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Varian Vacuum Technologies 121 Hartwell Avenue Lexington, MA 02421-3133 (781) 861-7200 (800) 8-VARIAN NHS-35 Diffusion Pump Instruction Manual Manual No. 6999-01-135 Revision G April 2000 Sales and Service Offices America Varian Vacuum Technologies 121 Hartwell Avenue Lexington, MA 02421, USA Tel: (781) 861 7200 Fax: (781) 860 5437 Toll Free: 1 (800) 882 7426 France Varian s.a. 7 avenue des Tropiques Z.A. de Courtaboeuf – B.P. 12 Les Ulis cedex (Orsay) 91941 France Tel: (33) 1 69 86 38 38 Fax: (33) 1 69 28 23 08 Argentina Varian Argentina Ltd. Sucursal Argentina Av. Ricardo Balbin 2316 1428 Buenos Aires Argentina Tel: (54) 1 783 5306 Fax: (54) 1 786 5172 Germany Varian GmbH Alsfelder Strasse 6 Postfach 11 14 35 64229 Darmstadt Germany Tel: (49) 6151 703 353 Fax: (49) 6151 703 302 Australia Varian Australia Pty., Ltd. 6/81 Frenchs Forest Road Frenchs Forest, NSW 2086 Australia Tel: (61) 2 9975 8805 Fax: (61) 2 9452 2600 Hong Kong Varian Technologies Asia, Ltd. Rm 2611 Concordia Plaza New Mandarin Plaza 1 Science Museum Rd., Tsimshatsui East, Kowloon Hong Kong Tel: (852) 26206173 Fax: (852) 26206338 Brazil Varian Industria e Comercio Ltda. Avenida Dr. Cardoso de Mello 1644 Vila Olimpia Sao Paulo 04548 005 Brazil Tel: (55) 11 820 0444 Fax: (55) 11 820 9350 Canada Varian Canada 6705 Millcreek Drive, Unit 5 Mississauga, Ontario L5N 5R9 Canada Tel: (905) 819 8188 Fax: (905) 819 8348 China Varian China Ltd. Room 1201, Jinyu Mansion No. 129A Xuanwumen Xidajie Xicheng District Beijing 100031 P.R. China Tel: (86) 10 6641 1530 Fax: (86) 10 6641 1534 Varian Shanghai Service Station 716 Yishan Road Shanghai P.R. China 200233 Tel: (86) 21 6483 5576 Fax: (86) 21 6485 9031 England Varian Ltd. 28 Manor Road Walton-On-Thames Surrey KT 12 2QF England Tel: (44) 1932 89 8000 Fax: (44) 1932 22 8769 India Varian India PVT LTD 1010 Compotent House 7, Nangal Raya Business Centre New Delhi 110 046 India Tel: (91) 11 5548444 Fax: (91) 11 5548445 Italy Varian Vacuum Technologies via Flli Varian 54 10040 Leini, (Torino) Italy Tel: (39) 011 997 9111 Fax: (39) 011 997 9350 Japan Varian Vacuum Technologies Sumitomo Shibaura Building, 8th Floor 4-16-36 Shibaura Minato-ku, Tokyo 108 Japan Tel: (81) 3 5232 1253 Fax: (81) 3 5232 1263 Korea Varian Technologies Korea, Ltd Shinsa 2nd Bldg. 2F 966-5 Daechi Dong Kangnam Gu, Seoul Korea 135-280 Tel: (82) 2 3452 2452 Fax: (82) 2 3452 2451 Netherlands Varian Vacuum Technologies Rijksstraatweg 269 H, 3956 CP Leersum The Netherlands Tel: (31) 343 469910 Fax: (31) 343 469961 Mexico Varian S.A. Concepcion Beistegui No 109 Col Del Valle C.P. 03100 Mexico, D.F. Tel: (52) 5 523 9465 Fax: (52) 5 523 9472 Singapore Varian Asia, Ltd. 1123 Serangoon Road #03-02 Singapore 328207 Tel: (65) 296 9688 Fax: (65) 296 9733 Spain Varian Iberica Avda Pedro Diez 25 28019 Madrid Spain Tel: (34) 91 4727612 Fax: (34) 91 4725001 Russia Varian Moscow 19A Khlebny per 121019 Moscow Russia Tel: (70) 95 9374280 Fax: (70) 95 9374281 Taiwan Varian Technologies Asia Ltd., Taiwan Branch 18F-13 No.79, Hsin Tai Wu Road Sec. 1, Hsi Chih Taipei Hsien Taiwan Tel: (886) 2 2698 9555 Fax: (886) 2 2698 9678 Internet Users: Visit us on the web at: www.eVarian.com Representatives in most countries WARRANTY Products manufactured by Seller are warranted against defects in materials and workmanship for twelve (12) months from date of shipment thereof to Customer, and Seller’s liability under valid warranty claims is limited, at the option of Seller, to repair, replacement, or refund of an equitable portion of the purchase price of the Product. Items expendable in normal use are not covered by this warranty. All warranty replacement or repair of parts shall be limited to equipment malfunctions which, in the sole opinion of Seller, are due or traceable to defects in original materials or workmanship. All obligations of Seller under this warranty shall cease in the event of abuse, accident, alteration, misuse, or neglect of the equipment. In-warranty repaired or replacement parts are warranted only for the remaining unexpired portion of the original warranty period applicable to the repaired or replaced parts. After expiration of the applicable warranty period, Customer shall be charged at the then current prices for parts, labor, and transportation. Reasonable care must be used to avoid hazards. Seller