Brooks Automation Inc. Polycold Systems · misuse, negligence, corrosive atmospheres, attack by...

Brooks Automation, Inc. Tel 978-262-2400 15 Elizabeth Drive Fax 978-262-2500 Chelmsford, MA 01824 U.S.A www.brooks.com

825101-00 (Rev C)

Brooks Automation Inc. Polycold Systems

Customer Instruction Manual

POLYCOLD® GAS CHILLERS

Models:

PGC-152 AC 700179-01 PGC-152 WC 700179-02 PGC-152 AC w/ Flow Control Unit 700179-03 PGC-152 WC w/ Flow Control Unit 700179-04 PGC-152 AC CE Back Line Layout 700179-05 PGC-152 AC CE/S2 M/OP 700179-06 PGC-152 WC CE/S2 M/OP 700179-07

825101-00 (Rev C)

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Safety Information PGC Manual

825101-00 (Rev C) Page i

Brooks Automation, Inc. Polycold Systems 15 Elizabeth Drive Chelmsford, MA 01824 U.S.A. Tel: 978-262-2400 Fax: 978-262-2500 Service: Contact Brooks Automation at http://www.brooks.com or the 24 hour emergency number: for the nearest service representative.

Before starting: Congratulations for purchasing a Brooks Automation Inc. Polycold

® Systems Cool Solutions

® Gas Chiller. If

any assistance is needed, please contact a local sales representative or Brooks Automation Inc.

To contact Brooks Automation Inc. by:

Telephone: 978-262-2400

Toll Free: (1) (800) FOR GUTS (800-367-4887) “within USA only”

Fax 978-262-2500

Mail: Brooks Automation, Inc. 15 Elizabeth Drive, Chelmsford, MA 01824 U.S.A

Website: www.brooks.com

Please have the following information available to help us expedite the service process:

Polycold® Model: __________________________

Polycold® Serial No: ________________________

Polycold® Item Code: _______________________

Date Manufactured: ________________________

The above information is on the nameplate of the Gas Chiller. It is best to enter this information now (before the equipment is installed).

North America 1 800-FOR-GUTS (800-367-4887)

Germany France UK

+49 1804-CALL-GUTS (1804-2255-4887)

Japan +81-3-5767-3412

China +86-21-5131-7066

Taiwan +886-3-5525225

Korea +82-31-288-2500

Singapore +65-6464-1481

http://www.brooks.com/


825101-00 (Rev C) Page ii

© 2010 by Brooks Automation Inc. Polycold Systems All rights reserved. Printed in the United States of America. Trademark Recognition:

Armaflex® is a registered trademark of Armstrong World Industries, Inc.

CPI UltraSeal™ is a trademark of Parker Hannifin Corporation. Phillips

® is a registered trademark of Phillips Screw Company.

Polycold® is a registered trademark of Brooks Automation Inc.

VCR® is a registered trademark of Cajon Company.

is a registered trademark of Brooks Automation Inc.


825101-00 (Rev C) Page iii

Polycold® Systems Cooling Products, CryoTiger®, AquaTrap

®, Polycold Compact Cooler, Repair Services and Certified

Refurbished Products

Polycold® Systems cryogenic cooling products, including water vapor cryopumps (PFC, PCT, FLC, FI), chillers (PGC, PGCL),

cryocoolers (P), CryoTiger, AquaTrap, Polycold Compact Cooler (PCC) and accessories, Certified Refurbished products (the

“Products”) and Repair Service (i.e.- repairs other than warranty repairs) are warranted to be free from defects in materials

and/or workmanship under normal service for the time period as set forth in Table A below from date of shipment from Brooks

Automation, Inc. (“Brooks”). The warranty for Repair Service and Products is limited to the component parts replaced or repair

performed by Brooks at Brooks’ facility. Customer is responsible for all charges and expenses for Brooks Services provided at

Customer’s location by Brooks technicians as set forth in a quotation. Certified Refurbished Products and warranty exchange

Products are remanufactured to like-new condition and contain used parts and materials.

Table A

Product New Product

Warranty

Repair Service

Warranty

Certified Refurbished

Cryogenic Cooling Products Warranty

Cryotiger® Products and Systems

AquaTrap® Products and Systems

Polycold® Compact Cooler (PCC)

15 Months

12 Months

N/A

Cryogenic cooling products, including: Water vapor cryopumps (PFC, PCT, FLC, FI), chillers (PGC, PGCL), cryocoolers (P), and accessories

24 Months

12 Months

12 months

BROOKS MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO PRODUCTS OR

SERVICES. UNLESS EXPRESSLY IDENTIFIED AS A WARRANTY, SPECIFICATIONS IN ANY PRODUCT DATASHEET CONSTITUTE

PERFORMANCE GOALS ONLY, AND NOT WARRANTIES. BROOKS MAKES NO WARRANTY RESPECTING THE MERCHANTABILITY OF

PRODUCTS OR THEIR SUITABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR RESPECTING INFRINGEMENT OF

INTELLECTUAL PROPERTY RIGHTS. BROOKS DISCLAIMS ANY WARRANTY WITH RESPECT TO PRODUCTS MODIFIED WITHOUT

BROOKS’ WRITTEN CONSENT, REPAIRS MADE OUTSIDE OF OUR FACTORY, PRODUCTS RENDERED DEFECTIVE BY CUSTOMER

MISUSE, NEGLIGENCE, CORROSIVE ATMOSPHERES, ATTACK BY FREE CHEMICALS WITHIN THE SYSTEM, ACCIDENT, DAMAGE

BY CUSTOMER OR CUSTOMER’S AGENT, OPERATION CONTRARY TO OUR RECOMMENDATION, IF THE SERIAL NUMBER HAS

BEEN ALTERED, DEFACED OR REMOVED, THE USE OF SERVICE REPLACEMENT REFRIGERANTS FROM ANY THIRD PARTY NOT

LICENSED BY BROOKS, OR THE PRODUCT IS OTHERWISE COMPROMISED BY USE OF UNAUTHORIZED PARTS OR SERVICE, ALL

AS DETERMINED BY BROOKS IN ITS SOLE DISCRETION.

IN NO EVENT WILL CUSTOMER BE ENTITLED TO, NOR WILL BROOKS BE LIABLE FOR INDIRECT, SPECIAL, INCIDENTAL, PUNITIVE

OR CONSEQUENTIAL DAMAGES OF ANY NATURE, INCLUDING WITHOUT LIMITATION NEGLIGENCE, STRICT LIABILITY, OR

OTHERWISE, ARISING AT ANY TIME, FROM ANY CAUSE WHATSOEVER, INCLUDING, WITHOUT LIMITATION, DOWN-TIME COSTS,

DATA LOSS, DAMAGE TO ASSOCIATED EQUIPMENT, REMOVAL AND/OR REINSTALLATION COSTS, REPROCUREMENT COSTS, OR

LOST PROFITS, EVEN IF BROOKS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, AND EVEN IF THE LIMITED

REMEDIES OF REPAIR OR REPLACEMENT FAIL OF THEIR ESSENTIAL PURPOSE. THIS WAIVER OF LIABILITY DOES NOT APPLY TO

EITHER BROOKS’ LIABILITY UNDER A STATUTE, ACT OR LAW PERTAINING TO BODILY INJURY, OR TO ANY LIABILITY INCURING

OUT OF DAMAGE TO THE BODY, HEALTH OR LIFE OF A PERSON.

The exclusive remedies for breach of warranty will be either repair or replacement of the nonconforming parts or Products during

the warranty period at the sole discretion of Brooks, shipped ExWorks (Incoterms 2000) Brooks factory. Customer’s recovery

from Brooks for any claim shall not exceed the amount paid by customer to Brooks for the Product or Service giving rise to such

claim, irrespective of the nature of the claim, whether in contract, tort, warranty, or otherwise. Customer must inspect the

Products within a reasonable time upon receipt, and must notify Brooks within 30 days of discovering a defect. Every claim on

account of defective material or workmanship shall be deemed waived unless made in writing within the warranty period

specified above. Brooks does not assume, or authorize any other person to assume, any other obligations or liabilities in

connection with the sale of the Products.

All Polycold Products are also subject to the Brooks Automation, Inc. General Terms and Conditions, Polycold® Products, an excerpt of which is set forth above.


