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Cryomech PT415 Installation, Operation And Routine Maintenance Manual

Helium reliquefier
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PT415
Helium Reliquefier
INSTALLATION, OPERATION and
ROUTINE MAINTENANCE MANUAL

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Summary of Contents for Cryomech PT415

  • Page 1 PT415 Helium Reliquefier INSTALLATION, OPERATION and ROUTINE MAINTENANCE MANUAL...
  • Page 2 Except as expressly contained in this document, there are no other warranties granted or extended by the manufacturer. 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.

  • Page 3: Table Of Contents

    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 Appendix A Appendix B Spray Lubricant Instructions...

  • Page 4: Overview

    Section 1 Overview...
  • Page 5 Overview ction 1 : Overv view This sectio on provides a an overview discussion of f Cryomech H Helium Reliq uefiers. It als provides a an overview o f this manual , including the e organizatio n, basic defin nitions of term...
  • Page 6 Cryomec ch Helium m Relique efier Man nual This manu ual covers the e complete C Cryomech He lium Reliquef fier. It is impo ortant that yo review this s manual care efully before b beginning the installation p process.
  • Page 7 The manu ual contains e essential info rmation for th he safe and effective ope eration of you Cryomech Cryorefigera ator. Sections s 2 and 3 cle early lay out all safety pr recautions yo should tak ke and also...
  • Page 8 Overview Cold Head The cold head is an n expansion device, whi ich is capab ble of reach hing cryogen res. In the AL L or GB syste ems the cold head is a Gif on style unit. temperatur fford-McMaho the PT ser ries systems t the cold head...
  • Page 9 (describe es a form of C Copper) PSIG ounds per Squ uare Inch Ga Cryomec ch Conta act Inform mation Cryomech , Inc. 113 Falso Drive Syracuse, NY 13211 Phone: +1 (315) 455-25 Fax: +1 (3 15) 455-2544 Email: pport@cryome ech.com...

  • Page 10: Warranty

    Section 2 Warranty...
  • Page 11 C Cryomech, In warranty on a all parts and w workmanship p for a period of three (3) y years or 12,00 extends a...
  • Page 12 Atte mpting to dis sassemble th cold h head will void d the warrant ty. Contact C Cryomech if t the cold head d needs to b returne ed for servicin ng. See Secti on 8. ...

  • Page 13: Safety

    Section 3 Safety...
  • Page 14 Safet ction 3 : Safety Safety a and inform mation sy ymbols .1.1 Equip pment sym mbols The safety y and informa ation symbol stickers plac ced on Cryom mech Cryore efrigerators ar defined be elow. Alternating current. The symbol signi fies that alter rnating curren nt is present.
  • Page 15 If you plan to opera ate the syste outside e any of the s specified cond ditions, conta ct Cryomech .2.2 Secti ion 6. Insta allation Section n 6.1 Relique efier installat tion UTION...
  • Page 16 Safet Section n 6.5 Compre essor installa ation UTION Failure e to follow the ese installatio n guidelines c could result in n voiding the warranty. Section n 6.5.1 Prepa are the comp pressor pack kage location RNING The co ompressor pa ackage must t be positione...
  • Page 17 Safet Section n 6.5.4 Conn ect the heliu um flex lines to the helium m reliquefier r assembly and the e compresso or package UTION Follow w the procedu ure carefully when connec cting and dis sconnecting t the helium fle lines.
  • Page 18 Safet 3.2.4 Secti ion 8. Rout tine mainte enance Section n 8.3 Cold he UTION The he elium reliquef fier contains n no user-servi ceable parts. Attempting t to disassemb the he lium reliquefie er will void th e warranty. CONT TACT CRYO OMECH IF...
  • Page 19 Safet Section n 8.7 Cleanin UTION Never wet either p part of the s system. Wate er getting into o the system m will void th warran nty. RNING Never remove an Aeroquip coupling from m the helium m flex lines, cold head o compr ressor withou...

