Sumitomo HC-4A Technical Manual
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Sumitomo HC-4A Technical Manual

Sumitomo HC-4A Technical Manual

Air-cooled helium compressors
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HC-4A and HC-4A2 Zephyr
Air-Cooled Helium Compressors
Technical Manual
Sumitomo (SHI) Cryogenics of America, Inc.
1833 Vultee Street
Allentown, PA 18103-4783
U.S.A.
Revision C: May 2014
267825A

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  • Page 1 ® HC-4A and HC-4A2 Zephyr Air-Cooled Helium Compressors Technical Manual Sumitomo (SHI) Cryogenics of America, Inc. 1833 Vultee Street Allentown, PA 18103-4783 U.S.A. Revision C: May 2014 267825A...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Page SAFETY......................... .1 SERVICE ........................5 INTRODUCTION ......................7 ® Helium Compressor, Models HC-4A and HC-4A2 Zephyr ........7 PRINCIPLES OF OPERATION ..................9 DESCRIPTION ......................11 Components ....................11 SPECIFICATIONS ...................... 17 Electrical Characteristics ................. 17 Refrigerant Quality ...................
  • Page 4 Figure 8 HC-4A Wiring Diagram (Main Electrical Chassis and Components) ................53 Figure 9 HC-4A2 Wiring Diagram (Main Electrical Chassis and Components) ................54 Figure 10 HC-4A and HC-4A2 Wiring Diagram (Air-Cooled Unit) ....55 Figure 11 HC-4A Electrical Schematic ............56...
  • Page 5 Components) ................57 Figure 13 HC-4A2 Electrical Schematic (Air-Cooled Unit) ......58 Figure 14 Parts Identification ................61 Figure 15 Parts Identification for HC-4A ............62 Figure 16 Parts Identification for HC-4A2 ............63 Figure 17 Parts Identification ................64 Figure 18 Adapter Fitting, 8F and 8M, with Valve ...........
  • Page 6 (This page is intentionally blank.)

  • Page 7: Safety

    SAFETY GENERAL ® The HC-4A Zephyr Series Air-Cooled Helium Compressor is designed to operate safely when the installation, operation and servicing are performed in accordance with the instructions in this technical manual. Consult the nearest SCAI Service Center with any questions you may have concerning the use or maintenance of these compressors.
  • Page 8 Safety WARNINGS AVOID ELECTRIC SHOCK. All electrical supply equipment must meet applicable codes and be installed by qualified personnel. Permit only qualified electrical technicians to open electrical enclosures, to perform electrical checks or to perform tests with the power supply connected and wiring exposed.
  • Page 9 Safety CAUTIONS (continued) AVOID GAS LEAKS. Check the condition of the gasket face seal on the male half of each Aeroquip coupling. Be sure the gasket face seal is in place and the sealing surfaces on both the male and female halves are clean before connecting. Replace the gasket face seal if it is damaged or missing.
  • Page 10 (This page is intentionally blank.)

  • Page 11: Service

    SERVICE HEADQUARTERS Sumitomo (SHI) Cryogenics of America, Inc. 1833 Vultee Street Allentown, PA 18103-4783 Sales and Parts TEL: (800) 525-3072 (610) 791-6700 FAX: (610) 791-0440 Service TEL: (800) 525-3071 TEL: (610) 791-6750 SERVICE CENTERS Eastern Sumitomo (SHI) Cryogenics of America, Inc.
  • Page 12 (This page is intentionally blank.)

  • Page 13: Introduction

    Self-sealing couplings allow for easy connection to and disconnection from the rest of the closed-cycle cryogenic refrigeration system. ® The information in this manual pertains only to the HC-4A Zephyr Series Compressors. Other components used to form an operating system are described in separate technical manuals.
  • Page 14 (This page is intentionally blank.)

  • Page 15: Principles Of Operation

    Oil Separator Internal Relief Valve Oil Capillary Filter Helium Pressure Relief Valve Oil Capillary Coolant Pressure Relief Valve Adsorber Circulator Internal By-pass Orifice Accumulator Surge Bottle Air Heat Exchanger Gas Supply Pressure Gauge ® Figure 1 HC-4A Zephyr Series Flow Diagram...
  • Page 16 Principles of Operation When gas leaves the compressor, the gas contains heat and compressor lubricant. Both must be removed. From the compressor, the hot gas with its entrained oil flows over the motor winding, where the gas loses some of its suspended oil, then out of the shell and through one circuit of a three-circuit heat exchanger, where it is cooled by circulating coolant (water/30% ethylene glycol).

