Telemark Cryogenics 1200 Instruction Manual
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Telemark Cryogenics 1200 Instruction Manual

Microprocessor based water vapor cryochiller
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Telemark Cryogenics Microprocessor Based Cryochillers
MICROPROCESSOR BASED
WATER VAPOR CRYO-CHILLER
Copyright © Telemark Cryogenics, 1998-2018 – All rights reserved
Rev 1.0.7 October 2018
Brand or products names are trademarks or registered trademarks
of their respective companies.
Models Covered in this manual
1200, 1800, 1800EXT, 2400, 3000, 3600
INSTRUCTION MANUAL
Part No 19-0001-00
www.telemark.com
Page 1 of 63
Revision 1.0.7 October 2018

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  • Page 1 Telemark Cryogenics Microprocessor Based Cryochillers MICROPROCESSOR BASED WATER VAPOR CRYO-CHILLER INSTRUCTION MANUAL Part No 19-0001-00 Copyright © Telemark Cryogenics, 1998-2018 – All rights reserved Rev 1.0.7 October 2018 www.telemark.com Brand or products names are trademarks or registered trademarks of their respective companies.
  • Page 2 Telemark Cryogenics Microprocessor Based Cryochillers Model 3600 Water Vapor Cryo-Chiller (Dual Coil Unit) Page 2 of 63 Revision 1.0.7 October 2018...

  • Page 3: Table Of Contents

    Page Table of Contents Safety Warnings Warranty User Responsibility Intended Use of Equipment Manufacturing Standards Specifications Models 1200, 1800 and 1800EXT Models 2400, 3000 and 3600 Environmental Requirements Recommended Breaker and Wire size Physical Dimensions Installation Cautionary Notes Unpacking and Inspection...
  • Page 4 Telemark Cryogenics Microprocessor Based Cryochillers Ethernet Communications 2.8.1 Ethernet Setup 2.8.2 Serial Commands Available 2.8.3 Using TCP/IP GUI 2.8.4 User Configuration Operation Controls and Display 3.0.1 LCD Display 3.0.2 Scroll Push Button 3.0.3 Cool Push Button 3.0.4 Defrost Push Button 3.0.5 Standby Push Button...
  • Page 5 Telemark Cryogenics Microprocessor Based Cryochillers LIST OF FIGURES/ILLUSTRATIONS Figures Page Removing Unit from Transport Pallet System Pressure Gauge Services Panel Water Flow requirements Position of Hand Valves Refrigerant Line Connections Access Hand Valve Refrigerant Manifold Refrigerant Line Insulation Metal “O” Ring Removal Tool...
  • Page 6 Telemark Cryogenics Microprocessor Based Cryochillers LIST OF TABLES/INFORMATION Table Page Model 1200. 1800 & 1800 EXT Specifications Model 2400, 3000 & 3600 Specifications Environmental Operating Conditions Recommended Breaker and Wire Size Physical Dimensions Recommended Breaker and Wire Size 37 Way Connector Pin Connection Details Volt vs.

  • Page 7: Safety Warnings

    Telemark Cryogenics Microprocessor Based Cr Cryochillers SAFETY WARNI NINGS THE P PHRASE WARNING IS USED WHERE THER ERE IS A HIGH PROBA BABILITY OF PERSONAL INJURY OR DEA EATH SHOULD THE P PROVISIONS HIGHLIGHTED BE IGNORED. IT IS THE DUTY...
  • Page 8 Telemark Cryogenics Microprocessor Based Cr Cryochillers WARNING During ins nstallation there is the potential to be exposed ed to high voltage co components (up to 400v ac), which may result ult in a fatal electrocuti ution. WARNING Units mus ust always be operated with a suitable ground/ d/earth line.
  • Page 9 Telemark Cryogenics Microprocessor Based Cr Cryochillers CAUTION The ph phrase “Caution” indicates a risk of damage t e to the produc uct or associated plant and machinery if the provis isions are not followed carefully. CAUTION Telemark w will not be responsible or liable for either dire...

  • Page 10: Warranty

    Telemark Cryogenics’ obligation under this Warranty is limited to the repair or replacement, at its option, of any parts, which upon examination at the Telemark Cryogenics factory or by an authorised sales/service representative, shall appear to have become defective.