  • Page 20: Inspection And Unpacking

    Section 4 Inspection and Unpacking...
  • Page 21 2) Check k for tip indic ators on the inside of the e packing cra ate and notif fy Cryomech interio r tip indicator rs have been n activated ev ven though ti ip indicators on the outsid were n not.
  • Page 22 nspection an nd Unpackin the co ompressor. S See Section 5 for the we eight of the compressor package. Th compr ressor should not be tipped d more than 5 5 at any time 3) The co ompressor pa ackage is equ uipped with ca astors and ca an be rolled b...
  • Page 23 Preparatio on of helium reliquefier, c compressor , and helium m flex lines 1) Contac ct Cryomech for an RMA A number and d for addition nal detailed i instructions o how to o properly retu urn system co omponents.

  • Page 24: Specifications

    Section 5 Specifications...
  • Page 25 Section 5: Specifications 5.1 Intended use of equipment The Cryomech Helium Reliquefier is designed to recondense the boil off from liquid helium dewar/cryostats, and then return the Liquid Helium to the dewar/cryostat establishing a closed Helium loop. It can be installed into cryostats already full of liquid helium or be utilized to liquefy helium gas from gas cylinder to fill a dewar.
  • Page 26 Specifications Water Flow Rate (LPM) 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 Water Flow Rate (GPM) Figure 5-1: Cooling water requirement* Water Pressure Drop (bar) 10 12 14 16 18 20 22 24 Water Pressure Drop (PSI) Figure 5-2: Cooling water pressure drop* * When using a 50-50% mixture of ethylene glycol and water, increase the flow rate 10%.
  • Page 27 Operation above 100F will cause overheating and subsequent problems. If a unit must be subjected to either extreme, consult Cryomech, Inc. 5.2.5 Safety devices A number of safety switches and valves are located inside the compressor package and on the cold head.
  • Page 28 Specifications Section 7 for further detail. The safety devices listed below are not monitored by the compressor control panel. High-Pressure Relief Valve The compressor package high-pressure relief valve is set at 420 ± 5 PSIG (29 ± .34 bar). At pressures above 420 PSIG (29 bar), the relief valve will open automatically and relieve pressure to the atmosphere.
  • Page 29 Specifications Figure 5-3: Helium Reliquefier A. Cryorefrigerator (Cold Head) The cold head is bolted to the top of the main assembly. An O-ring, located between the main assembly and the cold head, seals the helium gas inside the main assembly. B.
  • Page 30 We recommend that the needle valve is open to between 33-50%; and is set this way by Cryomech. Minor adjustments might increase the liquefaction rate for some installations. If ice forms on your vapor return line contact Cryomech for directions.
  • Page 31 PT410 Cold Head. If this does not happen effectively, the pressure inside the cryostat will drop below 1 Atmosphere, which Cryomech does not recommend. If the pressure inside the system drops to below 1 Atm., air might enter the system and solidify on the Cold Head heat exchangers.
  • Page 32 Specifications 5.5 Description of compressor Low Pressure Low Pressure Control Gauge Aeroquip Panel High Pressure Touch Gauge Screen High Pressure Aeroquip Cold Head Motor Connector Service Valve Main Circuit Breaker Service Access Power Cord Cooling Water Cooling Water Inlet Connection Outlet Connection Figure 5-5: Front panel of the compressor package 5.5.1 Front panel interfaces...
  • Page 33 Specifications Low-Pressure Aeroquip The low-pressure helium flex line (not shown) fastens to the low-pressure Aeroquip that returns helium gas from the cold head to the compressor package. Low-Pressure Gauge The low pressure gauge displays the pressure of the helium gas that is being returned to the compressor package.
  • Page 34 Specifications Cooling Water Outlet Connection The cooling water outlet connection carries heated water away from the compressor package after the water has been heated by cooling the compressor package during operation. The connector thread size is 3/8 FPT (3/8” Female National Pipe Thread). Power Cord The power cord supplies power from the wall to the entire system.
  • Page 35 The USB Port can be used to download recorded data from the system. RJ45 Ethernet Port The RJ45 port can be used to remotely monitor and control the compressor system. Refer to the compressor’s user guide or contact Cryomech for more information 5-11...
  • Page 36 RS485 Port The RS485 port can be used to remotely monitor and control the compressor system. Refer to the compressor’s user guide or contact Cryomech for more information System I/O Port The System I/O port is a DB15 female socket that can be used to remotely control the compressor package and monitor a limited number of its parameters.
  • Page 37 Specifications less than 30 volts(Min3mA) and close the selected input pin to the return of that supply. (An isolated 24 volt supply and return is provided on pins 11 and 10 of this connector respectively.) The minimum pulse width (high or low) for an input signal to be recognized is 200ms. It is possible for a signal to be recognized sooner, but due to the asynchronous nature of the design, a 200ms pulse width is necessary to guarantee the signal is recognized.
  • Page 38 For more information on the System I/O 15 pin connector, refer to the cm-db15.pdf file. This file can be located on the ship disk that was sent with each system in the Control Panel Computer Interface Package folder. You can also download information from our website: http://www.cryomech.com/fileshare/ 5-14...
  • Page 39 Specifications Figure 5-8: System I/O wiring diagram – Internal Supply - Local Mode 5-15...
  • Page 40 Specifications Figure 5-9: System I/O wiring diagram – Internal Supply - Remote Mode 5-16...
  • Page 41 Specifications Figure 5-10: System I/O wiring diagram – External Supply - Local Mode 5-17...
  • Page 42 Specifications Figure 5-11: System I/O wiring diagram – External Supply - Remote Mode 5-18...
  • Page 43 Specifications 5.6 Description of the Pressure Controller CAUTION DO NOT change settings of the pressure controller before reviewing this entire section. Changing these settings will cause the automatic operating system to malfunction. Pay close attention to Section 5.6 The dewar vapor pressure controller is used to monitor and control pressure in the dewar.
  • Page 44 Specifications F. Left & Right Arrow Button The Left and Right Arrow Button are similar to the up and down arrow button. J. Temperature Diode Receptacle The temperature diode receptacle is connected to a silicon diode mounted to the cold head’s helium condenser inside the dewar.

