HC - 4 MK2 HELIUM COMPRESSOR

TECHNICAL MANUAL

APD CRYOGENICS INC

1833 Vultee Street
Allentown, PA 18103

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REVISION A: August 1995 261803A

 TABLE OF CONTENTS

INTRODUCTION 3-1
Helium Compressor Model HC-4 MK2 3-1

PRINCIPLES
. OF OPERATION . 3-1

DESCRiPTION 3-3
Components 3-3

SPECiFiCATIONS 3-8
Electrical Characteristics 3-8
Cooling Requirements 3-8
Helium Gas Pressures 3-9
Compressor Lubricant. 3-9
Compressor Weight 3-9
Mounting Position 3-9
Installation Kit. 3-9
Dimensions 3-10

MAINTENANCE 3-11
Adsorber Replacement 3-12
Adsorber Removal 3-12
Adsorber Installation 3-13
Used Adsorber Venting and Disposal 3-14
Venting Procedure to Vent to Atmospheric Pressure 3-14
Gas Cleanup 3-15

TROUBLESHOOTING 3-18
Automatic Shutdown 3-18
Measure Resistance Values of Components 3-21
Compressor Motor 3-21
Winding Continuity, Grounding and Resistance 3-22
Current Measurement 3-23

PARTS 3-25
Ordering 3-25
Parts Identification and Numbers 3-27

iii - i
ILLUSTRATIONS LIST
Fig. 3.1 HC-4MK2 Flow Diagram 3-2
Fig. 3.2 Parts Identification 3-4
Fig. 3.3 Parts Identification 3-6
Fig. 3.4 Electrical Chassis Parts Identification 3-7
Fig. 3.5 HC-4 MK2 Outline Dimensions 3-10
Fig. 3.6 HC-4 MK2 Wiring Diagram 3-19
Fig. 3.7 HC-4 MK2 Electrical Schematic 3-20
Fig. 3.8 Compressor Terminals 3-23
Fig. 3.9 Parts Identification 3-26
Fig. 3.10 Parts Identification 3-28

RLE/dmk
261803A.DOC

iii - ii
 INTRODUCTION

Helium Compressor Model HC-4 MK2

The HC-4 MK2 Compressor is a single-stage, water-cooled, rotary compressor designed to

deliver high-pressure, oil-free, helium gas to cryogenic refrigerators. An expander cable
connected to the compressor supplies electrical power to the expander. Self-sealing couplings
allow for easy connection to and disconnection from the rest of the closed-cycle cryogenic
refrigeration system.

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 supply line to the
expander. See Fig. 3.1.

When gas leaves the compressor, it 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 the gas is cooled. Next, the gas passes through the oil
separator and the adsorber for oil and moisture removal. From the adsorber, the high
pressure gas is piped to the expander.

Through the system gas return line, low-pressure gas from the expander flows into the
compressor.

A gas line containing an internal bypass valve connects the high-pressure line to the low-
pressure line. The bypass valve will open to prevent overloading the motor when the system
gas lines are not connected to the compressor.

Oil is separated from the gas in three stages. The first stage is by precipitation when the gas
passes over the motor windings. The second-stage is the oil separator whose element collects
oil mist from the gas, agglomerates it and returns the oil to the compressor. The third stage is
the adsorber which removes any remaining oil the gas is carrying.

Oil collected in the separator flows back to the compressor through a capillary tube. The
differential gas pressure across the system is the moving force, and the capillary size limits the
amount of gas bypassed. The small amount of oil collected in the adsorber remains there and
is removed only by replacing the adsorber.

Oil in the compressor housing also collects heat. The shell-wrapped heat exchanger removes
heat from the compressor motor and the warm oil by direct conduction through the compressor
shell. Gas pressure pushes oil through the heat exchanger's outer tubes which cool the warm
oil from the compressor. This cooled oil is then reinjected into the gas return line, which
returns the oil to the compressor to reabsorb heat and lubricate the compressor.

3-1
 PRINCIPLES OF OPERATION

1. Oil Line Filter 11. Surge Bottle

2. Oil Differential Pressure Switch 12. Pressure Gauge
3. Oil Injection Orifice 13. Gas Equalization Solenoid Valve
4. Heat Exchanger 14. Gas Supply Coupling
5. Compressor 15. Gas Return Coupling
6. Oil Separator 16. Water Supply Fitting
7. Oil Capillary Filter 17. Water Return Fitting
8. Oil Capillary 18. Pressure Relief Valve
9. Adsorber 19. Temperature Overload Switch
10. Internal Bypass Valve 20. Water Solenoid Valve

Fig. 3.1 HC-4 MK2 Flow Diagram

3-2
 DESCRIPTION

The components of the HC-4 MK2 Compressor are identified schematically in Fig. 3.1. Figures
3.2,3.3 and 3.4 identify the parts pictorially. Features and functions of individual components
are described in the following paragraphs.

Components

Gas Supply and Return Couplings -- Both are self-sealing bulkhead couplings and are the
points of connection on the rear panel for the rest of the system.

Water Supply and Return Fittings -- Both fittings are compression-type bulkhead fittings
mounted on the rear panel, for 3/8" tubing.

Compressor Power Cord -- Terminating with a 3-prong plug, this power cord supplies
electrical power to the compressor.

Elapsed Time Meter -- The battery-operated LCD elapsed time meter shows the
compressor's cumulative runining time in hours up to a total of 99,999 hours.

WARNING

THE 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.

Power Switch -- This on/ off switch starts and stops the compressor. The switch lights to
indicate that power is on to the compressor.

Pressure Gauge -- A pressure gauge indicates gas supply pressure. When the compressor
is not running, the gauge shows the equalization pressure.

Expander (Displacer) Receptacle and Expander Cable -- A 28-socket receptacle mounted

on the rear panel and an expander cable supply electrical power from the compressor to the
expander.

Accessory Receptacle and Optional Cables -- The accessory receptacle mounted on the.
rear panel is a 14-socket connector for supplying auxiliary power or remote on/ off control. The
remote on/ off and auxiliary power cables are available as options.

Circuit Breaker -- A panel mounted circuit breaker in the main power supply protects the
compressor module from electrical overload.

Fuses -- Two 0.6 ampere fuses in the expander circuit and one 0.6 ampere fuse in the
primary of the control transformer are accessible in the rear panel. Two 5 ampere fuses in the
auxiliary power circuit (from the accessory receptacle) are located in the electrical chassis.

3-3
 DESCRIPTION

Electrical Chassis Box -- The electrical box contains electrical components and connections
and distributes power to all system circuits. It is accessible by removing the top cover of the
compressor.

TEMPERATURE OVERLOAD ELECTRICAL

SWITCH BOX

CIRCUIT
BREAKER

OIL DIFFERENTIAL-
PRESSURE SWITCH
REAR PANEL

Fig. 3.2 Parts Identification

3-4
 DESCRIPTION

Compressor -- The rotary, positive displacement compressor is hermetically sealed.

Electrical connections to the motor are made at terminals under a protective cover on top of
the housing.

The lubricant is a synthetic oil put in the compressor at the factory. Thereafter, oil is not
changed or added. The oil fill fitting on the top of the compressor housing must not be
opened.

Heat Exchanger -- The heat exchanger consists of three coils wrapped around the
compressor. One cools helium, another cools the compressor shell and another cools oil in
the oH injection circuit. This circuit cools oil that has absorbed heat from the compressor and
reinjects the cooled oil, which continues to absorb heat from the compressor.

Temperature Overload Switch -- Installed under the electrical terminal box cover on top of
the compressor, this switch senses compressor temperature through contact with the housing.
The switch opens the control circuit at a predetermined temperature and resets automatically
upon cooling.

