Telephone (508) 337-5000I HEIUX TECHNOLOGY CORPORATION

lansfield co~porate Center, Nine Hampshire Street, Mansfield, Massachusetts 02048-91:t

HELIX TECHNOLOGY CORPORATION

GI-CRY(XjENICSHELIX TECHNOLOGY CORPORATION

SAFETY CONSIDERATIONS

Your Cryodyne@ Cryocooler has been engineered to provide extremely safe and dependable operation when properly used.Certain safety considerations need to be observed during the normal use of your cryocooler equipment. ~ blocks \8Iithjn the Manualtext pinpoint these specific safety considerations. Warnings are defined as hazards or unsafe practices which could result in severe

injury or loss of life.

HIGH VO~ is present within the system and can cause severe injury from electric shock.

Disconnect the system from all power sources before making electrical connections be.tween system components and also before performing Troubleshooting and Maintenance

procedures.

Ensure that all electrical power switches on the controller/compressor units are in the offposition before connecting the compressor unit to its power source. .2.

Never connect the cold.head power cable to the cold head while the compressor is

running.3.

HIGH GAS PRESSURE is present within the system and can cause severe injury from propelledparticles or parts. -

Do not modify or remove the pressure relief valves, either on the cold head or within the

helium compressor.1

Always depressurize the adsorber to atmospheric pressure before disposing of it.2.

Always bleed the helium charge down to atmospheric pressure before servicing or

disassembling the self.sealing gas half-couplings.3.

BEFORE INSTALLING, OPERATING OR SERVICING EQUIPMENT,READ THIS MANUAL WHICH CONTAINS IMPORTANT SAFETY INFORMATION.

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CTI-CRY(XjENICSHELIX TECHNOLOGY CORPORATION

1.1 General 1.2 Installation, Operation andServicing Instructions

Installation, Operation and Servicing Instructions for

your Cryodyne refrigeration system provide completeand easily accessible information. All personnel withinstallation, operation, and servicing responsibilitiesshould become familiar with the contents of theseinstructions to ensure safe, reliable, and high refrigera-tion system performance.

This manual provides instructions for installing,operating and servicing the Model 1020C and 1050CCryodyne@Cryocoolers. If you are installing oroperating and servicing a Cryodyne RefrigerationSystem, you should also have available the 8500 or theModell020R Compressor manuals (8040251 or8040274 respectively).

The manuals cover two basic components: thecryodyne cryocooler and the compressor. Each manualpresents information for installation, operation andservicing of that component. A manual is shipped witheach system component (cryocooler and compressor).

The Modell 020 or 1050 Cold Head, which useshelium as the refrigerant, is designed to interface withmany kinds of apparatus that require cryogenictemperatures. The use of a Cryodyne refrigerator as asource of cryogenic temperatures offers a degree offreedom in the design of such interfacing apparatus (inparticular, size and operational flexibility) that isgenerally unobtainable when a liquid refrigerant isemployed. Moreover, the cold head can be operated inany orientation without loss of performance. At the endof an operating period of the refrigeratoc, the cold headcold stations can be raised to ambient temperature in arelatively short time.

Figure 1.1, shows front and rear overall views of theModel 1020 Cold Head and identifies major com-ponents. These components are identical on the Model1050 Cold Head; configuration of the Modell 050 isslightly different from the Modell 020.

Cold head and interconnections specifications forthe Modell 020 and 1050 Cold Head are summarized inTable 1.1.

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Legend

1. Cylinder !2. Second Stage Cold Station ./

3. Second Stage Cylinder4. First Stage Cold Station5. First Stage Cylinder6. Top Flange7. Pressure Relief Valve8. Crankcase (houses drive mechanism)9. Drive Motor10. Electrical Power Connector11. Helium Gas Return Connector (with dust cap)12. Helium Gas Supply Connector (with dust cap)

Figure 1.1 The Model 1 020 Cold Head

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Table 1.1 Model 1020 and 1050 Cold Head and Interconnections Specifications

Dimensions (approximate):14.6 inches (369 mm) Length6 inches (152 mm) Width

20.5 inches (521 mm) Height

Weight331bs (15 kg) approximate

Power requirement (supp]ied via the 8500 or ] 020 R/RW Compressor)] 50 V AC nomina], either 50 or 60 Hz, split phase

Ambient-temperature operating range40 to ] ]O~ (4.4 to 43°C)

Interface dataGas-supply connector: 1/2-inch self-sealing couplingGas-return connector: 1/2-inch self-sealing coupling

OrientationMay be operated in any orientation, but vertical mounting is preferred.

