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Summary of Contents for Sumitomo HC-4E1
- Page 1 HC-4E1 and HC-4E2 Helium Compressors Technical Manual Sumitomo (SHI) Cryogenics of America, Inc. 1833 Vultee Street Allentown, PA 18103-4783 U.S.A. Revision C: August 2012 267318A...
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Page 3: Table Of Contents
TABLE OF CONTENTS Page SAFETY......................... .1 SERVICE ........................5 INTRODUCTION ......................7 Helium Compressor, Models HC-4E1 and HC-4E2..........7 PRINCIPLES OF OPERATION ..................9 DESCRIPTION ......................11 Components ....................11 SPECIFICATIONS ...................... 17 Electrical Characteristics ................. 17 Cooling Requirements ..................18 Refrigerant Quality ................... - Page 4 Cables ......................60 ILLUSTRATIONS LIST Figure 1 HC-4E Flow Diagram ............... 9 Figure 2 HC-4E1 Outline Dimensions and Parts Identification ..... 14 Figure 3 HC-4E2 Outline Dimensions and Parts Identification ..... 15 Figure 4 Connections for Mains Power Supply ..........27 Figure 5 Connect and Remove the Water Lines ...........
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Page 5: Safety
SAFETY GENERAL The HC-4E1 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 6 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 7 Safety CAUTIONS (continued) AVOID CONTAMINATION. When checking the compressor for shipping damage, do not connect gas lines and cold head. The components may become contaminated with compressor oil. Follow the charging or venting procedures to prevent reversed flow of system gas. Do not charge through the supply coupling.
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Page 9: 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 10 (This page is intentionally blank.)
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Page 11: Introduction
INTRODUCTION Helium Compressor Models HC-4E1 and HC-4E2 The Compressors are single-stage, water-cooled, rotary, and designed to deliver high-pressure, oil-free helium gas to cryogenic refrigerators. Cold head cables are used to supply electrical power to cold heads. Self-sealing couplings allow for easy connection to and disconnection from the rest of the closed-cycle cryogenic refrigeration system. - Page 12 (This page is intentionally blank.)
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Page 13: Principles Of Operation
PRINCIPLES OF OPERATION The compressor continuously draws low-pressure helium from the system return line. It compresses, cools and cleans the gas, then delivers it through the system gas supply line to the cold head. See Figure 1. Oil Injection Filter Gas Supply Pressure Gauge Oil Injection Orifice Gas Equalization Solenoid Valve... - Page 14 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.
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Page 15: Description
DESCRIPTION The components of the HC-4E Series Compressors are identified schematically in Figure 1. Figures 2 and 3 identify front panel components. Features and functions of individual components are described in the following paragraphs. Components (See Figures 2 and 3) 50/60 Hz Toggle Switch (HC-4E2 only): This switch is used to select different phasing circuits for cold head operation at 50 Hz or 60 Hz. - Page 16 Description Fuses: Electrical Rating (250 VAC) Circuit Location HC-4E1 HC-4E2 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...
- Page 17 Description Pressure Relief Valve: The relief valve prevents the compressor from operating at an unsafe pressure. Shell High Temperature Switch: Located on top of the compressor next to the compressor º º motor terminals, the switch opens at 80 C (176 F) and stops the compressor if the shell temperature is too high.
- Page 18 Description Figure 2 HC-4E1 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 19 Description Figure 3 HC-4E2 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.
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Page 21: Specifications
SPECIFICATIONS Electrical Characteristics Service required: 2 Pole, 3 Wire (single phase plus ground) Compressor P/N Customer's Electrical Service Requires Setting of Transformer Voltage Taps 266958D18G 208/230 V~ (± 5%), 60 Hz 268159D18G 200 V~ (± 5%), 50 Hz 266958D1518G 208/230 V~ (± 5%), 60 Hz 268159D1518G 200 V~ (±... -
Page 22: Cooling Requirements
Helium Gas Pressures HC-4E2 with HC-4E2 with RDK-101D & RDK-101D & ⌀ ⌀ ⌀ ⌀ ½” x >20 ft. ⌀ ⌀ ⌀ ⌀ ½” x 20 ft. HC-4E1 with HC-4E1 with and ≤66 ft. Compressor CH-202 Cold CH-204S Flex Gas... -
Page 23: Compressor Lubricant
Specifications Equalization Pressures at Different Ambient Temperatures: P psig with DE- P psig with DE-202 204SL, CH-204S, or T° ° ° ° C Cold Head M204S Cold Heads 246 – 251 255 – 260 251 – 256 261 – 266 15.6 256 –... -
Page 24: Installation Kit
Remote On/Off Cable (Optional Accessory): A cable is available from SCAI to connect to the Accessory receptacle on the front panel to operate the compressor from a remote location. See the Parts section in this manual. Supplier Name and Address Sumitomo (SHI) Cryogenics of America, Inc. 1833 Vultee Street Allentown, PA 18103-4783 U.S.A. -
Page 25: Regulatory Compliance
Sumitomo (SCAI) Cryogenics of America Manufacturer’s Address 1833 Vultee Street Allentown, PA 18103 U.S.A. Authorized Representative’s Name Sumitomo (SHI) Cryogenics of Europe Limited Authorized Representative’s Address 3 Hamilton Close Houndmills Industrial Estate Basingstoke, Hants RG21 6YT England Type of Equipment... - Page 26 (This page is intentionally blank.)