  • Page 17: Description

    The HC-4A compressor can be supplied with cold head cables for operating a DE-202, DE-204SL, M204S or CH204S Cold Head. The HC-4A2 compressor can be supplied with a cold head cable for operating an RDK-101 series cold head.
  • Page 18 Description Fuses: Fuse HC-4A HC-4A2 Circuit Location 0.63 AT 1.0 AT Cold Head Front Panel 0.63 AT 1.0 AT Cold Head Front Panel 5.0 AT 5.0 AT Cold Head Front Panel 5.0 AT 5.0 AT Cold Head Front Panel 0.4 AT 0.4 AT...

  • Page 19: Outline Dimensions And Parts Identification

    Description ® Figure 2 HC-4A Zephyr Outline Dimensions and Parts Identification (Dimensions in mm) NOTE Three (3) 8 mm holes at the bottom of the front panel may be used for bolts to prevent movement of the compressor.

  • Page 20: Outline Dimensions And Parts Identification

    Description ® Figure 3 HC-4A2 Zephyr Outline Dimensions and Parts Identification (Dimensions in mm) NOTE Three (3) 8 mm holes at the bottom of the front panel may be used for bolts to prevent movement of the compressor.
  • Page 21 Description Accumulator: Contains reserve coolant and applies atmospheric pressure to the circulating coolant. A rubber diaphragm separates the coolant from the atmosphere. AVOID INJURY. Coolant fluid is a 30% ethylene glycol/water mixture. TOXIC: Do not ingest. Contact local environmental authorities for proper disposal of ethylene glycol mixtures.
  • Page 22 Description º º Oil High Temperature Switch: Located on the oil return line, the switch opens at 60 C (140 and stops the compressor if the oil temperature is too high. Oil Injection Orifice: This orifice is installed downstream of the oil filter in the oil injection line and controls the flow rate of oil into the compressor’s gas return line.

  • Page 23: Specifications

    SPECIFICATIONS Electrical Characteristics Service required: 2 Pole, 3 Wire (single phase plus ground) Compressor P/N Customer's Electrical Compressor Requires Setting of Service Transformer Voltage Taps 267794D26G or 16 A 220 V~ (± 10%), 60 Hz 268086D26G 200 V~ (± 5%), 50 Hz 268613D26G 220 V~ (±...

  • Page 24: Refrigerant Quality

    Operating Supply Pressure Compressor Only 1860 - 1900 kPa 2070 - 2210 kPa (270 - 275 psig) (300 - 320 psig) HC-4A with CH-202 Cold 1790 - 1830 kPa 1930 - 2070 kPa Head (260 - 265 psig) (280 - 300 psig)

  • Page 25: Compressor Lubricant

    Specifications Compressor Lubricant LB-300X, specially processed by SCAI. Coolant 30% ethylene glycol (inhibited) in water Coolant Relief Valve is set at 552 kPa (80 psig) Compressor Weight 102 kg (225 lbs.) without transformer 111 kg (245 lbs.) with transformer Compressor Dimensions (H x W x D) 715 mm x 453 mm x 488 mm (28.2”...

  • Page 26: Remote On/Off Cable (Optional Accessory)

    Sumitomo (SHI) Cryogenics of America, Inc. 1833 Vultee Street Allentown, PA 18103-4783 U.S.A. (610) 791 - 6700 Regulatory Compliance Declaration of Conformity – HC-4A Series Compressor Manufacturer’s Name Sumitomo (SCAI) Cryogenics of America Manufacturer’s Address 1833 Vultee Street Allentown, PA 18103 U.S.A.

  • Page 27: Installation

    INSTALLATION ® The HC-4A Zephyr Air-Cooled Compressor is shipped in an operable condition. Installation consists of: Unpacking Examining for damage Removing shipping bolt Placing the compressor at its point of use Connecting utilities Checking compressor operation Connecting other system components.
  • Page 28 Installation 2. Raise the left rear corner of the compressor to locate the hex head shipping bolt. Support the compressor base with blocks only high enough to gain access to the bolt. Do not raise the corner more than 50 mm (2”). 3.

