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Routine Maintenance

8-1

Section 8: Routine Maintenance

8.1 Introduction

This section contains maintenance information. For more detailed information, contact
Cryomech, Inc.

8.2 Maintenance schedule

Maintenance

Product Type

Frequency

Comment

Replace cold head seals

GM cold heads only

Every 10,000 hours

See Section 8.3

Replace cold head valve and
valve plate

GM cold heads only

Every 20,000 hours

See Section 8.3

Replace adsorber

CP100 series only

Every 15,000 hours

See Section 8.4

Replace adsorber

All CP series

(except CP100 series)

Every 20,000 hours

See Section 8.4

8.3 Cold head

CAUTION

The Pulse Tube style cold heads contain no user-serviceable parts. Attempting to disassemble the
cold head will void the warranty. Contact Cryomech, Inc. if the cold head needs to be returned for
servicing.

CAUTION

Service to Gifford-McMahon style cold heads must be performed using Cryomech, Inc. parts and
the appropriate work instructions. Contact Cryomech, Inc, before servicing the cold head.

8.4 Replace the adsorber

Required tools CP100

Quantity

Description

Comment

1

1 in open end wrench

For Aeroquip coupling

1

1-1/8 in open end wrench

For Aeroquip coupling

1

1-3/16 in open end wrench

For Aeroquip coupling

1

Slotted screwdriver

For hose clamps

1

Slotted screwdriver

For side panel fasteners

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Содержание CPA289C

Страница 1: ...CP PT410 CPA289C C Cryocooler PT410 CPA289C INSTALLATION and OPERATION MANUAL ...

Страница 2: ...facturer 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 changes and or deletions occur Any duplication of this manual or any of its parts without expressed written permission from Cryomech Inc is expressly prohibited Correspondence concerning this document ...

Страница 3: ...CP 2 Contents Section 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 ...

Страница 4: ...1 100 D Section 1 Overview ...

Страница 5: ...t section that provide the information needed to install operate and perform maintenance on a Cryomech cryocooler It is important to note that bulleted list may be performed in any order but numbered lists labeled 1 2 etc are representative of sequential actions that must be performed in the order listed 1 2 Glossary 1 2 1 Definitions Aeroquip Couplings The term Aeroquip couplings is used generica...

Страница 6: ...he helium gas and provides electrical interface controls Helium Flex Lines The helium flex lines are corrugated stainless steel hoses that transport helium between the helium compressor package and the cold head Pollution Degree 2 Pollution degree 2 refers to the extent to which the local environmental conditions could affect the electrical safety of the system See EN 61010 or UL 61010A for furthe...

Страница 7: ...2 100 C Section 2 Warranty ...

Страница 8: ...ons that can void the warranty Operation of this cryocooler in situations that do not meet the specifications in this manual will void the warranty If you intend to operate the cryocooler outside any of the specified conditions prior written authorization from Cryomech Inc must be granted Installing any software on a Cryomech Inc product that was not provided by Cryomech Inc will void the warranty...

Страница 9: ...oid the warranty Attempting to disassemble the cold head will void the warranty Contact Cryomech Inc if the cold head needs to be serviced See Section 8 When adding helium to the cryocooler the helium must be at least 99 999 pure Adding helium that is less than 99 999 pure will contaminate the cryocooler and void the warranty See Section 8 Consumable non electrical items such as adsorbers must be ...

Страница 10: ...3 100 B Section 3 Safety ...

Страница 11: ...nt of the UL and CSA marks Nation Recognized Testing Laboratories NRTL like TÜV Rheinland can test to the same standard and specifications as those defined by UL and CSA Power switch This symbol designates an in out or push push switch 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 sy...

Страница 12: ... Section 6 1 Cold head installation CAUTION Failure to follow these installation guidelines will void the warranty CAUTION Special care must be taken when handling the cold head The warranty will not cover dented or bent tubes CAUTION Operating the cold head in a magnetic field of greater than 500 gauss will void the warranty Section 6 1 2 Initial preparation of the cold head CAUTION Heating any p...

