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Telemark TVP-2000 Operation, Installation And Service Manual

Water vapor cryotrap
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Operation, Installation and Service Manual
Water Vapor Cryotrap
Models TVP-2000 and TVP-3500
Page i of 1
TVP Manual (full) March 2007 CE rev 03.doc

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  • Page 1 Operation, Installation and Service Manual Water Vapor Cryotrap Models TVP-2000 and TVP-3500 Page i of 1 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 2 Telemark Cryotraps TVP2000/3500 Page ii of 2 TVP Manual (full) March 2007 CE rev 03.doc...

  • Page 3: Table Of Contents

    Recommended spare parts list 4.80 Materials safety data sheet 4.90 CE Certification 4.95 Chinese Hazardous Substances Concentration Table Section 5 Warranty Limited Warranty for Telemark Water Vapor Pumps Glossary Page 3 of 3 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 4 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. HELP MAY BE SOUGHT FROM THE MANUFACTURER.
  • Page 5 The phrase Caution indicates a risk of damage to the product or associated plant and machinery if the provisions are not followed carefully. Telemark will not be responsible or liable for either direct or consequential personal injury or loss claims arising from the misuse of the product.
  • Page 6 (10) If the lines have visible frosting or water is seen to leak from them during defrost or standby, all of the line insulation must be replaced. (11) The most common cause of system malfunction are refrigeration leaks. Careful attention to the integrity of the system will ensure optimal performance. (12) Do NOT repeatedly bend the refrigerant line;...
  • Page 7 (25) Do not short circuit the 24 V AC supply (pins 35 & 36) against any pin designated as ground (GND) as this may damage the low voltage circuitry. The system is protected by a manual re-settable 2-Amp thermal fuse located on the left hand side of the remote connector. Ensure that there is sufficient resistance in any external circuit to prevent this value being exceeded.
  • Page 8 –100 to –150 c is required. Your investment in a Telemark TVP is backed by a 1-year warranty, which is detailed at the end of this manual. Page 8 of 8...
  • Page 9 Diagram 1 External view of TVP Page 9 of 9 TVP Manual (full) March 2007 CE rev 03.doc...

  • Page 10: Section 1 Systems Operation

    Section 1 System operation At any time a TVP system and in any control mode maybe safely turned off by depressing the stop / emergency off (EMO) button. (Figure 1) The following section assumes the system has been installed correctly and covers the following modes of operation.
  • Page 11 1.101 Resetting the system To reset the STOP button after actuation it must be turned 90o clockwise, at which point it will click outwards, all other buttons have a momentary actuation. The TVP will automatically reset itself after a forced stop, a manual start or renewed remote start signal are required for restart.

  • Page 12: Remote Mode Operation Of A Tvp Using The 37 Pin Isolated Interface

    1.106 System Recovery after defrost After defrost it is possible to enter cool immediately however, better results (faster cycle times and lower temperatures) are achieved if a short period (more than 4 minutes) in standby is allowed for the system to recover. The recovery period is in proportion to the defrost termination temperature and the duration of the defrost cycle.

  • Page 13: Full Computer Mode Remote Operation Using Rs232 Or Other Communication Standard

    Consult your PC manual or dealer for serial link cable and adapter. A standard adaptor to 9 pin serial port can be obtained directly from Telemark. Control is achieved using “hyper terminal”, which is normally shipped with your Windows PC to control and data log system parameters....
  • Page 14 Hyper Terminal Settings (assumes Windows 95 or newer) Select the connect using box and set to your serial port (usually COM1) Diagram 5 Select OK You will automatically be taken to COM1 properties window Select the following settings Bits per second = 9600 Data bits = 8...
  • Page 15 Enter return and the message following will appear if a connection has successfully been made. Diagram 7 Entering a query with a “? Return” will give the following screen Diagram 8 Note All commands must be executed as lower case characters followed by return. All commands apart from the specialised calibration routine follow a three-character format.
  • Page 16 Operational commands >Read Commands ‘r’ Read commands are used to interrogate the systems and are very helpful when diagnosing faults. >Write Commands ‘w’ are used to change status of the system from cool to defrost for example. >------------------------------ >w2o – write 232 control ON >w2f –...

  • Page 17: Operators Quick Reference Guide

    1.4 Operators quick reference guide Following system parameters ranges are normal any abnormal conditions will be reported via the display and the RS232 link if enabled. Parameter Description Acceptable (normal) range SP start up * Suction Pressure 20 to 120 psi DP start up * Discharge pressure...
  • Page 18 Note The system uses highly stable PT100 sensors, the temperature measurement system is designed for long-term reliability and stability of temperature measurement. Inferring vacuum performance from the CI/CO values is an unreliable method of process determination. Direct measurement and observation of the vacuum through either an RGA or Penning type gauge are the only reliable methods of evaluating the actual process conditions present.