Gas Equalization Solenoid Valve -- This solenoid valve opens when the compressor is
stopped. The valve allows the helium gas pressure across the compressor to equalize, to
prevent oil from being blown out of the compressor into the low-pressure gas line.

Oil Separator -- The bottom of the oil separator serves as a sump. A retainer plate above
the sump supports fibrous material that acts as the separating agent. Entrained oil coalesces
on it, forming large droplets which drain into the sump. This unit needs no servicing or
replacement.

Oil Capillary -- The capillary returns oil collected in the separator sump to the low-pressure
side of the compressor for recycling.

Adsorber -- The adsorber removes any oil and moisture the gas is carrying which did not
drop out in the separator. This vessel contains activated charcoal for oil adsorption. The
adsorber has a finite life and must be replaced every 10,000 operating hours. I

Pressure Relief Valve -- The relief valve prevents the compressor from operating at an
unsafe pressure.

Oil Filters -- There are two oil filters. One filter in the oil separator drain line protects the
return oil capillary. The other filter in the oil injection circuit protects the compressor.

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 compresor's gas return line.

Surge Bottle -- The surge bottle located in the return gas line dampens the pressure
pUlsations.

3-5
 DESCRIPTION

PRESSURE-RELIEF VALVE

POWER SWITCH
.- ELAPSED-TIME METER

- PRESSURE GAUGE

- FRONT PANEL

EQUALIZATION
~ SOLENOID VALVE
ADSORBER -.:-:::=

INTERNAL-RELIEF VALVE

FIg.3. 3
o Parts Identification

3-6
 DESCRIPTION

Oil Differential Pressure Switch -- This switch shuts down the compressor if oil injection flow
is too low or too warm for proper operation.

Internal Bypass (Relief) Valve -- The internal bypass valve opens to allow the compressor to
be run when the system gas lines are disconnected, to avoid overloading the motor.

Transformer -- Some 50 Hz applications include an externally-mounted transformer on the

rear panel of the compressor. See Specifications.

Water Solenoid Valve -- This normally closed solenoid valve opens when the compressor
starts to allow cooling water to flow.

./

MOTOR
RELAY

FUSES CIRCUIT DISPLACER TIME START ACCESSORY RUN START

(3) BREAKER RECEPTACLE DELAY RELAY RECEPTACLE CAPACITOR CAPACITOR
RELAY

Fig. 3.4 Electrical Chassis Parts Identification

3-7
 SPECIFICATIONS

Electrical Characteristics

Compressor Customer's Compressor

Part Number Electrical Transformer
Suffix Service Requirement

18G 208/230 VAC (± 5%) None

1 ph, 60 Hz

18G 200 VAC (± 5%) None

1 ph, 50 Hz

15G 220 VAC (± 5%) Transformer included,

1 ph, 50 Hz wired for step down
to 200 VAC.

16G 230/240 VAC (± 5%) Transformer included,

1 ph, 50 Hz wired for step down
to 200/208 VAC.

Power Required: 3.0 kW, 15.5 amps full load at 208 VAC; 68 amps locked rotor.

Power Cord Connector: NEMA L6-30P (2 Pole, 3 Wire, 30 A, 250 VAC) male plug to connect
to customer's receptacle.

Cooling Requirements

Room Ambient Temperature: 10° C to 38° C (50° F to 100° F)

Cooling Water Inlet Temperature: 4° C to 27° C (40° F to 80° F)
Cooling Water Outlet Temperature: 41° C (105° F) maximum
Cooling Water Pressure: 210 kPa (30 psig) minimum
690 kPa (100 psig) maximum
Cooling Water Flow: 2.7litersl min (0.7 gpm) minimum
Pressure Drop at Minimum Flow: 85 kPa (12 psi)
Water Chiller Cooling Capacity: 11,000 BTUI hour

NOTE

Operating the equipment out of specifications may void the warranty.

3-8
 SPECIFICATIONS

Helium Gas Pressures

Compressor Only With M204S Expander

Equalization Pressure at 68°F: 240 - 245 psig 240 - 245 psig

(1650 - 1690 kPa) (1650 - 1690 kPa)

Operating Supply Pressure: 300 - 320 psig 280 - 300 psig

(2070 - 2210 kPa) (1930 - 2070 kPa)

Equalization Pressures at Different Ambient Temperatures:

roc P kPa To F P psig

10 1600 - 1630 50 232 - 237

15.6 1630 - 1660 60 236 - 241
20 1650 - 1690 68 240 - 245
26.7 1690 - 1730 80 245 - 250
37.8 1750 - 1790 100 255 - 260

Pressure Relief Valve is set at 2750 kPa (400 psig).

Compressor Lubricant

UCON L8-300-X, specially processed by APD.

Compressor Weight 91 kg (200 pounds)

Mounting Position

Compressor must be mounted with its base down and level within 5 degrees.

Installation Kit

An installation kit, PIN 255437A, is furnished with the HC-4 MK2 Compressor.
The kit contains:

Item Quantity Description Part Number

1 12 m (40 Ft) Polyethylene Tubing, 3/8" 00 60751

2 2 Sets Swagelock Front and Rear Ferrules for 17567

3/8" 00 Tubing

3 2 Swagelock Nuts for 3/8" 00 Tubing 12341

4 1 Adapter Fitting, 8F with Valve 25591982

3-9
 SPECIFICATIONS

Dimensions

Dimensions are in millimeters and (inches).

IAI( 435 (17 1/8) ~ I I

508 (20) - - - - - -.~.

-..,.---.-

~Ai:~
452
(17 13/16)

514
(201/4)

62 (2 7/16)

Fig. 3.5 HC-4 MK2 Outline Dimensions

3 - 10
 MAINTENANCE

WARNING

DISCONNECT GAS LINES ONLY WHEN THE COMPRESSOR IS

STOPPED. DISCONNECTING THE EXPANDER WHILE IT IS COLD
MAY CREATE EXCESSIVELY HIGH INTERNAL PRESSURE AS
THE GAS WARMS. MATERIAL FAILURE AND UNCONTROLLED
PRESSURE RELEASE CAN CAUSE INJURY TO PERSONNEL
IN THE WORK AREA.

WARNING

THE COMPRESSOR IS CHARGED WITH HELIUM GAS. VENT

THE COMPRESSOR TO ATMOSPHERIC PRESSURE BEFORE
DISASSEMBLY, EXCEPT WHEN DISCONNECTING ADSORBER
OR GAS LINES. UNCONTROLLED PRESSURE RELEASE CAN
CAUSE INJURY TO PERSONNEL IN THE WORK AREA.

WARNING

NEVER USE COMPRESSED GAS FROM A CYLINDER WITHOUT

A PROPER REGULATOR. OVERPRESSURIZATION CAN CAUSE
PERSONAL INJURY IF THE SYSTEM EQUIPMENT RUPTURES.

WARNING

DURING OPERATION, SOME SURFACES UNDER THE

COMPRESSOR'S COVER BECOME HOT. AVOID INJURY FROM
BURNS BY ALLOWING THE COMPRESSOR TO COOL FOR 1/2
HOUR AFTER SHUTDOWN BEFORE REMOVING THE COVER
FOR MAINTENANCE.

WARNING

WHEN HANDLING PRESSURIZED GAS LINES AND OTHER

PRESSURIZED EQUIPMENT, ALWAYS WEAR EYE PROTECTION.

WARNING

NEVER APPLY HEAT TO A PRESSURIZED GAS LINE OR OTHER

PRESSURIZED COMPONENTS.