Страница 13: ...or commercial cleaning agents will not be covered by the warranty CAUTION Applying extreme bend stress to a flex line will cause permanent damage Bending a flex line to less than a 12 in 30 cm radius will void the warranty Section 6 2 Compressor installation CAUTION Failure to follow these installation guidelines could result in voiding the warranty Section 6 2 1 Prepare the compressor package loc...

Страница 14: ...low this procedure carefully when connecting and disconnecting the helium flex lines Failure to follow the procedure will void the warranty CAUTION Do not allow the flex lines to contact any corrosives or commercial cleaning agents Flex line damage caused by exposure to corrosives or commercial cleaning agents will not be covered by the warranty CAUTION Applying extreme bend stress to a flex line ...

Страница 15: ...eturned for servicing CAUTION Service to Gifford McMahon style cold heads must be performed using Cryomech Inc parts and the appropriate work instructions Contact Cryomech Inc before servicing the cold head Section 8 4 Replace the adsorber CAUTION At no time should the Aeroquip couplings be removed from the adsorber Replacement can be completed without relieving system pressure since the adsorber ...

Страница 16: ...ent improper oil migration within the system If such contamination occurs factory service will be required Section 8 7 Cleaning CAUTION Excluding the designated water cooling circuit never allow water to contact any of the components of the system Exposing the system to water will void the warranty WARNING Never remove an Aeroquip coupling from the helium flex lines cold head adsorber or helium co...

Страница 17: ...4 100 B Section 4 Inspection and Unpacking ...

Страница 18: ...ifted out of the crate 5 Remove the sides of the packing crate by unfastening the Klimp fasteners and screws that join the sides to the pallet 6 Remove packing material and any straps that anchor items to the pallet Retain the packing materials and crate for use in the future to ship the equipment to Cryomech Inc 7 Ensure that adequate space is prepared for the equipment see Section 6 for installa...

Страница 19: ... Section 5 contact Cryomech Inc 4 4 Returning a system to Cryomech Inc 1 Contact Cryomech Inc for a Return of Material Authorization RMA number and for additional detailed instructions on how to properly return system components 2 Repackage the system IMPORTANT Use the original crate and packaging materials to minimize the likelihood of damage during shipping a Using the original packing material ...

Страница 20: ...05 PT410 CPA289C B Section 5 Specifications ...

Страница 21: ...ate the system outside any of the specified conditions contact Cryomech Inc 5 2 1 System weight and dimensions Parameter Value Cold head weight 43 lb 19 5 kg Cold head dimensions See cold head drawing Figure 5 8 Water cooled helium compressor package weight 295 lb 134 kg Water cooled helium compressor package dimensions L x W x H 27 in x 19 in x 24 5 in 69 cm x 48 cm x 62 cm High pressure flex lin...

Страница 22: ...may result in system entering a warning or error state Figure 5 1 Cooling water requirement Figure 5 2 Cooling water pressure drop When using a 50 50 mixture of ethylene glycol and water increase the flow rate 10 Pressure drop values will increase 40 CAUTION The use of DI De Ionized water is prohibited DI water causes damage to the compressor package and will not be covered under warranty ...

Страница 23: ...ad maximum load 1st stage heat exchanger 22 lb 10 kg Cold head maximum load 2nd stage heat exchanger if applicable 11 lb 5 kg The compressor package is designed to operate in an ambient temperature range from 45 F to 100 F 7 C to 38 C If the temperature is below 45 F 7 C the increased viscosity of the oil could prevent start up and or cause poor lubrication Operation above 100 F 38 C will cause ov...

Страница 24: ...ch An internal motor overload switch located inside the helium compressor package module protects the system by sensing excessive current draw and temperature This switch automatically resets itself after the helium compressor package module cools to an acceptable level Cold Head High Pressure Relief Valve The cold head high pressure atmospheric relief valve is set at 425 5 psig 29 3 34 bar At pre...

Страница 25: ...o the cold head from the helium compressor package 3 Low Pressure Aeroquip Flex line connection for gas returning from the cold head to the suction side of the helium compressor package 4 High Pressure Aeroquip Flex line connection for gas going to the cold head from the discharge side of the helium compressor package 5 Service Valve Regulates the gas flow through the service access Aeroquip 6 Ser...