InterconnectionsHelium supply and return piping10 ft. (3 m) each with 1/2-inch self-sealing couplings at each termination.Longer lengths, elbows and tees are available.

Cold head power receptacleMates with compressor cold head power cable.

Refrigeration capacityThe values listed below represent the minimum refrigeration capacities of the second-stage cold station,assuming the following conditions:

Figures 1.3 and 1.4 are graphs showing typical refrigeration capacities at 60-Hz and 50-Hz of theMode11020 and 1050 Cryodyne Refrigerators respectively.

Note: When the refrigeration system is supplied with 50-Hz power, a s]ight reduction in cold head performancemay be observed, compared with the performance obtained with 6O-Hz power.

Temperature stabi1ity under constant 10ad:t 2.0K (at the second-stage cold station)

No-10ad cooldown time to 20K40 minutes; 60-Hz power50 minutes; 50-Hz power

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Figure 1.2 Typical refrigeration capacity of theModel 1020 Cryodyne Refrigerator

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TEMPERATURE OF COLD STATIONFIRST STAGE (KELVIN)

50-Hz Operation

z~I..J~

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za~cx~VI

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aI..JIr~~cxIrI..Ja.~I..J~ 30 40 70 80 9050 60

TEMPERATURE OF COLD STATIONFIRST STAGE (KELVIN)

50-Hz Operation

Figure 1.3 Typical refrigeration capacity of theModel 1050 Cryodyne Refrigerator

.5

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Inspection2.1Upon receipt, inspect the Model 1020 or Model 1050

Cryodyne Cryocooler for evidence of damage asdescribed below.

Report damage to the shipper at once.

Retain shipping cartons for storage or return shipment.

Inspect the exterior of the cold head for evidence ofdamage. Examples of such evidence are a bent coldstation and a dented cylinder.

2.2 Cold Head Installation

ELECTRICAL CABlE

-HELIUM LINE

-.-CUSTOMER'S VACUUM SYSTEM

The cold head and related components must haveadequate vacuum integrity for proper operation in yourvacuum system. Inadequate vacuum will result in anunwanted gas-conduction heat load from the room-temperature vacuum housing to the cold surface of thecold-head cold stations. A small vacuum leak will causehigher-than-normal cold station operating temperatures,combined with a gradual temperature increase; a largevacuum leak may prevent satisfactory cooldown. Yourroughing pump system should be isolated from yourvacuum system, once cool down has started, by closingthe roughing valve shown in Figure 2. I. This valveshould be of a high-vacuum isolation type (Hi- V acvalve) for isolation of your vacuum system during roughpumping, cooldown, and regeneration.

Cll-CRYOGENICS recommends that a suitablepressure relief valve be installed in your vacuum systemto prevent any possible positive pressure rise during

warmup.

Figure 2.1 Component interconnectiondiagram

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Verify proper helium supply static pressure byconfmning that the helium pressure gauge reads 200:!: 5psig (1380:!: 35 kPa), in an ambient temperature range of50 to 100Op (10 to 38°C).

2.3 Installing the Cold Head to

After cleaning all sealing surfaces, install the a-ringin the groove for the a-ring in your vacuum system

flange.

2. Mount the cold head to the flange; be sure that allmounting bolts are torqued to specified values.

2.4 Connecting the Cold Headto the Compressor

If the indicated pressure is higher than 205 psig (1415kPa), reduce the pressure as follows:

1. Remove the flare cap from the gas charge fittinglocated on the rear of the compressor.

2. Open the gas charge valve very slowly. Allow aslight amount of helium gas to escape until thehelium pressure gauge reads 200 psig (1380 kPa).

3. Close the gas charge valve and reinstall the flare cap.

If the indicated pressure is lower than 195 psig (1345kPa), add helium gas as described in the Maintenancesection of the manual for your cn-CRYOGENICS

compressor.A typical interconnecting diagram for the Cryodynerefrigeration system is shown in Figure 3.6. Refer alsoto Figure 1.1, for location of cold head componentsdiscussed below.

The last step required for installation is makingelectrical connections:

Make the connections between the cold head and

compressor:

1. Connect the cold head power cable to the rear panelof the compressor and the other end to the electricalpower connector on the cold head.

2. Plug the compressor input power cable into thepower source.

3. Switch the compressor power switch to the ON

position.

1. Remove all dust plugs and caps from the supplyand return lines, compressor and cold head. Checkall fittings.

2. Connect the helium return line from the gas-returnconnector on the rear of the compressor to the gas-return connector on the drive-unit displacerassembly on the cold head.

3. Connect the helium supply line from the gas-supplyconnector on the rear of the compressor to the gas-supply connector on the cold head.