825101-00 (Rev C) Page iv


Table of Contents PGC Manual

825101-00 (Rev C) Page i

Table of Contents

1 SAFETY INFORMATION ........................................................................................................................................... 1

1.1 Safety Hazards and Safeguards ................................................................................................................... 1

1.2 Danger, Warning, and Caution Alerts ........................................................................................................... 2

1.3 Safety Training Guidelines ............................................................................................................................ 4

1.4 Definition of Electrical Work Types ............................................................................................................... 4

1.5 Potential Hazards During Maintenance & Servicing ..................................................................................... 5

1.5.1 Air Cooled PGC 152 w/o Flow Control Unit ............................................................................................... 6

1.5.2 Water Cooled PGC 152 with Flow Control Unit .......................................................................................... 9

1.6 Material Safety Data Sheets ....................................................................................................................... 13

1.7 Refrigeration Compliance ........................................................................................................................... 13

1.8 Conversion Factors & Formulas ................................................................................................................. 13

1.9 Safety Devices ............................................................................................................................................ 14

1.10 Lock-Out and Tag-Out Instructions (LOTO) ............................................................................................... 15

1.11 Safety Interlocks.......................................................................................................................................... 16

1.12 Circuit Breaker Protection ........................................................................................................................... 16

1.13 Emergency Shut-Down Procedures............................................................................................................ 17

2 OVERVIEW ......................................................................................................................................................... 19

2.1 System Diagrams ........................................................................................................................................ 19

2.2 About the PGC ............................................................................................................................................ 21

2.3 PGC 152 Model Features ........................................................................................................................... 22

2.3.1 Exterior Features, Air Cooled PGC 152 w/o Flow Control Unit ................................................................ 23

2.3.2 Interior Features, Air Cooled PGC 152 w/o Flow Control Unit ................................................................. 24

2.3.3 Exterior Features, Water Cooled PGC 152 with Flow Control Unit .......................................................... 25

2.3.4 Interior Features, Water Cooled PGC 152 with Flow Control Unit ........................................................... 26

3 INSTALLATION................................................................................................................................................... 27

3.1 Tools and Materials Required ..................................................................................................................... 27

3.2 Inspect the PGC .......................................................................................................................................... 27

3.3 Position the PGC......................................................................................................................................... 27

3.4 Cooling Water Connection (WC Units) ....................................................................................................... 28

3.5 Connect the Gas-Outlet Thermocouple Wire to a Temperature Meter (Optional) ...................................... 29

3.6 Connect the Electrical Power ...................................................................................................................... 30

3.7 Connection of Flow Control Unit (Optional) ................................................................................................ 31

3.8 Power Interruption/Restoration ................................................................................................................... 31

3.9 PGC Remote Control System (Optional) .................................................................................................... 31

3.10 Enable Remote On/Off Operation ............................................................................................................... 32

3.11 Install the External Gas Circuit .................................................................................................................... 33

4 OPERATION ....................................................................................................................................................... 37

4.1 Starting the Polycold Gas Chiller ................................................................................................................ 37

5 INSPECTION & MAINTENANCE ....................................................................................................................... 39

5.1 Periodic Inspection ...................................................................................................................................... 39

5.2 Inspect for water condensation in the gas circuit. ....................................................................................... 39

5.3 If the unit is Air-Cooled, verify there is adequate air circulation through the condenser. ........................... 39


825101-00 (Rev C) Page ii

5.4 If the unit is Water-Cooled, verify the following: .......................................................................................... 39

5.5 Verify the insulation on the gas-out line is adequate. ................................................................................. 39

5.6 Verify the refrigerant circuit does not have a leak. ...................................................................................... 39

5.7 Remove moisture from the gas circuit. ....................................................................................................... 40

6 TROUBLESHOOTING ........................................................................................................................................ 41

6.1 The PGC's Compressor Does Not Start Or Run Properly .......................................................................... 41

6.1.1 Fan and compressor do not start (and make no noise). ............................................................................... 41

6.1.2 Compressor hums or starts, and then stops. ................................................................................................ 41

6.2 Gas Flow or Temperature Is Inadequate .................................................................................................... 41

6.3 PGC Makes Unusual Noises ...................................................................................................................... 41

6.4 Indicator Lamp Based Troubleshooting and Diagnostics ........................................................................... 42

7 DISCONNECTION, STORAGE, AND RESHIPMENT ........................................................................................ 47

7.1 Disconnection .............................................................................................................................................. 47

7.2 Packing for Reshipment or Storage ............................................................................................................ 47

8 APPENDIX .......................................................................................................................................................... 49

8.1 BRAZING SPECIFICATION ....................................................................................................................... 49

8.2 THERMOCOUPLE ATTACHMENT SPECIFICATION ............................................................................... 49

8.3 Specifications .............................................................................................................................................. 51

9 GLOSSARY ........................................................................................................................................................ 53

10 PROCESS & INSTRUMENTATION AND ELECTRICAL SCHEMATICS........................................................... 54


825101-00 (Rev C) Page iii

List of Tables

Table 1-1: Warning Label Legend ............................................................................................................................... 2

Table 1-2: PGC Safety Devices ................................................................................................................................. 14

Table 3-1: Cooling Water Flow/Temperature Requirements ..................................................................................... 29

Table 3-2: Electrical Requirements ............................................................................................................................ 31

Table 8-1: General Specifications .............................................................................................................................. 51

List of Illustrations

Figure 1-1: Typical Warning Labels ............................................................................................................................. 3

Figure 1-2: Hazard Labels, Exterior Side Panels, Air-Cooled PGC 152 ..................................................................... 6

Figure 1-3: Hazard Labels, Front, Left, & Top Sides, Air-Cooled PGC 152 ................................................................ 7

Figure 1-4: Hazard Labels, Rear & Left Sides, Air-Cooled PGC 152 .......................................................................... 8

Figure 1-5: Hazard Labels, Exterior Side Panels, Water-Cooled PGC 152 ................................................................ 9

Figure 1-6: Hazard Labels, Lower Front & Right Sides, Water-Cooled PGC 152 ..................................................... 10

Figure 1-7: Hazard Labels, Lower Rear & Left Sides, Water-Cooled PGC 152 ........................................................ 11

Figure 1-8: Caution Label, PGC 152 Optional Flow Control Unit .............................................................................. 12

Figure 1-9: Run & Start Capacitors ............................................................................................................................ 16

Figure 2-1: System Block Diagram ............................................................................................................................ 19

Figure 2-2: Electrical Distribution Diagram ................................................................................................................ 20

Figure 2-3: System Dimensions ................................................................................................................................. 21

Figure 2-4: Air Cooled PGC 152 w/o Flow Control (Ext. Panels Installed) ................................................................ 23

Figure 2-5: Air Cooled PGC 152 w/o Flow Control (Ext. Panels Removed) .............................................................. 24

Figure 2-6: Water Cooled PGC 152 w/ Flow Control (Ext. Panels Installed) ............................................................ 25

Figure 2-7: Water Cooled PGC 152 w/ Flow Control (Ext. Panels Removed) .......................................................... 26

Figure 3-2: Remote Bypass Jumper .......................................................................................................................... 32

Figure 3-3: Optional Flow Control Gas Inlet & Outlet ................................................................................................ 34

Figure 3-4: PGC Gas Inlet & Outlet ........................................................................................................................... 35

Figure 3-5: PGC-152 Typical Capacity (Flow Rate vs. Gas-Outlet Temperature) .................................................... 36

Figure 10-1: Process & Instrumentation Diagram, PGC-152 W/CE/S2 .................................................................... 55

Figure 10-2: Process & Instrumentation Diagram, PGC-152 CE/S2 W/ Flow Control .............................................. 56

Figure 10-3: Circuit Diagram, PGC-152 CE W/RMT IEC ........................................................................................... 57

Figure 10-4: Circuit Diagram, PGC-152 CE/S2 Flow Control Option ........................................................................ 58


825101-00 (Rev C) Page 1

1 SAFETY INFORMATION

1.1 Safety Hazards and Safeguards

This chapter summarizes safety concerns (hazards, precautions, and ergonomics) associated with the operation and service of Polycold’s Cool Solutions

® Gas Chillers.

The Gas Chillers have been designed to conform to all known safety requirements applicable to Brooks Automation Inc. wafer fab equipment. Under normal operation the direct refrigeration and heating equipment presents no hazard to its operator or other personnel. Tool secured access panels shield operators and other personnel working in the area of the equipment from the operation or possible failure of the components that compose the equipment.

Only qualified service personnel are authorized to open or remove the panels and must be in accordance with the safety instructions presented in this chapter and throughout the manual. In service and repair operations, the direct refrigeration and heating equipment may potentially expose personnel to the following hazards:

Electrical Shock

Hazardous Materials

Lifting Hazards

Cold Surfaces

Hot Surfaces

The information and instructions provided in this chapter and throughout this manual are intended to help service personnel work with the equipment in a safe, effective, and efficient manner. The emergency and safety procedures are provided to help service personnel develop safe practices and establish safe conditions for working with Polycold’s Cool Solutions

® Gas Chillers.