  • Page 45: Installation

    Section 6 Installation...
  • Page 46 The Liquid Helium Return Line extending out of the side of the Helium Re-liquefier Main Assembly is extremely delicate. Please handle with care. Do not bend or adjust without contacting Cryomech. The line is vacuum jacketed and constructed of very thin walled stainless steel tubing with very close tolerances.
  • Page 47 Installation 1) Inspect the reliquefier for any damage to the liquid return line or main assembly. Please notify Cryomech if scratches or dents are observed on any of the above- mentioned surfaces. 2) Make certain the flat gaskets are present and properly seated in the ends of the Aeroquip...
  • Page 48 Dewar. The line comes with a an o-ring fitting to connect to the Re-liquefier Main Assembly and a needle valve. Cryomech has supplied the other end of the vapor line with an o-ring fitting and a 1/4 MNPT adapter fitting to connect to your dewar/cryostat.
  • Page 49 If your cryostat boil off rate is smaller than the liquefaction rate of the re-liquefier, it is necessary to apply heat to the Pulse Tube condensing heat exchanger. This will ensure that the system pressure remains above atmospheric pressure. Cryomech recommends that you leave the pressure set point at 3psig. Please read the attached HRC-110 pressure controller manual for instructions on how to change this set point, if desired.
  • Page 50 Installation CAUTION Failure to follow these installation guidelines could result in voiding the warranty. 6.5.1 Prepare the compressor package location  Confirm that the physical space containing the compressor package has an ambient temperature in the range 45 to 100F (7 to 38C). ...
  • Page 51 Installation 5) Make certain the cooling water flow rate and inlet temperature meets the requirements in Section 5. 6.5.3 Connect the compressor package to the main power CAUTION A voltage deviation of more than 10% above or below the voltage rating can cause compressor motor overheating and possible failure.
  • Page 52 IMPORTANT When connecting or disconnecting the flex lines, Cryomech recommends using a small amount of Teflon spray lubricant. A can of lubricant is included with each system. Before using the lubricant, you must read the instructions for its use.
  • Page 53 Installation Turn this wrench Hold this wrench Figure 6-6: Connecting the flex lines to a compressor package 5) Connect the other end of the helium flex line to the low-pressure port on the cold head. The low-pressure port is marked “Low.” Tighten the connector until a positive stop is felt.
  • Page 54 Installation 6.5.5 Connect the cold head motor cord 1) Note that the female plugs attached to each end of the cold head motor cord are unique for both the compressor and the cold head. 2) Assure that the cold head motor cord is sufficiently long to reach the cold head. If the cord length is not sufficient to reach the cold head, adjust the location of the compressor package or the cold head.

