Telemark Cryogenics CRYO-CHILLER Instruction Manual
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Telemark Cryogenics CRYO-CHILLER Instruction Manual

Microprocessor based water vapor
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Cryogenics
MICROPROCESSOR BASED WATER VAPOR
CRYO-CHILLER
INSTRUCTION MANUAL
Part No 19-0001-00
Models Covered in this manual 1200, 1800, 1800EXT, 2400, 3000, 3600, 4800
Copyright © Telemark Cryogenics, 1998-2021 – All rights reserved
Manual Rev 1.0.9 March 2021
telemark.com
Download the current version of this manual at
https://telemark.com/water-vapor-cryochiller/cryochiller-models/
Brand and product names are trademarks or registered trademarks of their respective companies

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  • Page 1 INSTRUCTION MANUAL Part No 19-0001-00 Models Covered in this manual 1200, 1800, 1800EXT, 2400, 3000, 3600, 4800 Copyright © Telemark Cryogenics, 1998-2021 – All rights reserved Manual Rev 1.0.9 March 2021 telemark.com Download the current version of this manual at https://telemark.com/water-vapor-cryochiller/cryochiller-models/...

  • Page 2: Table Of Contents

    Cryogenics Microprocessor Based Cryochillers INTRODUCTION TABLE OF CONTENTS 1 INTRODUCTION ................7 SAFETY WARNINGS ................7 WARRANTY ..................11 USER RESPONSIBILITY ..............12 INTENDED USE OF THE EQUIPMENT ..........12 STANDARDS ..................13 2 SPECIFICATIONS ..............14 GAS CWP CHART ................17 ENVIRONMENTAL CONDITIONS ............
  • Page 3 Cryogenics Microprocessor Based Cryochillers INTRODUCTION “cal2309” Screen (User Configuration screen) ............ 45 3.9.5 3.9.6 USING THE TCPIP-RS232/485 PROGRAM ............48 4 OPERATION ................58 CONTROLS AND DISPLAYS ............. 58 4.1.1 LCD Display ......................58 SCROLL PUSH BUTTON ..............60 PUSH BUTTONS ................60 4.3.1 COOL Push Button(s)/Indicators(s) ..............
  • Page 4 Cryogenics Microprocessor Based Cryochillers INTRODUCTION LIST OF FIGURES Figure 3-1, Removing Unit from Transportation Pallet ...............22 Figure 3-2, Pressure Gauge ......................23 Figure 3-3, Service Panel ......................24 Figure 3-4, Water flow Requirements ..................25 Figure 3-5, Position of Hand Valves ..................26 Figure 3-6, Refrigerant Line Connections ..................27 Figure 3-7, Access Valve ......................28 Figure 3-8, Refrigerant Manifold ....................28 Figure 3-9, Refrigerant Line Insulation ..................31...
  • Page 5 Cryogenics Microprocessor Based Cryochillers INTRODUCTION Figure 3-32, Enter new IP address ....................54 Figure 3-33, Disconnect TCP/IP ....................55 Figure 3-34, Change Remote Host IP address ................55 Figure 3-35, Disconnect TCP/IP Again ..................56 Figure 3-36, Check first three IP numbers .................57 Figure 3-37, Connect to Remote Host ..................57 Figure 4-1, Front Panel Push Buttons (Single Coil Unit Shown) ..........58 Figure 4-2, LCD Display, Wait ....................58 Figure 4-3, LCD Display, Pre-Cool ....................59...
  • Page 6 Cryogenics Microprocessor Based Cryochillers INTRODUCTION LIST OF TABLES Table 2-1, Model 1200, 1800, 1800EXT, 2400 Specifications ...........15 Table 2-2, Model 3000, 3600, 4800 Specifications ..............16 Table 2-3, Current Models Gas CWP Chart ................17 Table 2-4, Discontinued Models Gas CWP Chart ..............17 Table 2-5, Environmental Conditions ..................17 Table 2-6, Recommended Breaker and Wire Size ..............18 Table 2-7, Physical Dimensions ....................19...