825101-00 (Rev C) Page 2

1.2 Danger, Warning, and Caution Alerts

Danger, Warning, and Caution alerts are integral parts of these instructions:

DANGER is used to indicate an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING is used to indicate a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION is used to indicate a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

CAUTION is also used when failure to follow instructions or precautions can result in damage to the equipment.

Danger, Warning, and Caution alerts must be read carefully, understood thoroughly, and observed at all times. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Pictorial hazard alerts affixed to the direct refrigeration and heating equipment and its components are in accordance with ANSI, FDA, SEMI, and (where applicable) IEC standards. Pictorial hazard alerts follow the format described below:

`

‡ SAFETY ALERT SYMBOL

DANGER - White Lettering / Red Background (Safety Red: per ANSI Z535.4 - 15 parts Warm Red, 1 part Rubine Red, 1/4 part Black)

White Triangle / Red Exclamation Point

WARNING - Black Lettering / Orange Background (Safety Orange: per ANSI Z535.4 - 13 parts Yellow, 3 parts Warm Red, 1/4 part Black)

Black Triangle / Orange Exclamation Point

CAUTION - Black Lettering / Yellow Background (Safety Yellow: per ANSI Z535.4 - Pantone 108C)

Black Triangle / Yellow Exclamation Point

Table 1-1: Warning Label Legend

Text describing how to

avoid the hazard

Text describing hazard and what might

/ could happen

Hazard Keyword Level Pictogram (icon) depicting nature

of hazard


825101-00 (Rev C) Page 3

This page includes pictogram representations used on semiconductor manufacturing equipment. Some of these pictograms will be found on Polycold’s Cool Solutions

® Gas Chiller equipment. Actual label

configurations and placement will be found in this chapter. Please note, for purposes of clarity, most illustrations depicting hazardous exposures show components in their most hazardous state (i.e., covers removed, safety interlocks, and other safeguards defeated) as they might appear during a major service

activity. Most tasks do not require that the hazards be exposed to this degree.

Figure 1-1: Typical Warning Labels


825101-00 (Rev C) Page 4

1.3 Safety Training Guidelines

The safety information in this chapter is a summary of the safety information that is to be successfully conveyed to service personnel as part of their training on Polycold’s Cool Solutions

® Gas Chillers. The

training program is intended to ensure that any person who undertakes the service of the Gas Chiller can demonstrate competence to perform the required tasks safely. Accordingly, training required for each task includes, but is not limited to, the following:

A review of applicable safety standards and procedures, such as those presented in this chapter.

A review of maintenance and safety recommendations applicable to vendor supplied equipment.

An explanation of the purpose of a subsystem and its operation.

An explanation of the specific tasks and responsibilities of each person (operator, service personnel, etc.) assigned to the Gas Chillers equipment.

The person(s) (identified by name, location, and telephone number) to be contacted when required actions are beyond the training and responsibility of the person being trained.

Identification of the recognized hazards associated with each task.

Identification of, and appropriate responses to, unusual operating conditions.

Explanation of the functions and limitations of all safeguards and their design characteristics.

Instructions for the functional testing (or other means of assurance) for proper operation of safeguarding devices.

Safe use and service of the Gas Chiller equipment also requires the following:

Service personnel should understand the operation of process-related hardware interlocks, and the sequences of hardware operation that are executed automatically, as explained in this chapter.

The equipment should not be used without assuring correct operation of all connected facilities, especially fugitive emissions exhaust.

Service personnel should always assume that high voltage is present unless they have personally turned it off and locked it out.

The equipment should not be operated without all guards and safety devices in place.

The equipment should be shutdown, locked-out, and not be operated while it is being maintained.

Users should not attempt to defeat, modify, or disable any of the equipment's safety interlock switches.

Only Brooks Automation Inc. trained service personnel should perform installation, assembly, operation, disassembly, service, or maintenance of the PGC.

All safety related incidents or near misses should be reported to a supervisor or to Brooks Automation Inc.

The user should carefully review and understand manufacturer provided material safety data sheets (MSDS) for materials used by this equipment.

1.4 Definition of Electrical Work Types

The following are the four types of electrical work in SEMI S2-0200:

Type 1- Equipment is fully deenergized.

Type 2- Equipment is energized. Energized circuits are covered or protected.

Note: Type 2 work includes tasks where the energized circuits are or can be measured by placing probes through suitable openings in the covers or insulators.


825101-00 (Rev C) Page 5

Type 3- Equipment is energized. Energized circuits are exposed and inadvertent contact with uninsulated energized parts is possible. Potential exposures are no greater than 30 volts rms, 42.4 volts peak, 60 volts dc or 240 volt-amps in dry locations.

Type 4- Equipment is energized. Energized circuits are exposed and inadvertent contact with uninsulated energized parts is possible. Potential exposures are greater than 30 volts rms, 42.4 volts peak, 60 volts dc or 240 volt-amps in dry locations. Potential exposures to radio-frequency currents exist; refer to SEMI S2-0200, Table A5-1 of Appendix 5 for a listing of these values.

1.5 Potential Hazards During Maintenance & Servicing

This section illustrates the placement of labels on both air & water-cooled versions of the PGC (and flow control option) that identify the location and type of potential hazards that may be encountered within the unit. Some labels identifying other notable features are also depicted.

For brevity, only (2) of (4) model configurations are illustrated. An air-cooled gas chiller without a flow control unit, and a water-cooled gas chiller with a flow control unit are shown, however both air and water-cooled models can be configured with or without the optional flow control unit. Selection of the optional flow control unit only affects one hazard label. Models configured with a flow control unit are rated for a maximum gas supply pressure of 100 psi. Models without the flow control unit are rated for a maximum gas supply pressure of 400 psi.


825101-00 (Rev C) Page 6

1.5.1 Air Cooled PGC 152 w/o Flow Control Unit

The figure below shows an Air-Cooled PGC 152 with all exterior panels installed. The (3) hazard labels shown below are affixed to all (4) exterior side panels.

Figure 1-2: Hazard Labels, Exterior Side Panels, Air-Cooled PGC 152

Front & Right Sides Rear & Left Sides


825101-00 (Rev C) Page 7

The figure below shows the front and right sides of an Air-Cooled PGC 152 with the exterior side panels removed. The caution label on top of the unit specifies the gas types and the maximum gas supply pressure that can be connected to the gas inlet tube. The hazardous voltage warning label is affixed to

the units’ electrical enclosure.

Figure 1-3: Hazard Labels, Front, Left, & Top Sides, Air-Cooled PGC 152

The maximum 400 psi (2760 kPa) rating shown, only applies when connecting directly to the PGC. When connecting to the optional Flow Control Unit, the maximum rating is 100 psi (690 kPa).


825101-00 (Rev C) Page 8

The figure below shows the rear and left sides of an Air-Cooled PGC 152 with the exterior side panels removed. These warning labels are affixed to the Primary Expansion Tank and the Compressor.

Figure 1-4: Hazard Labels, Rear & Left Sides, Air-Cooled PGC 152

PRIMARY REFRIGERANT EXPANSION TANK

407020 REV 01 XQS23689


825101-00 (Rev C) Page 9

1.5.2 Water Cooled PGC 152 with Flow Control Unit

The figure below shows a Water-Cooled PGC 152 with all exterior panels installed. (Shown with Optional Flow Control Unit installed.) The (3) hazard labels shown below are affixed to all (4) exterior side panels.

Figure 1-5: Hazard Labels, Exterior Side Panels, Water-Cooled PGC 152

Front & Right Sides Rear & Right Sides


825101-00 (Rev C) Page 10

The figure below shows the lower front and right sides of a Water-Cooled PGC 152 with the exterior side panels removed. The hazardous voltage warning label is affixed to the units’ electrical enclosure.

Figure 1-6: Hazard Labels, Lower Front & Right Sides, Water-Cooled PGC 152


825101-00 (Rev C) Page 11

The figure below shows the lower rear and left sides of a Water-Cooled PGC 152 with the exterior side panels removed. These warning labels are affixed to the Primary Expansion Tank and the Compressor.

Figure 1-7: Hazard Labels, Lower Rear & Left Sides, Water-Cooled PGC 152

PRIMARY REFRIGERANT EXPANSION TANK

407020 REV 01 XQS23689


825101-00 (Rev C) Page 12

The caution label on top of the Optional Flow Control Unit specifies the gas types and the maximum gas supply pressure that can be connected to the inlet tube of the Flow Control Unit.

Figure 1-8: Caution Label, PGC 152 Optional Flow Control Unit

The maximum 100 psi (690 kPa)

rating shown, only applies when

connecting to the optional Flow

Control Unit. When connecting

directly to the PGC , (See figure

1.3) the maximum rating is 400 psi

(2760 kPa).