expressly disclaims responsibility for loss or damage caused by use of its Products other than in accordance with proper operating procedures. Except as stated herein, Seller makes no warranty, express or implied (either in fact or by operation of law), statutory or otherwise; and, except as stated herein, Seller shall have no liability under any warranty, express or implied (either in fact or by operation of law), statutory or otherwise. Statements made by any person, including representatives of Seller, which are inconsistent or in conflict with the terms of this warranty shall not be binding upon Seller unless reduced to writing and approved by an officer of Seller. Warranty Replacement and Adjustment All claims under warranty must be made promptly after occurrence of circumstances giving rise thereto, and must be received within the applicable warranty period by Seller or its authorized representative. Such claims should include the Product serial number, the date of shipment, and a full description of the circumstances giving rise to the claim. Before any Products are returned for repair and/or adjustment, written authorization from Seller or its authorized representative for the return and instructions as to how and where these Products should be returned must be obtained. Any Product returned to Seller for examination shall be prepaid via the means of transportation indicated as acceptable by Seller. Seller reserves the right to reject any warranty claim not promptly reported and any warranty claim on any item that has been altered or has been returned by non-acceptable means of transportation. When any Product is returned for examination and inspection, or for any other reason, Customer shall be responsible for all damage resulting from improper packing or handling, and for loss in transit, notwithstanding any defect or non-conformity in the Product, in all cases, Seller has the sole responsibility for determining the cause and nature of failure, and Seller’s determination with regard thereto shall be final. If it is found that Seller’s Product has been returned without cause and is still serviceable, Customer will be notified and the Product returned at its expense; in addition, a charge for testing and examination may be made on Products so returned. 3/5/97 OPERATION AND MAINTENANCE OF THIS EQUIPMENT INVOLVES SERIOUS RISK. IT IS THE RESPONSIBILITY OF THE USER TO MAINTAIN SAFE OPERATING CONDITIONS AT ALL TIMES. VARIAN ASSUMES NO LIABILITY FOR PERSONAL INJURY OR DAMAGE RESULTING FROM OPERATION OR SERVICE OF THE EQUIPMENT. Carelessly or improperly operated equipment can cause serious injury or death and/or damage to the equipment. The emergency and safety procedures in this manual are provided to help users and qualified persons to operate and service the unit safely. Recommendations are believed to reflect accepted industry practices in effect on the date of publication of this manual. Special applications must be reviewed and approved by an industrial hygienist or chemical safety engineer. Varian has no control over the use of this equipment and is not responsible for personal injury or damage resulting from its use. The safe use and disposal of hazardous or potentially hazardous materials of any kind is the sole responsibility of the user. Observe all WARNINGS and CAUTIONS to minimize the serious hazards involved. It is the sole responsibility of users of Varian equipment to comply with all local, state, and federal safety requirements (laws and regulations) applicable to their system. Employ the services of an industrial hygienist and/or a qualified chemical safety engineer in order to ensure safe installation and use. This instruction manual contains information which will assist qualified operators in the operation, and qualified service engineers to carry out field-servicing the Varian equipment. i SAFE INCORPORATION OF VARIAN DIFFUSION PUMPS INTO VACUUM SYSTEMS IS THE RESPONSIBILITY OF THE SYSTEMS DESIGNER. TAKE APPROPRIATE ACTION THROUGH REDUNDANCY, AND/OR OTHER SAFEGUARDS TO PROTECT PERSONNEL AND PROPERTY FROM THE HAZARDS DESCRIBED BELOW AND IN THE INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTION MANUAL. SAFE OPERATION IS THE RESPONSIBILITY OF THE USING ORGANIZATION AND ITS PERSONNEL. READ THE INSTRUCTION MANUAL AND UNDERSTAND HOW TO AVOID HAZARDS PRIOR TO OPERATING THE DIFFUSION PUMP. ALL