Telemark TVP-2000, Operation, Installation And Service Manual

Page 1: ...Page i of 1 TVP Manual full March 2007 CE rev 03 doc Operation Installation and Service Manual Water Vapor Cryotrap Models TVP 2000 and TVP 3500...

Page 2: ...Page ii of 2 TVP Manual full March 2007 CE rev 03 doc Telemark Cryotraps TVP2000 3500...

Page 3: ...ion standard 2 4 Calibration routine cal2309 2 5 Preparation for operation 2 6 Decommissioning Section 3 Trouble Shooting guide 3 0 TVP 4 essential sub systems 3 1 Initialisation and start up 3 2 Prob...

Page 4: ...ls other than the front door will expose the operator to high voltage components which may result in a fatal electrocution 4 failure to leak test the system as a whole may result in the catastrophic r...

Page 5: ...hand valves whilst the system is at cryogenic temperatures may damage the valve seats and invalidate the systems warranty It must only be attempted on a cryogenically cold system in the case of an eme...

Page 6: ...ted 18 Ensure the Cryocoil is located in a vacuum chamber and that the chamber is evacuated to at least 0 01 Torr or 1 x 10 2 mbar to prevent overheating of the coil from latent heat 19 Before any lea...

Page 7: ...is sufficient resistance in any external circuit to prevent this value being exceeded 26 The remote is fully isolated there will be a small AC potential difference above the chassis ground earth It is...

Page 8: ...frigeration technology to give industry leading energy and vacuum performance A Telemark TVP couples speed with a sophisticated computer control package which includes a simple and adaptable user inte...

Page 9: ...Page 9 of 9 TVP Manual full March 2007 CE rev 03 doc Diagram 1 External view of TVP...

Page 10: ...isuse therefore it will not permit operation when system parameters are outside acceptable values Likewise you may need to wait a short time before engaging a different mode At any time while the syst...

Page 11: ...e to indicate the system is able to start cooling At all times the scroll button remains illuminated 1 103 Standby Standby is the normal resting state both cool and defrost may be selected when the st...

Page 12: ...connection of the remote The system automatically switches to remote operation if a link between pin 9 and 24 is made this link is already made in the mating connector supplied with the TVP The remot...

Page 13: ...gram 4 Connection to your PC is via your serial port to an RJ11 US style phone jack Consult your PC manual or dealer for serial link cable and adapter A standard adaptor to 9 pin serial port can be ob...

Page 14: ...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 Bi...

Page 15: ...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 thre...

Page 16: ...Standby 2 Standby coil 2 dual coil units only wsc write Cool 1 Cool or coil 1 dual coil units ws2c write Cool 2 cool coil 2 dual coil units only wsd write Defrost 1 defrost coil 1 or defrost w2d writ...

Page 17: ...meter is breached a manual reset is required actuate EMO and resetting CAUTION A forced manual reset means it is the users responsibility to investigate and correct any cause of error before re starti...

Page 18: ...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...

Page 19: ...NG Internal parts of the system may either be very hot or very cold presenting a possible burn hazard Always take precautions where the system has been running within the last hour WARNING Read the in...

Page 20: ...ms shipped with the TVP The unit has been shipped with a comprehensive set of tools and components to enable you to install and maintain the unit Please check all items listed on the packing list are...

Page 21: ...supported and are manufactured from annealed copper tubing allowing for thermal expansion and vibration CAUTION 70mm access to left hand panel must be maintained to ensure air flow to the unit compres...

Page 22: ...t at connectors Open the cabinet and check visually for water leaks inside the cabinet Water temperature below ambient may cause condensation Additional insulation of the internal water lines may be r...

Page 23: ...ctory way to verify the system is leak tight to the required standard is by using a mass spectrometer It is good practice for cryo coils with attached feed through to be installed from inside the cham...

Page 24: ...re such as water vapour which causes rapid degradation of any foam type insulation An effective vapour barrier is best achieved by using the approved rubber based impact adhesive followed by sealing o...

Page 25: ...as these are more delicate than the female flat face seal half of the coupling Position the refrigerant lines to suit the installation Bend the refrigerant line as necessary The minimum bend radius is...

Page 26: ...re closed see diagrams 14a and 14b Remove the blank off fittings from the coupling lines on the unit Some refrigerant gas may escape If this continues the valves are not properly closed or have failed...

Page 27: ...ent Diagram 14b TVP 2000 3500 dual coil unit 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 Defrost solenoi...

Page 28: ...ogen Diagram Refrigeration manifold Detecting leaks without a helium mass spectrometer can be time consuming The target leak rate should be less than 5 x 10 8 mbar L S this is outside of the detection...