825101-00 (Rev C) Page 13

1.6 Material Safety Data Sheets

The user is advised to retain current copies of material safety data sheets (MSDS) for refrigerants and cleaning agents used in the operation and maintenance of this equipment. One copy of the MSDS for the system refrigerant has been attached to this users manual.

1.7 Refrigeration Compliance

The PGC 152 is free of HCFC refrigerants in accordance with the Montreal Protocol and the European law banning HCFC refrigerants EC 2037/2000.

1.8 Conversion Factors & Formulas

1 psig = 0.07 bar = 0.07 kg/cm5 °F = (9/5 x °C) + 32

1 inch = 2.54 centimeters, exactly C = 5/9 x (°F -32)

1 pound = 0.45 kilograms

1 standard cubic foot per hour (SCFH) = 0.47 standard liters/minute


825101-00 (Rev C) Page 14

1.9 Safety Devices

Safety Devices incorporated in the PGC and their functions are described below:

Descriptor

Name

Function

MCB1

Main Circuit Breaker

The Main Circuit Breaker provides overcurrent and short circuit protection for the PGC. In the event of an overcurrent/short circuit the contacts of the Main Circuit Breaker separate, removing power from conductors and components downstream of the breaker. Host equipment should provide a circuit breaker with 10,000 ampere interrupt capacity (AIC).

OL1

Thermal Overload

Protector

The Thermal Overload Protector is coupled to the hermetic compressor in the area of the motor windings. In the event of excess temperature at the motor, the thermal switch opens removing power from the compressor. This switch is configured for auto reset.

FP1

Fusible Plug

A fusible plug is installed in the discharge plumbing of the compressor and serves as the controlled release point for refrigerant should a fire occur in the area of the PGC. The fusible plug provides a means to reduce high pressures caused by excessive ambient temperatures in a manner which does not result in an explosion.

HPS

High Pressure

Switch

A high pressure switch is incorporated in the discharge side of the compressor. The switch opens contacts if the refrigerant pressure exceeds normal operating pressure, interrupting power to the compressor and turning it off. This switch requires manual reset. It should not be adjusted by the user.

HTS

High Temperature

Switch

A high temperature switch is coupled to the condenser liquid side. In the event that the condenser is obstructed or air or water flow is otherwise interrupted (including fan failure), the liquid temperature will rise, opening the contacts on the high temperature switch. This removes power from the compressor and fan (where applicable). This switch requires manual reset. It should not be adjusted by the user.

Table 1-2: PGC Safety Devices

Safety devices are identified in the P& ID and Circuit diagrams in Section 10.


825101-00 (Rev C) Page 15

1.10 Lock-Out and Tag-Out Instructions (LOTO)

WARNING ELECTRICAL HAZARD Contact could cause electric shock and result in death or serious injury. After performing LOTO of the Power Disconnect Switch, Line Voltage is still present at input terminals of the Power Disconnect Switch. To remove electrical power to the input terminals of the Power Disconnect Switch, refer to end-user’s Facility Power LOTO instructions.

Electrical Lock Out and Tag Out

Notify personnel you are performing a Lock-Out Tag Out (LOTO).

Shut down system following normal procedure: Turn the PGC-152 power switch to the OFF position. Verify that the compressor is off and the indicator lights Power and Run are OFF.

Isolate the system from the electrical supply by opening the customer supplied disconnect switch or unplugging the unit from the power receptacle. Verify that the Line indicator light is not lit.

Prevent re-connection of the electrical supply to the unit by applying a suitable lock-out device (not supplied) to the customer switch or the disconnected plug. Attach a tag stating: “This equipment is locked out. Do not operate.” to the switch or plug. Write your name and phone number on the tag.

Verify the system is locked-out. Observe that all indicator lights are OFF, turn the PGC-152 power switch to ON and verify that the compressor does not start and all indicator lights remain off. Then turn the PGC-152 power switch to OFF.

Caution!

Safety devices are installed on the PGC to help protect it from permanent damage. If a protective device is triggered, the cause of the problem must be corrected before continuing to use the PGC. Please see "Trouble-Shooting" section or call the Brooks Automation Inc. Service Department for assistance. Bypassing or repeated resetting of a protective device may expose personnel and or the facility to hazards, permanently damage the equipment, and may void your warranty.


825101-00 (Rev C) Page 16

It may be necessary to discharge the capacitors directly by connecting a 10KΩ resister from each capacitor terminal to ground. A qualified and trained technician must perform this procedure. The capacitors are located inside the electrical enclosure. See figure below.

Figure 1-9: Run & Start Capacitors

Use a voltmeter to verify “0” volts in the area you will be working. Service can now be performed.

To reenergize, reverse first 4 steps.

Gas Supply Lock Out and Tag Out

Notify personnel you are performing a Lock-Out Tag Out (LOTO)

Isolate the system from the gas supply by closing the customer supplied gas shutoff valve.

Lock the customer shutoff valve in the off position using a lockout device (not supplied) and place a tag, which states “This equipment is locked out”, and include your name, and “Do not operate.”

Verify the system is locked-out by cracking the gas inlet fitting on the PGC unit and allow the pressure to bleed down for 2 minutes—the flow should gradually slow to a stop.

To re-establish gas supply, reverse first 3 steps.

1.11 Safety Interlocks

The PGC safety interlock circuitry design is a positive logic, hardware based, fault tolerant device (approved by an authorized testing agency and NRTL approved for use as a safety device), providing operator notification, requiring manual reset, and which places the equipment in a safe standby condition upon activation.

1.12 Circuit Breaker Protection

Over Current Protection is provided by the Main Circuit Breaker (MCB1) located on the PGC 152’s Front Panel. (MCB1 is labeled “Power”.) The rating voltage and amperage for MCB1 are 230V and 20A.

Note: Units built prior to April 11, 2005 are equipped with a 16A circuit breaker.

Run & Start

Capacitors


825101-00 (Rev C) Page 17

1.13 Emergency Shut-Down Procedures

Refrigerant Leak

WARNING CHEMICAL HAZARD Do not release refrigerant to the atmosphere. Opening the refrigerant circuit or changing valve settings along with the failure to following instructions in this manual could result in death or serious injury. Review this manual before performing any procedure including routine operation of

Polycold’s Cool Solutions ®

Gas Chillers. Do not release refrigerant to the

atmosphere.

For all leaks: Follow the instructions in the Material Safety Data Sheets.

Electrical Problem

WARNING ELECTRICAL Failure to have a qualified electrician do all electrical work could result in death or serious injury. Do not reach inside the refrigeration unit. A qualified electrician must do all electrical work.

Turn off the unit.

Turn the power disconnect switch to the OFF position.

Disconnect the refrigeration unit from your electrical supply, if necessary.

Refer to the Lock-out Tag-out procedure on preceding pages if the unit requires service.


825101-00 (Rev C) Page 18


Overview PGC Manual

825101-00 (Rev C) Page 19

2 OVERVIEW

2.1 System Diagrams

Figure 2-1: System Block Diagram

Refrigeration Compressor

Unit

Air or Water Cooled

Condenser

Pressure Gauge

Refrigeration Cooling Stack

Flow Control Option

Host Equipment

Customer Gas

Supply

Valve

Flow Sw.

Vent Gas Out

Gas In

Gas In Gas Out

Supply

Return

Cooling Water*

* Water Cooled units only.

Expansion Tank

Overview PGC Manual

825101-00 (Rev C) Page 20

Figure 2-2: Electrical Distribution Diagram

Power Switch MCB1

Refrigeration Compressor

Unit

Host

Equipment

EMO

Remote/Local Bypass

System Remote Interface

EMO*

Flow Switch

Valve

Flow Control Option

Remote Controller

Motor Contactor

Safety Interlocks

Thermocouple Gauge

Gas Outlet

Customer Supplied Optional Equipment * Flow Control Option EMO does not operate locally. It is provided for customer to wire as a remote EMO for the host equipment.

Facility Power Drop 208 1 Phase 50/60 Hz

Overview PGC Manual

825101-00 (Rev C) Page 21

Figure 2-3: System Dimensions

2.2 About the PGC

The PGC is a refrigeration unit that cools a stream of gas to cryogenic temperatures. It consists of two separate circuits: a refrigerant circuit and a gas circuit.

The refrigerant circuit is located entirely within the PGC. The compressor pumps the refrigerant in a continuous loop through the Polycold

® stack. The condenser removes heat from the refrigerant, and the

Polycold® stack cools the refrigerant to cryogenic temperatures. (The refrigerant is actually a proprietary

mixture of refrigerants provided by Brooks Automation Inc.)

The gas circuit consists of a continuous copper tube that runs next to the refrigerant circuit. The gas is cooled as it runs parallel to the cold refrigerant. (Performance specifications assume that ambient air temperature is no higher than 79°F (26°C).

