Brooks 8032549G001 Installation & Operation Manual Download

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8200 Compressor

Installation, Operation and

Service Instructions

8040353 Revision AA

Summary of Contents for 8032549G001

Page 1: ...8200 Compressor Installation Operation and Service Instructions 8040353 Revision AA...

Page 2: ...k Marathon Marathon 2 Marathon Express Micro Ion MiniConvectron On Board Polycold Razor Simplicity Solutions the Simplicity Solutions logo Stabil Ion TrueBlue TurboPlus Vision Zaris and the Brooks Aut...

Page 3: ...Servicing Instructions 1 3 Safety Introduction 2 2 Signal Word Descriptions 2 3 Safety Shape Descriptions 2 4 References 2 4 Inspection The Compressor 3 2 Installation Compressor Installation 4 2 Pre...

Page 4: ...pendix A Customer Brooks Automation Technical Support Information 6 2 Appendix B Troubleshooting Procedures 6 3 Appendix C Electrical Schematics for 8200 Compressor 6 7 Appendix D Components in the El...

Page 5: ...sor Installation 4 10 5 1 Adjusting the Self Sealing Connectors 5 3 5 2 Disconnecting Connecting the Adsorber Self Sealing Coupling 5 3 5 3 Removing the Adsorber from the Compressor 5 4 6 1 8200 Compr...

Page 6: ...Figures 8200 Compressor Installation Operation and Service Instructions 8040353 Brooks Automation vi Revision AA This Page Intentionally Left Blank...

Page 7: ...53 Revision AA vii Tables 1 1 Power Requirements Steady State Conditions 1 5 1 2 General Specifications 1 5 2 1 Safety Signal Words 2 3 2 2 Safety Shapes 2 4 4 1 Cooling Water Specifications 4 6 6 1 C...

Page 8: ...Tables 8200 Compressor Installation Operation and Service Instructions 8040353 Brooks Automation viii Revision AA This Page Intentionally Left Blank...

Page 9: ...vice Instructions Brooks Automation 8040353 Revision AA 1 1 1 Introduction Overview This chapter describes this manual and the compressor including specifications Chapter Contents General 1 2 Installa...

Page 10: ...and servicing the 8200 Compressor This compressor is available in two versions air cooled part number 8032549G001 G002 and water cooled part number 803255G001 G002 If you are installing or operating...

Page 11: ...Instructions Installation Operation and Servicing Instructions for your 8200 Compressor provide easily accessible information All personnel with installation operation and servicing responsibilities...

Page 12: ...iew Water Cooled Rear View Air Cooled Front View Air and Water Cooled 1 Compressor Input Power Block 2 Cold Head Power Receptacle 3 On Board Power Receptacle 4 Helium Gas Fitting and Charge Valve 5 He...

Page 13: ...12 30A See the nameplate on the back of the compressor for more details Table 1 2 General Specifications Specification Description Weight 150 lbs 68 kg max Weight shipping 155 lbs 70 kg max Power con...

Page 14: ...er terminal block enclosure Mates with input power cable fabricated by customer or avail able from BROOKS Cryogenics Gas supply connector 1 2 inch self sealing coupling Gas return connector 1 2 inch s...

Page 15: ...r maintenance of the product must be familiar with the safety precautions outlined in this section NOTE These safety recommendations are basic guidelines If the facility where the Prod uct is installe...

Page 16: ...ing installation normal operation and when servic ing BROOKS Cryogenics products This chapter explains the safety conventions used throughout this manual BROOKS Cryogenics uses a specific format for c...

Page 17: ...mple Definition CAUTION A signal word that indicates a situa tion or unsafe practice which if not avoided may result in equipment damage A CAUTION is highlighted in yellow CAUTION A signal word accomp...

Page 18: ...safety standards see the following documents ISO 7010 2003 E Graphic symbols Safety colours and safety signs Safety signs used in workplaces and public areas ISO 3864 1 2002 E Graphic symbols Safety c...

Page 19: ...ection Overview This chapter details unpacking the compressor A High Vacuum Pump or Refrigerator System is packaged in separate cartons for each major component An Installation Operation and Servicing...