  • Page 7: Introduction

    Cryogenics Microprocessor Based Cryochillers INTRODUCTION INTRODUCTION 1.1 SAFETY WARNINGS THE PHRASE WARNING IS USED WHERE THERE IS A HIGH PROBABILITY OF PERSONAL INJURY OR DEATH SHOULD THE PROVISIONS HIGHLIGHTED BE IGNORED. IT IS THE DUTY OF BOTH THE INSTALLER/OWNER AND OPERATOR OF THE EQUIPMENT TO BE FAMILIAR AND COMPETENT WITH THE OPERATION AND USES OF THE PRODUCT.
  • Page 8 Cryogenics Microprocessor Based Cryochillers INTRODUCTION WARNING 1) The system contains specific hazards, which present a significant danger to personal safety: (a) High voltage electrical components and high-pressure refrigerant gases, which are a significant frostbite hazard. (b) Refrigerant gases, which will cause asphyxiation in confined areas.
  • Page 9 Cryogenics Microprocessor Based Cryochillers INTRODUCTION WARNING Units must always be operated with a suitable ground/earth line. Failure to comply may result in fatal electrocution. Never tamper with or remove any ground/earth connection from inside of the machine. WARNING Isolate system before connection. Ensure the connection cable used is compliant with local electrical requirements.
  • Page 10 Cryogenics Microprocessor Based Cryochillers INTRODUCTION WARNING The refrigeration system contains a mixed blend of refrigerants and polio-ester oil. These do not present acute health risks, but it is essential that the following basic precautions are followed: Always wear eye protection. Always wear surgical type rubber or latex gloves.

  • Page 11: Warranty

    Telemark Cryogenics Cryochiller products are warranted to be free from defects in materials and/or workmanship under normal usage until warranty effective date listed on serial number label. 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 authorized sales/service representative, shall appear to have become defective.

  • Page 12: User Responsibility

    Cryogenics Microprocessor Based Cryochillers INTRODUCTION location of repair shall be at the discretion of Telemark Cryogenics. Repairs carried out at Telemark Cryogenics factory shall be FOB Telemark factory and shall constitute fulfilment of obligations to the purchaser. All transportation costs for defective parts or products shall be borne by the purchaser.

  • Page 13: Standards

    Cryogenics Microprocessor Based Cryochillers INTRODUCTION The ranges of tasks to which your Cryochiller can be applied are not limited to pumping water vapor in vacuum. Many are used as substrate coolers (chuck coolers) or other applications where a continuous level of high-power cooling in the range –100 to – 150oc is required.

  • Page 14: Specifications

    Cryogenics Microprocessor Based Cryochillers SPECIFICATIONS 2 SPECIFICATIONS Specifications for models 1200, 1800, 1800EXT, 2400, 3000, 3600 and 4800 are on the following pages. 14 of 81 telemark.com Rev 1.0.9...

  • Page 15: Table 2-1, Model 1200, 1800, 1800Ext, 2400 Specifications

    Cryogenics Microprocessor Based Cryochillers SPECIFICATIONS Model 1200 Model 1800 Model 1800EXT Model 2400 Maximum Load (Watts) 1,200 1,800 1,800 2400 Typical Pumping Speed 65,000 100,000 100,000 135,000 (l/sec) 2 x10 mbar 2 x10 mbar 2 x10 mbar 2 x10 mbar Ultimate Vacuum (2 x10 (2 x10...

  • Page 16: Table 2-2, Model 3000, 3600, 4800 Specifications

    Cryogenics Microprocessor Based Cryochillers SPECIFICATIONS Model 3000 Model 3600 Model 4800 Maximum Load (Watts) 3000 3,600 4,800 Typical Pumping Speed 165,000 200,000 275,000 (l/sec) Ultimate Vacuum 2 x10 mbar 2 x10 mbar 2 x10 mbar (2 x10 (2 x10 (2 x10 Weight (Kg) 384 (845 lbs) 412 (930 lbs)

  • Page 17: Gas Cwp Chart

    Cryogenics Microprocessor Based Cryochillers SPECIFICATIONS IMPORTANT The above performance figures are based for a unit running at 60Hz mains power frequency. For units running on 50 Hz mains frequency the figures above need to be de-rated by 0.83. 2.1 GAS CWP CHART Current Production Models Mass (kg) CO2 tons eq...

  • Page 18: Recommended Breaker And Wire Size

    Cryogenics Microprocessor Based Cryochillers SPECIFICATIONS 2.3 RECOMMENDED BREAKER AND WIRE SIZE Recommended circuit breaker values and wire size for 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...

  • Page 19: Physical Dimensions

    Cryogenics Microprocessor Based Cryochillers SPECIFICATIONS 2.4 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 35.3 70.25 1784...