3 -11
 MAINTENANCE

CAUTION

MODIFICATION TO EQUIPMENT WITHOUT THE CONSENT OF

THE MANUFACTURER WILL VOID THE WARRANTY.

CAUTION

FOLLOW CHARGING AND VENTING PROCEDURE TO PREVENT

REVERSED FLOW OF SYSTEM GAS. REVERSED FLOW CAN
RESULT IN CONTAMINATION OF THE SYSTEM WITH THE
COMPRESSOR OIL.

CAUTION

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 MAY FREEZE IN THE EXPANDER.

CAUTION

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.
REPLACE THE GASKET SEAL IF IT IS DAMAGED OR MISSING.

CAUTION

DO NOT ALLOW AIR TO GET INTO THE SYSTEM. MOISTURE

FROM THE ATMOSPHERE CAN SERIOUSLY DEGRADE
EXPANDER PERFORMANCE.

Adsorber Replacement
/3,n; T, ! i

The adsorber must be replaced every 10,000 operating hours. The used adsorber has no
salvage or repair value. Venting of the compressor is not required when replacing the
adsorber, because the couplings are self-sealing.

Adsorber Removal

1. Stop the compressor and disconnect the power to the compressor.

2. Disconnect the supply gas line from the supply coupling on the compressor. Screw a dust
plug into the disconnected gas line coupling.

3 -12
 MAINTENANCE

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. Remove the compressor's cover.

NOTE

Trace the outline of the adsorber on the compressor base to help

locate the proper position of the new adsorber.

4. Disconnect the self-sealing coupling on the tube from the oil separator to the inlet side
of the adsorber.

5. Elevate the compressor to gain access underneath the bottom panel. Use a 9/16"
wrench to remove the 3/8" cap screw and lock washer holding the adsorber to the base.

CAUTION

DO NOT TIP THE COMPRESSOR GREATER THAN 5 DEGREES,

TO AVOID FLOWING OIL INTO UNWANTED PLACES AND
CAUSING A NUISANCE SHUTDOWN.

6. Remove the lock nut and nylon washer on the supply coupling on the rear panel.

7. Pull the adsorber back until the supply coupling clears the rear panel. Remove the
adsorber. Remove the lock washer from the Aeroquip supply coupling. Retain all
hardware to use with the new adsorber.

WARNING

THE ADSORBER IS CHARGED WITH HELIUM GAS. FOLLOW

THE ADSORBER VENTING PROCEDURE FOR SAFE DISPOSAL
OF THE USED ADSORBER.

Adsorber Installation

1. Remove the caps from the gas lines of the new adsorber. Do not vent the new
adsorber.

2. Position the adsorber on the base within the traced line and insert the supply coupling
through the rear panel. Be sure the lock washer is installed on the coupling prior to
inserting it through the rear panel.

3 -13
 MAINTENANCE

3. Apply Locktite 242 to the threads of the cap screw used to fasten the adsorber to the
base. Install and tighten this cap screw and lock washer. Torque the cap screw to
3.5 kgf m (25 ft. Ibs.). Lower the elevated compressor to the floor.

4. Install the nylon washer and the locknut on the supply coupling. Torque the locknut to
5.5 kgf m (40 ft. Ibs.).

5. Connect the adsorber's self-sealing coupling on its inlet side to the oil separator's outlet
coupling. With wrenches, torque the size 4 Aeroquip coupling to 1.4 to 2 kgf m (10 to
15 ft. Ibs.).

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. Ibs.).

7. Leak check all Aeroquip couplings just completed. See Leak Checking in the
Maintenance section of the System Manual.

8. Check the equalization pressure. See Specifications in this manual.

9. Reinstall the compressor's cover.

This completes the procedure for replacing an adsorber.

Used Adsorber Venting and Disposal

For safe disposal of the used adsorber:

1. A venting adapter fitting is included with the new adsorber. Attach it to one of the self-
sealing couplings on the used adsorber. Vent the used adsorber to atmospheric
pressure.

2. Discard the used adsorber and the adapter fitting.

Venting Procedure to Vent to Atmospheric Pressure

This procedure includes disconnecting the adsorber to prevent venting it.

1. Stop the compressor and disconnect the power to the compressor.

2. Disconnect both the supply and return gas lines from the couplings on the compressor.
Screw dust plugs into the disconnected gas line couplings.

3. Remove the compressor's cover.

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.

3 -14
 MAINTENANCE

5. Locate adapter fitting PIN 257246C2. Also locate adapter fitting PIN SK8217A2 and be
sure its valve is closed. Move the part of the supply line fastened to the adsorber out of
the way. Connect the adapter fittings to the female Aeroquip coupling on the supply line
from the oil separator.

6. Slowly open the valve on the adapter fitting. Vent the system to atmospheric pressure.
Close the valve on the adapter fitting.

7. Remove the adapter fittings.

8. Perform the required maintenance.

NOTE

Do not reconnect the adsorber if the compressor has been vented to

atmospheric pressure.

This completes the procedure to vent the compressor to atmospheric pressure.

Gas Cleanup

Gas cleanup is required if the compressor's interior has been opened to the atmosphere
or the equalization pressure is 140 kPa (20 psig) or lower. Gas cleanup is performed
with the compressor disconnected from the other system components. The adsorber
must be disconnected unless it also has been opened to the atmosphere or its charge
pressure is less than 140 kPa (20 psig).

NOTE

If the compressor's interior has been exposed to the atmosphere

for an extended period, gas cleanup may not suffice to guarantee
system gas purity and adsorber replacement will be required.

1. Disconnect the gas lines from the compressor. Screw dust plugs into the disconnected
gas line couplings.

2. Locate two adapter fittings PIN 25591982. 8e 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 adapter fittings

PIN 257246C2 and PIN SK8217A2 to the supply line from the oil
separator, for venting the compressor during this procedure.

3. Connect a charge line to the pressure regulator of a helium gas cylinder containing
99.995% pure helium gas with a dew point less than -50 0 C (-58 0 F) at 2065 kPa
(300 psig). Adjust the gas cylinder pressure regulator to 35 kPa (5 psig).

3 -15
 MAINTENANCE

4. While connecting the charge line to the adapter fitting on the compressor's return
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. Adjust the pressure regulator to 1520 kPa (220 psig). Open the valve on the adapter
fitting and charge the compressor to 1520 kPa (220 psig). If the adsorber is connected,
increase the charge pressure to 1690 kPa (245 psig).

6. Close the valve on the adapter fitting used for charging.

7. Run the compressor for at least 30 minutes to heat the oil to operating temperature. Stop
the compressor.

8. Adjust the pressure regulator to 690 kPa (100 psig).

9. Open the vent valve on the supply coupling of the compressor. Watch the compressor's
pressure gauge. When the pressure falls to 35 to 70 kPa (5 to 10 psig), close the vent
valve. Open the charge valve to build the pressure back up to 690 kPa (100 psig).
Close the charge valve.

10. Repeat Step 9 five (5) times.

11. Adjust the pressure regulator to the equalization pressure of the system. See
Specifications.

12. Open the valve on the adapter fitting and charge the compressor to the equalization
pressure. Close the charge valve on the adapter fitting. Start the compressor.

13. After running 30 to 45 seconds, stop the compressor. Open the vent valve and vent the
compressor to 35 to 70 kPa (5 to 10 psig). Close the vent valve.

14. Repeat Steps 12 and 13 five (5) times; then go to Step 15.

15. Open the charge valve on the adapter fitting. Charge the compressor to the equalization
pressure. See Specifications in this manual. Close the charge valve.