Page 20: ...idence of damage as follows c Inspect the compressor overall exterior for damage d Report damage to the shipper at once e Retain shipping cartons for storage or return shipment When installing your sy...

Page 21: ...ks Automation Product Chapter Contents Compressor Installation 4 2 Preparing the Compressor Input Power Cable 4 2 Cooling Water Requirements Water Cooled Compressors Only 4 4 Cooling Water General Con...

Page 22: ...al and thick ness to the earth and unearth branch circuit supply conductors except that it is green with or without one or more yellow stripes is to be installed as part of the branch cir cuit which s...

Page 23: ...the two power leads to terminals X and Y DO NOT USE TERMINAL Z 6 Tighten all terminals to 18 22 in lbs torque 7 Tighten down screws on strain relief 8 Remount the terminal enclosure cover and secure...

Page 24: ...ace Figure 4 2 Assembly of Conductors to Terminal Block Cooling Water Requirements Water Cooled Compressors Only If flexible water hose connections are used install the barbed fittings supplied with t...

Page 25: ...oling water when the compressor is not running NOTE If cooling water below 45 F 7 C runs through the compressor while the compres sor is not operating the compressor oil will change viscosity and thic...

Page 26: ...temperatures Table 4 1 Cooling Water Specifications Parameter Value Maximum Inlet Temperature 90 F 32 C Minimum Inlet Temperature 50 F 10 C Flow Rate 1 0 0 5 gpm 3 8 1 9 lpm Pressure Drop inlet to ou...

Page 27: ...ture Rise Heat load to facility water is approximately 5000 Btu hr or 1500 Watts With a 1 0 GPM water flow this translates to an approximate water temperature rise of 10 F 5 6 C 0 25 0 50 0 75 1 00 1...

Page 28: ...ter cooled compressor 3 Set the compressor ON OFF switch 3 to OFF Connect the input power cable to the power source Refer to Table 1 1 on page 1 5 for electrical power require ments 4 Turn the compres...

Page 29: ...line identification decals BROOKS Cryogenics supplied to their respective connecting piping ends 5 Verify proper helium supply static pressure by confirming that the helium pressure gauge reads 245 2...

Page 30: ...cold head b Connect the compressor input power cable to the power source c Turn on compressor d Your system is now ready for operation Figure 4 5 Typical 8200 Compressor Installation High Voltage Hig...

Page 31: ...oks Automation 8040353 Revision AA 5 1 5 Maintenance Procedures Overview This chapter provides complete maintenance procedures for the Brooks Automation Product Chapter Contents Scheduled Maintenance...

Page 32: ...in place 5 Use the two wrenches supplied to avoid loosening the body of the coupling from its adapter 6 Unscrew the two self sealing coupling halves quickly to minimize gas leakage as shown in Figure...

Page 33: ...H HOLD WITH 1 1 8 INCH WRENCH HOLD WITH 1 1 8 INCH WRENCH TURN WITH 1 3 16 INCH WRENCH To Disconnect The Coupling This 1 3 16 in wrench is used to loosen the self sealing coupling connector Note the d...

Page 34: ...ompressor Adsorber 1 Install the replacement adsorber as follows a Remove the dust caps from the self sealing coupling halves at each end of the replacement adsorber b Write installation date on the a...

Page 35: ...5 1 on page 5 3 for proper coupling of the self sealing connection 3 Replace the cover and the front and rear grilles and secure them 4 Ensure that the pressure gauge reads 245 250 psig 1690 1725 kPa...

Page 36: ...8032040G004 Available from stock consult the factory or your sales representative Adding Helium Gas Use only 99 999 pure helium gas If the compressor helium pressure gauge reads 0 decontamination is...

Page 37: ...m stops flowing c Connect the charge line to the helium pressure regulator d Remove the flare cap of the gas charge fitting on the rear of the compres sor Loosely connect the charge line to the charge...

Page 38: ...pressure gauge rises to 245 255 psig 1688 1757 kPa tightly close the charge valve 3 Ensure that the helium charge valve on the compressor is tightly closed Shut off the helium pressure regulator on t...