  • Page 11: User Responsibility Intended Use Of Equipment

    Telemark Cryogenics Microprocessor Based Cryochillers INTENDED USE OF THE EQUIPMENT Water vapor Cryochiller is a device that improves the performance of vacuum pumping due to the efficient trapping of water vapor in the chamber. Classically a Cryochiller is used with an evaporative surface (Meissner/cryo- coil), which is located within the vacuum chamber.

  • Page 12: Specifications

    Output Voltage range 300mA 300mA 300mA Balance Pressure Range as Shipped from Telemark 270-300 220-250 180-210 USA facility (1.86-2.07MPa) (1.51-1.72MPa) (1.24-1.45MPa) (PSI) @20° C (hand valves closed) Table 1 Model 1200, 1800, 1800EXT Specifications Page 12 of 63 Revision 1.0.7 October 2018...

  • Page 13: Models 2400, 3000 And 3600

    Telemark Cryogenics Microprocessor Based Cryochillers Model 2400 Model 3000 Model 3600 Maximum Load (Watts) 2400 3000 3,600 Typical 135,000 165,000 200,000 Pumping Speed (l/sec) Ultimate Vacuum 2 x10 mbar (2 x10 2 x10 mbar (2 x10 2 x10 mbar (2 x10...

  • Page 14: Environmental Requirements

    Telemark Cryogenics Microprocessor Based Cryochillers Environmental conditions (all models) Parameter Value Type Indoor use Altitude Up to 2000m Temperature range (° C) 5 - 40 Maximum relative 80% for temperatures up to 31 ⁰ C Humidity (%Rh) decreasing linearly to 50% relative humidity at 40 ⁰ C...

  • Page 15: Physical Dimensions

    Telemark Cryogenics Microprocessor Based Cryochillers 1.3 Cryochiller Physical Dimensions Model A (inch) A (mm) B (inch) B (mm) C (inch) C (mm) 1200 59.5 1511 1800 59.5 1511 1800EXT 59.5 1511 2400 59.5 1511 3000 23.6 35.3 70.25 1784 3600 23.6...

  • Page 16: Cautionary Notes

    Telemark Cryogenics Microprocessor Based Cr Cryochillers INSTALLAT ATION Safety and Caution onary Notes for Installation. WARNING Failing to leak ak test the system as a whole may result in the catastrophic r ic release of refrigerant, which presents a very hig...

  • Page 17: Unpacking And Inspection

    Telemark Cryogenics Microprocessor Based Cr Cryochillers WARNING- TIP OVER RI RISK Use proper per lifting equipment and protocols when removing ing the unit from the pa pallet WARNING – HEAVY OBJ BJECT RISK Telemark Cryochillers weigh a minimum of 193Kg (432lb)

  • Page 18: System Pressure

    Telemark Cryogenics Microprocessor Based Cryochillers Fig 1 Removing Unit from transportation pallet System Pressure The unit is shipped fully charged. See Tables 1 and 2 (Section 1 “Specifications”) above for shipping pressure range of each model. The exact shipping pressure is noted on the packing list. A pressure gauge is mounted behind the front panel or to the right hand side of the unit.

  • Page 19: Location

    Telemark Cryogenics Microprocessor Based Cryochillers Location The unit should be placed and a clean level floor and positioned to minimise the length of the refrigeration lines. It is also important that the lines are well supported and are manufactured from annealed copper tubing allowing for thermal expansion and vibration.

  • Page 20: Water Connections

    Telemark Cryogenics Microprocessor Based Cryochillers Water Connections The advanced design of the unit means it is capable of operating over a wide range of water temperatures. While Liquid Line temperature (LT on the display) is preset to 40° C maximum, there is littl e loss of performance with °...

  • Page 21: Refrigerant Line Connection

    These need to be thoroughly checked to ensure that they are clean and free from debris, damage or any other contaminants. Note: If refrigerant lines manufactured/supplied by parties, other than Telemark Cryogenics, are being connected to the Telemark Cryochiller, ensure that the refrigerant lines meet the required specifications of the Cryochiller.

  • Page 22: Metal O Seals

    Telemark Cryogenics Microprocessor Based Cr Cryochillers CAUTION - HOT SU SURFACE High temper peratures are generated during normal operation. n. Avoid contact with ith exposed pipe-work as this can get hot during n g normal operation. CAUTION - COLD S...

