Poly Cold Data
Poly Cold Data
Poly Cold Data
Tel 978-262-2400
15 Elizabeth Drive Fax 978-262-2500
Chelmsford, MA 01824 U.S.A www.brooks.com
®
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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825101-00 (Rev C)
Safety Information PGC Manual
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.
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.
Table A
Product New Product Repair Service Certified Refurbished
Warranty Warranty Cryogenic Cooling Products Warranty
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.
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
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
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.
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:
Text describing
hazard and what might
/ could happen
` ‡
SAFETY ALERT SYMBOL
DANGER - White Lettering / Red Background
(Safety Red: per ANSI Z535.4 - 15 parts Warm Red, White Triangle / Red Exclamation Point
1 part Rubine Red, 1/4 part Black)
WARNING - Black Lettering / Orange Background
(Safety Orange: per ANSI Z535.4 - 13 parts Yellow, 3 Black Triangle / Orange Exclamation Point
parts Warm Red, 1/4 part Black)
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.
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:
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.
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.
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.
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
Figure 1-3: Hazard Labels, Front, Left, & Top Sides, Air-Cooled PGC 152
PRIMARY REFRIGERANT
EXPANSION TANK
407020 REV 01 XQS23689
Figure 1-4: Hazard Labels, Rear & Left Sides, Air-Cooled PGC 152
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
Figure 1-6: Hazard Labels, Lower Front & Right Sides, Water-Cooled PGC 152
PRIMARY REFRIGERANT
EXPANSION TANK
407020 REV 01 XQS23689
Figure 1-7: Hazard Labels, Lower Rear & Left Sides, Water-Cooled PGC 152
Figure 1-8: Caution Label, PGC 152 Optional Flow Control Unit
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 The Thermal Overload Protector is coupled to the hermetic
Protector 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 A high pressure switch is incorporated in the discharge side
Switch 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 A high temperature switch is coupled to the condenser liquid
Switch 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.
Safety devices are identified in the P& ID and Circuit diagrams in Section 10.
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.
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.
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.
Note: Units built prior to April 11, 2005 are equipped with a 16A circuit breaker.
WARNING
CHEMICAL HAZARD
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.
2 OVERVIEW
2.1 System Diagrams
Gas Out
Customer Vent Host
Gas Equipment
Supply Gas In
Flow
Sw. Flow
Control
Option
Valve
Expansion Refrigeration
Tank Cooling Stack
Supply
Pressure Air or Water
Gauge Cooled
Cooling Water*
Condenser
Return
Refrigeration
Compressor * Water Cooled units only.
Unit
EMO
Power Switch
MCB1
Safety
Interlocks
Motor
Remote/Local Contactor
Bypass
System Refrigeration
Remote Compressor
Interface Flow
Unit
Control
Option
Remote Valve
Controller
Flow
Thermocouple Host
Switch
Gauge Equipment
EMO*
Gas
Outlet
* Flow Control Option EMO does not operate locally. It is provided for customer to
wire as a remote EMO for the host equipment.
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).
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.
2.3.1 Exterior Features, Air Cooled PGC 152 w/o Flow Control Unit
Top Rear
Edge Gas
Outlet
Gas
Inlet
Figure 2-4: Air Cooled PGC 152 w/o Flow Control (Ext. Panels Installed)
2.3.2 Interior Features, Air Cooled PGC 152 w/o Flow Control Unit
Fan &
Cooling
Coils
Gas Outlet
Thermo-
Couple Wire
1of 4 Seismic
Anchor Points
Figure 2-5: Air Cooled PGC 152 w/o Flow Control (Ext. Panels Removed)
2.3.3 Exterior Features, Water Cooled PGC 152 with Flow Control Unit
Gas
Inlet Gas
Outlet
Figure 2-6: Water Cooled PGC 152 w/ Flow Control (Ext. Panels Installed)
2.3.4 Interior Features, Water Cooled PGC 152 with Flow Control Unit
Gas Outlet
Thermo-Couple Wire
Cooling Water
Inlet & Outlet
Figure 2-7: Water Cooled PGC 152 w/ Flow Control (Ext. Panels Removed)
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
Air Out
Front PGC-152
Front
0.3m
12" MIN
}
PGC-152
} 0.3m
12" MIN
Air In
Fig 3.1
‡
CAUTION!
EQUIPMENT DAMAGE
Do not turn on the unit until the cooling water
has been connected and turned on.
®
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.
‡
WARNING †
HAZARDOUS VOLTAGES
‡
WARNING †
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.
3
Nominal Acceptable Voltage Range
1, 2, 3
Compressor Rated Load Amps
At 50 Hertz
Rating (volts)
200/208-1-50 180-229 10A, 16A
At 60 Hertz
208/230-1-60 10A, 16A
187-253
1
Rated 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.
2
RLA 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.
3
Units 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.
Table 3-2: Electrical Requirements
Connect the Flow Control Unit to the Host Equipment to enable the remote Flow Control and Monitoring.
Specifications:
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
Specifications:
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.
Remote
Bypass
Jumper
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.
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.
Gas
Inlet
Gas
Outlet
‡
WARNING †
EXPLOSION HAZARD
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.
Top
Rear Edge Gas
Outlet
Gas
Inlet
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.)
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.
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)
4 OPERATION
4.1 Starting the Polycold Gas Chiller
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.
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.)
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
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.
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.
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 .
If the On/Off switch has returned to the OFF position (by its circuit breaker), verify the following.
Power supply is adequate.
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)
Power supply is adequate.
POWER SW=
N.A.
LINE YELLOW ON
POWER SW=
OFF
LINE YELLOW ON
RUN GREEN ON
POWER ORANGE ON
POWER SW =
ON
LINE YELLOW ON
FAULT RED ON
POWER ORANGE ON
POWER SW =
ON
LINE YELLOW ON
POWER SW =
ON
LINE YELLOW ON
RUN GREEN ON
POWER ORANGE ON
POWER SW =
ON
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.
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.
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.
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.
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.
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.
8 APPENDIX
8.1 BRAZING SPECIFICATION
Tools and materials needed:
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
Sand paper
Propane torch
Rosin flux
Harris Bridgit or equivalent lead-free solder
Neutralizing agent (to remove the flux)
8.3 Specifications
Air Cool w/ Water Cool w/
Model Type Air Cooled Water Cooled
Flow Control Flow Control
Maximum Gas
500 SCFH, 100psig max.
Flow Rate:
Ambient Air
4 - 32°C (40 - 90°F)
Temperature:
Approximate Heat
4650w (15,870 BTUH)
Rejection Rate:
Cooling Water
See Table 3-1
Requirements
Electrical
See Table 3-2
Requirements:
9 GLOSSARY
ANSI: American National Standards Institute
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).
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.
Liquid line: A portion of the refrigerant circuit containing high pressure refrigerant just after it has been
cooled by the water-cooled condenser,
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
Figure 10-2: Process & Instrumentation Diagram, PGC-152 CE/S2 W/ Flow Control