16. Allow the compressor to cool. Read the pressure gauge with the compressor at 20 0 C
(68 0 F). Adjust the equalization pressure by charging or venting to conform to the
Specifications.

17. Close the gas cylinder valve and adjust the pressure regulator to zero psig.

18. Disconnect the charge line from the adapter fitting. Store the charge line to keep it clean.

19. Remove both adapter fittings.

3 -16
 MAINTENANCE

NOTE

Reconnect the adsorber if it was disconnected prior to gas cleanup.

Torque the Aeroquip coupling to 1.4 to 2 kgf m (10 to 15 ft. Ibs.).

20. If other components need cleaning, refer to the procedure in their manuals. Otherwise,
reconnect the supply and return gas lines. Torque the couplings
to 4.85 ± 0.7 kgf m (35 ± 5 ft. Ibs.).

21. Leak check the Aeroquip couplings. See Leak Checking in the System manual.

This completes the gas clean-up procedure for the compressor.

3 - 17
 TROUBLESHOOTING

Automatic Shutdown

The compressor will shut down automatically if any of the following are open:

• the oil differential pressure switch

• the compressor temperature overload switch
• the motor over-current relay
• the circuit breaker or a control circuit fuse.

If the compressor has been shut down by one of these interlocks, do not restart until the
problem has been found and corrected. Refer to the Troubleshooting Guide to identify the
problem.

If the shut down was caused by the oil differential pressure switch, wait until the pressure
gauge indicates the equalization pressure. The compressor should start by turning the power
switch off, then on.

If the unit shuts down again, refer to the Troubleshooting section to determine the cause and
corrective action.

When the shut down is caused by the temperature overload switch, the compressor will restart
only after it has cooled enough for the switch to close. Press the power switch to off. After
waiting for the compressor to cool, press the power switch to restart. Should the compressor
fail to start, turn it off and allow more cooling time. Repeat the restart procedure.

The motor over-current relay, mounted inside the compressor motor, is temperature
dependent. It will automatically reset after the relay has cooled. To restart the compressor,
press the power switch to the on position. If the compressor fails to start, turn it off and allow
more cooling time. Repeat the start procedure.

If the circuit breaker opens, reset the breaker by pushing its lever to the up position.

If a fuse is open, disconnect the compressor power cord, replace the fuse, then restart the
compressor.

Refer to the Troubleshooting Guide in the System manual and the following procedures
for checking the electrical components of the compressor.

3 -18
 TROUBLESHOOTING

, I

.
c•

Cl
~..CT
U'f'.

r:-9
7S...fJ.
R
uHE- .

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r-.L-.....~_"'....J''C.~-t----_...L_....J

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Fig. 3.6 HC-4 MK2 Compressor Wiring Diagram

3 -19
 TROUBLESHOOTING
rr~tP

, ')

Fig. 3.7 HC-4 MK2 Compressor Electrical Schematic

3 - 20
 TROUBLESHOOTING

Measure Resistance Values of Components

The values listed below are approximate and are intended to be used as guides. Disconnect
any wires from the component to be checked or disconnect the component from the circuit
before measuring its resistance.

Component Resistance

Control Circuit Transformer Primary 40 ohms

Control Circuit Transformer Secondary ! 12 ohms l(\?:l n 1/'

Motor Relay Coil 300 Ohms

Gas Equalization Solenoid Valve Coil 94 ohms

Start Relay Coil 14,400 ohms

/ Water Solenoid Valve Coil 380 ohms

(~ Time Delay Relay Coil Solid State, Normally Open Coil.

Compressor Motor

Compressor motor checks for winding continuity, resistance and grounding will isolate most
motor electrical problems. Current measurements will separate a locked rotor condition from
other electrical problems. When the checks indicate a faulty compressor, a replacement is
needed. Contact an APD Service Center.

WARNING

DISCONNECT THE POWER TO THE COMPRESSOR BEFORE

TROUBLESHOOTING THE ELECTRICAL COMPONENTS.

WARNING

DURING OPERATION, SOME SURFACES UNDER THE

COMPRESSOR'S COVER BECOME HOT. AVOID INJURY FROM
BURNS BY ALLOWING THE COMPRESSOR TO COOL FOR 1/2
HOUR AFTER SHUTDOWN BEFORE REMOVING THE COVER FOR
MAINTENANCE.

3 - 21
 TROUBLESHOOTING

WARNING

PERMIT ONLY QUALIFIED ELECTRICAL TECHNICIANS TO OPEN

ELECTRICAL ENCLOSURES, TO PERFORM ELECTRICAL CHECKS
FOR TO PERFORM TESTS WITH THE POWER SUPPLY
CONNECTED AND WIRING EXPOSED. FAILURE TO OBSERVE
THIS WARNING CAN RESULT IN INJURY OR DEATH FROM
ELECTRIC SHOCK.

Winding Continuity, Grounding and Resistance

1. Disconnect the power to the compressor.

2. Remove the compressor's cover.

3. Remove the terminal box cover from the top of the compressor motor to expose the three
terminals R, S, and C. See Fig. 3.8. Disconnect wires 40, 60, and 30 from terminals R, S,
and C respectively.
I
4. With an ohmmeter, check the resistance across compressor terminals C and R.
Resistance should be 0.8 to 1.2 ohms. If the resistance is outside this range, consult
an APD Service Center. If there is no continuity, the winding is open. Consult an APD
Service Center.
'd.' I
5. With an ohmmeter, check the tesistance across compressor terminals C and S.
Resistance should be 1.8 to '2.2 ohms. If the resistance is outside this range, consult
an APD Service Center. If there is no continuity, the winding is open. Consult an APD
Service Center.

6. With an ohmmeter, check for continuity between compressor terminal C and one of
the copper tubes entering the compressor housing. If there is continuity, the motor is
grounded. Consult an APD Service Center. ex.

7. If the motor passes these electrical checks, reconnect wires 40,60, and 30 to compressor
terminals R, S, and C respectively.

8. Replace the terminal box cover and the cover of the compressor module, unless current
measurement is to be performed.

3 - 22
 TROUBLESHOOTING

Compressor Motor Terminals

Temperature
Overload Switch

.
., Fig. 3.8 Compressor Terminals

Current Measurement

1. Disconnect the power to the compressor.

2. Remove the compressor's top cover and the cover from t ctrical chassis box.

3. Clamp the ammeter onto one of the power wires on the ,.

breaker. The current can range up to 70 amperes. Use a·
clamp-on ammeter.

4. Reconnect the power to the compressor.

5. Start the compressor.

6. Read the ammeter, then stop the compressor.

• A reading of 0 amps indicates an open circuit.

• A reading of 14 to 20 amps is normal at steady-state operating conditions.

3 - 23
 TROUBLESHOOTING

• A reading of 20 to 40 amps indicates a defective relay, start-run capacitor, or

bad motor windings. Check the resistance of each to detect the faulty
component.

• A reading of 68 amps indicates a locked rotor. Consult an APD Service Center.

• A reading of full scale, along with a tripped circuit breaker or a blown control
circuit fuse, indicates a short circuit in the chassis wiring or motor.

7. Remove the ammeter.

8. Replace the electrical chassis box cover and the compressor's cover.

'
i~".~.: .
'::, ",
',-.,
');

3 - 24
 PARTS

Ordering

The nameplate fastened to the rear panel of the compressor housing identifies the compressor
as follows:

Model Number
Part Number
Serial Number.

Furnish this complete information when ordering parts. Also, order parts by part number and
name. Refer to the next section for Parts Identification and Numbers.