  • Page 23: Evacuate Refrigerant Lines

    Telemark Cryogenics Microprocessor Based Cryochillers 2.6.4 When satisfied that the refrigerant lines connections are secure carefully release the test gas using the refrigerant manifold. Re-check the metal seal connections to ensure that they are tight using the torque settings as per 3.5.1 above.

  • Page 24: Connections

    Telemark Cryogenics Microprocessor Based Cryochillers 2.6.8 Refrigerant Line Installation notes Refrigeration lines manufactured should conform to the following norms. Coil inlet line diameter 9.5mm – 3/8” to 15mm – 5/8” Maximum recommended length 5m (15ft) Coil outlet line diameter 15mm – 5/8” to 19mm – ¾ “...
  • Page 25 Inspect and clean all coupling faces. Ensure they are free from dents or scratches. Small imperfections on the couplings of the refrigerant lines may be rectified by using 1200 grade wet or dry mounted onto a glass plate. Special care needs to be taken when handling VCR fittings. It is critical that the faces are totally flat and square.

  • Page 26: Electrical Connections

    Telemark Cryogenics Microprocessor Based Cryochillers Main Electrical connections 2.7.1 Connect the 3 phase power and the ground to the main isolator. Note: It may be required that the 3 phase connections have to be altered to ensure the correct rotation of the compressor The unit does not require a neutral line;...

  • Page 27: Transformer Taping

    Telemark Cryogenics Microprocessor Based Cryochillers 200-230VAC Vac Three-Phase Nominal current Fuse Minimum copper Cable Type rating[A] Rating [A] wire (recommended) AWG/mm 8 / 10 H07RN-F 450/750V 4G10 6 / 16 H07RN-F 450/750V 4G16 4 / 25 H07RN-F 450/750V 4G25 380-444VAC Three-Phase 14 / 2.5...

  • Page 28: Remote Connections

    Telemark Cryogenics Microprocessor Based Cryochillers Remote Connections Telemark Cryochillers can be controlled remotely using digital connections through a 37 way Amphenol socket, or Ethernet, RS 232 or RS 485 serial communications. This section describes how to connect the unit remotely.
  • Page 29 Telemark Cryogenics Microprocessor Based Cryochillers Table 7. Pin Connection for 37 way Amphenol Connector Input/Output Description Action High input will start the UNIT. With Low input the UNIT Input Operate Unit will stop. UNIT must be in “remote operation” mode for this input to be active.
  • Page 30 Telemark Cryogenics Microprocessor Based Cryochillers Input/Output Description Action Indicate Common Indicate common for all output contact closures User selectable output via “cal2309” setup (See section 2.9.4 below). Signal present irrespective if unit in LOCAL 1)COMP RUNNING Relay Output 1 or REMOTE operation.

  • Page 31: Analogue Outputs

    Telemark Cryogenics Microprocessor Based Cryochillers 2.8.1.2 Analogue Output voltage On pin 32 and pin 34 of the remote connector the analogue voltages are scaled as the table below. The formula below can be used for the Temp Volts calibration of the analogue output voltage 1.76...

  • Page 32: Ethernet Communications

    Telemark Cryogenics Microprocessor Based Cryochillers Ethernet Communication. Telemark Cryochillers are capable of being controlled and data logged via an integral Ethernet port, this is accessible on the services panel diagram. This can be achieved using a portable laptop or can be used via a Ethernet hub to interrogate the unit as well as send command functions.

  • Page 33: Ethernet Setup

    Telemark Cryogenics Microprocessor Based Cryochillers spending time trying to fit those tiny little wires into each of the corresponding holes in the RJ-45 connector. 2.9.1 Ethernet (Laptop) set up Install the software sent with the unit. The software is self extracting and then follow the on-screen instructions.
  • Page 34 Telemark Cryogenics Microprocessor Based Cryochillers Fig 17 TCP/IP Fig 18 Set up for TCP/IP Power up system and wait 10 seconds or so and then open up the software supplied on the USB thumb drive. Page 34 of 63 Revision 1.0.7 October 2018...

  • Page 35: Serial Commands Available

    Telemark Cryogenics Microprocessor Based Cryochillers 2.9.2 Commands Available when Using Ethernet, RS232/485 Control Command Command Operation Type Write Turns TCP/IP Communications link on Write Turns all communication links off Write Turns the Unit on (compressor running) Write Turns the unit off (turns the compressor...