PIN 80402732-2

the Vacuum System

Proceed as follows to install the cold head in yourvacuum system. Refer to Appendix J for the majorinterface dimensions of the Model 1020 and] 050 ColdHeads.

CTI-CRy(~ENICSHELIX TECHNOLOGY CORPORATION

Installing the Load

3.1

Before Startup

The load can be either attached directly to the coldstation concerned, or coupled to it with heat wicks(braided copper straps). Use indium foil (0.002 to0.005-inch thick) between the mating surfaces toimprove thermal conduction.

After installing the load, rough-pump your vacuumchamber down to 5 x 10-2 torr or better. Then close theroughing valve prior to starting cool down of therefrigerator. Upon cooldown, the refrigerator willcryopump residual gasses in the chamber and aninsulating vacuum between 10-4 and 10.S torr will beachieved.

Operating LogIt is highly advisable to create and maintain a detailed

operating log. The record will assist in troubleshooting,should problems arise. Figure A. I, page A-2, is asample operating log included for your use. You maymake photocopies of this sample log as necessary. 3.2 Startup and CooldownTemperature Indication I. Confinn that the roughing valve is closed.

2. Turn on system power ON/OFF switch.

3. During cooldown, record the operating log data at15-minute intervals. To ensure minimum cooldowntime, do not apply electrical power to any loadduring the cool down.

The second-stage cold station temperature is measuredby one of two devices: a diode temperature sensor or ahydrogen-vapor-pressure gauge. The diode temperaturesensor is designed to be used with the remote temper-ature indicator or the cryopump monitor (Appendix C).

While the Cryodyne refrigerator can be operatedwithout temperature indication, it is advisable to installthe temperature indicator or the cryopump monitor tofacilitate accurate operating characteristics. Refer toAppendix C for detailed descriptions of both temperatureindicating devices.

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3.3 Normal Operation

The Cryodyne refrigeration system is designed tooperate without operator assistance.

The cool down time associated with a nonnalcooldown, with no load attached to a second-stage coldstation, is specified in Table 1.1, page 1-3. Thecooldown time will increase approximately 15 minutesfor each pound-of-mass increase of the attached load. Ifthe cold head cool down time is not within specifiedrequirements refer to Table 4.1, page 4-2, Cold HeadTroubleshooting Procedures.

Pressure regulation during cooldown is automatic.The compressor pressures will vary during cool down butwill usually attBin steady values nominally within 45minutes after cooldown.

During the first lOO hours of operation, a slight drop incompressor pump oil level may occur, but a drop is of noconcern as long as the oil level is visible. If oil level isnot visible, contact the Product Service Department.

The helium return pressure gauge should be checkedonce a week and the reading noted in the operating log.If the gauge reading falls outside the satisfactory oper-ating range between 60 and 85 psig (4]5-590 kPa) on thegauge, refer to Section 4, Troubleshooting Procedures.Plots for typical cool down data for the Model] 05OC

Cryodyne refrigeration system are shown in Figure 3.] .The sharp increase in the helium supply pressure andreturn pressure that occur immediately after startup arelimited by the compressor differential-pressure reliefvalve.

3.4 Cryodyne RefrigeratorShutdown Procedures

I. Close the Hi- V ac va]ve in your vacuum system.

2. Turn off the system power ON/OFF switch on thecompressor.

3. Allow the cold head to wann up to ambient

temperature.

Figure 3.1 Typical cooldown data

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HELIX TECHNOLOGY CORPORATION

The Cryodyne refrigeration system is fully protectedduring storage if kept under positive helium pressure andall component connections left connected. Periodicallycheck the helium return pressure gauge on the com-pressor. If the gauge reads below 195 psig (1345 kPa),

add helium as described in the Maintenance section ofthe manual for your CTI-CRYOGENICS compressor.

If the cold head is removed from your vacuum system,be careful not to damage the cold head cylinder andsealing surfaces.

For Your Information Compressor Gas and Oil Flows

How the Cold Head Operates

Refer to Figure 1, while reviewing this subsection

Helium returning from the cold head enters thecompressor, and a small quantity of oil is injected intothe gas stream, thereby overcoming helium low specificheat and inability to carry heat produced during com-pression. Helium is then compressed and passedthrough a heat exchanger for removal of compression-caused heat. The helium flows through a bulk oilseparator, oil-mist separator, arKi charcoal filter adsorber,where oil and contaminants are removed.

A differential pressure relief valve in the compressorlimits the operating pressure differential between thehelium supply and retum lines, thereby allowing com-pressor operation without cold head operation. Whencold head operation reaches a steady-state condition,funher pressure regulation is unnecessary.