PERSONS WHO WORK WITH OR ARE EXPOSED TO DIFFUSION PUMPS OR EQUIPMENT WHICH UTILIZES SUCH PUMPS OR DIFFUSION PUMP FLUID MUST TAKE PRECAUTIONS TO PROTECT THEMSELVES AGAINST POSSIBLE SERIOUS BODILY INJURY OR DEATH. DO NOT BE CARELESS AROUND SUCH PRODUCTS. THESE SHEETS AND THE INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS CAN HELP YOU TO OPERATE THIS PUMP SAFELY AND EFFICIENTLY. READ THEM. SPECIAL OPERATING CONSIDERATIONS AND PRECAUTIONS WILL BE FOUND IN THE OPERATION INSTRUCTIONS. UNINFORMED OR CARELESS OPERATION OF THIS PUMP CAN RESULT IN POOR PERFORMANCE, DAMAGE TO THE PUMP OR OTHER PROPERTY, SERIOUS BODILY INJURY, AND POSSIBLE DEATH. USERS OF THIS EQUIPMENT SHOULD BE ALERT TO TWO LEVELS OF HAZARDS IDENTIFIED BY THE FOLLOWING SYMBOLS: WARNING _____________ Warnings are used when failure to observe instructions or precautions could result in injury or death to humans. CAUTION ________ Cautions are used when failure to observe instructions could result in significant damage to equipment and/or facilities. Designers of systems which utilize diffusion pumps must design out hazards wherever possible; provide guards, safety features, and interlocks for hazards which cannot be designed out; warn with respect to hazards which cannot be designed out and which remain after utilizing guards, safety features, and interlocks; and lastly, provide procedures and instructions on proper use, servicing, etc., so as to minimize risk. ii THE INSTALLATION, OPERATION, AND/OR SERVICING OR DIFFUSION PUMPS INVOLVES ONE OR MORE OF THE FOLLOWING HAZARDS, ANY ONE OF WHICH, IN THE ABSENCE OF SAFE OPERATING PRACTICES AND PRECAUTIONS, COULD POTENTIALLY RESULT IN DEATH OR SERIOUS HARM TO PERSONNEL. Hazard Suggested Corrective Action Loss of utility: water and/or electricity Provide sufficient water and backup power to effect a safe shutdown under worst case conditions. Overpressure in foreline Provide an interlock to ensure that the power supply to the pump heater cannot be activated if the foreline pump is not running AND/OR pressure in foreline is above 0.5 Torr (66.5 Pa). Overtemperature Fit temperature sensors and pump fluid level sensors with feedback to an interlock on the heater power supply. Insufficient water flow through the main cooling coils Use water flow sensor and feedback to interlock on the heater power supply. Water trapped between inlet and outlet of quick-cool coil, or liquid nitrogen trapped between inlet and outlet of liquid nitrogen trap Provide vent or pressure relief valves for both quick-cool coil and liquid nitrogen trap. Loss of ground integrity Incorporate ground fault interrupt circuit into heater power supply. Positive pressure in pumping system Integrate pressure relief valve in vacuum system. High voltage (up to 480 V) Prevent personnel contact with high voltages; design and attach warnings. Toxicity/Corrosivity Toxic and/or corrosive gases must be vented to a safe location, ensuring adequate dilution or scrubbing to safe levels, taking all action required to meet air quality standards. Explosion Integrate pressure relief valves in all systems using pumps 10 inches or larger in diameter. Do not use or recommend the use of hydrocarbon-based pumping oils. iii Hazard Suggested Corrective Action a. Explosion – Operation of the diffusion pump without prior and continuous evacuation (below 0.5 Torr (66.5 Pa)) or coolant and introducing a strong oxidizer (such as air) or explosive vapors or powders or materials which may react with pumping fluids into a hot (above 300°F or 150°C) pump can cause an explosion. Such an explosion can violently expel valves and other hardware, slam open doors that are not designed for appropriate pressure relief, or burst other components of the vacuum system. Serious injury or death may result from expelled parts, doors, shrapnel, and/or shock waves. b. All diffusion pumps are typically cleaned with acetone and alcohol. When combined with air, oxygen, and other oxidizers, alcohol and most other solvents are very flammable and explosive. Never permit any trace of these cleaners to remain in or on the pump. Always remove all traces of alcohol and acetone and other cleaners with clean, dry, oil-free compressed air. Three elements are required: fuel, oxidizer, and source of ignition. A combination of temperature and pressure can be a source of ignition. Most diffusion pump fluids