  • Page 55: Operation

    Section 7 Operation...
  • Page 56 Pulse Tube condensing heat exchanger. This will ensure that the system pressure remains above atmospheric pressure. Cryomech recommends that you leave the pressure setpoint at 3psig. Please read the attached HRC-110 pressure controller manual for instructions on how to change this set point, if desired.
  • Page 57 The needle valve on the helium vapor line in Figure A-2 is used to control the natural convection flow within the Helium Re-liquefier. b. Cryomech recommends that the needle valve is opened 2½ to 3 turns from the fully closed position. Cryomech has preset it for optimum performance with our test cryostat when there is liquid in the system.
  • Page 58 The high and low pressures should be monitored daily. Cryomech recommends that you maintain a regular record, at intervals that make sense for the way you use your system, of the high and low pressure readings. The RS232/488 port can be used to remotely monitor and record the pressure data.
  • Page 59 Operation 7.5.3 Cooling water input and output If possible, Cryomech recommends keeping a regular record of the input and output cooling water temperatures and of the cooling water flow rate. The RS232/488 port can be used to remotely monitor and record the water temperature data.
  • Page 60 Operation IMPORTANT When connecting or disconnecting the flex lines, Cryomech recommends using a small amount of Teflon spray lubricant. A can of lubricant is included with each system. Before using the lubricant, you must read the instructions for its use.
  • Page 61 Operation 7.7 Troubleshooting 7.7.1 System will not start SYMPTOM System will not start. POSSIBLE No power supplied to the compressor package. CAUSE Circuit breakers off. “Compressor Error” message displayed on display screen. REMEDY Check the power supply to the system and verify that it meets the requirements outlined in Section 5.
  • Page 62 Operation 7.7.3 System has shut itself down SYMPTOM System has shut itself down. POSSIBLE 1) Circuit breaker tripped. CAUSE 2) Interruption of the power supply to the compressor package. 3) “Compressor Error” message displayed on front panel screen. REMEDY 1) Reset the circuit breaker on the front panel of the compressor package.
  • Page 63 Operation 7.7.5 Error diagnostics on display screen Errors will cause the compressor system to stop. Errors are displayed on the bottom line of the display screen. If more than one of the errors below is present, only the highest priority one will be displayed. The table lists errors from highest to lowest priority. If the error is a lockout contributor, it will be noted in the Explanation column.
  • Page 64 2 of the 3 input power wires. "Power Supply Error!" Power supply has exhibited a fault, verify voltage output or contact Cryomech 7.7.6 Warning diagnostics on display screen Warnings do not cause the compressor to stop and do not prevent the compressor from starting.
  • Page 65 Operation Water outlet temperature is approaching low error set point; increase "Water Out Temp inlet water temperature or reduce flow rate to prevent overcooling or Running Low" overheating caused by reduced oil temperature Helium discharge temperature approaching high error set point; “Helium Temp Running check cooling water temperatures, may also be caused by low oil High!”...
  • Page 66 120°F (49°C) “Oil Temp Running Low!" 45°F (7°C) 7.8 Contact Cryomech with Questions It is hoped that the Operations Section of this manual has helped you to obtain satisfactory results in the use of your cryorefrigerator. While the information offered should facilitate set up and operation, you may have a special situation that requires further considerations.
  • Page 67 Operation Syracuse, NY 13211 Phone: (315) 455-2555 Fax: (315) 455-2544 Email: cryoservice@cryomech.com Website: www.cryomech.com 7-12...