The cold head consists of a two-stage cold headcylinder and drive-unit displacer assembly that togetherproduce closed-cycle refrigeration at temperatures thatrange from 40 to lOOK for the first-stage cold station to10 to 20K for the second-stage cold station, dependingon operating conditions. Within the drive unit displacerassembly, the drive unit actuates the displacer-regenerator assembly located in the cold head cylinderand thereby controls the flow of helium into the coldhead. Within the drive unit are located the crankcase (8)and drive motor (9), which is a direct-drive constant-speed motor operating at 72 rpm on 60 Hz power and 60rpm on 50 Hz power.

During operation, high pressure helium from thecompressor enters the cold head at the helium supplyconnector (12), and flows through the displacer-regenerator assembly, crankcase, and motor housingbefore exiting through the helium gas-return connector(] ]) and returning to the compressor. Helium expansionin the displacer-regenerator assembly provides cooling atthe first and second-stage cold station.

The temperature of the second-stage cold head stationis measured by a temperature sensor and transmitted toa temperature indicator, cryopump monitor or vapor

pressure gauge.

Refer to Appendix B. for detailed infonnation on theprinciples of operation.

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Troubleshooting theCold Head

4.2 Technicallnquiries4.1Please refer to Appendix G of this manual for a

complete list of the C11-CRYOGENICS' world widecustomer support centers.

The problems in the troubleshooting table are allfollowed by a number of possible causes and correctiveactions. The causes and corresponding actions are listedin their order of probability of occurrence I) is mostlikely, 2) is next most likely, etc.

Maintaining a log of the readings (see Appendix A) ofthe temperature indicator during normal operation is avaluable tool in troubleshooting the cold head. Valueshigher than 20K indicate that the second-stage coldstation is too warm. A temperature below 20K meansthe cold head is cold enough for operation.

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crl-CRY~ENICSHELIX TECHNOLOGY CORPORATION

Table 4.1 Cold Head Troubleshooting Procedures

Problem Possible Cause Corrective Action

l) Cold head fails to cooldown to the required

operating temperatureor takes too long to reachthat temperature.

1) Low system charge pressure in the

compressor.1) Add helium gas per the maintenance

instructions of your compressormanual.

2) Vacuum leak in your vacuum

system.2) Check your vacuum system for

leaks.

3) Excessive heat load. 3) Eliminate excessive heat load.

4) Contamination of thehelium gas.

4) Refer to DecontaminationProcedures, Section 5.4, page 5-2.

5) Refer to Troubleshooting Proceduresin your compressor manual.

5) Compressor problem.

6) Contact the Product ServiceDepartment.

6) Internal malfunctionin the compressor.

2) The cold-head driveunit fails to run, eventhough dte compressoris operating.

1) Lack of power fromthe compressor.

I) a. Ensure that the system powerON/OFF switch on the rear panelof the compressor is ON.

b. Ensure that the cold head powercable is properly attached to theelectrical power connector of thecold head drive unit.

c. Ensure the integrity of thecontrol power fuses in theelectrical control chassisof the compressor. (SeeFigure B.2 of the compressormanual for the location ofthese fuses.)

d. Contact the Product ServiceDepartment for assistance.

2) An internal malfunction. 2) Contact the Product ServiceDepartment for assistance.

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Table 4.1 Cold Head Troubleshooting Procedures (Cont.)

Problem Possible Cause Corrective Action

3) The cold-head drive unit

operates erratically,usually accompanied byconsiderable noise.

1) Contamination of the helium gas. 1) Refer to DecontaminationProcedures, Section 5.4, page 5-2.

2) IncoITect wiring connection totransformer 1'2 and T3 (8500

Compressor only).

2) Conflnn correct transformer(T2 and T3) preparation asdescribed in Figure 3.6 of thecompressor manual.

3) Low input voltage (8500

Compressor only).3) Measure and compare input voltage

to operating voltage range, Table 1.1of the compressor manual. Ifnecessary, adjust transfonner tapsettings.

4) Internal malfunction of the coldhead.

4) Contact the Product ServiceDepartment for assistance.

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This decontamination procedure will remove contam-inants from the cold head and/or compressor, therebyrestoring system performance. The cold-trapping ofcontaminants inside the cold head during this procedurewill also decontaminate the compressor if the contamin-ation of the system is not severe. Separate decontamina-tion of the compressor is required whenever thecompressor has been opened to atmosphere, or thepressure has dropped to zero.

Two types of unscheduled maintenance may berequired from time to time. These are 1) the addition ofhelium gas to the cryodyne crycooler, and 2) heliumcircuit decontamination.