3 - 25
 PARTS

Fig.3.9 Parts Identification

3 - 26
 PARTS

Parts Identification and Numbers (See Fig. 3.9)

Item Part Name Part Number

1 Compressor Assembly 256035E

2 O-Ring (2), Size 4 Aeroquip Coupling 77183
3 Caster (4) 49133
4 Pressure Relief Valve 53028
5 Adsorber Assembly F256390A
6 Internal By-Pass Valve 270067A
7 Oil Capillary Filter 50315
8 Gas Equalization Solenoid Valve 254990C
9 Pressure Gauge, Panel Mount, 2-lnch Dial 50532
10 Oil Separator Assembly 2547320
11 Power Switch 38850
12 Elapsed Time Meter 35008

3 - 27
 PARTS

Fig. 3.10 Parts Identification

3 - 28
 PARTS

Parts Identification and Numbers (See Figs. 3.9 and 3.10)

Item Part Name Part Number

13 Oil Differential Pressure Switch Assembly 256089C

14 Oil Injection Filter Assembly 2550088
15 Oil Injection Orifice 2560668
16 Oil Capillary Assembly 254763C
17 Gasket Seal (2), Aeroquip Coupling 77002
18 O-Ring (2), Aeroquip Coupling 47102
19 Nylon Washer (2), Aeroquip Coupling 72628
20 Lock Washer (2), Aeroquip Coupling 46401
21 Lock Nut (2), Aeroquip Coupling 46101
22 Dust Cap (2), Aeroquip coupling 45301
23 Power Cable 2565078
24 Circuit 8reaker S1, 30AJ 250 VAC/2 Pole 34668
25 Fuse F1, F2, F3, 0.6 amp 34653
26 Fitting (2), Water 14505
27 Gasket Seal, Size 4 Aeroquip Coupling 77003
28 Temperature Overload Switch in Retainer 256034A2
29 Receptacle Cap (2) 34489

3 - 29
 PARTS

Parts Identification and Numbers (See Fig. 3.7)

Item Part Name Part Number

30 Transformer T1, Control Circuit 39409

31 Time Delay Relay 37414
32 Resistor R2; 1,000 ohms 37904
33 Resistor R3; 1,500 ohms 37520
34 Capacitor C1, Start, 75 mfd 256034A10
35 Resistor R1; 47,000 ohms 256034A14
36 Capacitor C2, Expander Circuit, 0.8 mfd 32517
37 Capacitor C3, Run, 40 mfd 256034A11
38 Start Relay K1 256034A13
39 Motor Contactor K2 37104
40 Transformer for 220 VAC, 1 ph, 50 Hz Electrical Service 39417
or
Transformer for 230/ 240 VAC, 1 ph, 50 Hz Electrical Service 39401
41 Water Solenoid Valve 256415C
42 Fuse F4, F5, 5 amp 34665
43 Capacitor C4, 0.4 mfd 32522

3 - 30
 OIL CHARGING VESSEL

TECHNICAL MANUAL

APD CRYOGENICS INC

1833 Vultee Street
Allentown, PA 18103

Revision A: April 1997 263776A

 READ THESE INSTRUCTIONS BEFORE USING THE OIL CHARGING VESSEL

NOTE
File this manual in the Accessory section of your technical manual.

1.0 SCOPE
The following instructions define the proper use of the oil charging vessels
PIN 263775A 1, - A2 and - A3 for helium compressors.

WARNINGS

THE OIL CHARGING VESSEL IS PRESSURIZED WITH 210 kPa (30 psig) HELIUM GAS
AS RECEIVED. AFTER USE IT WILL CONTAIN SYSTEM PRESSURES OF - 2070 kPa
(300 psig). UNCONTROLLED PRESSURE RELEASE CAN CAUSE INJURY TO
PERSONNEL IN THE WORK AREA.
WHEN HANDLING PRESSURIZED COMPONENTS, ALWAYS WEAR EYE PROTECTION.
USE TWO WRENCHES WHEN DISCONNECTING THE OIL CHARGING VESSEL FROM
THE COMPRESSOR TO AVOID LOOSENING THE COMPRESSOR OIL FILL COUPLING.
NEVER APPLY HEAT TO A PRESSURIZED COMPONENT.
WHEN VENTING THE USED OIL CHARGING VESSEL, AIM THE EXHAUST FROM THE
VENTING ADAPTER AWAY FROM PERSONNEL TO PREVENT INJURY DUE TO THE
RELEASE OF HELIUM GAS AND REMNANT OIL.

CAUTIONS

BE SURE THE GASKET SEAL IS IN PLACE AND CLEAN ON THE MALE AEROQUIP OIL
FILL COUPLING ON THE TOP OF THE COMPRESSOR MOTOR.
DO NOT ALLOW AIR TO GET INTO THE COMPRESSOR. KEEP THE COUPLINGS
ALIGNED WHEN CONNECTING THE OIL CHARGING VESSEL TO THE COMPRESSOR OIL
FILL COUPLING.
VENT THE USED OIL CHARGING VESSEL PER THE PROCEDURE FOR SAFE DISPOSAL
IN SECTION 3.0.
MODIFICATION TO EQUIPMENT WITHOUT THE CONSENT OF THE MANUFACTURER
WILL VOID THE WARRANTY.

2.0 PROCEDURE FOR ADDING OIL TO A COMPRESSOR

2.1 Turn off the compressor.
2.2 Disconnect the electrical power to the compressor.
2.3 Remove the top cover from the compressor.

1
READ THESE INSTRUCTIONS BEFORE USING THE OIL CHARGING VESSEL

2.4 Locate the size 4, male Aeroquip coupling on top of the compressor motor.
This is the oil fill connection. Refer to the schematic diagram, Figure 1,
in this manual.

2.5 Remove the dust cap from the compressor oil fill coupling and retain the cap.
2.6 Unpack a new oil charging vessel. Verify that you have the correct vessel for
the compressor to be charged. Read these instructions. Set aside the separate
male Aeroquip venting adapter.

PART NUMBER OIL QUANTITY COMPRESSOR

263775A1 100 mL HC - 20 Series
263775A2 150 mL HC-4 Series
263775A3 200 mL HC-8 Series

2.7 Remove the dust cap from the oil charging vessel female Aeroquip coupling.
2.8 Check that the mating surfaces of both couplings are clean and that the gasket
seal is in place on the male Aeroquip oil fill coupling.

2.9 Align and thread the oil charging vessel coupling onto the oil fill coupling.
2.10 Use two 3/4" (19 mm) wrenches: one to hold the compressor oil fill coupling
stationary, and one to tighten the oil charging vessel coupling onto it. Tighten
to 1.4 - 1.6 kgf m (1 0 - 12 Ib ft).

2.11 Allow the oil in the charging vessel to drain into the compressor for 3 hours.
2.12 After 3 hours, remove the oil charging vessel. Use two wrenches to avoid
loosening the compressor oil fill coupling.

2.13 Re-install the dust cap on the compressor oil fill coupling.
2.14 Re-install the compressor top cover.
2.15 Re-connect the electrical power to the compressor. The compressor can now be
returned to normal operation.

3.0 PROCEDURE FOR VENTING A USED OIL CHARGING VESSEL

3.1 The oil charging vessel is supplied with a separate venting adapter, consisting of
a male Aeroquip coupling attached to a fitting that contains a small orifice. The
orifice prevents the pressurized helium and remnant oil from venting too rapidly.

3.2 After using the oil charging vessel to add oil to a compressor, align the venting
adapter male Aeroquip coupling with the oil charging vessel female Aeroquip
coupling.