  • Page 36: Using Tcp/Ip Gui

    Telemark Cryogenics Microprocessor Based Cryochillers 2.9.3 Using TCPIP-RS232/485/Ethernet GUI During installation it is possible through a computer running the TCPIP™ software (supplied on USB thumb drive) to adjust a number of system parameters to match your application requirements. This software must be installed in a PC/laptop prior to communication with the Cryochiller.
  • Page 37 Telemark Cryogenics Microprocessor Based Cryochillers Note: Once the host IP address has been changed the board the TCPIP “GUI” will no longer respond until changes have been made to the remote computer IP addressing has been made to suit (see 2.8.1 above).
  • Page 38 Telemark Cryogenics Microprocessor Based Cryochillers Fig 20 Ethernet TCP/IP and RS232/485 Help Screens The above are the help Setup Screens to aid the user in connection an external communications device to the Cryochiller. Note: The default serial communications method is Ethernet.

  • Page 39: User Configuration

    Telemark Cryogenics Microprocessor Based Cryochillers 2.9.4 “cal2309” Screen (User Configuration screen) Telemark Cryochillers have “user settable” parameters that allow the user to configure the unit to meet there particular process requirements. To access the “cal2309” screen type in ““cal2309”” in the “Send”...
  • Page 40 Telemark Cryogenics Microprocessor Based Cryochillers The use of ““cal2309”” page allows the user to change certain parameters to suite the user requirements, such as the defrost termination temperature. Note: After entering and commend the user will need to re enter ““cal2309”” to change another user set-point of required.
  • Page 41 Telemark Cryogenics Microprocessor Based Cryochillers Defrost Active (defr) activated when the unit is in the defrost mode. NOTE – on dual coil models this output can only be selected for coil NOTE – When in the “Calibrate Active” if the correct modes are selected you will then be prompted to input the temperature of the set point.

  • Page 42: Controls And Display

    Telemark Cryogenics Microprocessor Based Cryochillers OPERATION The operations below describe how to operate the unit in manual mode. For remote operation please refer to section 2.7 of this manual. Controls and Displays Fig 22 front Panel Push Buttons (Single Coil Unit Shown) 3.0.1 LCD Display...
  • Page 43 Telemark Cryogenics Microprocessor Based Cryochillers Fig 24 Screen Shot above display that the unit is in “pre-cool” condition. On the lower line display is showing the DP, Discharge pressure and SP Suction pressure running parameters Fig 25 Screen shot above showing that the unit is ready for operation.

  • Page 44: Scroll Push Button

    Telemark Cryogenics Microprocessor Based Cryochillers 3.0.2 SCROLL Push Button 3.0.3 COOL Push Button(s)/Indicators(s) By pressing this button the unit will go into “COOL”. The Button will need to be depressed for a period of about 3 seconds before the unit will go into the “COOL” mode.

  • Page 45: On/Off Puss Button

    Telemark Cryogenics Microprocessor Based Cryochillers 3.0.5 STOP/RESET Push Button. Pulling on this button will turn the power on to the machine. The green “STANDBY”, “SCROLL” and the LCD Display will light up. Pushing this will turn of the unit. The unit will automatically reset itself after the STOP/REST button has been depressed and released.

  • Page 46: Defrost Recovery Period

    Telemark Cryogenics Microprocessor Based Cryochillers monitors the returning gas temperature in determining if the cryo-coil has been defrosted. If defrost terminates prematurely check the discharge and water temperatures first. When defrost ends the system automatically enters standby this is indicated both on the display and by the standby button illuminating.

  • Page 47: Trouble Shooting Guide

    Telemark Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Trouble Shooting Cryochiller water vapour vacuum pumps are made up of 4 essential sub systems. Refrigeration system Power electrical / Water supply Low voltage electrical and interface Control electronics Refrigeration Leaks These are the number one cause of poor system performance and failure.

  • Page 48: Safety Systems

    Telemark Cryogenics Microprocessor Based Cryochillers Fig 27 “OVER PRESSURE” alarm message Fig28 “E1” with fault shown as “DP HIGH” " " # " % " " & '( ) * #( - " # -- ) * " * /* '( 1 "...
  • Page 49 Telemark Cryogenics Microprocessor Based Cryochillers Thermal Snap Switch – on units fitted with a Bitzer compressor, this is located about 6” away from the compressor in the discharge line. If the discharge temperature exceeds the limit of the switch then, the unit will shut down and the unit will display “COMPRESSOR ERROR”.