  • Page 20: Installation

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 3 INSTALLATION Safety and Cautionary Notes for Installation. WARNING Failing to leak test the system may result in the catastrophic release of refrigerant, which presents a very high risk from frostbite and/or asphyxiation. See emergency shut down procedure and material safety data sheet.
  • Page 21 Cryogenics Microprocessor Based Cryochillers INSTALLATION WARNING The system contains gases under pressure, which may constitute both a frostbite hazard and a burn hazard. Refrigerant gases are known asphyxiates and are mildly narcotic. Precautions must be taken. Work must only be carried out by suitably qualified personnel.

  • Page 22: Unpacking And Inspection

    Cryogenics Microprocessor Based Cryochillers INSTALLATION CAUTION – ENVIROMENTAL RISK Do not release refrigerant into the atmosphere it is illegal and dangerous; please refer to your local authorities’ instructions regarding the disposal of reclaimed refrigerants. Read the Material Safety Data Sheet before installing the system. Verify compliance to your local regulations.

  • Page 23: System Pressure

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 3.2 SYSTEM PRESSURE The unit is shipped fully charged. See Table 2-1, Model 1200, 1800, 1800EXT, 2400 Specifications and Table 2-2, Model 3000, 3600, 4800 Specifications 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 24: Water Connections

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Main Power Isolator Digital Interface Port (Ethernet) Balance/Suction Pressure Gauge 24 VDC Circuit Breaker Remote Interface Power Cable Entry Connector Point Figure 3-3, Service Panel 3.5 WATER CONNECTIONS The advanced design of the unit means it can operate over a wide range of water temperatures.

  • Page 25: Figure 3-4, Water Flow Requirements

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Connect the water lines to the unit ensuring the correct orientation of the water lines (see Figure 3-3, Service Panel above). Turn on water flow and ensure no leakage is present at connectors. Open the cabinet and check visually for water leaks inside the cabinet.

  • Page 26: Refrigerant Line Connection

    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 27: Figure 3-6, Refrigerant Line Connections

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-6, Refrigerant Line Connections CAUTION - HOT SURFACE High temperatures are generated during normal operation. Avoid contact with exposed pipework as this can get hot during normal operation. CAUTION - COLD SURFACE Freeze Burn Risk. Very low temperatures generated during normal operation.

  • Page 28: Figure 3-7, Access Valve

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Using new silver plated “O” seal (supplied in accessory Kit), carefully inset the O-ring s and mate the refrigerant line connection to the corresponding fitting. The “Coil In” (CI) is a ½” metal seal male fitting (from the unit to the Meissner coil) and the “Coil Out” (CO) is a ½”...

  • Page 29: Refrigerant Line Installation Notes

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Note: When pressurizing the lines, DO NOT exceed the balance pressure of the unit. 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 above.
  • Page 30 Cryogenics Microprocessor Based Cryochillers INSTALLATION Note: It is vital that a new O-ring is used every time a connection is made or broken. Always use the O-ring removal tool when removing an “O-Ring”. Take care not to damage mating surfaces of the connections. 30 of 81 telemark.com Rev 1.0.9...

  • Page 31: Figure 3-9, Refrigerant Line Insulation

    Cryogenics Microprocessor Based Cryochillers INSTALLATION line into unit from coil outlet (CO) line from unit to coil inlet (CI) ½” wall ½” ID line insulation ½” wall 2- ” ID final insulation Figure 3-9, Refrigerant Line Insulation When installing the refrigerant lines, it is essential to protect the lines and fittings from the entrance of moisture, such as water vapor, which causes rapid degradation of any foam type insulation.

  • Page 32: Main Electrical Connections

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Position the refrigerant lines to suit the installation. Bend the refrigerant line, as necessary. The minimum bend radius is 12 inches (300mm). Ensure at least 5 inches (150mm) of straight line runs to the unit and to the feed-through coupling. It is vital that a new O-ring is used every time a connection is made or broken.

  • Page 33: Transformer Connections

    Cryogenics Microprocessor Based Cryochillers INSTALLATION The mains power cable should be fixed in place using a cable strain relief gland so that the cable cannot be accidently pulled from the unit. The “Power Cable Entry Point” size is 1 ⅝” (approx. 41mm). The cable size used must meet local electrical installation regulations for the voltage and current of the unit.

  • Page 34: Figure 3-12, Transformer Tapings

    Cryogenics Microprocessor Based Cryochillers INSTALLATION The voltage the unit is allocated at time of manufactured to must be determined at time of order. Once ordered, the unit cannot be changed to operate using a different voltage. A transformer is fitted to the unit to drop down the incoming voltage to 24VAC and 110VAC.