  • Page 29: Compressor Position

    Installation If the compressor shuts down during the two (2) hour test, contact the nearest SCAI Service Center. 5.2 If the equalization pressure is outside the specified range or there is physical damage to the compressor enclosure or the compressor has been on its side or upside down for an extended period of time (more than one hour), contact the nearest SCAI Service Center.
  • Page 30 Installation Tools required: #2 Phillips screwdriver Flat-blade torque screwdriver 1. Disconnect the mains power supply to the compressor (if connected). 2. Remove the field wiring access panel located on the compressor front panel. 3. Using Table 1, find the electrical supply voltage and frequency, then determine the proper terminal positions for connecting the mains power supply cable.

  • Page 31: Field Wire The Compressor

    Flat blade screwdriver (2) Open end wrenches, 33mm (1 5/16”) ® The HC-4A Zephyr Series Air-Cooled Compressor is normally furnished with a power cord attached. However, the compressor can be hard wired to customer’s power source if required. To hard wire the compressor, first remove the power cord from the compressor.

  • Page 32: Compressor Checkout

    Installation 3. Feed the conductors through the conduit. Insulated conductors should extend approximately 125 mm (5") from the end of the conduit into the compressor enclosure. Strip 9 mm (0.35”) of cover from the end of each conductor. Twist stranded conductors to prevent fraying when feeding the wires into the terminal block.

  • Page 33: Figure 5 Connect Gas Line To Compressor Or Manifold

    Installation DAMAGE TO GAS LINES can result from crimping by repeated bending and repositioning. AVOID GAS LEAKS. Check the condition of the gasket seal on the male half of each Aeroquip coupling. Be sure the gasket seal is in place and the sealing surfaces on both the male and female halves are clean before connecting.

  • Page 34: Remote On/Off Cable (Optional Accessory)

    Installation 6. Leak check all Aeroquip couplings. See the Leak Check procedure. 7. Read the equalization pressure. Compare it to the equalization pressure stated in the Specifications section. 8. Connect the other system components according to the instructions supplied for them. Connect the cold head power cable(s) to the cold head receptacle(s) on the front of the compressor.
  • Page 35 Installation base panel to restrain the compressor during shipment. Hand tighten the bolt until it bottoms. Use a 17-mm wrench to tighten the bolt 2½ turns. Return the compressor using the original shipping container or reuse the packaging from a replacement compressor.
  • Page 36 (This page is intentionally blank.)

  • Page 37: Operation

    OPERATION Starting and stopping are the only operating procedures performed at the compressor. Prestart Check Before starting the compressor, be sure that all other system components to be used are properly connected and ready for operation. Refer to the instructions supplied with the other components.
  • Page 38 (This page is intentionally blank.)

  • Page 39: Maintenance

    MAINTENANCE AVOID INJURY. Disconnect gas lines only when the compressor is stopped. Disconnecting the cold head while it is cold may create excessively high internal pressure as the gas warms. Material failure and uncontrolled pressure release can cause serious injury. AVOID INJURY.

  • Page 40: Air Filter Cleaning Or Replacement

    Tools required: Open end wrenches 17 mm, 1", 1 1/8", 1 3/16" #2 Phillips screwdriver ® The absorbers in the HC-4A Zephyr Series Air-Cooled Compressor must be replaced every 30,000 operating hours. A used adsorber has no salvage or repair value. Venting the compressor is not required when replacing the adsorber because the gas line couplings are self-sealing.

  • Page 41: Adsorber Installation

    Maintenance 2. Disconnect the supply gas line from the supply coupling on the compressor. Screw a dust plug into the disconnected gas line. NOTE Always hold the stationary nut on the gas line coupling with one wrench while turning the moveable coupling nut with the other wrench. 3.

  • Page 42: Used Adsorber Venting And Disposal

    Maintenance 6. Reconnect the supply gas line to the supply coupling on the compressor. Torque the coupling to 4.85 ± 0.7 kgf m (35 ± 5 ft. lbs.) 7. Leak check all Aeroquip couplings just completed. 8. Check the equalization pressure. See Specifications. 9.

  • Page 43: Helium Venting Procedure To Adjust The Equalization Pressure

    Maintenance 2. The adapter fitting is charged with helium gas; do not vent. Be sure the valve on the adapter fitting is closed. With two wrenches, attach the adapter fitting to the compressor’s return gas Aeroquip coupling. 3. Remove the dust plug, Swagelok P/N B-400-P (SCAI P/N 17505), from the adapter fitting. 4.