2
READ THESE INSTRUCTIONS BEFORE USING THE OIL CHARGING VESSEL

3.3 DO NOT TIGHTEN THE COUPLINGS TOGETHER UNTIL AFTER YOU AIM
THE EXHAUST FROM THE VENTING ADAPTER AWAY FROM PERSONNEL
TO PREVENT INJURY DUE TO THE RELEASE OF HELIUM GAS AND
REMNANT OIL. Aim the exhaust into a receptacle to catch any oil that may
stream out.

3.4 Tighten the couplings together and vent all the pressure.
3.5 After safely venting, dispose of the empty, depressurized oil charging vessel
in accordance with your local ordinances.

Oil Fill Connector

Gas Return Gas Supply

Surge Bottle Oil Separator Adsorber

Compressor

Figure 1 Compressor Schematic Diagram

3
 CHAPTER 5

GAS LINES

APD CRYOGENICS INC

1833 Vultee Street
Allentown, PA 18103

Revision C: December 1994 261320A

 CHAPTER 5 - GAS LINES

Page

DESCRIPTION . . 5.1

SPECIFICATIONS 5.2
Minimum Bend Radius 5.2
Pressure and Temperature Ratings. 5.2
Identification Labels 5.2
Installation Tools. 5.2

MAINTENANCE . . . . . . . 5.3
Disconnecting Gas Lines 5.3
From the Compressor. 5.3
From the Expander. 5.4
Leak Checking . 5.4
Gas Line Repair . . 5.5
Venting . . . . . . 5.5
Repair Self-Sealing Couplings 5.6
Replace the Gasket Seal . . 5.6
Repair or Replace the Coupling 5.7
Gas Cleanup and Recharging. . . . 5.8
Gas Cleanup and Recharging (Systems Using Nycoi1 Gas Lines) 5.9

PARTS 5.11
Ordering.. . . 5.11
Parts Identification and Numbers. 5.11

ILLUSTRATIONS LIST

Fig. 5.1 Typical Gas Line Construction . . . . . 5.1

Fig. 5.2 Disconnect Gas Line from Compressor . . 5.3
Fig. 5.3 Break Gas Line Connection from Expander 5.4
Fig. 5.4 Disconnect Gas Line from Expander . . . 5.4
Fig. 5.5 Aeroquip Male Coupling Parts . 5.6
Fig. 5.6 Remove Coupling from Gas Line 5.7
Fig. 5.7 Aeroquip Female Coupling Parts 5.7
Fig. 5.8 Parts Identification . . 5.11

RLE/dmk
PL410EN2/48

- v.i -
 DESCRIPTION

Gas lines are needed to connect compressors to expanders to complete the

system. Gas lines are constructed from convoluted stainless steel tubing
covered with metal braid or from soft copper tubing or Nycoil tubing.
All gas lines are equipped with Aeroquip self-sealing couplings and are
furnished cleaned, charged with helium gas and leak checked.

Nycoil gas lines are permeable. Gas can diffuse through the nylon tubing
wall. System equalization pressure may decrease in as little time as two (2)
months. Also, air may diffuse into the gas line and contaminate the system
helium gas with other gases and water vapor.

System performance and adsorber life will be less than that of a system using
stainless steel or copper gas lines.

See special procedures for Gas Cleanup and Recharging in the Maintenance
section.

Each cryogenic system includes interconnecting gas lines to carry helium gas
refrigerant to and from the components. A gas line carries high pressure gas
from the compressor to the expander and another gas line returns lower
pressure gas to the compressor.

Flexible gas lines simplify installation. The self-sealing couplings maintain

the gas charge and purity by minimizing gas loss when connections are being
made or broken and by preventing the entrance of contaminants. Dust plugs
protect the coupling threads from damage and also help to maintain cleanliness.

OUST
FEMALE COUPLING
CONVOLUTED PLUG
~
METAL TUBING

l"ETAL BRAID
ADAPTER
II
lCOUPLING
NUT

Fig. 5.1 Flexible Gas Line Construction

- 5.1 -
 SPECIFICATIONS

Minimum Bend Radius

Diameter Minimum Bend Radius
Gas Line Type mm (inches) mm (inches)

Convoluted Stainless Steel 13 (1/2) I.D. 230 (9)

Copper Tubing, using a 17 (5/8) O.D. 57 (2 1/4)

tube bender

Copper Tubing, without 17 (5/8) O.D. 457 (18)

'a tube bender

NOTE

Working length of a Nycoi1 gas line is two (2)

times its coiled length.

Pressure and Stainless Steel

Temperature Ratings and Copper Nycoil

Design pressure, max. 2760 kPa (400 psig) 2760 kPa (400 psig)
Operating pressure, max. 2410 kPa (350 psig) 1930 kPa (280 psig)
Charge pressure, max. 1860 kPa (270 psig) 1380 kPa (200 psig)
Operating temperature, max. 49°C (120°F) 49°C (120°F)
Operating temperature, min. 4°C, (40°F) 4°C (40°F)

Identification Labels

Labels on the gas lines identify their function in the system as follows:

SUPPLY (color coded red) helium gas supply to the expander

from the compressor.

RETURN (color coded green) helium gas return from the expander
to the compressor.

Separate labels are furnished with standard gas lines for the customer to
attach the labels. See the Installation section in the System chapter.

Installation Tools

Properly sized open end wrenches are needed to install and remove gas lines.

For installation, gas lines with size 8 Aeroquip couplings require one each of
these open end wrenches, contained in wrench kit PIN 255438A:

1" PIN 43800; 1 1/8" PIN 43413; 1 3/16" PIN 43802

For MRI systems with an RF shield, gas feedthroughs may be furnished for
installation through the shield. Wrench kit PIN 260454A contains the above
three wrenches plus a 1 7/8" open end wrench, PIN 43447, to fit the nut on the
magnet side of the gas feedthroughs.

- 5.2 -
 MAINTENANCE

Disconnecting Gas Lines

WARNING

EXTREME COLD CAN CAUSE FROSTBITE. WEN HANDLING

SYSTEM COMPONENTS, BE CAREFUL NOT TO TOUCH ANY
FROSTED PARTS.

WARNING

DISCONNECT GAS LINES ONLY WEN THE COMPRESSOR IS

STOPPED. DISCONNECTING THE EXPANDER WILE IT IS
COLD CAN CREATE EXCESSIVELY HIGH INTERNAL PRESSURE
AS THE GAS WARMS. MATERIAL FAILURE AND UNCONTROLLED
PRESSURE RELEASE CAN CAUSE INJURY TO PERSONNEL IN
THE WORK AREA.

WARNING

USE TWO WRENCHES WEN DISCONNECTING A GAS LINE

COUPLING TO AVOID LOOSENING THE MATING COUPLING.
GAS PRESSURE CAN PROJECT THE COUPLING WITH
ENOUGH FORCE TO CAUSE INJURIES.

CAUTION

KEEP THE GAS LINE COUPLINGS ALIGNED WEN MAKING

OR BREAKING A COUPLING CONNECTION. LEAKAGE CAN
OCCUR DUE TO THE WEIGHT OF THE GAS LINE OR DUE
TO A SHARP BEND NEAR THE CONNECTION.

From the Compressor

1. Always use two wrenches. Use one wrench to hold the coupling
adapter. Use the second wrench to turn the gas line coupling nut
from the compressor coupling. See Fig. 5.2.

2. Screw a dust cap finger tight on to the compressor coupling.

TURN

'-----y-JJ "
GAS LINE COUPLING
COMPRESSOR COUPLING

Fig. 5.2 Disconnect Gas Line from Compressor

- 5.3 -
 MAINTENANCE

From the Expander

1. Always use two wrenches. Use one wrench to hold the expander
coupling. Use the second wrench on the gas line coupling nut to
break the connection. See Fig. 5.3.