Page 39: ...ructions Helium Circuit Decontamination Brooks Automation 8040353 Revision AA 5 9 Helium Circuit Decontamination Refer to Section 4 Maintenance of the appropriate On Board Cryopump Installation Operat...

Page 40: ...Maintenance Procedures 8200 Compressor Helium Circuit Decontamination Installation Operation and Service Instructions 8040353 Brooks Automation 5 10 Revision AA This Page Intentionally Left Blank...

Page 41: ...ted to the Brooks Automation Product Contents Appendix A Customer Brooks Automation Technical Support Information 6 3 Appendix B Troubleshooting Procedures 6 4 Appendix C Electrical Schematics for 820...

Page 42: ...Appendices 8200 Compressor Installation Operation and Service Instructions 8040353 Brooks Automation 6 2 Revision AA...

Page 43: ...cription of the events relating to the error Time that the equipment has been in operation Work that was done on the equipment prior to the error Functions that the equipment was performing when the e...

Page 44: ...ompressor Table 6 1 Compressor Troubleshooting Procedures Problem Possible Cause Corrective Action 1 System power ON OFF switch CB1 and compressor switch S1 remains in the ON position when switched on...

Page 45: ...on but the com pressor will not run 2a No power coming from the power source 2a Check service fuses circuit breakers and wiring associ ated with power source and repair as needed 2b Incorrect or disco...

Page 46: ...hour minimum 3c Very cold cooling water is circulating through the com pressor The resulting low oil temperature causes a restric tion of oil flow through the metering orifice during startup 3c Rechec...

Page 47: ...220V 50 Hz and restore if necessary 5 Compressor oper ates but cold head motor does not run 5a Loose or defective cable 5a Check cold head cable 6 Cooling water leav ing the compressor exceeds 100 F 6...

Page 48: ...nd Ser 8040353 Brooks Automation 6 8 Revision AA Appendix C Electrical Schematics for 8200 Compressor The following electrical schematics for the 8200 Compressor are in this appendix 8200 Compressor E...

Page 49: ...W YEL W VIO WHT WHT WHT RED 4 4 3 3 2 2 1 1 7 1 5 GRA NOTES 1 VOLTAGE SELECTION FREQUENCY LINE VOLTS S1 S2 180 212 50 Hz 208V 50 Hz 213 220 220V 50 Hz 60 Hz 198 212 213 250 220V 208V 60 Hz 60 Hz CH VO...

Page 50: ...00 Compressor Appendix C Electrical Schematics for 8200 Compressor Installation Operation and Ser 8040353 Brooks Automation 6 10 Revision AA Figure 6 2 8200 Compressor Electrical Schematic part number...

Page 51: ...is page Components in the Electrical Control Chassis of the 8200 Compressor Sin gle Phase RC Configuration Figure 6 3 Components in the Electrical Control Chassis of the 8200 Compressor Three Phase Sc...

Page 52: ...gle Phase RC Configuration 1 Coldhead Phase Shifting ResistorR3 2 Overtemperature Resistor R1 3 Run Capacitor 35 f C1 4 Start Capacitor 119 f C2 5 Transformer T2 6 Run Capacitor 2 f C4 7 Run Capacitor...

Page 53: ...ereby overcoming helium low specific head and inability to carry heat produced during compression Helium is then compressed and passed through a heat exchanger for removal of compression caused heat T...

Page 54: ...dices 8200 Compressor Appendix E Flow Diagrams for 8200 Air Cooled and Water Cooled CompressorsInstalla 8040353 Brooks Automation 6 14 Revision AA Figure 6 5 Flow Diagram of the 8200 Air Cooled Compre...

Page 55: ...ompressor Appendices Installation Operation and Service Instructions Appendix E Flow Diagrams for 8200 Brooks Automation 8040353 Revision AA 6 15 Figure 6 6 Flow Diagram of the 8200 Water Cooled Compr...

Page 56: ...ters Water Constituent Unit Acceptable Limits Saturation Index SI delta pH value 0 2 0 0 2 Total hardness dH 6 15 Conductivity mg l 10 500 Filtered substances mg l 30 Chlorides mg l 500 Free chlorine...

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