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Page 27: Installation
INSTALLATION The HC-4E Compressor is shipped in an operable condition. Installation consists of: Unpacking Examining for damage Placing the compressor at its point of use Connecting utilities Checking compressor operation Connecting other system components. Introduction Install the Compressor and the Gas Lines according to the following procedures. To prevent contaminating the components or the system, it is important to follow the procedures in this manual step by step. - Page 28 Installation 3. Use a 17-mm wrench to remove the bolt. Retain the bolt for future use. The shipping bolt must be reinstalled prior to shipment. See the section Compressor Shipping Preparation. 4. Remove the blocks and lower the compressor onto its wheels. NOTE Retain the shipping container if reusable for returning the compressor to the factory if reconditioning is required.
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Page 29: Compressor Position
Installation 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. Compressor Position Place the compressor in a location that is protected from the elements and where the ambient temperature will always be within the range of 4°... -
Page 30: Mains Power Supply Connection
Installation Mains Power Supply Connection Before power is supplied, the following procedure must be used if the transformer voltage taps must be changed. PREVENT EQUIPMENT DAMAGE. If the compressor boost transformer tap settings do not match the mains supply voltage, it can result in damage to the compressor. -
Page 31: Table 1 Terminal Position For Mains Power Supply
Installation Compressor Incoming Electrical Terminal Power Variation Position Volts L1 L2 L1 L2 L3 L4 L1 L2 L1 L2 230-240 L3 L4 L1 L2 L1 L2 L1 L2 L1 L2 L3 L4 Table 1 Terminal Position for Mains Power Supply Mains Power supply Connected to L1-L2 Mains Power supply Connected to L3-L4 Figure 4 Connections for Mains Power Supply... -
Page 32: Field Wire The Compressor
Flat blade screwdriver (2) Open end wrenches, 33mm (1 5/16”) The HC-4E1 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 33: Compressor Checkout
Installation 3. Secure the cable by tightening the cap of the strain relief fitting. Use two wrenches to prevent turning the body of the strain relief fitting. 4. Reinstall the terminal block access cover. This completes the procedure for hard wiring the compressor. Compressor Checkout Tools required: Open end wrenches, one 15/16”... -
Page 34: Interconnections
Installation Interconnections Tools required: Open end wrenches 1", 1 1/8", 1 3/16". AVOID INJURY. When handling pressurized gas lines and other pressurized equipment, always wear eye protection. Never apply heat to a pressurized gas line or other pressurized components. DAMAGE TO GAS LINES can result from crimping by repeated bending and repositioning. -
Page 35: Remote On/Off Cable (Optional Accessory)
Installation 6. Using two wrenches, connect the return (green) gas line to the compressor’s return gas coupling. Torque the coupling as stated in the previous step. Figure 6 Connect Gas Line to Compressor or Manifold 7. Leak check all Aeroquip couplings. See the Leak Check procedure. 8. -
Page 36: Compressor Shipping Preparation
Compressor Shipping Preparation PREVENT EQUIPMENT DAMAGE. Do not over tighten the shipping bolt. PREVENT EQUIPMENT DAMAGE. Always thoroughly drain the coolant from the cooling circuit if the compressor is to be shipped or stored. A shipping bolt, P/N 70498, was installed on the compressor when it left the factory. If the compressor is to be shipped, reinstall the shipping bolt from the bottom of the compressor’s base panel to restrain the compressor during shipment. -
Page 37: Operation
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.)
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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: Adsorber Replacement
Maintenance AVOID A MALFUNCTION. Repeatedly charging the system with helium gas rather than locating and repairing gas leaks may cause a malfunction. Impurities are introduced at an abnormal rate and can freeze in the cold head. AVOID GAS LEAKS. Check the condition of the gasket seal on the male half of each Aeroquip coupling. -
Page 41: Adsorber Installation
Maintenance AVOID EQUIPMENT FAILURE, CONTAMINATION OR A NUISANCE SHUTDOWN. Do not tip the compressor greater than 5 degrees from horizontal to avoid flowing oil into unwanted places and causing a nuisance shutdown. 6. Remove the lock nut on the supply coupling on the front panel. 7. -
Page 42: Charging And Venting
Maintenance Charging and Venting Charging or venting is required whenever the equalization pressure of the system is outside the range as stated in the Specifications. See Specifications for equalization pressures at different ambient temperatures. See also the section Gas Cleanup. Venting is required if leaking self-sealing couplings need to be disassembled for repairs. -
Page 43: Venting Procedure To Adjust The Equalization Pressure
Maintenance 6. Adjust the pressure regulator to the desired operating or equalization pressure. See Specifications. Slowly, fully open the adapter fitting’s valve. Charge the system with helium gas until the desired pressure is indicated on the compressor’s pressure gauge. 7. Close the adapter fitting’s valve and the gas cylinder valve. 8. -
Page 44: Gas Cleanup
Maintenance 4. With wrenches, disconnect the Aeroquip coupling in the supply line between the oil separator and the inlet side of the adsorber. This keeps the adsorber pressurized. 5. Locate the adapter fitting; be sure its valve is closed. Move the part of the supply line fastened to the adsorber out of the way. - Page 45 Maintenance 4. While connecting the charge line to the adapter fitting on the compressor’s return gas coupling, thoroughly purge the charge line from the regulator. It is important to remove all air contaminants to prevent them from entering the system. 5.