  • Page 68: Routine Maintenance

    Section 8 Routine Maintenance...
  • Page 69 8.3 Reliquefier/Cold head CAUTION The helium reliquefier contains no user-serviceable parts. Attempting to disassemble the helium reliquefier will void the warranty. CONTACT CRYOMECH IF THE HELIUM RELIQUEFIER NEEDS TO BE RETURNED FOR SERVICING. 8.4 Replace the adsorber Required tools: Quantity...
  • Page 70 6) Loosen and disconnect the hose clamp that attaches the adsorber to the front panel. 7) Remove the adsorber from the compressor package. 8) Check the Aeroquip couplings for oil residue. If oil is present, contact Cryomech for further assistance.
  • Page 71 Routine Maintenance 8.5 Vent excess helium Required tools: Quantity Description Comment 3/4” Open end wrench For Aeroquip coupling Service Aeroquip coupling For service access port CAUTION Venting more than 5 PSIG (.34 bar / 34 kilopascal) of helium per minute will lead to improper oil migration within the system.
  • Page 72 Routine Maintenance 1) Turn the system off. 2) Allow the entire system, both the compressor package and the cold head, to come to room temperature. 3) Use only high purity helium with a minimum purity of 99.999%. 4) Check that the helium source and regulator are capable of pressurizing to the desired pressure.
  • Page 73 Routine Maintenance Line to Helium  Vent Valve  Tank  Vacuum  Sending Unit  Relief Valve Vacuum Valve  Charging Lines  Service  Aeroquips  Figure 8-4: Close up of vacuum/charging manifold and pump 8) Evacuate to 50 microns. 9) Isolate the vacuum pump and add 50 PSIG (3.4 bar / 340 kilopascal) of helium. 10) Vent the helium and repeat steps 8 &...
  • Page 74 Helium flex lines The helium flex lines must be handled with care. If they become damaged and need to be replaced, new ones must be obtained from Cryomech and installed using the directions in the installation section of this manual.
  • Page 75 Routine Maintenance Main power cord If the power cord becomes damaged, a replacement should be obtained from Cryomech. Cold head motor cord If the cold head motor cord becomes damaged, a replacement must be obtained from Cryomech.
  • Page 76 Appendix A Main Assembly Drawing Reliquefier Stand Assembly (Optional) Mounting the Reliquefier to Optional Stand...
  • Page 77 Appendix A Figure A-1: Reliquefier Main Assembly Drawing...
  • Page 78 Appendix A Reliquefier Stand Assembly Tools Required:  ¼” hex wrench  (2) ½” wrench’s  7/16” wrench 1) Carefully unpack the main beam assembly and base assembly. 2) Using a ¼” hex wrench, loosen the main beam side supports only enough to be able to move them and slide them towards the corners.
  • Page 79 Appendix A 3) Place the main beam in between the two side supports and slide the main beam mounting hardware into place. Be sure the winch faces the side of the base assembly with the single rear post mounted to it. Do not fully tighten the hardware down. Note: This is step takes two people to complete.
  • Page 80 Appendix A 5) Install all the main beam side support hardware using the method shown for each bolt/washer combination. A) Remove one bolt from the washer B) Slide the mounting hardware up C) Tighten the bolt with using the ¼” hex wrench as support using the wrench, lining the threads up the ¼”...
  • Page 81 Appendix A 7) Remove (3) of the (4) rear post cap bolts and swivel the cap away from the counter weight tank as shown by loosening the fourth bolt. 8) Install the rear support beam onto the rear post by sliding it vertically (depicted below) while keeping the mounting hardware loose.
  • Page 82 Appendix A 9) Using the method of installation in step 5, mount the opposite side of the rear support beam that attaches to the main beam. 10) With the rear support beam able to slide vertically on the main beam and single post on the rear of the base assembly, slide the rear support beam until it is just below the bottom of the winch (this is for ease of hardware installation).
  • Page 83 Appendix A 11) Install the Reliquefier top support bracket using (4) 5/16”-18 x 1” mounting bolts and nuts as shown in pictures. Top Support Bracket 12) Install the Reliquefier bottom support bracket using the bottom (2) 5/16”-18 x 1” mounting bolts and nuts.
  • Page 84 Appendix A 13) Crank the winch handle to give slack in the steel cable until the loop in the cable reaches the top hole of the Reliquefier bottom bracket and install the cable retaining bolt as shown. 14) Install the other (2) 5/16”-18 x 1” mounting bolts and nuts being sure to tighten all (4) bolts.
  • Page 85 Appendix A 15) Fill the counter weight tank with water and using the post level, level the stand before mounting Cryomech Reliquefier. Post Counter Level Weight Tank Fill...
  • Page 86 Appendix A Mounting the Reliquefier to Optional Stand 1) Carefully place the Reliquefier on a stable flat surface relatively close to the Reliquefier stand. 2) Unscrew the protective cap on the drain leg. While supporting the shipping tube, remove the screw that holds the shipping tube to the mounting plate of the Reliquefier assembly.
  • Page 87 Appendix A 5) Adjust the lower bracket on the stand so that the drain leg has enough clearance to avoid damage. Apply the brake on the lower bracket bearing. Adjust the upper bracket so that it is approximately 24" from the bottom bracket. 6) Carefully mount the Reliquefier on the lower mounting bracket with the drain leg located opposite the vertical post on the stand.
  • Page 88 Appendix A Adjust the Reliquefier mounting plate so that the mounting holes on the mounting plate align with the mounting holes on the lower bracket. Secure the Reliquefier to the bracket using the five (5) 5/16-18 UNC-2B screws supplied. 10) Tighten the screw securing the Reliquefier to the upper bracket. 11) Complete installation per Section B of the Reliquefier manual.