  • Page 19: Section 2 Installation Guide

    Section 2 Installation Guide Installation WARNING The system contains gases under pressure, which may constitute both a frostbite hazard and a burn hazard. Refrigerant gases are known asphyxiants and are mildly narcotic. Precautions must be taken. Work must only be carried out by suitably qualified personnel. Always wear suitable eye and hand protection.
  • Page 20 Inspect the unit for any signs of damage during shipping. If damage is noted contact the carrier immediately. For any further information contact Telemark or your distributor. System shipping pressure The TVP was shipped with an approximate standing pressure of 250psi the exact pressure, which the unit shipped with, is noted on the packing list.
  • Page 21 Diagram 9 Services panel Warranty Card Included with every system is a warranty card. Please complete this and either post, email or fax the form to the address shown. We will register your machine and ensure that you receive the latest software upgrades. Failure to complete the warranty card may cause delays in servicing or providing parts....
  • Page 22 2.05 Cooling Water requirement The advanced design of a TVP means it is capable of operating over a wider range of water temperatures than traditional systems. Optimal water outlet temperature (WT on the display) is 25 C, however there is little loss of performance with water outlet temperatures as high as C.
  • Page 23 Telemark supplies a range of high quality vacuum feedthroughs, which compliment its range of refrigeration lines.
  • Page 24 ” (30 mm) final insulation Diagram 11 Insulation of refrigerant lines Telemark manufactures conventionally insulated refrigeration lines to order to suit your installation. When installing the refrigerant lines it is essential to protect the lines and fittings from the entrance of moisture, such as water vapour, which causes rapid degradation of any foam type insulation.
  • Page 25 2.08 Refrigeration line fitting instructions for Parker connection Inspect and clean all coupling faces. Ensure they are free from dents or scratches. Small imperfections on the Parker fittings 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 Swagelok VCR fittings.
  • Page 26 Swagelok (VCR) fitting instructions CAUTION VCR fittings are very susceptible to damage to the sealing surfaces therefore extreme caution must be taken not to damage the sealing surfaces. Always use the correct washers supplied in your tool kit. It is not possible to redress the surfaces as described for Parker fittings.
  • Page 27 Diagram 14b Diagram 14a TVP 2000/3500 dual coil unit valve TVP 2000/3500 single coil unit arrangement valve arrangement Valve box 1. Access hand valve 2. Suction (common return valve) 3. Common defrost hand valve 4. Defrost solenoid valve coil 1. 5.
  • Page 28 2.09 Leak checking the cryo-coil and refrigerant lines CAUTION Connection of the refrigerant line and final preparation of the system must be carried out by a fully qualified and experienced refrigeration engineer. CAUTION Leak checking should always be carried out with a helium mass spectrometer leak detector. Any other method may lead to contamination of the system, leaks and system failure.

  • Page 29: Preparation Of Cryo-Coil And Refrigerant Lines

    CAUTION Most leaks are found at the connections of refrigerant lines, pay particular attention to these areas. These joints should be checked regularly throughout the life of the installation. Check all brazed joints for any leaks. Check valve bodies in the valve box. If a leak is found at a Parker coupling, ensure that the joint is fully tightened.
  • Page 30 Diagram 15 Remote sensor attached to copper line. Telemark has supplied high quality sensors with a ductile stainless steel sheaths never directly silver solder these couplings onto refrigeration lines. Solder a ¼” copper line on to the refrigeration where they leave the vacuum feed-through and insert the sensor into the pocket formed use a little thermally conductive grease....
  • Page 31 TVP. Where the vacuum system provides voltage signals these must be isolated from the TVP by a relay. A range of adapters for common interface patterns are available directly from Telemark  CAUTION...

  • Page 32: Configuration Of Remote Interface

    In practice this means only two relay closures are required for effective operation, system operate and cool. If defrost is permanently linked within the interface connector the systems automatic termination of defrost can be exploited. 2.20 Configuration of the remote interface The User Interface is automatically enabled when pin 9 is connected to system GND (pin 24);...
  • Page 33 Dual coil systems Caution The system updates the I/O @ 70 milliseconds, if cool is removed before defrost is applied the system will go into STANDBY momentarily. This can cause a problem for some slow to update systems.      1) Full interface This shows the complete I/O for the two coil TVP.