Page 29: ...less As evacuation refrigeration lines are severely conductance limited a minimum evacuation time of at least two hours is recommended Close the TVP unit s access valve while the vacuum pump is still...

Page 30: ...as supplied high quality sensors with a ductile stainless steel sheaths never directly silver solder these couplings onto refrigeration lines Solder a copper line on to the refrigeration where they le...

Page 31: ...work with the remote connected The TVP provides a 2 AMP 24VAC supply to power relays and to provide signalling to your vacuum systems See section 4 for suggested wiring schemes CAUTION The TVP cannot...

Page 32: ...ignals faster than 5khz can be effected 2 22 Digital Outputs The digital outputs are fully isolated they provide a contact closure to ground rated for up to 1A 24 VAC The commons are all linked for th...

Page 33: ...cause a problem for some slow to update systems 1 Full interface This shows the complete I O for the two coil TVP The control inputs are exactly the same as above but with two additional inputs for C...

Page 34: ...tion to your PC is made via your serial port to an 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...

Page 35: ...doc 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 bi...

Page 36: ...CE rev 03 doc 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...

Page 37: ...l commands apart from the specialised calibration routine follow a three character format W2o Turns the comms link on W2f Turns the link off Operational commands Write Commands w w2o write 232 control...

Page 38: ...efrost termination temperature Type dt return You will be asked to input a value type value followed by enter note a lower temperature can dramatically shorten the overall cycle time 2 42 Changing Wat...

Page 39: ...ode Type v enter the unit is now in verbose mode and data logging The rate at which logging occurs is defined by the Logging Interval function li under cal2309 The data appears in columns in the follo...

Page 40: ...is sufficient for the inlet temperature See graph Apply power to system Check all 3 phases are present and that they are roughly equivalent voltages Damage maybe caused if unit is run with missing br...

Page 41: ...check that SP reaches 27 psi or less and DP achieves less than 170 psi If the water temperature is lower than 20o c values for DP and SP will also be lower If the value for SP falls below 3 psi durin...

Page 42: ...out at lest three complete cool defrost standby cycles before checking for leaks especially at the couplings to the refrigeration lines Re check the couplings braze points etc for any leaks with a hal...

Page 43: ...in confined areas c Refrigerant gases which if exposed to high temperatures decompose to form very toxic by products never smoke in the vicinity of a TVP or any other similar system including the gas...

Page 44: ...ischarge gas temperature has exceeded 145o c E7 O P Switch System over pressure trip has been triggered E8 Phase error Phase rotation wrong or missing or Over Pressure switch tripped 3 02 Refrigeratio...

Page 45: ...sting 90o clockwise System runs and then stops Check LCD for system status Most common cause of this is either the value for discharge pressure DP being too high or the suction pressure too low Check...

Page 46: ...ered During initial cool down it is possible 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 restar...

Page 47: ...flare and refrigeration line joints before topping system up to recommended pressures If SP is above 45 psi start valve may have become stuck open Typically CT will also not be lower than 100o c With...

Page 48: ...ve valve solenoid and heat valve gently to 100oc with hot air gun Replace solenoid and attempt cooling TVP systems have a patented refrigeration system which prevents valve problems under normal opera...

Page 49: ...heat load aim for 5 x 10 3 mbar Consult tables in section 4 System is slow to cool It typically takes 15 30 seconds for an appreciable drop in the temperature at CI This may be longer if remote senso...

Page 50: ...that the remote sensor connection plug is in place if removed CI and CO sensors will read open circuit value grater than 200 oC Spare sensors are fitted to system and maybe found behind female side of...

Page 51: ...r displays nonsense Power failure Check power supply HV RF electrical interference from vacuum plant Check interface is earthed and electrically isolated Use the 10mm earthing stud to make bond betwee...

Page 52: ...07 CE rev 03 doc 4 11 System with side panel removed showing main sub systems Key 1 Computer mother board 2 System interface board sensor inputs 3 Main electrical power distribution board 4 External s...

Page 53: ...Page 53 of 53 TVP Manual full March 2007 CE rev 03 doc Diagram 17 showing interface board and snap on off edge connectors see PDF attachments for wiring schematic...

Page 54: ...Manual full March 2007 CE rev 03 doc Diagram 18 Front view with door open Key 1 Compressor oil sight glass 2 Main system isolator 3 Earth distribution larger 10mm stud supplied for customer earth bon...

Page 55: ...e system panel removed Key 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...

Page 56: ...These inputs are useful for detecting contact closures or sensing devices with open collector transistor outputs logic level outputs can also be detected as long as they are from a CMOS logic output...

Page 57: ...e To cool The systems needs to requires a single closure between 11 and GND so long as pin 11 is low the system will remain in COOL When the relay switch is opened pin 13 will be observed as low the T...

