 11 Crane eyelets Detachable 2 2 12 Fuses S...

Page 12: ...indicated is too low top up with helium or notify the Leybold Service Department Keep the packaging for re use in case it should become necessary to return equipment to the factory Check the delivery...

Page 13: ...mption at 25 C inlet temperature 5 l min Max coolant throughput 10 l min Pressure drop p between coolant inlet and outlet depending on the throughput 0 2 to 0 6 bar Water quality Appearance Colorless...

Page 14: ...100 m Replace it in regular intervals To protect the heat exchanger against chemical attack fully demineralized or very soft water may be used only with the addition of suitable inhibitors Permanent o...

Page 15: ...2 02 05 2002 Coolant IN OUT Fig 9 Coolant connection Fig 10 Coolant consumption 5 10 20 30 C 40 60 80 F Coolant inlet temperature 10 l min 1 6 5 4 3 2 0 Permissible range Maximum 2 6 Gal min 1 6 1 1...

Page 16: ...ver delivered with the compressor unit Use a Phillips screwdriver instead The 2 0 mm screwdriver shall exclusively be used on the mains voltage and the motor type selector terminal slits see below Cau...

Page 17: ...GD or COOLPOWER 5 100 Fig 11 Power supply connection Cover plate Cold head Socket for the mains power cord 380 V 400 V 480 V 480 V 400 V 380 V 380 V 400 V 480 V Checking the direction of the rotating...

Page 18: ...t the cold head Use shielded cables to connect the Sub D connec tors and attach the shielding to the metal housings of the Sub D plugs Operation via the interfaces The interfaces can be used to run th...

Page 19: ...Error 0 V 24 V REMOTE Fig 12 Pin assignments on the Sub D connectors 24 V status signals 24 V DC required for remote operation Pin 24 V is present 0 V is present 3 Reset 4 Cold head on Cold head off 6...

Page 20: ...s 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...

Page 21: ...r 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...

Page 22: ...d 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 g...

Page 23: ...and 2 4 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 insufficie...

Page 24: ...function may be utilized only after the mal function has been corrected refer to Section 5 Trouble shooting If the current consumption is too high either the motor protection switch is tripped and the...

Page 25: ...adsorbers without the appropria te protective caps Vent the helium when the compressor unit is to be taken out of service permanently 3 4 1 Transport and storage Store the compressor unit in a dry pla...

Page 26: ...input pin 5 GND Communication with COOLPAK No handshake is needed no XON XOFF During communication the COOLPAK is always the slave and the PC always the HOST The host PC can send two types of messages...

Page 27: ...ne on the display 23 5 01 7 06 9 15 Leybold internal use only 003 3 1 Switch ON timer seconds 0 system can be switched on without any delay prevents switching on immediately after switching off 1 1 1...

Page 28: ...yy xx yyyyy CR Description Switch system x 0 OFF x 1 ON STX SYS1 CR will also reset after failures if failu re is no longer active except OVERLOAD Request data Request logged errors Description System...

Page 29: ...cooling The compressor unit has tripped via the 100 C thermal switch possible causes are insufficient cooling or incorrect connection to water supply RAM error ROM error EEPROM error Is no longer disp...

Page 30: ...unit off and allow it to cool down to room temperature 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 Warni...

Page 31: ...ch 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 fill...

Page 32: ...tenance Fig 19 Replacing the adsorber 1 Cover 2 Foam rubber insert 3 Nut 4 Washer 5 Fixing element 6 Tooth lock washer 7 High pressure helium connection 8 Self sealing coupling 9 Adsorber 10 Screws 11...

Page 33: ...is filled with helium of highest purity to a level of 16 bar 232 psig 1 6 MPa Seal the old adsorber with the protective caps and for ward it to Leybold for reconditioning Warning The adsorber may con...

Page 34: ...the control voltage right F1 F3 F2 F4 F5 Completed maintenance work Maintenance work Date Reading at the operat Helium filling Helium filling ing hours meter pressure beforehand pressure afterward Fil...

Page 35: ...3 03 The plug CM 10 was unplugged and then plugged incorrectly Repair note Refer to the Section indicated Recommended corrective action Check power lead and plug Check line voltage and line voltage se...

Page 36: ...LECT button The current drawn when switching on was too high The compressor unit has failed 3 times to run with an Locked rotor message see malfunction 9 Thermal switch in compressor capsu le Klixon h...

Page 37: ...led either completely or intermittently in one or more phases The compressor auto matically restarts after the malfunction disappears Line voltage fails in one or more pha ses for longer than 5 minute...

Page 38: ...Hose nipple DN 12 Brass 200 19 460 9 2 Nut G 1 2 Brass 200 49 033 10 2 Clamping ring 12 Brass 200 49 052 11 2 Threaded elbow joint incl Pos 9 10 G 1 2 x12 200 49 053 not shown 1 Thermal switch 38 C 20...

Page 39: ...Compressor M W V U 3 F1 F2 F3 Tr2 Tr1 F5 F4 24V 5V Display 16 x 1 Processor Board CM1 CF1 RS232 485 REMOTE 8 1 CM10 CM8 1 CM6 1 CM7 1 K2 a 3 Pressure Sensor not connected Oil cct Sensor Helium Temp S...

Page 40: ...OLPAK 6000 1 Catalog number 892 35 Conformity assessment procedures in accordance to EC Pressure Equipment Directive Assembly compressor unit Module A Separator Module A Adsorber Module A Safety valve...

Page 41: ...ipment and components which have been contaminated by biological explosive or radioactive substances will not accepted without written evidence of decontamination Please list all substances gases and...

Page 42: ...operation type GD gas distributor type MC electrical distribution unit etc These Leybold refrigerator units are registered under the recognition mark UR cUR reference No SA 8676 Labelling for the sys...

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