  • Page 34: Full Computer Mode Remote Operation Using Rs232 Or Other

    RJ11 (US style phone jack). Consult your PC manual or dealer for serial link cable and adapter. An adapter cable is available from Telemark. Connection to your PC is achieved using hyper terminal, which is normally shipped with your Windows to control and data log system parameters....
  • Page 35 Select the connect using box and set to your serial port usually COM1 Select OK You will automatically be taken to COM1 properties window Select the following settings Bits per second = 9600 Data bits = 8 Parity = None Stop bits = 1 Flow control = Hardware Page 35 of 35...
  • Page 36 Enter return and the message will appear if a connection has successfully been made. >?R for read Commands, ?W for Write Command >v – RS232 to Verbose mode >q – RS232 to Quiet Entering a query with a “? Return” will give the following screen Page 36 of 36 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 37 2.31 Commands available when using RS232 control NOTE All commands must be executed as lower case characters followed by return. All commands apart from the specialised calibration routine follow a three-character format. Turns the comms link on Turns the link off Operational commands...

  • Page 38: Calibration Routine "Cal2309

    2.40 Calibration routine “cal2309” During installation it is possible through a computer running hyper terminal to adjust a number of system parameters to match your application requirements. Type return at the prompt “Bad Command, ? For Help” in the hyper terminal window type “cal2309 return”...
  • Page 39 2.44 Changing the logging interval (li) Type li return when in the “>Calibrate Active” mode and you will be prompted to enter a logging interval between 1 and 1000 seconds. Logging only occurs when the unit is in verbose mode. 2.45 Data logging...

  • Page 40: Preparation For Operation

    2.50 Preparation for operation The pressure in the refrigeration line / cryo-coil should be equal to the system balance pressure (235 – 250 psi). Fully open the hand valves in this order – Defrost, Cool and Common return (underneath the valve box cover inside the front door). Turn each valve back ¼...
  • Page 41 2.51 Starting the unit for the first time Reset the STOP button after actuation it must be turned 90o clockwise, all other buttons have a momentary action. The TVP will automatically reset after a forced stop, manual start or renewed remote start signal are required for restart. If the unit is ready for operation the green start / standby button will illuminate.
  • Page 42 NOTE To reduce the cycle time for any given system it is good practice to use the remote sensors and place them on the refrigeration lines as close as possible to the vacuum feed-through. The best thermal contact is made if the sensors are placed into copper using a thermally conductive grease into sleeves which have in turn been silver soldered directly on to the refrigeration lines....

  • Page 43: Decommissioning

    2.6 Decommissioning Should it be necessary to remove the TVP 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: Always wear eye protection.

  • Page 44: Section 3 Trouble Shooting Guide

    Section 3 Trouble shooting guide 3.00 TVP water vapour vacuum pumps are made up of 4 essential sub systems. 1. Refrigeration system  2. Power electrical / Water supply 3. Low voltage electrical and interface 4. Control electronics Of these the first two account for almost all system problems. When diagnosing a fault take time to discover and record all system parameters always treat the TVP and related vacuum system as a “black box”...
  • Page 45 3.1 Trouble shooting guide – initialisation and start up Corrective Action Symptom Possible Cause LCD does not No system power Check mains input illuminate Missing phase – Blue on machine Check mains input EMO not reset Reset EMO by twisting 90 clockwise LCD illuminates but Check LCD for error message...
  • Page 46 E7 Dp Trip System mechanical over protection During initial cool down it is possible triggered the balance pressure was too high the cooling water flow is too low / reversed or there was a problem with the systems off-load valve. Reset system and restart if fault persists allow system to warm up until CT is at least +10...
  • Page 47 3.2 Trouble shooting guide – problems during cool Corrective Action Symptom Possible Cause System does not cool CT fails to Water temperature too high Correct water temperature and flow get colder than –150 c after 45 or too low rate reset system minutes in standby System has a leak System should be shut down for a...
  • Page 48 CT While in cool, and standby and compare with previous logged values Poor system design Consult Telemark for free application advice. Aim for a cryo-coil, which has low mass, high surface area, low volume and a small resistance to flow.
  • Page 49 Corrective Action Symptom Possible Cause System has poor cooling with Process problem The TVP is designed to have small temperature differential a maximum stabilised between CI and CO temperature differential between CI and CO values of c. It is possible for absolute temperatures and in chamber conditions to vary for the following reasons...
  • Page 50 Check with your service center for details. System defrosts Either the defrost or Consult Telemark service center, repair normally for a period common return hand valve requires skilled technician to correct. and then stops...