Page 58: ...s type of interface The standard Leybold interface places 24VAC from indicate common 24VAC relays are therefore required to isolate operates Telemark supplies at nominal cost a directly mating adapter...

Page 59: ...with any system ground will operate unit 14 15 Indicate defrost coil 1 SC Read back signal 16 Indicate defrost complete coil 1 SC Read back signal 17 Indicate common 18 19 20 21 Operate cool coil 2 22...

Page 60: ......

Page 61: ...rom a conventional system in that it has several different gases and a complex array of heat exchange surfaces are used to achieve the cryogenic temperature required The TVP uses the auto cascade prin...

Page 62: ......

Page 63: ...ip High pressure Defrost line Low pressure trip Oil return line 1 2 Ultraseal Main Service port Cap5 Cool solenoid valve Suction hand valve Cool hand valve 3 8 Ultraseal Cryo coil Defrost hand Valve D...

Page 64: ...charge pressure b Terminates defrost if predetermined level exceeded 8 Discharge pressure c Prevents system switch on if resting pressure limit exceeded 9 Phase protection determines correct compresso...

Page 65: ...ct when the system is in standby for long periods or where it is operating close to its maximum duty Caution A system operating outside of its design parameters may be harbouring a quiescent system ma...

Page 66: ...efficiency 150 140 130 120 110 100 90 80 70 60 50 40 6 7E 00 1 3E 00 2 7E 01 6 7E 02 1 3E 02 2 7E 03 6 7E 04 1 3E 04 2 7E 05 6 7E 06 1 3E 06 2 7E 07 6 7E 08 1 3E 08 2 7E 09 mbar T oC 98 efficiency 95...

Page 67: ...1 3E 02 86 80 76 6 7E 03 90 84 80 2 7E 03 95 90 86 1 3E 03 98 93 90 6 7E 04 102 97 93 2 7E 04 106 102 98 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...

Page 68: ...emperature the cool no load temperature will be reduced by approximately 5 o C TVP2000 cooling capacity Watts vs Average coil temperature 400 VAC 50 Hz 140 0 135 0 130 0 125 0 120 0 115 0 110 0 105 0...

Page 69: ...0 l S TVP3500 2 4 M2 357 600 l S 250 320 l S The value for the sustainable pumping speed represents a 30 reduction to account for factors such as proximity of system components reducing conductance an...

Page 70: ...ively shielded by aluminium foil In systems where there is a great deal of water evolved such as roll web coating of paper and other materials or where the film is moisture sensitive process improveme...

Page 71: ...l to socket weld connector 86QHWSS Scroll comp ZF40K4E TWC220vac3ph50 60Hz 8516229 Scroll compzf33k4e TWC220vac3ph50 60Hz 8509716 Pressure trip HP man reset KP 5 060 117366 Hand valve BML105 009G01220...

Page 72: ...INECS EC No Proprietary blend of HFC hydro fluorocarbon refrigerant gases N A N A N A Inert Gas N A N A N A 3 Hazards identification Asphyxiant Possible slight narcotic effects at high concentration U...

Page 73: ...ns of use Hazardous reactions Conditions to avoid May decompose on contact with hot surfaces and flames Materials to avoid No dangerous reaction known with common products Decomposition products toxic...

Page 74: ...valve is closed and not leaking valve outlet cap nut or plug where provided is correctly fitted there is adequate ventilation compliance with applicable regulations 15 Regulations Number in Annex 1 o...

Page 75: ...t high concentration Uncontrolled release from pressurised container severe frostbite hazard Pressurised gas Toxic decomposition products avoid fire smoking and high temperatures 4 First aid measures...

Page 76: ...at ambient temperature and under normal conditions of use Hazardous reactions Conditions to avoid May decompose on contact with hot surfaces and flames Materials to avoid No dangerous reaction known w...

Page 77: ...ly secured and cylinder valve is closed and not leaking valve outlet cap nut or plug where provided is correctly fitted there is adequate ventilation compliance with applicable regulations 15 Regulati...

Page 78: ...tandard Class Domestic Commercial and Light Industry EN50082 1 Electromagnetic Compatibility General Immunity Standard Generic Standard Class Domestic Commercial and Light Industry IEC1010 1 Safety Re...

Page 79: ...VP2000 or 2000D TVP3500 or TVP3500D X X X X X X Compressor X X X X X X Accessory X X X X X X O Indicates that this toxic or hazardous substance contained in all of the homogeneous materials for this p...

Page 80: ...of its factory by non authorised personnel All claims on account of defective material or workmanship shall be deemed waived unless made in writing within the aforementioned warranty period The forego...

Page 81: ...mplete 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 Fax Email D...