Overview PGC Manual

825101-00 (Rev C) Page 22

2.3 PGC 152 Model Features

Suction Gage: This gage displays the compressor's suction pressure while the PGC is operating; it also displays the balance pressure after the PGC is off for 24 hours.

Gas Inlet: This is the beginning of the internal gas circuit, and the tube to which you connect your gas

source. Note: The materials used in the gas portion of the system are intended for use with dry gases (Air and inert gasses N2, Argon, Helium) only.

Gas Outlet: This is the end of the internal gas circuit where the cold gas exits.

Gas-Outlet Thermocouple Wire: (See Figure 2-5.) If attached to a type-T temperature meter, this wire

indicates the temperature of the Gas Outlet just inside the Polycold® stack. You may use it to monitor

the PGC's performance when gas is flowing.

Power Switch with Thermal Circuit Breaker: If the current exceeds 16 amps, the circuit breaker is

triggered and turns off the power switch.

Fan & Cooling Coil: The condenser on air-cooled models removes heat from the refrigerant by drawing ambient air across a coil.

Cooling Water Inlet & Outlet: The condenser on water-cooled models requires customer supplied cooling water to remove heat from the refrigerant.

Note: The PGC does not have a thermostat on the gas outlet. It is designed to cool the gas stream to the coldest temperature possible, depending on the load. (See Figure 3-4.)

The above features are illustrated on an air-cooled gas chiller without a flow control unit and a water-cooled gas chiller with a flow control unit. For brevity, only (2) of (4) model configurations shown, however both air and water-cooled models can be configured with or without the optional flow control unit.

Overview PGC Manual

825101-00 (Rev C) Page 23

2.3.1 Exterior Features, Air Cooled PGC 152 w/o Flow Control Unit

Figure 2-4: Air Cooled PGC 152 w/o Flow Control (Ext. Panels Installed)

Top Rear Edge Gas

Outlet

Gas Inlet

Suction Gauge

Power Switch Circuit Breaker

Overview PGC Manual

825101-00 (Rev C) Page 24

2.3.2 Interior Features, Air Cooled PGC 152 w/o Flow Control Unit

Figure 2-5: Air Cooled PGC 152 w/o Flow Control (Ext. Panels Removed)

Rear View Fan & Coils

Fan & Cooling

Coils

1of 4 Seismic Anchor Points

Gas Outlet Thermo-

Couple Wire

Overview PGC Manual

825101-00 (Rev C) Page 25

2.3.3 Exterior Features, Water Cooled PGC 152 with Flow Control Unit

Figure 2-6: Water Cooled PGC 152 w/ Flow Control (Ext. Panels Installed)

Suction Gauge

Power Switch Circuit Breaker

Gas

Inlet Gas

Outlet

Overview PGC Manual

825101-00 (Rev C) Page 26

2.3.4 Interior Features, Water Cooled PGC 152 with Flow Control Unit

Figure 2-7: Water Cooled PGC 152 w/ Flow Control (Ext. Panels Removed)

Gas Outlet Thermo-Couple Wire

Cooling Water Inlet & Outlet

Installation PGC Manual

825101-00 (Rev C) Page 27

3 INSTALLATION

3.1 Tools and Materials Required

Pallet Truck, Hand Truck, or Dolly

230V plug to fit power supply (may be supplied with power cord assembly)

Wire Stripper

Small Screwdriver

3.2 Inspect the PGC

Notify the carrier immediately if you suspect the PGC was damaged during shipping. Read the outer black dial of the SUCTION GAGE and record the balance pressure: ________ psig. The balance pressure should be 140-160 psig for a PGC-152. If not, contact your local sales representative or Brooks Automation Inc. for assistance.

3.3 Position the PGC

Place the PGC as close as possible to the desired location of your cold gas stream.

The PGC should be transported from the receiving area to its installed location on a hand truck, dolly, or pallet truck

The PGC must remain vertical during transport and installation.

The PGC installation location must be indoors, in a well-ventilated area greater than 100 ft3 (2.83

m3), ambient temperature 40-90°F(4-32°C), relative humidity (RH) 20-80%, no condensation.

Placing the PGC in a confined area will increase the time required to service and maintain the unit. We recommend providing as much clear service access as the facility will allow. If possible, allow 36 inches (90cm) of clear space at the front and rear of the unit.

Water-Cooled PGC’s may be placed side by side without clear space between them.

The Air-Cooled PGC requires 12 inches (30 cm) of clear space on the left and right sides, and 18 inches (45cm) of clear space on the top and rear sides to ensure sufficient air flow to cool the

condenser.

WARNING! Allowing hot air exhaust from one unit to enter an adjacent unit will result in a high temperature fault. When installing multiple air cooled units, hot air exhausting from one unit must be directed away from the air intake of adjacent units. See Fig. 3-1.

The Air-Cooled PGC requires air in the acceptable ambient temperature range to cool its condenser. Do not place the Air-Cooled PGC adjacent to equipment that emits heated air. The heated air will not cool the units condenser adequately.

Performance specifications assume the ambient air temperature is no higher than 79°F (26°C). Performance will decrease as the ambient temperature rises.

The base frame of the PGC can be secured to the floor at the four locations labeled Seismic Anchor Point.

WARNING! Due to its weight, two persons are required to move the PGC from the transport unit.


825101-00 (Rev C) Page 28

Front

Air In

Air Out

PGC-152PGC-152PGC-152

Fig 3.1

Front

Air Out Air In

PGC-152

PGC-152

PGC-152

0.3m

12" MIN

}

}

0.3m

12" MIN

3.4 Cooling Water Connection (WC Units)

Tools and materials needed:

1/2-inch (15 mm) standard pipe size wrench.

Adjustable or open ended wrench for fittings supplied by customer

Verify your cooling water is adequate:

The inlet water temperature must be 55-85°F (13-29°C).

Refer to the table below to determine the minimum acceptable cooling water flow rate based on the cooling water temperature.

Cooling water temperature varies between seasons. Cooling water lines within the PGC are not insulated. To prevent condensation inside the system enclosure, ensure that the cooling water temperature is higher than the dew point at the installed location.

Maximum working pressure of the cooling water circuit is 200 psig (1380 kPa).

Cooling water must be clean and suitable for use in copper based heat exchangers. Filter cooling water that is dirty or contains abrasives.

Chemical impurities in the cooling water must be compatible with copper.


825101-00 (Rev C) Page 29

Connect a supply and a drain line to the refrigeration unit.

Use the pipe size specified at the beginning of this section.

The Cooling Water connections are 1/2-inch female NPT fittings.

Connect the supply line to the port marked IN. Connect your drain line to the port marked OUT. The cooling water must flow in this direction to properly cool the unit.

Verify that the cooling water plumbing does not leak.

Refrigeration Unit

Water Inlet Temperature ° F (° C)

Minimum Flow Rate Gpm (L/min)

Pressure Drop Inside Unit Psi (kPa)

Heat Rejection Btu/hour (kW)

PGC 152

59 (15) 75 (24) 87 (30)

.68 (2.6) 1.1 (4.3) 2.0 (7.6)

<1 (<7) <1 (<7) 3 (21)

23,900 (7.0)

Table 3-1: Cooling Water Flow/Temperature Requirements

‡ CAUTION! EQUIPMENT DAMAGE

Do not turn on the unit until the cooling water has been connected and turned on.

3.5 Connect the Gas-Outlet Thermocouple Wire to a Temperature Meter (Optional)

Tools Required:

Philips®

Screwdriver

Thermal Wire Stripper

Temperature Meter (Suitable for reading type-T copper-constantan thermocouple wire)

First, lock-out & tag-out the unit as described in the Safety section. Then remove the PGC's front panel. Locate the Gas-Outlet Thermocouple Wire, which is the brown insulated wire directly to the left of the Suction Gage. Uncoil the wire, thread it through the ventilation grating and re-install the front panel.

Strip the thermocouple wires' brown jacket to fit your temperature meter. Separate and strip insulation from the ends of the red & blue thermocouple wires. Connect the thermocouple wires to your temperature meter. (Red is negative; blue is positive.)

Note: You may also want to attach a type-T (copper-constantan) thermocouple to the end of your insulated gas-out line. This thermocouple would allow you to measure the actual temperature of your exiting gas stream, and determine the amount of heat loss on the gas-out line (by comparing the temperatures of the two thermocouples). See section 8.2 "Thermocouple Attachment Specification" for instructions.


825101-00 (Rev C) Page 30

3.6 Connect the Electrical Power

‡ WARNING †

HAZARDOUS VOLTAGES

Electrical power to the PGC-152 must be connected by qualified personnel according to local codes.