Страница 26: ...s as a power disconnect 12 Power Cord Electrical connection that supplies power to the system 13 Cooling Water Inlet Connection A 3 8 FPT Female National Pipe Thread fitting used to provide coolant to the helium compressor package 14 Cooling Water Outlet Connection A 3 8 FPT Female National Pipe Thread fitting used as an exit for the coolant from the helium compressor package 15 Touch Screen Displ...

Страница 27: ...m 3 Helium Compressor Package OFF Button Mechanical interface used to stop the system 4 Helium Compressor Package OFF Indicator Light Illuminates red when the system is off flashes red with the system is in an error state 5 Helium Compressor Package ON Button Mechanical interface used to start the system 6 Helium Compressor Package ON Indicator Light Illuminated green when the system is running 7 ...

Страница 28: ...via SMDP or Modbus RTU protocol 13 RS485 Port Used for remote monitoring and control of the system via SMDP or Modbus RTU protocol 14 Running hours Total number of hours the helium compressor package has run this does not include idle time 15 Software Version Unique number used for tracking changes to the PLC program 16 System I O Port Used to remotely control the helium compressor package and mon...

Страница 29: ...unning mode If the Start pin is disabled the system will enter Stopping mode If the Compressor OFF Button Screen OFF Button Modbus or SMDP OFF command Remote Interlock pin or Stop pin are enabled while the system is running the system will enter Stopping mode If the system is off when the Remote Interlock pin or Stop pin are enabled the system will not start When SLVL is enabled the Compressor ON ...

Страница 30: ...the compressor package exceeds the high pressure limit the High Pressure relay between pins 3 and 4 will close High Temperature Pins 5 6 If the helium gas of the compressor package exceeds the high temperature limit the High temperature relay between pins 5 and 6 will close Faultless Pins 7 8 If the system is powered on and in a running or idle state and the system is experiencing no warnings or e...

Страница 31: ...Specifications 5 11 Figure 5 6 System I O wiring diagram ...

Страница 32: ...Specifications 5 12 Figure 5 7 System I O wiring diagram external supply ...

Страница 33: ...Specifications 5 13 5 4 Cold head drawing Figure 5 8 Cold Head Drawing ...

Страница 34: ...6 100 E Section 6 Installation ...

Страница 35: ...t the mounting surface of the base plate for any scratches in the sealing area Scratches or dents on the sealing surface will cause a leak from the ambient into the vacuum vessel 2 Inspect the interface surfaces of the copper heat exchanger for scratches or dents before attaching anything to it Scratches or dents will prevent good thermal contact between the heat exchanger and the object s attache...

Страница 36: ...Installation 6 2 Inspect the cold head Figure 6 2 Outline drawing of standard cold heads A E D C B F ...

Страница 37: ...xceed the value specified in Section 5 Excessive loading will damage the cold head This type of damage is not covered by the warranty If your application requires a load heavier than the weight specified in Section 5 prior written authorization from Cryomech Inc must be granted CAUTION Mounting the cold head in an orientation other than vertical will void the warranty without prior written authori...

Страница 38: ...r assembly s flex line if applicable 1 Remove the dust plug from the Aeroquip fitting attached to the end of the remote motor s flexible line and place in the tool kit for future use 2 Remove the dust cap from the cold head s mating Aeroquip fitting labeled Motor and place in the tool kit for future use 3 Make certain the flat gasket is present and properly seated in the cold head s Aeroquip fitti...

Страница 39: ...adius will void the warranty 5 Connect the Aeroquip fittings until a positive stop is felt See Figure 6 3 Figure 6 4 Connecting the remote motor assembly s flex line to the cold head Attaching the external reservoirs if applicable 1 Remove the dust plugs from the external reservoirs Aeroquip fittings and place in the tool kit for future use 2 Remove the dust caps from the cold head s Aeroquip fitt...

Страница 40: ...or the helium compressor package to operate under optimal conditions it must be oriented within 5 of being level WARNING The helium compressor package must be positioned to provide easy access to the front panel mounted circuit breaker Locate the helium compressor package so that it may be easily repositioned to allow for sufficient space change the adsorber If the helium compressor package cannot...