  • Page 35: Remote Connections

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 3.8 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. The unit is supplied as standard with Ethernet communication.
  • Page 36 Cryogenics Microprocessor Based Cryochillers INSTALLATION Input/Output Description Action High input will start the UNIT. With Low input the UNIT will stop. UNIT must be in “remote operation” mode for this Input Operate Unit input to be active. Isolated Ground Common line for remote inputs. Contact closure indicates that unit is OK and set point 1 is Indicate Set Point 1 Output...

  • Page 37: Figure 3-13, 37-Way Amphenol™ Connector, Front View

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Indicate Defrost Contact Closure: Indicates that cooling circuit 2 has Complete (2) completed defrost. During Defrost the contacts will open. Output Signal present irrespective if UNIT in LOCAL or REMOTE (Dual circuit systems operation only) Indicate Common Indicate common for all output contact closures User selectable output via “cal2309”...

  • Page 38: Analogue Output Voltage

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 3.8.2 Analogue Output voltage On pin 32 and pin 34 of the remote connector the analogue voltages are scaled as the table below. Temp Volts 1.76 The formula below can be used for the calibration of the analogue output 2.67 voltage to temperature.

  • Page 39: Ethernet Communication

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 3.9 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 an Ethernet hub to interrogate the unit as well as send command functions.

  • Page 40: Ethernet (Laptop) Set Up

    Cryogenics Microprocessor Based Cryochillers INSTALLATION or required in 100BASE-TX as well. So why bother using these wires, well for one thing it is simply easier to make a connection with all the wires grouped together. Otherwise you will be spending time trying to fit those tiny little wires into each of the corresponding holes in the RJ-45 connector.

  • Page 41: Figure 3-17, Tcp/Ip

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-17, TCP/IP Figure 3-18, Set up for TCP/IP Power up system and wait 10 seconds or so and then open the software supplied on the USB thumb drive. 41 of 81 telemark.com Rev 1.0.9...

  • Page 42: Commands Available When Using Ethernet, Rs232/485 Control

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 3.9.2 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 off) Write Puts coil #1 into Standby Write...

  • Page 43: Using Tcpip-Rs232/485/Ethernet Gui

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Note: “write” commands are case sensitive. 3.9.3 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 several system parameters to match your application requirements.
  • Page 44 Cryogenics Microprocessor Based Cryochillers INSTALLATION RS232/485 Setup – displays help screen in setting up RS232 and RS485 connection information and protocols. Change Remote Host TCP/IP (only on units with software versions TVP_2018_02_08 or later only)– allows the user to change the host IP address of the Cryochiller.

  • Page 45: Cal2309" Screen (User Configuration Screen)

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-20, 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. RS232/485 serial communications are availed as a no-cost option must be specified at time of order.

  • Page 46: Figure 3-21, "Cal2309" Screen Setup

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-21, “cal2309” Screen Setup Compressor Cycling(1) Non-Cycling(0) 0 SPLOW = 14 psi Single=0 or Dual=1 (Coil). = 0 ---Analog Output Option ctemp=1 co1=2 co1=3 ci1=4 ci2=5 (AO 1) = 2 ctemp.2=1 co1.2=2 co2.2=3 ci1.2=4 ci2.2=5 (AO 2) = 2 ---Set Point 1 Option = 1 Option 1: Comp.
  • Page 47 Cryogenics Microprocessor Based Cryochillers INSTALLATION Tcp Ip Address (ip) = IP: 192.168.1.100 Select parameter to change or 'def' for defaults 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 reenter ““cal2309””...

  • Page 48: Using The Tcpip-Rs232/485 Program

    Cryogenics Microprocessor Based Cryochillers INSTALLATION 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. 3.9.5.6 Data Logging The data logging function works even when the Ethernet link is not activated, however the Ethernet link must be opened to activate the logging mode.

  • Page 49: Figure 3-22, Change Com Port

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-22, Change Com Port Figure 3-23, Select Com Port 49 of 81 telemark.com Rev 1.0.9...

  • Page 50: Figure 3-24, Com Connection Shown

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-24, Com Connection Shown Figure 3-25, Enter rip 50 of 81 telemark.com Rev 1.0.9...

  • Page 51: Figure 3-26 Display Ip Address

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-26 Display IP Address Figure 3-27, Change Remote Host 51 of 81 telemark.com Rev 1.0.9...