  • Page 50: Trouble Shooting Guide

    Telemark Cryogenics Microprocessor Based Cryochillers Trouble Shooting Guide Symptom Possible Cause Corrective Action No system power Check mains input LCD does not Missing phase Check mains input illuminate Reset by pushing and pulling the Start Stop/Reset not reset stop button.
  • Page 51 Telemark Cryogenics Microprocessor Based Cryochillers Symptom Possible Cause Corrective Action System does not Correct water temperature and Water temperature too high or too low cool CT fails to get flow rate reset system colder than -140 to System should be shut down for a...
  • Page 52 Telemark Cryogenics Microprocessor Based Cryochillers Symptom Possible Cause Corrective Action System has poor Too much heat is being applied to the Remove Internal heat source cooling with large cryo-coil temperature Check values of differential between CI and CO CT Possible refrigeration leak...

  • Page 53: Use Of Top-Off Charges

    Telemark Cryogenics Microprocessor Based Cryochillers The Use of “Top-off” gas Charges The use should periodically shut the system down and check the balance pressure of the unit. The unit should be sit down for a period of 24 hours to allow the unit to warm up. Ideally the CT (coldest temperature) should be between 15°...
  • Page 54 Telemark Cryogenics Microprocessor Based Cryochillers Emerson (Copeland™) Compressor Some units are fitted with an Emerson Compressor. The following section is for these Models 3000 and 3600 units only and should not be used with units that are fitted with Bitzer compressors.

  • Page 55: Emerson Diagnostics

    Telemark Cryogenics Microprocessor Based Cr Cryochillers 4.5.1 Compressor Dia iagnostics WARNING • Failure to follo llow these warnings could result in serious person onal injury. • Only qualified ied and authorised HAVC or refrigeration perso rsonnel are permitted to ca carry out repairs and or install the compressor.
  • Page 56 Telemark Cryogenics Microprocessor Based Cryochillers The CoreSense™ module will continue to display the code until the fault condition has been rectified and or manual power reset (unit Powered off) has been carried out. More than one LED can be illuminated depending upon the fault.
  • Page 57 Telemark Cryogenics Microprocessor Based Cryochillers Status LED Status LED Description Status LED Troubleshooting Information High Discharge Line 1. Possible loss of refrigeration. Yellow Alert Temperature Trip. 2. Blocked condenser. Discharge line greater 3. Discharge line blocked or 1 Flash than 250° F (121° C) Rotolok™...

  • Page 58: Decommissioning

    Telemark Cryogenics Microprocessor Based Cr Cryochillers Decommissio ioning Should it be necessar ary to remove the unit from the vacuum system th following procedure m must be followed. WARNING The refrigeration s system contains a mixed blend of refrigerants a s and polio- ester oil.

  • Page 59: Design Of Cryo-Coils

    Telemark Cryogenics Microprocessor Based Cryochillers DESIGN OF CRYO-COILS The design and placement of a cryo-coil is a specialised task, which must be carried out by a skilled vacuum practitioner. Free technical help is available directly from Telemark. Telemark also manufactures cryo-coils to order to suit your installation.
  • Page 60 Telemark Cryogenics Microprocessor Based Cryochillers Suggested Sustainable H O pumping Model cryo-surface speed (30% de-rating) 1200 0.798 M 65,000 l/s 1800 0.997 M 100,000 l/s 1800 EXT 0.997 M 100,000 l/s 2400 1.197 M 135,000 l/s 3000 1.596 M 165,000 l/s 3600 1.995 M...
  • Page 61 Telemark Cryogenics Microprocessor Based Cryochillers a. The surface should be clear of any moving parts within the vacuum system. b. No closer than 25mm to any chamber wall and out of direct line of sight with heaters or other forms of heat (magnetrons etc) – if this is unavoidable then the surface can be effectively shielded by aluminium foil.
  • Page 62 Telemark Cryogenics Microprocessor Based Cryochillers INTENTIONALY LEFT BLANK Page 62 of 63 Revision 1.0.7 October 2018...

  • Page 63: Chinese Hazardous Substance Concentration Table

    THE Refrigerant Charge Safety data Sheets can be located on the Flash drive under the heading Safety Data sheets Telemark Cryogenics Water Vapor Cryotraps Models: 1200, 1800, 1800 EXT, 2400, 3000, 3600 Including “D” Models Declaration of Hazardous Substance Toxic or hazardous Substances and Elements 有毒或有害物...

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