Страница 41: ...ling water flow rate and inlet temperature meets the requirements in Section 5 Connect the helium compressor package to the main power CAUTION The mains supply voltage to the helium compressor package must be within 10 of the nominal voltage specification in Section 5 Operating the helium compressor package outside the voltage specification will void the warranty 1 Each helium compressor package m...

Страница 42: ...sure to corrosives or commercial cleaning agents will not be covered by the warranty CAUTION Applying extreme bend stress to a flex line will cause permanent damage Bending a flex line to less than a 12 in 30 cm radius will void the warranty 1 Remove the dust plug from the Aeroquip fitting attached to the end of flexible line and place in the tool kit for future use 2 Remove the dust caps from the...

Страница 43: ...sitive stop is felt A dry Teflon spray is recommended See Figure 6 3 Figure 6 6 Connecting the flex lines to a helium compressor package 6 Connect helium flex line marked LOW to the low pressure port on the to the cold head or remote motor Connect a helium flex line marked HIGH to the high pressure port on the cold head or remote motor Tighten the connector until a positive stop is felt A dry Tefl...

Страница 44: ...age 2 Navigate through the PLC to find the helium pressure screen 3 If the pressures exceed what is indicated in Section 5 make sure that the service valve is closed 4 Attach the inch service Aeroquip to the service access 5 Slowly open the service valve to reduce the static charge Do not vent more than 5 psi 0 34 bar of gas per minute 6 Observe the PLC pressure reading Once the pressure reaches t...

Страница 45: ...7 100 C Section 7 Operation ...

Страница 46: ...is manual If the pressure is too low refer to Section 8 of this manual 5 Make sure the cold head motor cord is connected to both the helium compressor package and the cold head 6 Make sure the input power meets the specifications on the identification label CAUTION A voltage deviation of more than 10 above or below the voltage rating can cause helium compressor motor overheating and possible failu...

Страница 47: ...error conditions will occur are listed in Section 7 7 The screen normally shown on the display is referred to as the run time screen The messages described in Section 7 7 are displayed on the top line of the run time screen The bottom line displays the number of hours the helium compressor package has run Please refer to the CPA User Guide separate document for detailed instructions on the capabil...

Страница 48: ...e system by switching the dedicated circuit breaker to the off position 2 Disconnect the power cord from the external breaker panel Coil up the power cord in preparation for transport or storage 3 Disconnect the cold head motor cord from the cold head and from the helium compressor package Coil the cold head motor cord in preparation for transport or storage 4 Turn off the water supply at the sour...

Страница 49: ... 7 1 Disconnecting flex lines from a helium compressor package IMPORTANT When connecting or disconnecting Aeroquips Cryomech Inc recommends using a small amount of dry Teflon spray lubricant Follow the manufacturer s instructions for its use Do not spray lubricant onto sealing surfaces of the Aeroquips Hand tighten Aeroquips then spray small amount lubricant on the threads of the male Aeroquip See...

Страница 50: ... the dust caps on the male Aeroquip fittings located on the helium compressor package and the cold head 11 If necessary disconnect the cold head from its mounting surface taking care not to damage any components Once disconnected place the cold head in the original packaging container WARNING Do not touch the cold end of the cold head until it has warmed to room temperature If there is frost on th...

Страница 51: ...flex lines are reversed REMEDY 1 Turn off the helium compressor package and connect the cold head motor cord to the cold head and or to the helium compressor package 2 Tighten all Aeroquip connectors 3 Verify that one of the helium flex lines connects the high pressure port on the helium compressor package to the high pressure port on the cold head and that the other helium flex line connects the ...

Страница 52: ...helium compressor package cannot be restarted until the error lockout has been reset You must select the lockout menu and reset the number of lockouts In doing this you must acknowledge the relevant errors and therefore take the necessary steps to prevent these errors from reoccurring Resetting the lockout status will enforce a 30 min cool down period before the helium compressor package can be re...