‡ WARNING †

HAZARDOUS VOLTAGES EXIST AT ALL TIMES AFTER THE POWER IS CONNECTED

Adhere to the Lock-out Tag-out procedures described in the Safety section when performing any subsequent installation or

maintenance operations.

The circuit breaker on the host equipment used as the main disconnect switch for the PGC should be operator accessible, located in sight and within 25' of the PGC. Before connecting the PGC to your power source, verify the following:

Your actual voltage falls within the acceptable range listed in the Table below

Your electrical supply must have enough capacity to handle the Rated Load Amps and should be provided through a circuit breaker rated with at least 10,000 AIC. Recommended circuit breaker rating is 20 amps.

The PGC is grounded according to your local codes.

The PGC has been installed so that it is protected by the Emergency Off circuitry of the host equipment. (The PGC is intended to function as a subsystem of the host equipment, it does not have its own EMO circuitry.)

For additional information, you may wish to refer to the electrical schematics in section 10.


825101-00 (Rev C) Page 31

Table 3-2: Electrical Requirements

3.7 Connection of Flow Control Unit (Optional)

Refer to the Flow Control Unit’s circuit diagram in the Process & Instrumentation and Electrical Schematics section for wiring details.

Connect the Flow Control Unit to the Host Equipment to enable the remote Flow Control and Monitoring.

Specifications:

Flow Switch Rated 20VA (0-30V .3A, 240V .06A)

Solenoid Valve 24V DC @ 37mA (minimum requirement)

The EMO switch on the Flow Control Unit does not operate locally. If desired, the EMO switch may be incorporated into the host equipment EMO circuitry

3.8 Power Interruption/Restoration

The PGC system is configured with a single on/off switch. In the event of power interruption, the PGC ceases operation. On restoration of electrical power, the PGC system will restart without operator intervention. To place the equipment in a safe shut-down condition, turn the PGC Main Power Switch OFF.

3.9 PGC Remote Control System (Optional)

The remote control system provides two distinct functions: Remote monitoring of the run status of the unit, and remote on/off control of the unit. The remote monitoring feature is always available. Availability of the remote on/off feature is controlled by jumper configuration. (See following section.) Isolation between the remote control and the high voltage circuits of the system is provided by the Relays. The isolation between coil circuit and contact circuit is rated at a minimum of 2000 VAC.

Specifications:

ON/OFF Control Voltage = 24V DC @ 37mA (minimum requirement)

Nominal Compressor Rating (volts)

Acceptable Voltage Range3

Rated Load Amps1, 2, 3

At 50 Hertz

200/208-1-50 180-229 10A, 16A

208/230-1-60 At 60 Hertz

10A, 16A 187-253

1Rated Load Amps (RLA) is the current drawn by the compressor at rated load. It may also

be referred to as the maximum full load amps.

2RLA listed is based on 80% of unit circuit breaker rating and adherence to the specified

voltage range. Operation outside this voltage range (particularly higher voltage at 50 Hz) will result in excessive current draw and may cause the circuit breaker to trip.

3Units built prior to April 11, 2005 had a 16A circuit breaker. This limits the 50Hz voltage

range to 180-220V and has a corresponding RLA of 12.8A.

Note: The compressor is provided with motor over temperature protection that complies with UL and NEC definitions of inherent thermal protection.


825101-00 (Rev C) Page 32

Run Monitor Output Rated: 300V @ 1 AMP (maximum)

Remote Connector Pin outs

Pin #1 = + 24 VDC On/Off Control Input

Pin #2 = - 24 VDC On/Off Control Input

Pin #3 = Run Status Contact (Source)

Pin #4 = Run Status Contact (Return)

3.10 Enable Remote On/Off Operation

First, lock-out & tag-out the unit as described in the Safety section. Then, remove the PGC front panel. Locate the E-Box cover retaining screws. Use a standard flat blade screwdriver to loosen the screws then, swing open the cover. Disconnect the Remote Bypass Jumper located in the bottom of the E-Box. (See figure on following page.) Close the E-Box cover, tighten the screws, and re-install the front panel.

Re-establish power to the unit and set the power switch to the ON (l) position. The unit will now respond to remote ON/OFF control.

Figure 3-2: Remote Bypass Jumper

5

4

3

2

1

FRONT VIEW DE9 MALE

Remote Bypass Jumper


825101-00 (Rev C) Page 33

To turn the unit ON, apply 24 VDC of the proper polarity to Pin #1 & Pin #2 (see pin outs above).

CAUTION! Reversing the polarity of this connection may cause permanent damage to the parallel protection diode across the relay coil.

The Run Status Contact should close once the unit is running. This will close the connection from Pin #3 to Pin #4. This contact may be used to turn on a remote indication device, or be monitored by a PLC.

For more specific information, refer to the circuit diagrams in the Process & Instrumentation and Electrical Schematic section.

3.11 Install the External Gas Circuit


Tubing or hoses with 3/8-inch inner diameter

Armaflex® or equivalent closed-cell insulation rated for cryogenic temperatures

Armaflex® tape or equivalent

Armstrong® 520 adhesive or equivalent


825101-00 (Rev C) Page 34

Verify the Gas Source is Adequate.

If your gas contains moisture, the water will condense and freeze in the gas circuit. The PGC performance will degrade as the gas circuit becomes blocked. The PGC system is designed for use with inert gases (Nitrogen, Argon, Helium) only. Contact Brooks Automation Inc. prior to introduction of gases other than those specified.

To avoid any blockage, your gas should have a dew point colder than -80°C. However, if your gas has a dew point of -60°C, the PGC will perform long enough for most applications. If the gas circuit becomes

blocked, see the Inspection & Maintenance section.

‡ WARNING †

EXPLOSION HAZARD

Do not exceed 100 psi supply pressure to PGC flow control unit.

The figure below identifies the gas inlet and outlet on the optional Flow Control Unit of the PGC. Do not exceed 100 psi supply pressure when connecting gas to the inlet of the Flow Control Unit.

Figure 3-3: Optional Flow Control Gas Inlet & Outlet

‡ WARNING †

EXPLOSION HAZARD

Do not exceed 400 psi supply pressure to PGC.

The following figure identifies the gas inlet and outlet on a PGC without the optional Flow Control Unit. Do not exceed 400 psi supply pressure when connecting gas directly to the inlet of the PGC.

Gas

Outlet

Gas

Inlet


825101-00 (Rev C) Page 35

Figure 3-4: PGC Gas Inlet & Outlet

Connect:

The gas source to the unit’s GAS INLET

The unit’s GAS OUTLET to the location you wish to direct the cold gas stream.

Hoses with clamps or metal tubing are both acceptable.

Use hoses with clamps or metal tubing with flare unions if you want to be able to disconnect the external gas circuit easily. (This allows for easier removal of moisture from the internal gas circuit, especially if your equipment is sensitive to water.)

Use copper tubing (not stainless steel) if you want to attach a thermocouple to the gas-out line. (See section 3.4 for thermocouple installation details.)

If you will be brazing, see the section on “Brazing Specifications”.

Insulate the full length of the gas-out line with at least 1-1/4 inches of insulation for maximum performance. Completely seal all seams with glue or tape. This keeps moisture from collecting on the gas-out line when it is cold.

Set the Flow Rate at the gas supply tanks.

CAUTION! If using Armstrong adhesive, the work area must be adequately ventilated and free of ignition sources. Read the container label and follow the manufacturer’s instructions.

Top Rear Edge

Gas Inlet

Gas Outlet


825101-00 (Rev C) Page 36

Rotameter-type flow meters assume standard temperature and pressure to determine flow rate. They should be installed upstream on the gas-in line. You can use this meter on the gas out line temporarily to calibrate gas flow when the PGC is off.

Use the following chart to determine the desired flow rate. The chart is based on data from units powered by a 60 Hz electrical supply and operated at an ambient air temperature no higher than 79°F (26°C).

Outlet temperatures are typically 5°C higher when the units are powered by a 50 Hz electrical supply.

Performance will decrease as the ambient temperature rises.

Figure 3-5: PGC-152 Typical Capacity (Flow Rate vs. Gas-Outlet Temperature)

Operation PGC Manual

825101-00 (Rev C) Page 37

4 OPERATION

4.1 Starting the Polycold Gas Chiller

Condensation of water in the gas circuit could occur while your are waiting for the stack to cool after turning on the PGC, and up to four hours after turning off the PGC.

If your equipment is sensitive to water, avoid condensation while not in use by plugging the open end(s) of the gas circuit, or by allowing a small amount (about 5 SCFH) of dry gas to purge the gas circuit.

Turn on the PGC*. Allow it to cool for 20 minutes. Supply the gas flow for your application. The Gas Outlet should reach temperature in 25 minutes. (See Figure 3-4.)