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Page 46: Leak Check
Maintenance Leak Check In addition to identifying suspected leaks, check the compressor for helium leaks each time it has undergone any amount of disassembly. Use a helium mass spectrometer leak detector if available. Follow its manufacturer’s instructions. If a leak detector is not available, use a commercial leak detection solution. However, small leaks may not be detected. -
Page 47: Replace The Compressor Shell High Temperature Switch
Maintenance 3. Install dust caps on all disconnected gas couplings except the one to be repaired. 4. Remove the compressor’s cover. 5. Use the Venting Procedure to Vent to Atmospheric Pressure to discharge all gas from the compressor. This procedure includes disconnecting the adsorber to prevent venting it. 6. - Page 48 Maintenance Terminal Box Cover Temperature Overload Switch in Retainer Figure 7 Compressor Shell High Temperature Switch...
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Page 49: 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 water, oil or gas high-temperature switch; • the motor over-current relay; • the circuit breaker. -
Page 50: Troubleshooting Guide
Troubleshooting PRESERVE YOUR WARRANTY. Modification to equipment without the consent of the manufacturer will void the warranty. 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. - Page 51 Troubleshooting Problem Possible Cause Corrective Action Compressor starts, but shuts Low oil flow. Look for oil leaks in the down after a few minutes of compressor capsule. Consult a operation. (continued). SCAI Service Center. Orifice or the oil cooling line Replace the orifice and the filter.
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Page 52: Compressor Capsule
Troubleshooting Problem Possible Cause Corrective Action Compressor runs, but cold Wrong cold head cable. Be sure correct cold head cable head valve motor operation is is connected (Page 56.) abnormal Cold head problem. Consult cold head manual. Gradual loss of helium gas Gas is leaking from the Leak check the compressor and pressure. -
Page 53: Current Measurement
Troubleshooting 2. Remove the compressor’s cover. 3. Remove the terminal box cover from the top of the compressor motor to expose the three terminals M, S, and C. See Figure 8. Disconnect wires 7, 8, and 9 from terminals C, M, and S respectively. - Page 54 Troubleshooting 2. Remove the wiring terminal block access cover from the front panel. 3. Locate the incoming power leads at the terminal block. 4. Expose the power leads enough to use a clamp-on ammeter. 5. Clamp the ammeter on one of the power leads. 6.
- Page 55 Troubleshooting Figure 9 HC-4E1 Wiring Diagram...
- Page 56 Troubleshooting Figure 10 HC-4E2 Wiring Diagram...
- Page 57 Troubleshooting Figure 11 HC-4E1 Electrical Schematic...
- Page 58 Troubleshooting Figure 12 HC-4E2 Electrical Schematic...
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Page 59: Parts
PARTS Ordering The nameplate fastened to the front panel of the compressor housing identifies the compressor as follows: Model Number Part Number Serial Number Date of Manufacture Furnish this complete information when ordering parts. Also, order parts by part number and name. - Page 60 Time delay relay replacement kit F37476A Power cord assembly 267286B Oil charging vessel (with oil) 263775A3 Shipping bolt 70498 Electrical chassis assembly, HC-4E1 266955D Electrical chassis assembly, HC-4E2 268685D Fuse, 0.4 ampere, 250 V 34691 Fuse, 0.63 ampere, 250 V 34687 Fuse, 5.0 ampere, 250 V...
- Page 61 Parts Figure 13 Parts Identification...
- Page 62 Parts Figure 14 Parts Identification for HC-4E1 Figure 15 Parts Identification for HC-4E2...
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Page 63: Adapter Fittings
Parts Adapter Fittings The following adapter fittings, required for servicing the HC-4E1 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 64: Cables
Parts Cables The following cables for use with the HC-4E1 Compressor are available as accessories from SCAI. Item Quantity Description Part Number Accessory cable for remote On/Off, 263887B20 6 m (20 ft.) long. Cold head cable, DE202/204SL, 3.3 m 263941Bxxx (11 ft.) long...
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