except mercury are fuels. Hydrocarbon oils are more prone to oxidize and explode than synthetic silicone-based oil. Oxidizers can be air (a strong oxidizer) from a leak or can be deliberately introduced in a process or can be inadvertently admitted to the system by operator or process controller error. Oxygen and other strong oxidizers are even more dangerous. Certain conditions of temperature and pressure can cause a combustible mixture to explode. The larger the diffusion pump, the greater the risk of explosion and the greater the risk of damage and/or injury. Never operate diffusion pumps larger than 10 inches in diameter with hydrocarbon oils without a full safety analysis for the complete system and application. Never operate any diffusion pump in the following ways because they increase the probability of an explosion. Prohibited Action Explosion-Causing Condition Run pump with no cooling water Overtemperature Run pump with low level of pump fluid Overtemperature Run pump without proper backing or holding pump Overpressure Run pump when not evacuated below 0.5 Torr (66.5 Pa) Overpressure Admit air to, or rough through, a pump with hot boiler Overpressure plus strong oxidizer Open drain or fill plug while pump is under vacuum, especially when it is hot Overpressure plus strong oxidizer iv Prohibited Action Explosion-Causing Condition Contaminate pump with explosive vapors, powders, or reactive materials Lower explosive threshold of gas mixtures Remove, defeat, or override safety countermeasures such as pressure and thermal switches and valve sequencer interlocks Overtemperature, overpressure, more combustible mixtures Machine or weld without removing all oil or solvent residue in pump Source of ignition Use unsuitable pumping fluid especially in large pumps Lower explosive threshold of gas mixture Systems larger than 10 inches must be designed with pressure relief devices to provide safe pressure relief from internal explosions. Always recognize that safety devices can fail or malfunction. Provide redundant protection by installing devices having different failure modes, failure mechanisms, and failure causes. Be certain that exhaust duct materials are capable of withstanding the corrosivity, temperature, and pressure of exhausted products. c. Pressure – Pumps and their components are designed for vacuum service; they are not designed to be pressurized which could cause them to burst possibly expelling shrapnel at lethal velocities. Serious accidents have been caused by intentional pressurization of vacuum systems and their components. Never pressurize any part of a vacuum system for test or any other purpose. Always provide pressure relief when designing diffusion pumps into systems and ensure that pressure relief motion is limited to safe envelopes. Never permit the following: Prohibited Action Result Block inlet and vent of liquid nitrogen trap and lines LN2 trap and/or lines burst Close isolation valves at inlet and discharge of main watercooling coils and pump is reheated Water turns to steam and bursts coils Pressurize pump body Body of pump bursts Hole through vacuum wall Loss of structural integrity of wall v d. Poisonous and/or Corrosive Compounds – When pumping poisonous, reactive, and/or corrosive gas, vapors, or chemicals, even proper operation and regeneration will not always ensure that all hazardous materials have been totally removed. If hazardous gas, vapors, chemicals, or combustible mixtures are pumped, sufficient quantities may exist during operation or remain after regeneration to cause severe injury or death. Overheating the pump oil, exposing it to air or reactive materials, or overpressurizing it above the normal operating range (approximately 1 mTorr (.133 Pa)) will decompose the oil and possibly make it toxic. This is especially true of backstreamed mechanical pump oils which are more volatile (unstable). Overheating of accidentally introduced or backstreamed mechanical pump oils cannot be protected against by thermal switches which are set for diffusion pump oil. d. Refer to specific instruction manuals for detailed instructions and precautions. Always vent the pump and relief valve to a safe location thus ensuring adequate dilution to safe levels, and take all other action required to meet quality air standards. Always handle pump fluids and hardware with an awareness of the possible