Страница 53: ...te temperature check compressor module oil level by checking sight glass when the helium compressor package is running Helium Temp Too Low Helium discharge temperature below the low set point check cooling water temperatures increase ambient temperature if system has been off and ambient temperature is below 40 F Oil Temp Too High The oil temperature is above the high set point check flow rate and...

Страница 54: ...n If not check static pressure and helium flex line connections Delta Pressure Running Low Differential pressure approaching low error set point helium flex lines may be reversed Static Pressure Running High Static pressure approaching high error set point verify required static pressure before starting the helium compressor package Static Pressure Running Low Static pressure approaching low error...

Страница 55: ...ibutor Trip Clear High pressure too High YES 400 psig 27 6bar 375 psig 25 9 bar High pressure too Low YES 150 psig 10 3bar 170 psig 11 7 bar Low Pressure Too Low YES 40 psig 2 8 bar 50 psig 3 4 bar Low Pressure Too High YES 250 psig 17 2 bar 240 psig 16 5 bar Delta Pressure Too High YES 300 psig 20 7bar 290 psig 20bar Delta Pressure Too Low YES 50 psig 3 4 bar 75 psig 5 2 bar Static Pressure Too H...

Страница 56: ... 25 9 bar High Pressure Running Low 170 psig 11 7 bar Low Pressure Running Low 50 psig 3 4 bar Low Pressure Running High 240 psig 16 5 bar Delta Pressure Running High 290 psig 20 0 bar Delta Pressure Running Low 75 psig 5 2 bar Static Pressure Running High 280 psig 19 3 bar Static Pressure Running Low 170 psig 11 7 bar Water In Temp Running High 85 F 29 C Water In Temp Running Low 45 F 7 C Water O...

Страница 57: ...Operation 7 12 7 7 8 Contact Information Cryomech Inc 6682 Moore Road Syracuse NY 13211 Phone 315 455 2555 Fax 315 455 2544 Email support cryomech com Website www cryomech com ...

Страница 58: ...8 100 C Section 8 Routine Maintenance ...

Страница 59: ... 000 hours See Section 8 4 8 3 Cold head CAUTION The Pulse Tube style cold heads contain no user serviceable parts Attempting to disassemble the cold head will void the warranty Contact Cryomech Inc if the cold head needs to be returned for servicing CAUTION Service to Gifford McMahon style cold heads must be performed using Cryomech Inc parts and the appropriate work instructions Contact Cryomech...

Страница 60: ...rber Replacement can be completed without relieving system pressure since the adsorber is equipped with Aeroquip couplings for sealed removal 1 Shut down the system a Press the OFF button on the helium compressor package b Switch off the circuit breaker mounted on the front panel to shut down the entire system c Switch of the dedicated circuit breaker d Disconnect the input power from the helium c...

Страница 61: ...install the new adsorber reverse steps 1 through 9 8 5 Vent excess helium from the helium compressor package Required tools Quantity Description Comment 1 3 4 in open end wrench For Aeroquip coupling 1 Service Aeroquip coupling For service access port CAUTION Venting more than 5 psig 0 34 bar of helium per minute will lead to improper oil migration within the system If this condition occurs factor...

Страница 62: ...Contamination of the helium by other gases is a common cause of premature failure and is not covered by the warranty 1 Turn the helium compressor package off 2 Allow the entire system both the helium compressor package and the cold head to come to room temperature 3 Use helium with a minimum purity of 99 999 4 The helium source and regulator must be capable of pressurizing to the desired pressure ...

Страница 63: ... vacuum charging manifold and pump 3 0 7 0 SCFM Vacuum Pump Helium Tank Valve 99 999 Helium Vacuum Gauge Helium Line Charging Lines Vacuum Manifold High Pressure Regulator Service Aeroquips Charging Lines Line to Helium Tank Vacuum Sending Unit Vacuum Valve Vent Valve Relief Valve ...

Страница 64: ...m compressor package and cold head The helium compressor package and cold head require no cleaning other than wiping the outside of each if it becomes dusty or dirty CAUTION Excluding the designated water cooling circuit never allow water to contact any of the components of the system Exposing the system to water will void the warranty 8 7 2 Aeroquip couplings WARNING Never remove an Aeroquip coup...

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