  • Page 52: Figure 3-28, Go To Ip Properties

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-28, Go to IP Properties Figure 3-29, Check IP Addresses 52 of 81 telemark.com Rev 1.0.9...

  • Page 53: Figure 3-30, Parameter Setup

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-30, Parameter Setup Figure 3-31, Select IP Address for Changing 53 of 81 telemark.com Rev 1.0.9...

  • Page 54: Figure 3-32, Enter New Ip Address

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-32, Enter new IP address 54 of 81 telemark.com Rev 1.0.9...

  • Page 55: Figure 3-33, Disconnect Tcp/Ip

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-33, Disconnect TCP/IP Figure 3-34, Change Remote Host IP address 55 of 81 telemark.com Rev 1.0.9...

  • Page 56: Figure 3-35, Disconnect Tcp/Ip Again

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-35, Disconnect TCP/IP Again 56 of 81 telemark.com Rev 1.0.9...

  • Page 57: Figure 3-36, Check First Three Ip Numbers

    Cryogenics Microprocessor Based Cryochillers INSTALLATION Figure 3-36, Check first three IP numbers Figure 3-37, Connect to Remote Host 57 of 81 telemark.com Rev 1.0.9...

  • Page 58: Operation

    Cryogenics Microprocessor Based Cryochillers OPERATION 4 OPERATION The operations below describe how to operate the unit in manual mode. For remote operation please refer to section 3.8 of this manual. 4.1 CONTROLS AND DISPLAYS Figure 4-1, Front Panel Push Buttons (Single Coil Unit Shown) 4.1.1 LCD Display Displays the status of the unit as well as, the current running parameters.

  • Page 59: Figure 4-3, Lcd Display, Pre-Cool

    Cryogenics Microprocessor Based Cryochillers OPERATION Figure 4-2 shows the LCD screen with the unit in the wait mode prior to being turned on. Figure 4-3, LCD Display, Pre-Cool Figure 4-3 shows the LCD screen with the unit is in “pre-cool” condition. On the lower line display is showing the DP, Discharge pressure and SP Suction pressure running parameters.

  • Page 60: Scroll Push Button

    Cryogenics Microprocessor Based Cryochillers OPERATION 4.2 SCROLL PUSH BUTTON This button will change what reading is displayed on the LCD. Each time you push the button you will advance the display. 4.3 PUSH BUTTONS 4.3.1 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”...

  • Page 61: Operation

    Cryogenics Microprocessor Based Cryochillers OPERATION 4.4 OPERATION 4.4.1 Turn on the main ISO isolator Turn on the main ISO isolator located to the right-hand side of the unit. Refer to Figure 4.4.2 Turning the Unit On Pull the black STOP/RESET button. SCROLL and STANDBY lamps should illuminate. Depressing the illuminated STANDBY button will start the system.

  • Page 62: Normal Operating Ranges

    Cryogenics Microprocessor Based Cryochillers OPERATION good rule of thumb is if the discharge pressure is less than 250 psi then it is fully recovered. 4.5 NORMAL OPERATING RANGES The table below provides the range of acceptable parameters during normal operation. Should observations reveal running out-side the ranges as given below, then you should contact Telemark or their representative at the earliest opportunity.

  • Page 63: Trouble Shooting Guide

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE 5 TROUBLE SHOOTING GUIDE 5.1 TROUBLE SHOOTING Cryochiller water vapor vacuum pumps are made up of 4 essential sub systems. Refrigeration system Power electrical / Water supply Low voltage electrical and interface Control electronics 5.2 REFRIGERATION LEAKS These are the number one cause of poor system performance and failure.

  • Page 64: Safety Systems

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Note: Observe and note all alarm messages before resetting unit. Repeated alarm messages can be an indication of imminent system failure or failure of the water supply The system will shut down if control parameters are breached and an error message will be displayed: If a system parameter breached a manual reset is required.

  • Page 65: Trouble Shooting Guide

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Over Pressure Switch – located inside the machine this is a pressure switch to protect the unit from being over pressurized or run in an over pressure condition. To Rectify and over pressure condition it will need to be manually reset using the green re-set button located on the top of the pressure switch.
  • Page 66 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. Check LCD for error message LCD illuminates but Consult error message guide for START/STANDBY...
  • Page 67 Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Symptom Possible Cause Corrective Action System does not Water temperature too high Correct water temperature and flow rate cool CT fails to get or too low reset system colder than -140 to - System should be shut down for a period of 150oc after 45 approximately 48 hours (or until the value of...