deadly hazards involved and the necessity for great care and attention to safety precautions. d. Diffusion pumps are typically cleaned with acetone or alcohol. Acetone, alcohol, and most other solvents are irritants, narcotics, and depressants, and/or carcinogenic. Their inhalation and ingestion may produce serious effects. Even absorption through the skin can result in moderate toxicity. Always ensure that cleaning operations are performed in large, well-ventilated rooms. Use of selfcontained breathing apparatus may be necessary depending upon the solvent type and vapor concentration in surrounding air. e. High Voltage – Diffusion pumps operate at voltages (up to 480 V) high enough to kill through electrical shock. Design equipment utilizing these pumps to prevent personnel contact with high voltages. Securely attach prominent hazard warnings. Personnel should always break the primary circuit to the power supply when direct access to the heater or wiring is required. f. Hot Surfaces – Boiler temperatures reach 530°F (275°C) which can cause serious burns when touched. Always ensure that surfaces have cooled near room temperature before touching them. g. Hot Coolant and/or Steam – The water used to cool the pump can reach scalding temperatures. Touching or rupture of the cooling surface can cause serious burns. Water left inside quick cool coils from previous use will turn to steam when the pump is reheated. This steam must be allowed to escape without contacting personnel. Whenever possible, design the water system with interlock valves so that power cannot be applied to the pump unless water is flowing in the main cooling coils (not quick-cooling coils). h. Cold Surfaces – Liquid nitrogen traps cooled by liquid nitrogen are commonly used in diffusion pumps. Metal surfaces at liquid nitrogen temperature can cause severe frostbite if contacted by unprotected skin. These surfaces remain cold for some time (at least a half hour) after the liquid nitrogen has evaporated. vi i. Cold Coolant – Liquid nitrogen, a cryogenic liquid, is used in traps. If it is splashed on body tissues or eyes, it can cause severe frostbite or blindness. The extremely low temperature of liquified nitrogen can cause skin damage similar to high temperature burns. Contact with the cold gas evolving from the liquid may produce the same effect. Delicate tissues, such as the eye tissues, are most easily damaged by exposure to cold gas or liquid. To minimize the risk of hazardous contact of cold gaseous nitrogen with any part of the body, wear personal safety equipment recommended for use with cryogenic materials including face shield, full-sleeved lab coat, and clean, dry gloves which fit loosely so they can be thrown off quickly if frozen by contact with the gas. j. Asphyxiation – If a large amount of liquid nitrogen is spilled in a small, poorly ventilated room or equipment, death from suffocation can result. All diffusion pumps are typically cleaned with acetone or alcohol. Acetone, alcohol, and most other solvents are very volatile (unstable). During cleaning, the volatility of these cleaners may permit their gases to displace air and its life-supporting oxygen which could cause death or serious injury by asphyxiation. Always ensure that cleaning operations are performed in large, well-ventilated areas. j. While still hot, the diffusion pump may also contain decomposed and/or overheated pump oils which can also be an asphyxiant. k. Large, Heavy Weights – Diffusion pumps larger than 10 inches in diameter require powerassisted equipment and the use of trained moving/installation personnel in order to avoid dropping, slipping, and/or overturning the pump thus severely injuring personnel. Check weight of equipment before lifting and do not stand under equipment being moved. vii WARNING _____________ High voltages (up to 480 V) can kill. Always break the primary circuit to the power supply before starting to work on the heater and/or its wiring. WARNING _____________ Diffusion pumps are typically cleaned with acetone, alcohol, or other solvents. When heated, sprayed or exposed to high temperature equipment, these solvents become flammable and explosive, causing serious injury or death. Do not use near a high-temperature source. Ventilate working area with a blower and use in large, well-ventilated room. When heated or sprayed, solvents also becomes 