  • Page 44: Helium Venting Procedure To Vent To Atmospheric Pressure

    Maintenance Helium Venting Procedure to Vent to Atmospheric Pressure Tools required: Adapter fitting P/N P/N 266395C or 255919B2 Open end wrenches 1", 1 1/8", 1 3/16" #2 Phillips screwdriver This procedure includes disconnecting the adsorber to prevent venting it. 1. Stop the compressor and disconnect the power from the compressor. 2.
  • Page 45 Maintenance 2. Locate two adapter fittings. Be sure their valves are closed. Attach them to the supply and return Aeroquip couplings on the compressor. NOTE If the adsorber has been disconnected, connect a P/N 266395C adapter fitting to the supply line from the oil separator, instead of connecting to the supply gas coupling, for venting during this procedure.

  • Page 46: Helium Leak Check

    Maintenance 18. Disconnect the charge line from the adapter fitting. Store the charge line to keep it clean. 19. Remove both adapter fittings. NOTE Reconnect the adsorber if it was disconnected prior to gas cleanup. 20. If other components need cleaning, refer to the procedures in their technical manuals. Otherwise, reconnect the supply and return gas lines to the compressor.

  • Page 47: Coolant System Leak Repair

    Maintenance Leaks at welded joints require special skills to repair. Consult a SCAI Service Center. Replacing worn or damaged parts can repair leaks at the self-sealing couplings. Vent the compressor before beginning to disassemble it. Tightening the coupling frequently stops leaks at threaded joints. Continued leakage after tightening requires coupling repair.

  • Page 48: Replace The Compressor Shell High Temperature Switch

    Maintenance AVOID INJURY. Coolant fluid is a 30% ethylene glycol/water mixture. TOXIC: Do not ingest. Contact local environmental authorities for proper disposal of ethylene glycol mixtures. Tools required: Open end wrenches 1”, 7/8”, 13/16” If leaks occur at compression fitting joints with nylon plastic tubing, re-tighten compression nut until firmly seated.

  • Page 49: Replace Fuses

    1. Front Panel a. Auxiliary power, solenoid valve, coolant circulator, fan circuit: (2) 5.0 ampere b. Cold head valve motor circuit: (2) 0.63 ampere [HC-4A] or (2) 1.0 ampere [HC-4A2] 2. Behind left side compressor cover: a. Coolant circulator and fan circuit: (2) 1.0 ampere and (1) 0.63 ampere 3.
  • Page 50 Maintenance 2. Remove open fuse from cap and replace with new fuse of the same ampere rating 3. Replace cap and new fuse into holder, push and rotate clockwise into locked position. Behind Left Side Cover Fuse Replacement: 1. Remove left side compressor cover. 2.

  • Page 51: Troubleshooting

    TROUBLESHOOTING Automatic Shutdown The compressor will not start or will shut down automatically if any of the following are open: • the compressor shell high-temperature switch; • the oil or gas high-temperature switch; • the motor internal protector; • the circuit breaker. If the compressor has been shut down by one of these interlocks, do not restart until the problem has been found and corrected.

  • Page 52: Troubleshooting Guide

    Troubleshooting Troubleshooting Guide Problem Possible Cause Corrective Action Compressor and items No electrical power. Check that the power source is powered from it do not start on and the power cord is when the start switch on the connected. compressor is closed. Run light is not on.
  • Page 53 Troubleshooting Problem Possible Cause Corrective Action Compressor starts but shuts Water high-temperature Check the coolant flow and down sometime later. switch is open. temperature. Refer to the Specifications. Circuit breaker or fuse is Reset the circuit breaker or open. replace a fuse. Compare the electric service with system specifications.
  • Page 54 Troubleshooting Problem Possible Cause Corrective Action Gradual loss of helium gas Gas is leaking from the Leak check the compressor and pressure. compressor. repair. Compressor runs; elapsed Defective elapsed time meter Consult a SCAI Service Center. time meter does not run. or motor contactor.

  • Page 55: Compressor Capsule

    Troubleshooting AVOID INJURY. The compressor’s elapsed time meter contains a lithium battery. Do not remove the battery. Do not recharge, disassemble, mutilate, wet or dispose of the meter in fire. Contact local environmental authorities for proper disposal of the lithium battery. Compressor Capsule Compressor motor checks for winding continuity, resistance and grounding will isolate most motor electrical problems.