2. After breaking the connection, hold the coupling adapter with one
wrench.

Remove the gas line coupling from the expander coupling with the
second wrench. See Fig. 5.4.

3. Screw a dust cap finger tight on to the expander coupling.

TURN TURN

~i

Fig. 5.3 Break Gas Line Fig. 5.4 Disconnect Gas Line
Connection from Expander from Expander

Leak Checking

Leakage of helium gas is the only likely problem to originate on a gas line.
Use of a helium mass spectrometer leak detector is recommended. If no mass
spectrometer is available, a liqUid leak detector solution may be used on the
coupling joints.

With the gas lines connected to the compressor and to the expander, leak check
the connected coupling joints.

The flat gasket in the face of the male coupling seals the joint. A leak at
this gasket seal can be detected only when a gas line is connected. A leak
here can be caused by:

* the coupling not fully tightened.

* a worn, damaged or missing gasket seal.
* dirt on or under the gasket seal.
* dirt on the female coupling's mating surface.
* damaged parts on either coupling which prevent proper mating or
sealing.

- 5.4 -
 MAINTENANCE

Gas Line Repair

Leaks in the convoluted metal tubing cannot be repaired. Discard the damaged
gas line and install a new one.

Leaks at welded joints require special skills to repair. Consult the APD
Service Department.

Leaks at the self-sealing couplings can be repaired by replacing worn or

damaged parts. Vent the gas line before beginning to disassemble it, except
when replacing a gasket seal.

When couplings are frequently disconnected and reconnected, it is important to

wipe the mating parts (threads and faces) with a clean, lint-free tissue or
cloth.

Venting

1. Disconnect the gas line from the system. Install a dust cap on each
of the male couplings of the compressor and expander, or on the RF
gas feedthroughs, if used in the system.

NOTE

Adapter fittings are available as optional accessories

from APD.

2. Be sure the valve on adapter fitting PIN SK82l7A2 is closed. If

only one coupling on the gas line assembly is to be repaired,
install the adapter fitting on the good coupling. Use two wrenches.

3. Slowly open the valve on the adapter fitting to vent the entire
charge of helium gas.

4. Close the valve on the adapter fitting. Do not remove the adapter
fitting. It will be used for gas cleanup and recharging.

NOTE

Gas cleanup and recharging of the gas line are

always required if a coupling has been repaired.
Instead of venting the gas line to atmospheric
pressure, some operators prefer to connect an
adapter fitting and a charge line to the coupling
not being repaired, to purge the gas line with
helium during repair. Set the helium gas
regulator at 5 psig or less to prevent air from
entering the gas line and contaminating it.

- 5.5 -
 MAINTENANCE

Repair Self-Sealing Couplings

WARNING

ALWAYS VENT A GAS CHARGED COMPONENT BEFORE BEGINNING

TO DISASSEMBLE ITS COUPLINGS. GAS PRESSURE CAN
LAUNCH A LOOSE COUPLING WITH ENOUGH FORCE TO CAUSE
PERSONAL INJURY.

CAUTION

MODIFICATION TO EQUIPMENT WITHOUT THE CONSENT OF

THE MANUFACTURER WILL VOID THE WARRANTY.

Damaged threads, leaking seals or a leaking valve assembly may require

replacement of coupling parts or replacement of the complete coupling half.

Replace the Gasket Seal

From repeated connecting and disconnecting the coupling, the gasket seal just
inside the face of a male coupling may begin to leak and require replacement.

The gasket seal is replaced while the gas line is disconnected. See Fig. 5.5.

1. Carefully pry the old gasket seal from its recessed ring in the body.

2. Lightly coat the new gasket seal with vacuum grease and press it
into the ring.

ADAPTER O-RING r VALVE ASSEMBLY r BODY

eM Q--I4ftnrr~

GASKET SEAL

Fig. 5.5 Aeroquip Male Coupling Parts

- 5.6 -
 MAINTENANCE

Repair or Replace the Coupling

This procedure applies to both male and female couplings on gas lines,
compressor and expander.

1. Vent the charged component using the venting procedure in the

Maintenance section of the appropriate chapter.

2. If the coupling to be repaired has the venting adapter fitting

attached, remove the adapter fitting.

3. Use two wrenches to disconnect the coupling body from the adapter.
Hold the adapter with one wrench. Remove the coupling body with the
other wrench. See Fig. 5.6.

TURN

HOLD

Fig. 5.6 Remove Coupling from Gas Line

4. Push the valve assembly from the coupling body. It is not

fastened. Examine all parts and replace any that are damaged or
replace the entire coupling half. See Figures 5.5 or 5.7.

--""'t
- --
ADAPTER VALVE ASSEMBLY COUPLING ADAPTER

I~~
,....-,

'011( COUPLING NUT

-
"--... -",-

ADAPTER O·RING t L- BODY-.J

Fig. 5.7 Aeroquip Female Coupling Parts

- 5.7 -
 MAINTENANCE

5. Remove the O-ring from the gas line adapter.

6. Wipe the O-ring groove to be sure it is clean. Lightly coat a new

O-ring with vacuum grease. Install the O-ring in the gas line
adapter.

7. Wipe the valve assembly with a clean, lint-free cloth. Insert the
valve assembly into the coupling body from the rear.

8. Through1y degrease or apply Locquic Primer T (a degreasing agent) to

the threads of the adapter and to the internal threads of the
coupling body. Do not get Primer T on the O-ring or any of its
seating surfaces.

9. Allow about 5 minutes for the primer to dry. Apply Loctite 242 to
one full thread in the coupling adapter. Use a needle applicator.
Start at the second thread from the lead thread and work toward the
hexagon. Shake the Loctite before use.

10. Assemble the coupling body to the adapter. Use two wrenches. Hold
the adapter with one wrench and screw the two parts together.
Tighten the size 8 Aeroquip coupling parts to 4.85 to 6.25 kg f m (35
to 45 ft. 1bs.).

11. Allow at least a 6-hour curing period before applying gas pressure.

This completes the procedure for repairing or replacing a self-sealing

coupling.

Gas Cleanup and Recharging

Cleaning and recharging are always required when a gas line has been vented
and repaired or if the gas pressure has dropped to less than 140 kPa (20
psig). Each gas line is cleaned and charged individually using adapter
fittings.

1. Locate and connect adapter fitting PIN SK8217A2 to one gas line
coupling. Connect adapter fittings PIN 255919B2 and 257246C5 to the
other coupling. Be sure the valve on each adapter fitting is closed
before it is connected.

NOTE

Adapter fittings are available as optional

accessories from APD.

2. Connect a charge line to the pressure regulator of a helium gas

cylinder containing 99.995% pure helium gas with a dew point less
than -50°C (-58°F) at 2065 kPa (300 psig).

- 5.8 -
 MAINTENANCE

WARNING

NEVER USE COMPRESSED GAS FROM A CYLINDER WITHOUT

A PROPER REGULATOR. OVERPRESSURIZING CAN CAUSE
PERSONAL INJURY IF THE SYSTEM EQUIPMENT RUPTURES.

3. Open the gas cylinder valve. While connecting the charge line to
the valve on one of the adapter fittings, thoroughly purge the
charge line from the regulator. It is important to remove all air
contaminants to prevent them from entering the gas line.

4. Adjust the gas cylinder regulator to 690 kPa (100 psig). Open the
valve on the adapter fitting and charge the gas line to 690 kPa (100
psig).