  • Page 89: Spray Lubricant Instructions

    Appendix B Spray Lubricant Instructions...
  • Page 90 Failure to follow these instructions will cause performance degradation and will void the warranty on your system. The purpose of this work instruction is to document the proper use of TFL-50® Dry Lube on Cryomech systems with Aeroquip® connectors. Related documents and work instructions: TFL-50® MSDS Connection, Installation 1.
  • Page 91 Appendix B b. Make certain the flat gasket is properly seated in the male Aeroquip®. Flat Gasket Figure B-2: Cleaning the male Aeroquip® 2. Thread the female Aeroquip® onto the male by hand, until tight. Figure B-3: Female to male connection, hand tightened CAUTION Never apply lubricant to the open ends of the Aeroquips®.
  • Page 92 Appendix B Figure B-4: Typical amount of lubricant 4. Apply a small amount of TFL-50® to the swivel portion of the female Aeroquip®. Swivel portion Figure B-5: Apply lubricant to swivel portion 5. Apply a small amount of TFL-50® to the threaded portion of the male Aeroquip®. Threaded portion Figure B-6: Apply lubricant to threaded portion 6.
  • Page 93 Appendix B Disassembly 1. Apply a small amount of TFL-50® to the swivel portion of the female Aeroquip® as shown in Figure B-5. 2. Use wrenches to loosen and remove the Aeroquips® (see manual for instructions). 30Jan07...

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