*If equipped with Optional Flow Control Unit:

Supply the control voltage to start the unit. (See section 3.7)

The EMO switch on the Flow Control Unit does not operate locally. If desired, the EMO switch may be incorporated into the host equipment EMO circuitry

Caution! The PGC will condense water in the gas circuit if the Polycold

® stack is cold, and dry gas is not being pumped

though the gas circuit.

Operation PGC Manual

825101-00 (Rev C) Page 38


Inspection & Maintenance PGC Manual

825101-00 (Rev C) Page 39

5 INSPECTION & MAINTENANCE

5.1 Periodic Inspection

Inspect the PGC:

Every six months.

Whenever it is necessary to remove water from the gas circuit.

Whenever there is a leak.

5.2 Inspect for water condensation in the gas circuit.

Condensation of water in the gas circuit could occur while waiting for the stack to cool after turning on the PGC, and up to four hours after turning off the PGC.

If your equipment is sensitive to water, avoid condensation while not in use by plugging the open end(s) of the gas circuit, or by allowing a small amount (about 5 SCFH) of dry gas to purge the gas circuit.

5.3 If the unit is Air-Cooled, verify there is adequate air circulation through the condenser.

The Air-Cooled PGC requires 12 inches (30 cm) of clear space on the left and right sides, and 18 inches (45cm) of clear space on the top and rear sides to ensure sufficient air flow to cool the condenser.

The PGC requires that approximately 1200 CFM of air be drawn across the condenser coil to achieve optimum performance of the system.

Performance specifications assume the ambient air temperature is no higher than 79°F (26°C). Performance will decrease as the ambient temperature rises.

The condenser fins must be clean and straight. If not, turn the unit off. Lockout the power as discussed in the Safety section. Then, clean and inspect the unit. . Use a vacuum to remove dust and lint. Use a condenser fin comb to straighten the fins.

5.4 If the unit is Water-Cooled, verify the following:

There are no leaks in the cooling water circuit.

The cooling water hoses are in good condition.

The cooling water flow and temperature are adequate. (See Table 3-1.)

5.5 Verify the insulation on the gas-out line is adequate.

The insulation should be air tight.

It should not be cracked or holding moisture.

If necessary, turn off the PGC and replace the insulation. (See section titled "Install the External Gas Circuit".)

5.6 Verify the refrigerant circuit does not have a leak.

Turn off the PGC and wait 24 hours.

Inspection & Maintenance PGC Manual

825101-00 (Rev C) Page 40

The balance pressure should be within 7 psig of the pressure you recorded in the section 3.2. (Inspect the PGC)

If the balance pressure has dropped more than 7 psig, the refrigerant circuit may have a leak.

5.7 Remove moisture from the gas circuit.

If your equipment is sensitive to water, disconnect your external gas-out line from the Gas-Outlet.

Verify the refrigerant circuit does not leak. (See previous paragraph.)

Allow your gas supply to flow (at about 50 SCFH) through the gas circuit until the exiting gas is dry.

The exiting gas should be dry in about 10 minutes.

WARNING! Moisture in the gas circuit while the PGC is operating will freeze, and may block gas flow.

Troubleshooting PGC Manual

825101-00 (Rev C) Page 41

6 TROUBLESHOOTING

6.1 The PGC's Compressor Does Not Start Or Run Properly

Note: See Section 6.4 for troubleshooting and diagnostics based on the indicator lights.

6.1.1 Fan and compressor do not start (and make no noise).

If the On/Off switch stays in the ON position, verify the following.

PGC has power.

Power supply is adequate.

If the On/Off switch has returned to the OFF position (by its circuit breaker), verify the following.


6.1.2 Compressor hums or starts, and then stops.

The circuit breaker for the On/Off switch may have tripped. Or, the thermal overload protector for the compressor may be cycling the compressor on and off. Verify the following.

Fan is working. (Air-Cooled Models)

Cooling Water supply is adequate. (Water-Cooled Models)


6.2 Gas Flow or Temperature Is Inadequate

See Inspection & Maintenance, and verify the following:

Inlet gas flow is within specification. (See Figure 3-4.)

Gas circuit is not plugged.

Gas circuit does not have a leak.

Insulation on the gas-out line is adequate.

Air circulation through the condenser is adequate.

Cooling water supply to condenser is adequate

Refrigerant circuit does not have a leak.

6.3 PGC Makes Unusual Noises

Verify the following.

There are no loose parts (such as the fan shroud or fan blade).

WARNING! Contact your local sales representative or the Brooks Automation Inc. Service Department if you need assistance trouble-shooting or repairing your PGC. Be sure to do this if the compressor has an internal problem, if the refrigerant circuit has a leak, or if the fan needs to be replaced.


825101-00 (Rev C) Page 42

A tube is not rubbing or rattling against another surface.

The fan blade is not bent. (Air-Cooled Models)

Fan motor bearings are not worn. (Air-Cooled Models)

6.4 Indicator Lamp Based Troubleshooting and Diagnostics

This symbol represents an indicator light being ON in the diagrams below.

STATIC MODE 1 (UNIT NOT RUNNING – NO LINE POWER PRESENT)

INDICATOR

COLOR

STATUS

LINE

YELLOW

OFF

RUN

GREEN

OFF

FAULT

RED

OFF

POWER

ORANGE

OFF

POWER SW= N.A.

STATIC MODE 2 (UNIT NOT RUNNING – LINE POWER PRESENT)

INDICATOR

COLOR

STATUS

LINE

YELLOW

ON

RUN

GREEN

OFF

FAULT

RED

OFF

POWER

ORANGE

OFF

POWER SW= OFF


825101-00 (Rev C) Page 43

RUN MODE (UNIT RUNNING - SYSTEM OK)

INDICATOR

LED COLOR

STATUS

LINE

YELLOW

ON

RUN

GREEN

ON

FAULT

RED

OFF

POWER

ORANGE

ON

POWER SW = ON

FAULT MODE 1 (NOT RUNNING - PRESS/TEMP TRIP OCCURRED)

INDICATOR

LED COLOR

STATUS

LINE

YELLOW

ON

RUN

GREEN

OFF

FAULT

RED

ON

POWER

ORANGE

ON

POWER SW = ON

FAULT MODE 2 (NOT RUNNING - CIRCUIT BREAKER SWITCH TRIPPED)

INDICATOR

LED COLOR

STATUS

LINE

YELLOW

ON

RUN

GREEN

OFF

FAULT

RED

OFF

POWER

ORANGE

OFF

POWER SW = ON


825101-00 (Rev C) Page 44

FAULT MODE 3 (NOT RUNNING - COMPRESSOR OVERLOAD TRIPPED)

INDICATOR

LED COLOR

STATUS

LINE

YELLOW

ON

RUN

GREEN

ON

FAULT

RED

OFF

POWER

ORANGE

ON

POWER SW = ON

Indicator Lamp Fault Conditions Explained

The FAULT INDICATOR was designed to show over-pressure (compressor discharge) or over-temperature (condenser liquid line) fault conditions (FAULT MODE 1). However, there are two other fault conditions which have the same overall effect on the system, but won’t show as a normal FAULT indication. These are as follows:

FAULT MODE 2 would be the result of the Circuit Breaker Switch tripping under excessive load conditions, something that would occur if a short circuit were present or if the compressor seized. The symptoms would resemble a STATIC MODE 2 condition. With the exception that the switch would have automatically turned it self OFF, following a previous RUN MODE condition.

FAULT MODE 3 would usually only occur if the internal overload of the compressor were to open. This would appear to be RUN MODE and there would be no indication of this on any of the status indicators. The Fault would show itself as a cyclic action of the compressor (automatically turning on and off). This type of fault would be indicative of a bad compressor.

Fault Mode 1 Corrective Actions

If a FAULT MODE 1 condition has occurred, the RED light will be lit and the compressor will be inoperative. On Air-Cooled Models, the cooling fan will also be inoperative. First, perform a lock-out / tag-out procedure. Remove the left and rear panels to provide access to the manual resets for the pressure switch and the thermostat. To reset the pressure switch (located at the rear of the unit) move the green lever upwards. To reset the thermostat (located on left side of unit) depress the green button. A click will be heard when either component resets. The compressor will attempt a restart when electrical power is restored, safety devices are reset, and the unit is switched ON again.

Following a reset, it is important to determine what caused the fault in initially:

In the case of a thermostat trip on a unit with an air-cooled condenser, observe whether the fan resumes operation and produces a steady breeze when the unit is re-started. Also, watch the fan for a few minutes to see if it is instable, or slows over time. Check the inlet side of the condenser cooling coil for any accumulated build-up of dirt. If so, clean it out with either an air hose, or a vacuum cleaner.


