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Telemark Cryogenics Instruction Manual

Water vapor cryo-chiller
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READ THE MANUAL ! UNDERSTAND ALL SAFETY CONCERNS !
Cryogenics
WATER VAPOR CRYO-CHILLER
INSTRUCTION MANUAL
Part No 19-0001-00
Copyright © Telemark Cryogenics, 1998-2016 – All rights reserved
Rev 1.0.2 June 2016
www.telemark.com
Brand or products names are trademarks or registered trademarks
of their respective companies.

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Summary of Contents for Telemark Cryogenics

  • Page 1 READ THE MANUAL ! UNDERSTAND ALL SAFETY CONCERNS ! Cryogenics WATER VAPOR CRYO-CHILLER INSTRUCTION MANUAL Part No 19-0001-00 Copyright © Telemark Cryogenics, 1998-2016 – All rights reserved Rev 1.0.2 June 2016 www.telemark.com Brand or products names are trademarks or registered trademarks of their respective companies.
  • Page 2 How to recharge your Cryochiller Required items: 1) Refrigeration service “manifold”. 2) Charge recovery system. 3) Dry nitrogen gas. If a high pressure cylinder is used, a pressure regulator will be needed 4) Cylinder of leak detectable gas 5) Halogen leak detector for refrigerants. 6) Leak check soap 7) Vacuum pump capable of 5 x 10 Torr or 50 microns.
  • Page 3 Gas charge recovery units • There are many different models of gas recovery units available on line or at any HVAC parts center. • This will be used to recover any gas charge left in your unit if required for service •...
  • Page 4 Refrigeration service manifold • There are many different models of service manifolds available on line or at any HVAC parts center. • There is a low side (blue color)gauge and a high side (red)gauge. The low side will be connected to the Suction side of the compressor and the high side will be connected to the discharge side of the compressor •...
  • Page 5 Refrigeration Vacuum pump • There are many different models of vacuum pumps available on line or at any HVAC parts center. • With proper adaptors you can use the vacuum pump on your vacuum coating system • There are many portable refrigeration vacuum pumps available too...
  • Page 6 Understanding valves on the compressor • The following terms will be used to describe the position of the 3 way compressor service valve: • • Back Seated Position: Turn valve stem counter-clockwise until the valve stem is fully extended. This closes off the service port ( the small port on the side of the valve with the brass blank off nut).
  • Page 7 Compressor valve back seated • Turn valve stem counter-clockwise until the valve stem is fully extended. This closes off the service port ( the small port on the side of the valve with the brass blank off nut).
  • Page 8 Compressor valve Mid seated • From the backseat (per above) turn the valve stem three turns clockwise. This allows refrigerant to flow to the service port. This is a common position during servicing.
  • Page 9 Compressor valve front seated • Turn valve stem clockwise until fully shortened. This stops any flow of refrigerant. THE COMPRESSOR SHOULD NOT BE RUN WITH THE VALVE IN THIS POSITION.

  • Page 10: Let's Get Started

    Lets get started • Step #1 Check the Cryochiller for Leaks. • You must locate the source of leak before putting new a charge into the Cryochiller • • Remove side panels to access compressor area. • • Leak check the full system before adjusting any valves or installing the manifold.
  • Page 11 • Step #2 Connect the Manifold to the Unit • • Insure Manifold’s valves are closed. • Connect the manifolds suction hose to the compressors suction service valve. • Connect the manifolds discharge hose to the compressor’s discharge service valve. •...
  • Page 12 Discharge valve Bitzer Comp. Suction valve Bitzer Comp. Suction valve Emerson Comp. Discharge valve Emerson Comp.
  • Page 13 Step #3 Recover Any Remaining Refrigerant from the Unit You may need one or two recovery cylinders depending on how much gas in the Cryochiller. Remove the cap from the recovery cylinder’s vapor access port (the one with the blue hand valve). Evacuate each recovery cylinder according to the cylinder manufacturer’s instructions.
  • Page 14 • Step #4 Re-Check the Cryochiller for Leaks. • • Connect the trace gas cylinder to the manifolds enter hose. Open both manifold valves and the cylinder valve to pressurize the unit to 10 to 20 psig (70 – 140 kPa). Close both manifold valves and the trace gas cylinder valve.
  • Page 15 • Step #5 Evacuate the Cryochiller. • • Turn on the unit and allow the compressor to run for 30 seconds. • Remove the dry nitrogen connection from the manifold’s center hose. Release the vapors/gasses from the unit by opening both manifold valves.
  • Page 16 • Evacuate the unit for a second time • • Connect the dry nitrogen to the manifold’s center hose. Open the manifold’s suction valve and pressurize to 100 – 120 psig. Turn on the unit and allow the compressor to run for 30 seconds. •...
  • Page 18 Disposable cylinders 2-3 per charge Re-fillable cylinder 1 per charge • The full gas charge can come in disposable cylinders or in a reusable cylinder. • Depending on your countries laws and what Cryochiller model you have this can be from 1 to 3 tanks for a full gas charge.
  • Page 19 • Step #6 Recharge the Cryochiller • • Insure manifold’s valves are closed. Insure the compressor’s suction and discharge valves are in the midseated position. • Connect tank #1 of the replacement refrigerant charge to the manifold’s center hose. • Purge the manifold’s center hose of air: loosen the hose where it connects to the manifold; slightly open the cylinder’s valve for no more than 1 to 2 seconds;...
  • Page 20 Charging with disposable tank using recovery pump...
  • Page 21 Charging with refillable tank using recovery pump...
  • Page 22 • A) With a charge recovery system (preferred) • A1) Connect the manifold’s center port to the outlet of your charge recovery system. Connect cylinder #1 to the inlet of your charge recovery system. Purge hoses of air. • A2) Open the valves on the manifold and on the cylinder. Turn on the charge recovery system to pump the refrigerant into the Cryochiller.
  • Page 23 • B) Using the Cryochiller compressor • B1) Connect Tank #1 to the manifold’s center port. • • B2) Start compressor and open the manifold’s suction valve and the valve on tank #1. • • B3) When the system reaches the Standby Ready mode, close the manifold’s suction valve and the valve on Tank #1 when you see a reading of under 40 psig.
  • Page 24 Charging using compressor on suction side of compressor...
  • Page 25 • Step #7 Prepare the Cryochiller Unit for Operation • • Remove the manifold • • Backseat the compressor’s suction and discharge service valves. • • Remove the hoses. • Re-install the flare nuts and seals on the access fittings of the service valves on the compressor. •...