5. Close the valve on the helium gas cylinder (not on the regulator).

6. Open the vent valve. Watch the regulator pressure gauge. When the
pressure falls to 35 to 70 kPa (5 to 10 psig) , close the vent
valve. Open the gas cylinder valve to increase the pressure to 690
kPa (100 psig). Close the gas cylinder valve.

7. Repeat step 6 five times.

8. Close the valve on the adapter fitting used for charging. Open the
gas cylinder valve. Adjust the pressure regulator to the
equalization pressure of the system. Refer to the Specification
section in the System chapter.

9. Open the valve on the adapter fitting and charge the gas line to the
equalization pressure.

10. Close the valve on the adapter fitting. Close the gas cylinder
valve. Disconnect the charge line from the adapter fitting. Store
the charge line to keep it clean.

11. Remove the adapter fittings.

This completes the procedure for gas cleanup of a gas line.

Gas Cleanup and Recharging (Systems Using Nycoil Gas Lines)

Because Nycoil gas lines are permeable, frequent, scheduled maintenance is

required on the system every 60 or 90 days, depending on the system components.

For system using compressor models HC-4 (series), lR04WSL or lR04WOI, perform
Gas Cleanup and Recharging every 90 days even if the system has not
operated.

For systems using compressor models HC-2 (series), lR02W, lR02A, lR02WOI,
lL02W or lL02A, perform Gas Cleanup and Recharging every 60 days even if
the system has not operated.

- 5.9 -
 MAINTENANCE

This schedule is based on a system equalization pressure loss of 70 kPa (10

psig). If the equalization pressure drops 70 kPa (10 psig) or more during the
60- or 90-day period, perform Gas Cleanup and Recharging procedure as soon as
the pressure loss is detected. Do not wait for the expiration of the 60 or 90
days.

1. Using two wrenches, disconnect the gas lines from the compressor
and from the expander.

2. For gas cleanup of Nycoil gas lines, follow the same procedure for
Gas Cleanup and Recharging (Stainless Steel and Copper Gas Lines)
in this section.

3. For gas cleanup of the compressor and expander, see the Gas Cleanup
procedures in the compressor and Expander sections.

4. Using two wrenches, reconnect the components. Check the

equalization pressure of the system after completing the
reinstallation.

This completes the procedure for gas cleanup of components used in a system
containing Nycoil gas lines.

- 5.10 -
 PARTS

Ordering

Order parts by part number and name. See Fig. 5.8.

Parts Identification and Number

Fig. 5.8 Parts Identification

Item Part Name Part Number

Size 4 Size 8 Size 12

1 Dust Cap N/A 45301 45401

2 Gasket Seal N/A 77002 77046

3 Coupling Half N/A 44701 44801

4 O-Ring 77183 77196 77113

5 Coupling Half 44901 45001 45101

6 Dust Plug 45501 45601 45701

- 5.11 -
 Addendum To Helium Compressor Technical Manuals
For a Compressor With a Gas Fill Port

APD CRYOGENICS INC.

1833 Vultee Street
Allentown, PA 18103

Revision A: May 1996 262780A

 ADDENDUM 262780A

NOTE

Place this Addendum in the Compressor section of your technical

manual, ahead of the Compressor technical manual.

This Addendum applies to the following compressors which have a gas fill and vent port
on the compressors front panel:

Compressor Model Number Compressor Part Number

HC - 20 - FF 256639E 18G - FF
256639E 15G - FF
256639E 16G - FF

HC - 4MK2 - FF 260341E 18G - FF

260341E 15G - FF
260341 E 16G - FF

HC - 8C1 - FF 258492E 20J - FF

HC - 8C5 - FF 261200E 20J - FF

1.0 Scope
This addendum to the compressor technical manual describes the charging and venting
procedures for a compressor with the gas fill port.

2.0 Tools and Materials Required

WARNING
NEVER USE COMPRESSED HELIUM GAS FROM A CYLINDER WITHOUT A
PROPER REGULATOR. OVER PRESSURIZATION CAN CAUSE PERSONAL
INJURY IF THE SYSTEM EQUIPMENT RUPTURES

WARNING
WHEN HANDLING PRESSURIZED GAS LINES AND OTHER PRESSURIZED
EQUIPMENT, ALWAYS WEAR EYE PROTECTION

• Gas Supply -- A regulated helium gas cylinder containing 99.995% pure helium
with a dew point less than -50 0 C (-58 0 F) at 2070 kPa (300 psig).
• 1/4" 0.0. tube charge line from helium supply to compressor.
• Swagelok~ nut and ferrules (PIN's 8-402-1, 8-403-1 and 8-404-1; reference APD
PIN's 12301,12302 and 12303, respectively).
• Two 9/16" open-end wrenches.

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 ADDENDUM 262780A

3.0 Charging Procedure {with or without the compressor ooeratinal

WARNING

BE SURE THE GAS FILL VALVE IS COMPLETELY CLOSED

BEFORE REMOVING THE SWAGELOK® NUT AND PLUG. GAS
PRESSURE CAN PROJECT THE PARTS WITH ENOUGH FORCE
TO CAUSE INJURIES.

CAUTION

USE ONE WRENCH TO SUPPORT THE BODY OF THE GAS FILL

PORT FITTING WHILE REMOVING OR INSTALLING THE DUST
CAP OR CHARGE LINE NUT WITH THE OTHER WRENCH. DO
NOT OVER-TORQUE.

1. Remove the dust plug (Swagelok~ PIN B-400-P; reference APD PIN 17505)
from the gas fill port.

2. Adjust the helium gas supply regulator to 5 psig. Thoroughly purge the charge line
while connecting the charge line to the gas fill port. It is important to remove all air
contaminants to prevent them from entering the system.

3. Adjust the helium gas supply regulator to the desired pressure. See the
Specifications section of the compressor technical manual for proper operating
or equalization pressure. 211fo -24-Sp Si

4. Slowly open the gas fill valve. Charge the system until the desired pressure is
indicated on the compressor gauge. If the compressor is operating, wait at least
30 seconds for the system pressure to reach equilibrium.

5. Close the gas fill valve and the helium gas supply valve.

6. Disconnect the charge line from the gas fill port. See CAUTION above.

7. Install the dust plug on the gas fill port. See CAUTION above.

4.0 Venting Procedure (with or without the compressor operating)

WARNING

BE SURE THE GAS FILL VALVE IS COMPLETELY CLOSED

BEFORE REMOVING THE SWAGELOK® NUT AND PLUG. GAS
PRESSURE CAN PROJECT THE PARTS WITH ENOUGH FORCE
TO CAUSE INJURIES.

2
 ADDENDUM 262780A

CAUTION

USE ONE WRENCH TO SUPPORT THE BODY OF THE GAS FILL

PORT FiniNG WHILE REMOVING OR INSTALLING THE DUST
CAP WITH THE OTHER WRENCH. DO NOT OVER-TORQUE.

1. Remove the dust plug (Swagelok,!l PIN B-400-P; reference APD PIN 17505) from
the gas fill port.

2. Slowly open the gas fill valve, less than 2 turns. Vent the system until the desired
pressure is indicated on the compressor gauge. See the Specifications section
of the compressor technical manual for proper operating or equalization pressure.
If the compressor is operating, wait at least 30 seconds for the system pressure
to reach equilibrium.

3. Close the gas fill valve.

4. Install the dust plug on the gas fill port. See CAUTION above.

Compressor Front Panel

HELIUM
CHARGENENT
SEE ""ISTRUCTIONS IN
MANUAL ADDENDUM