  • Page 56: Current Measurement

    Troubleshooting 5. With an ohmmeter, check the resistance across compressor terminals C and S. Resistance should be 1.8 to 2.2 ohms. If the resistance is outside this range, consult a SCAI Service Center. If there is no continuity, the winding is open. Consult a SCAI Service Center. 6.

  • Page 57: Fan And Circulator

    Troubleshooting 8. Read the current draw for each lead, then stop the compressor. • A reading of 0 amperes indicates an open circuit. • A reading of 10 to 14 amperes (steady state) is normal. • A reading slightly higher than 10 to 14 amperes suggests possible minor system problems, i.e.
  • Page 58 Troubleshooting 2. Remove the compressor’s left, right, and top covers exposing terminal blocks 12 through 18. 3. For checking the fan motor, remove wires 73, 74 and 75 from terminal blocks 14, 15 and 16 respectively. 4. With an ohmmeter, check the resistance between wires 73 and 74. Resistance should be between 122 and 130 ohms.

  • Page 59: Figure 8 Hc-4A Wiring Diagram (Main Electrical Chassis And Components)

    Troubleshooting Figure 8 HC-4A Wiring Diagram (Main Electrical Chassis and Components)

  • Page 60: Figure 9 Hc-4A2 Wiring Diagram (Main Electrical Chassis And Components)

    Troubleshooting Figure 9 HC-4A2 Wiring Diagram (Main Electrical Chassis and Components)

  • Page 61: Figure 10 Hc-4A And Hc-4A2 Wiring Diagram (Air-Cooled Unit)

    Troubleshooting Figure 10 HC-4A and HC-4A2 Wiring Diagram (Air-Cooled Unit)

  • Page 62: Figure 11 Hc-4A Electrical Schematic

    Troubleshooting Figure 11 HC-4A Electrical Schematic...
  • Page 63 Troubleshooting Figure 12 HC-4A2 Electrical Schematic (Main Electrical Chassis and Components)

  • Page 64: Figure 13 Hc-4A2 Electrical Schematic (Air-Cooled Unit)

    Troubleshooting Figure 13 HC-4A2 Electrical Schematic (Air-Cooled Unit)

  • Page 65: Parts

    77002 Nylon washer (2), Aeroquip coupling 72628 Lock washer (2), Aeroquip coupling 46401 Lock nut (2), Aeroquip coupling 46101 Dust cap (2), Aeroquip coupling 44642 Caster (4), swivel 49137 Air filter, HC-4A Compressor (2) F267830A * Part is not shown.
  • Page 66 Time delay relay replacement kit F37476A Power cord assembly 267286B Oil charging vessel (with oil) 263775A3 Shipping bolt 70498 Electrical chassis assembly, HC-4A 266955D Electrical chassis assembly, HC-4A2 268085D Fuse, 0.4 ampere, 250 V 34691 Fuse, 0.63 ampere, 250 V 34687 Fuse, 1.0 ampere, 250 V...

  • Page 67: Figure 14 Parts Identification

    Parts Figure 14 Parts Identification (Fan, Circulator and Air Heat Exchanger not shown)

  • Page 68: Figure 15 Parts Identification For Hc-4A

    Parts Figure 15 Parts Identification for HC-4A...

  • Page 69: Figure 16 Parts Identification For Hc-4A2

    Parts Figure 16 Parts Identification for HC-4A2...

  • Page 70: Figure 17 Parts Identification

    Parts Figure 17 Parts Identification...

  • Page 71: Adapter Fittings

    Adapter Fittings The following adapter fittings, required for servicing the HC-4A Compressor, are available as accessories from SCAI. Item Quantity Part Name Part Number Figure 266395C Adapter fitting, 8F and 8M , with valve Adapter fitting, 8Fwith valve 255919B2 Denotes size 8, female, Aeroquip coupling.

  • Page 72: Cables

    Parts Cables The following cables are available for use with the HC-4A Series Compressors as accessories from SCAI. Item Quantity For Use Description Part Number With: HC-4A/ Accessory cable for remote On/Off, 263887B20 HC-4A2 6 m (20 ft.) long. HC-4A Cold head cable, DE202/204SL, 3.3 m...

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