  • Page 51: Section 4 Tables And Data

    Section 4. Tables and data This section is intended to be a primary reference for the installation and operation of Telemark TVP water vapor cryotraps. Details of products are subject to continuous revision and improvement. 4.10 Description of electrical supplies, and controls electrical and system schematics 4.11 System with side panel removed showing main sub-systems...
  • Page 52 4.11 System with side panel removed showing main sub-systems 1. Computer mother board 2. System interface board – sensor inputs 3. Main electrical power distribution board 4. External services and interface connection panel Page 52 of 52 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 53 Diagram 17 showing interface board and “snap on / off” edge connectors – see PDF attachments for wiring schematic Page 53 of 53 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 54 Diagram 18 Front view with door open 1. Compressor oil sight glass 2. Main system isolator 3. Earth distribution (larger 10mm stud supplied for customer earth bonding requirements) Page 54 of 54 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 55 Diagram 19 With left hand side system panel removed. 1. Over-pressure trip (slide green button on top to reset) 2. Discharge line 3. Suction line 4. high stability pressure transducers Diagram shows side removed for the location of over pressure trip which is more easily accessed by opening the front door of a TVP Page 55 of 55 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 56 4.20 Interfacing to the TVP The TVP is supplied as standard with a remote interface; connection is via an industry standard 37 pin AMP plug Diagram 20 AMP style 37 pin connector - connector side The User Interface is automatically enabled when pin 9 is connected to system GND (pin 24);...
  • Page 57 Caution The interface will not accept analogue inputs e.g. Voltages. Applying a voltage to the control pins of the interface will cause control problems. Use additional relays to produce the no-volt contact closures required. 4.23 Basic Interface configuration and control via a single relay Connecting pin 9 (remote enable), pin 1 (operate unit), pin 13 (operate defrost) to pin 24 (GND).
  • Page 58 4.25 Interfacing to OEM equipment. Telemark has experience of a wide number of differing schematics and pin designations used by OEM’s around the World. We can provide either pre-wired connections or direct TVP to vacuum system adapters upon request. Leybold interface One of the most common vacuum control systems encountered is based upon the Leybold / Balzers / Unaxis type of interface.
  • Page 59 4.26 Isolated interface schematic T VP side Description T ype Notes Customer side requireme nt Operate unit Zero volt contact closure with any system ground will operate unit System ground Set point relay 1b. (duplicate of pin 28) Read back signal Indicate common Customer supplied signal to be read back Indicate power...
  • Page 61 This is different from many other low temperature refrigeration systems, which achieve low temperatures by linking together two or more compressive refrigeration steps to form a classical cascade system. Further background information on auto-cascade systems can be obtained from Telemark. 1. Compressor 2. Condenser 3.
  • Page 63 Cap5 Heat exchange array Cool hand 1/2" Ultraseal valve Cool solenoid Cryo-coil valve Suction hand valve 3/8" Ultraseal Main Service port Telemark Cryogenics Limited EVAP General system schematic Page 63 of 63 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 64 4.40 Description of safety systems Several types of safety devices protect the TVP. These classified into two functional types, software and hard ware devices. In the scheme of protection the software devices provide first line protection however in many cases where the rate of change is faster than the electronics is capable of processing the primary protection is a mechanical device.
  • Page 65 4.42 Operation temperatures and pressures The following table gives the typical values, which maybe experienced during the operation of a TVP. It is important to appreciate that the values are influenced strongly by the operational mode and the amount of heat being pumped by the unit. The supply water temperature also has a profound impact when the system is in standby for long periods or where it is operating close to its maximum duty.
  • Page 66 Partial pressure of water vs. Temperature and pumping efficiency 98% efficiency 95% efficiency 90% efficiency -100 -110 -120 -130 -140 -150 mbar Diagram 23 Pumping efficiency of H O at partial pressure (mbar) vs. Temperature Page 66 of 66 TVP Manual (full) March 2007 CE rev 03.doc...
  • Page 67 Pumping efficiency Mbar 6.7E+00 2.7E+00 1.3E+00 6.7E-01 2.7E-01 1.3E-01 6.7E-02 2.7E-02 1.3E-02 6.7E-03 2.7E-03 1.3E-03 6.7E-04 -102 2.7E-04 -106 -102 1.3E-04 -109 -105 -102 6.7E-05 -112 -108 -105 2.7E-05 -116 -112 -109 1.3E-05 -119 -115 -112 6.7E-06 -122 -118 -115 2.7E-06 -125 -122...