  • Page 68: Table 5-2, Troubleshooting Guide

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Symptom Possible Cause Corrective Action System has poor Too much heat is being Remove Internal heat source cooling with large applied to the cryo-coil temperature Check values of differential between CI and CO Possible refrigeration leak While in cool, and standby and compare with previous logged values...

  • Page 69: The Use Of "Top-Off" Gas Charges

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE 5.6 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 shut down for a period of 24 hours to allow the unit to warm up.

  • Page 70: Figure 5-3, Emerson Compressor Front Panel Fault Code Led's

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Fault code LED’s Figure 5-3, Emerson Compressor Front Panel Fault Code LED’s CoreSense Current ™ module Transformer with green, (CT) yellow and red fault code LED’s Thermostat Connection Figure 5-4, Emerson Compressor Internal Electronic Parts 70 of 81 telemark.com...

  • Page 71: Compressor Diagnostics

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE 5.7.1 Compressor Diagnostics WARNING • Failure to follow these warnings could result in serious personal injury. • Only qualified and authorized HAVC or refrigeration personnel are permitted to carry out repairs and or install the compressor. •...
  • Page 72 Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE PRESSURISED SYSTEM HAZARD • Failure to follow these warnings could result in serious personal injury. • System contains refrigerant and oil under pressure. • Use only approved refrigerants and refrigeration oils. • Personal safety equipment must be used. The table below describes the Emerson (Copeland®) fault descriptions via the CoreSense™...
  • Page 73 Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Status LED Status LED Description Status LED Troubleshooting Information Module supply voltage Green Alert LED Supply voltage present. present. Solid Compressor Running OK Compressor running OK Check pressure or temperature control. Green Alert LED Short Cycling.

  • Page 74: Table 5-3, Emerson Leds

    Cryogenics Microprocessor Based Cryochillers TROUBLE SHOOTING GUIDE Status LED Status LED Description Status LED Troubleshooting Information Possible loss of refrigerant charge. LOCKED OUT ON: Red Alert LED Blocked Condenser. High discharge line Discharge line blocked or Rotolok™ valve 1 Flash temperature trip closed.

  • Page 75: Decommissioning

    Cryogenics Microprocessor Based Cryochillers DECOMMISSIONING 6 DECOMMISSIONING Should it be necessary to remove the unit from the vacuum system the following procedure must be followed. WARNING The refrigeration system contains a mixed blend of refrigerants and polio-ester oil. These do not present acute health risks it is essential that the following basic precautions are followed: •...
  • Page 76 Cryogenics Microprocessor Based Cryochillers DECOMMISSIONING There are strict regulations concerning the recovery and discharge of all refrigerants into the environment. Penalties can be severe if decommissioning is carried out by untrained persons or if release to the environment occurs. (a) Run the system in standby mode until the unit reaches a stable value for SP. (b) Then close all hand valves.

  • Page 77: Design Of Cryo-Coils

    Cryogenics Microprocessor Based Cryochillers DESIGN OF CRYO-COILS 7 DESIGN OF CRYO-COILS The design and placement of a cryo-coil is a specialized 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 78: Table 7-1, Coil Surfaces And Theoretical Pumping

    Cryogenics Microprocessor Based Cryochillers DESIGN OF CRYO-COILS It is important to appreciate that a unit will only pump water efficiently in conditions of molecular flow i.e. In vacuums of less than 1 x 10 mbar. Where the pressure exceeds this value before the system is switched to cool there is a risk of over loading and saturating the cryo-surface, which may lead to poor process quality and slower pump downs.
  • Page 79 Cryogenics Microprocessor Based Cryochillers DESIGN OF CRYO-COILS ▪ Internal volume of not less than 0.4 Liters ▪ A pressure drop between the inlet and outlet of less than 0.3 bar or equivalent to 40M 12.5mm (1/2”) smooth tubing. ▪ Capable of handling a pressure of 17 bar (250PSIG) over a temperature range of +160°C to -160°C ▪...

  • Page 80: Chinese Safety Data Sheet

    Cryogenics Microprocessor Based Cryochillers CHINESE SAFETY DATA SHEET 8 CHINESE SAFETY DATA SHEET The Refrigerant Charge Safety Data Sheets can be located on the Flash drive under the heading Safety Data sheets 80 of 81 telemark.com Rev 1.0.9...
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