825101-00 (Rev C) Page 45

In the case of a thermostat trip on a unit with a water-cooled condenser, check the cooling water for adequate flow and temperature.

If the fault condition tripped the pressure switch, it may indicate that the process load may be too excessive for the units’ compressor, causing high discharge pressures to exist. Reducing the process gas flow or lowering the gas inlet temperature would in effect lower the system load, and the discharge pressure. The condenser may also be dirty. There is also the possibility, although remote, that a refrigerant leak has caused higher discharge pressures. To ascertain if this is the reason; allow the unit to fully warm up then, check the units’ balance pressure on the front panel gauge. See if the pressure has dropped noticeably, perhaps repeating the check on subsequent days, to verify a dropping pressure.

Fault Modes 2 and 3 Corrective Actions

Call your certified service agent or Brooks Automation Inc.


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Disconnection, Storage and Reshipment PGC Manual

825101-00 (Rev C) Page 47

7 DISCONNECTION, STORAGE, AND RESHIPMENT

7.1 Disconnection

Shut down power to the PGC and allow the system to reach ambient temperature (allow 24 hours to reach thermal equilibrium)

Disconnect facility electrical power from the PGC.

Disconnect remote operation or EMO cabling from the unit.

Disconnect the gas supply line.

Cap the gas inlet & outlet to prevent diffusion of moisture into the system.

If water-cooled, turn off the cooling water lines and disconnect. Use compressed air to blow out remaining water from the lines.

7.2 Packing for Reshipment or Storage

‡ WARNING †

LIFTING HAZARD (235 pounds (107 kg))

Use appropriate lifting technique & proper equipment to prevent injury.

The PGC should be appropriately packaged for shipment. (Securely strapped to shipping pallet and covered for protection.) Contact Brooks Automation Inc. for additional information on packaging and shipping.

Disconnection, Storage and Reshipment PGC Manual

825101-00 (Rev C) Page 48


Appendix PGC Manual

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8 APPENDIX

8.1 BRAZING SPECIFICATION


Tubing cutter

Reamer

Sandpaper or wire brush or steel wool

Pressure or flow regulated dry nitrogen gas

Oxy-acetylene torch or air-acetylene torch (propane is not hot enough)

For copper-to-copper joints use: Harris Dynaflow or Handy & Harman Sil-Fos 6M or equivalent alloy

For copper-to-stainless steel or copper-to-brass joints use: Harris Safety-Silv 56 or Handy & Harman Braze 560 or equivalent silver alloy

Harris Stay-Silv black flux or Handy Flux Type B-1 or equivalent

Note: Brazing operations should be performed by qualified technicians.

Thoroughly clean all mating surfaces to bare metal.

Purge the tubes with dry nitrogen gas while brazing and until the tubes and joints have cooled to below 190EC. (This prevents internal scale formation or oxidation.)

Remove all excess flux from the brazed joints. Use a wet rag while the brazed joint is still hot. Dispose of the contaminated waste in a manner approved by the location.

Carefully inspect each joint for the proper flow of the brazing alloy. Both surfaces should be "wetted" by the alloy.

Carefully check all joints for leaks.

8.2 THERMOCOUPLE ATTACHMENT SPECIFICATION


Type T (copper-constantan) thermocouple wire

Thermal wire stripper

Tools and materials needed for soldering:

Sand paper

Propane torch

Rosin flux

Harris Bridgit or equivalent lead-free solder

Neutralizing agent (to remove the flux)

Note: Brazing operations should be performed by qualified technicians.

Appendix PGC Manual

825101-00 (Rev C) Page 50

Thoroughly clean all mating surfaces to bare metal.

Purge the tubes with dry nitrogen while brazing and until the tubes and joints have cooled to below 190’C.

Remove 2 inch (13 mm) of insulation from one end of the thermocouple wire. Twist the two wires together, and apply flux and pre-tin the twisted wires.

Use sandpaper to remove oxidation from the copper tube, and apply flux and pre-tin the tube.

Apply flux to the pre-tinned wires and to the pre-tinned copper tube.

Position the thermocouple wire so that the first twist of wire (nearest the insulation) is against the tube.

Solder the wire twist to the copper tube. Do not overheat the flux. Do not melt or cut the plastic insulation on the thermocouple wire or it may create false readings.

Important! Make certain the wire twist closest to the insulation is in contact with the copper tube. (It is the first twist of wire closest to the insulation that senses and determines the temperature reading.)

Remove the flux residue using a wet cloth. Dispose of the contaminated waste in an approved manner.

Wrap the thermocouple wire tightly around the tube 3-4 times.

Secure the wire with tie wrap(s) or tape suitable for cryogenic temperatures. Allow enough thermocouple wire to reach your temperature meter.

Apply insulation as described in the Section titled “Install the External Gas Circuit”.

Appendix PGC Manual

825101-00 (Rev C) Page 51

8.3 Specifications

Model Type Air Cooled Air Cool w/ Flow Control

Water Cooled Water Cool w/ Flow Control

Shipping Weight: 235 pounds. (107 kg)

247 pounds (112 kg)

235 pounds. (107 kg)

247 pounds (112 kg)

Voltage

Frequency NominalVoltage Acceptable VoltageRange 50-60Hz 200, 208V 180-229V 208, 230V 187-253V

Gas-Inlet & Outlet Lines:

3/8-inch OD tube

3/8-inch male comp. ftg

3/8-inch OD tube

3/8-inch male comp. ftg

Cooling Air Required: Note: Internal fan provides air circulation

1200 CFM 1200 CFM N/A N/A

Cooling Water Requirements

N/A N/A See Table 3-1 See Table 3-1

Balance Pressure: 140-160 psig

Maximum Gas Flow Rate:

500 SCFH, 100psig max.

Ambient Air Temperature:

4 - 32°C (40 - 90°F)

Approximate Heat Rejection Rate:

4650w (15,870 BTUH)

Noise Emissions: Less than 70 dB(A)

Dimensions: See Figure 2-3

Cooling Water Requirements

See Table 3-1

Electrical Requirements:

See Table 3-2

Cooling Capacity See Figure 3-4

Refrigerant Charges: Refrigerant charges are specified on unit nameplates. Contact your local sales representative or Brooks Automation Inc. for a current price list.

Table 8-1: General Specifications

Appendix PGC Manual

825101-00 (Rev C) Page 52


Glossary PGC Manual

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9 GLOSSARY

ANSI: American National Standards Institute

ASHRAE: American Society of Heating, Refrigerating, and Air-Conditioning Engineers

AWG: American wire gauge

balance pressure: The pressure in the refrigeration unit when the suction and discharge sides of the compressor are equal, and after the refrigerants have fully warmed up (24 hours).

CE: European conformity

Compressor: A component in the refrigeration unit that raises the refrigerant pressure and causes the refrigerant to move through the circuit.

Condenser: A component in the refrigeration unit that removes heat from the refrigerant vapor after it exits the compressor.

EC: European community.

EEC: European economic community

EN: European norm (or standard).

IEC: International Electrotechnical Commission.

Liquid line: A portion of the refrigerant circuit containing high pressure refrigerant just after it has been cooled by the water-cooled condenser,

NEC: national electrical code.

NPT: national pipe thread.

Polycold® stack: The upper portion of the refrigeration unit that is insulated with foam.

Refrigerant: A proprietary mixture of refrigerants made by Brooks Automation Inc. Polycold Systems.

Refrigerant circuit: The path of the refrigerant which goes from the refrigeration unit, through the feed line, through the cryosurface, through the return line and back to the refrigeration unit.

Refrigerant expansion tank: A tank inside the refrigeration unit that maintains the gaseous refrigerant at a safe pressure when the unit is not at operating temperature.

Refrigeration unit: The machine containing the compressor, condenser and Polycold® stack that cools

the refrigerant mixture to cryogenic temperatures.

TC: thermocouple

TÜV: Technical Supervision Society—verifies compliance with EN and IEC standards.

UL: Underwriters Laboratories—verifies compliance with NEC standards

.

Process & Instrumentation and Electrical Schematics PGC Manual

825101-00 (Rev C) Page 54

10 PROCESS & INSTRUMENTATION AND ELECTRICAL SCHEMATICS


825101-00 (Rev C) Page 55

Figure 10-1: Process & Instrumentation Diagram, PGC-152 W/CE/S2


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Figure 10-2: Process & Instrumentation Diagram, PGC-152 CE/S2 W/ Flow Control


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Figure 10-3: Circuit Diagram, PGC-152 CE W/RMT IEC


825101-00 (Rev C) Page 58

Figure 10-4: Circuit Diagram, PGC-152 CE/S2 Flow Control Option

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