  • Page 68: Cooling Curve Tvp Models

    4.5 Cooling curve TVP models The cooling curves shown indicates the approximate cooling capacity of the each system operating at 400VAC / 50Hz were the supply is 60Hz the capacity is increased by approximately 15% at any given temperature the “cool – no load temperature” will be reduced by approximately 5 TVP2000 cooling capacity Watts vs.

  • Page 69: The Design And Placement Of Cryo-Coils

    4.60 The design and placement of cryo-coils Caution The design and placement of cryo-coils assumes a basic understanding of the principles of vacuum pumping, many good texts on the subject are available. From Leybold, BOC Edwards and other general vacuum equipment suppliers. It is important to appreciate that a TVP will only pump water efficiently in conditions of molecular flow i.e.
  • Page 70 4.61 Location of cryo-surface The surface should be clear of any moving parts within the vacuum system. No closer than 25mm to any chamber wall 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 71: Recommended Spare Parts List

    4.7 Recommended Spare parts list The spare parts list may be used as a guideline, please note prices are not listed as they can change over time. Please contact Telemark for current pricing and availability. Note. Complete top sections and compressor assemblies are available upon request.
  • Page 72 4.8 Material safety data sheet The Telemark non-flammable mixed blend (melange) of refrigerants is fully compliant with. EC 2037 / 2000 and therefore contains no substances prohibited under the Montreal protocol or subsequent prohibitions regarding damage to stratospheric ozone. Safety Data Sheet...
  • Page 73 6 Accidental release measures Ensure ventilation – vapour significantly heavier than air and may accumulate in low-lying areas. Wear eye protection PVC gloves to protect against cold surfaces 7 handling and storage Compressed gas Non-toxic Non-flammable Keep container closed Avoid temperatures above 30 Protect containers from weather.
  • Page 74 • Separate health and safety data for components is available on request. • Product is considered safe only when used as a refrigerant charge for Telemark TVP water vapor cryotraps all other uses are at personnel’s own risk. • It is assumed that the material is used only by competent persons who have achieved certification in the...

  • Page 75: Materials Safety Data Sheet

    Material Safety Data Sheet Product Name Telemark 2000 Cryogenic Refrigerant Charge (Standard) Version 01.06 1 Product and company identification Product name Telemark 2000 Cryogenic Refrigerant Supplier Telemark Cryogenics Address 52 Leveroni Court, Suite D Novato, California 94949 USA Telephone 415-883-1004...
  • Page 76 6 Accidental release measures Ensure ventilation – vapour significantly heavier than air and may accumulate in low-lying areas. Wear eye protection PVC gloves to protect against cold surfaces 7 handling and storage Compressed gas Non-toxic Non-flammable Keep container closed Avoid temperatures above 30 Protect containers from weather.
  • Page 77 • Separate health and safety data for components is available on request. • Product is considered safe only when used as a refrigerant charge for Telemark TVP water vapor vacuum pumps all other uses are at personnel’s own risk. •...
  • Page 78 4.90 DECLARATION OF CONFORMITY Telemark Cryogenics 52 Leveroni Court, Suite D Novato, California 94949 USA Declares that the products: 320-0012-1 TVP2000 200-230VAC/3ph/50-60Hz CE 320-0012-2 TVP2000D (Dual Circuit) 200-230VAC/3ph/50-60Hz CE 320-0014-1 TVP2000 380-440VAC/3ph/50-60Hz CE 320-0014-2 TVP2000D (Dual Circuit) 380-440VAC/3ph/50-60Hz CE 335-0012-1...
  • Page 79 4.95 Telemark Cryogenics Water Vapor Cryotraps Models: TVP1000, TVP2000, TVP2000D, TVP3500, TVP3500D Declaration of Hazardous Substance Toxic or hazardous Substances and Elements Lead Mercury Cadmium Hexavalent Polybrominated Polybrominated Part Name (Pb) (Hg) (Cd) Chromium biphenyls diphenyl ethers (Cr (VI)) (PBB)
  • Page 80 Correction of defects by repair or replacement shall be either at the Telemark factory or in-situ by an authorised service representative. The location of repair shall be at the discretion of Telemark. Repairs carried out at Telemark factory shall be FOB Telemark factory and shall constitute fulfilment of obligations to the purchaser.
  • Page 81 Failure to complete and return this warranty card by the end user will void warranty cover from Telemark Serial Number Model Part Number Contact Name Company Address 1 City / Town State Country Telephone Email Date of delivery Date of installation...

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