5.1Your CfI-CRYOGENICS compressor is supplied

with appropriate maintenance equipment and disposablesupplies for servicing this unit. In addition, you shouldhave a Maintenance Tool Kit, PIN 8140000KOO I, thatprovides wrenches, etc. for connecting self-sealingAeroquip couplings between the cold head(s) and the

compressor.

5.4 Cold Head DecontaminationProcedures

Cool down the cold head and operate it for one tothree hours. If the system will not cool down,proceed to step 2. Operating the cold head willisolate the contaminants by "freezing" them in thecold head. The contaminants in the helium-gascircuit of the refrigerator tend to become frozeninside the cold head. The longer the cold head isoperated beyond the one-hour period, the greater isthe amount of contamination that becomes isolatedinside the cold head.

5.2 Adding Helium Gas

Refer to the Maintenance section of the manual foryour C11-CRYOGENICS compressor for detailedinstructions on adding helium gas to your Cryodyne

cryocooler.

5.3 Helium CircuitDecontamination

Contamination of the helium-gas circuit is indicated bysluggish or intermittent operation (ratchetting) of thecold head drive mechanism. With severe contaminationthe cold head drive may seize and fail to operate. One ofthe major sources of contamination is using helium gasof less than the required purity. When perfonning thedecontamination process, use only 99.999% pure-heliumgas, and the regulator and charging line must be properlyconnected and purged.

2. Shut down the refrigerator per Section 3.4, page 3-2.

3. Immediately disconnect the helium supply andreturn lines from the gas-supply and gas-returnconnectors at the rear of the compressor. Leavethem attached to the cold head.

4. Attach the maintenance manifold to the discon-nected ends of the helium return and supply lines.

5. Reduce the pressure in the cold head to a level of30 psig by using the maintenance manifold. Re-ducing the pressure in the cold head below 30 psig(200 kPa) may introduce more contaminants intothe helium circuit.

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6. Allow the second-stage of the cold head to warm upto room temperature. The warmup time can bedecreased by backfilling the vacuum chamber toone atmosphere with dry argon or nitrogen gas.Using the gas heater, Cll PIN 8080250K020, willreduce the warmup time about 50 percent, and willmaintain the gas temperature below the 150Op (66°C)limit.

8. Perfonn in sequence:

a. Backfill the cold head with helium to a staticcharge pressure of ]95-205 psig (]345-14]5kPa) by adjusting the regulator to the requiredpressure, and opening the Hoke valve on themanifold. Close the Hoke valve when the pres-sure is correct.

b. Depressurize the cold head to between 30 and50 psig (200 and 330 kPa) by slowly opening theball valve and allowing the helium to bleed outslowly. Do not reduce the pressure to less than30 psig or the cold head may be further contam-inated.

Once the cold head has reached room temperature,attach a two-stage regulator (0-3000/0-400 psig)and charging line to a helium bottle (99.999% pure).DO NOT OPEN lHE BOTTLE VALVE AT lHISTIME. Purge the regulator and charging line asinstructed in steps a through d below. Do not usehelium gas that is less than 99.999% pure.

a. Open the regulator a small amount by turningthe adjusting knob c1ockwise until it contactsthe diaphragm; then turn approximately 1/8 to1/4 turn more, so that the regulator is barely

open.

b. Slowly open the bottle valve, and purge theregulator and line for 10 to 15 seconds. Turn theregulator knob counterclockwise until the helium

stops flowing.

c. Loosely connect the charge line to the 1/8-inchHoke valve on the maintenance manifold.

d. Purge the charge line again, as in step a, for 30seconds, and tighten the charge line flare fittingonto the Hoke valve while the helium is flowing.

c. Perfonn flushing steps a and b four more times.

d. Pressurize the cold head to the static chargepressure of 195-205 psig (]345-1415 kPa) andrun the cold head drive motor for 10 to 30seconds by actuating the system ON/OFFswitch to ON.

e. Perfonn steps b through d four more times for atotal of 25 flushes and a total of 5 drive-motorruns.

9. Verify that the cold head is pressurized to the staticcharge pressure of ]95-205 psig (]345-]415 kPa).

10. Disconnect the maintenance manifold from thehelium return and supply Jines.

I]. Reconnect the helium return and supply lines to thereturn and supply connectors on the rear of thecompressor. The cold head is now ready foroperation.

This procedure is required to ensure that both theregulator and the charging line will be purged of air andthat the air trapped in the regulator will not diffuse backinto the helium bottle. For best results, Cll suggests adedicated helium bottle, regulator, and line, which arenever separated, for adding helium.

PIN 80402735-2