Warning

This is an incomplete work instruction.

CRC Block Diagrams¶

CRC Daily Workflow¶

graph LR
  A[Leak Check] -->|Then| B[Carryover / Evac / Oil Change / De-Scale];
  B -->|Then| C[CH Capacity Test];
  C -->|Then| D[On Deck];
  D -->|Then| E[Meeting Agenda];
  E -->|Then| F[Tuning];

Workflow Principals¶

The idea behind the order of operations in this workflow is to essentially create space for incoming product to the next workstation. By addressing the compressors in leak check first, space is made for compressors that pass the cold head capacity test and so on.

Compressor Test¶

graph LR
  A[Compressor Test] -->|Pass| B[Move Forward];
  A -->|Fail| F[Update Card]
  F -->  C[Repair <20m?];
  C -->|Yes| D[Repair Immediately];
  D --> A;
  C -->|No| E[Tuning Area];
  E --> H[Log Test];
  B --> H;

Compressor Workflow Concept¶

graph LR
  A[Bump Test] -->|Pass| B[Oil Change/Descale];
  A -->|Fail| H[Tuning];
  B -->|Pass| C[Evac];
  B -->|Fail| H;
  C -->|Pass| D[0th Test];
  C -->|Fail| H;
  D -->|Pass| E[Carryover];
  D -->|Fail| H; 
  E -->|Pass| F[CH Capacity];
  E -->|Fail| H;
  F -->|Pass| G[Leak Check];
  F -->|Fail| H;
  G -->|Pass| I[Cosmetic Refurb];
  G -->|Fail| H;
  H -->|Pass| D;
  H -->|Fail| K;
  I --> K[END];

Compressor Workflow Troubleshooting¶

graph LR

  B{Bump Test} -->|Pass| D[Evac];
  B -->|Fail| Y{Bump Test Tuning};
  Y -->|Pass| B;
  Y -->|Fail| Z[END];
  D --> E{0th Test};
  E -->|Pass| F{Carryover};
  E -->|Fail| G{0th Test Tuning};
  G -->|Pass| E; 
  G -->|Fail| Z;
  F -->|Pass| H{CH Capacity};
  F -->|Fail| X[Carryover Tuning];
  X -->|Pass| E;
  X -->|Fail| Z;
  H -->|Pass| I{Leak Check};
  H -->|Fail| W[Capacity Tuning];
  W -->|Pass| H;
  W -->|Fail| Z;
  I -->|Pass| J[Cosmetic Refurb];
  J --> Z;
  I -->|Fail| V[Leak Tuning];
  V -->|Pass| I;
  V -->|Fail| Z;

Bump Test Troubleshooting¶

graph LR

  A{Capsule Resistance} -->|Good| B{Incoming Voltage};
  A -->|Bad| Y[LTS];
  B -->|Good| C{Pase Rotation};
  B -->|Bad| D[Troubleshoot Voltage];
  D --> Z[Bump Test];
  C -->|Good| E{Contactor};
  C -->|Bad| F[Reverse Phase Rotation];
  F --> Z;
  E -->|Good| G{Pressure/Temp Limits};
  E -->|Bad| H[Repair Limit];
  H --> Z;
  G -->|Good| I{Control Board};
  G -->|Bad| J[Repair Limit];
  J --> Z;
  I -->|Good| Z;
  I -->|Bad| K[Replace Board];
  K --> Z;

Capsule Resistance¶

Capsule resistance should be the same between all the legs within a decimal point or two.

Incoming Voltage¶

The voltage requirements should be within ±10% of the wall voltage.

Phase Rotation¶

Units that have phase protection will not start with the phase is backwards. Reverse phase to test.

Contactor¶

The coil in the contactor can go bad as well as the terminal contacts causing issues with powering the compressor.

Pressure/Temp Limits¶

Pressure¶

Most compressors are equipped with a pressure limit that shuts the compressor down when the pressure becomes too low.

Temperature¶

All compressors have thermal protection in multiple locations. These can be in the form of temperature thermistor and thermal switches.

Control Board¶

The compressor control board can sustain temperature damage, individual component failure, or firmware corruption.

0^th Test Troubleshooting¶

Ambient Temp¶

The ambient temperature is controlled by heating and air conditioning.

graph LR
  A{Ambient Temp} -->|High| B{Outside Doors Open?};
  B -->|Yes| C[Close Doors];
  C --> D{Is the AC ON?};
  B -->|No| D;
  D -->|Yes| Z[End;]
  D -->|No| E[Turn on AC]
  E --> Z;
  A -->|Low| F{Outside Doors Open?};
  F -->|Yes| G[Close Doors];
  G --> H{Is the heat ON?};
  F -->|No| H;
  H -->|Yes| Z;
  H -->|No| I[Turn on heat]
  I --> Z;

Water Supply Temperature¶

The water supply temperature is controlled by the chiller system. Make sure that the chiller is operating properly and that the isn't too much load on it.

graph LR
  A{Water Supply Temp} --->|High| B{Chiller Overloaded?};
  B --->|Yes| C[Turn off Compressors];
  C ---> Z[End];
  B --->|No| D{Coolant level low?};
  D --->|Yes| E[Refill Coolant];
  E ---> Z;
  D --->|No| F[Call refrigeration service];
  F --->Z
  A --->|Low| F;

Water Temp Delta¶

If the water temp delta is too wide there is an excess amount of heat in the helium compressor. If the water temp delta is too small there is efficiency loss within the heat exchanger.

graph LR
  A{Water Temp Delta} --->|High| B{Chiller Flow?};
  B --->|Good| C{Oil level};
  C --->|Good| D[Change Capsul];