4 to 5 times heavier than air and will flow down, settling in tanks, pits, and low areas, thus displacing air which can kill by asphyxiation. Use in a large, well-ventilated room. Use of a self-contained breathing apparatus may be necessary. Acetone, alcohol, and other solvents are irritants, narcotics, depressants, and/or carcinogenics. Their inhalation and/or ingestion may produce serious effects. Prolonged or continued contact with the skin will result in absorption through the skin and moderate toxicity. Always ensure that cleaning operations are carried out in large, well-ventilated rooms, and wear eyeshields, gloves, and protective clothing. WARNING _____________ Varian has no control over the types of gases passing through this pump. These are entirely under the control of the process user and/or the hardware systems integrator. Frequently, process gases are toxic, flammable, corrosive, explosive, or otherwise reactive. Since these gases can cause serious injury or death, it is very important to plumb the exhaust of the pump to the facility’s hazardous gas exhaust system which incorporates appropriate filters, scrubbers, etc., to insure that the exhaust meets all air and water pollution control regulations. WARNING _____________ Certain gases can become corrosive and toxic when trapped in oil. Always wear protective gloves when handling dirty pump oil, drain it into a closable container, and do not breathe the fumes of the oil. Always use fully self-contained breathing apparatus. viii WARNING _____________ If hazardous gas, vapors, chemicals, or combustible mixtures are pumped, sufficient quantities may exist during operation. This pump may contain decomposed and/or overheated pump oils or poisonous and/or overheated pump oils or poisonous and/or corrosive process materials which are highly toxic and also can be an asphyxiant. Proper operation will not always ensure that all hazardous materials have been removed. WARNING _____________ Hot oils can cause serious burns. Wear protective gloves and long sleeved, loose fitting, heat resistant garments when draining pump oil. WARNING _____________ When lifting some Varian diffusion pumps, use power-assisted equipment and trained moving/installation personnel to avoid dropping, slipping, and/or overturning the pump and severely injuring personnel. Check weight of equipment before lifting and do not stand under equipment being moved. CAUTION ________ Alcohol, acetone, and other solvents degrade O-ring materials reducing their ability to hold a vacuum. Do not use acetone or other solvents on O-rings. If necessary to clean O-rings, wipe with lint-free, clean cloth, wash in detergent and water, or use a small amount of pump oil. NOTE ________ Always dispose of used or dirty oil properly and in compliance with all local, state, and federal environmental laws and regulations. ix x Table of Contents Section Page Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Section I – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Cleaning a New Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Utility and System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Adding Pump Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Section II – Operation ....................................................... 2-1 2-1 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2 Section III – Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembling and Reassembly the Cold Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembling and Reassembling the Jet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-2 3-3 3-4 3-4 3-6 Section IV – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Outgassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Poor Pump or System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-1 List of Illustrations Figure 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 3-1 3-2 Title Speed and Throughput Curves – NHS-35 Diffusion Pump . . . . . . . . . . . . . . . . . . . . . . . Physical Specifications – NHS-35 Diffusion Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section Drawing – NHS-35 Diffusion Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Cooling Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240/400/440V Wiring Diagram – NHS-35 Diffusion Pump . . . . . . . . . . . . . . . . . . . . . . . . 380/415V Wiring Diagram – NHS-35 Diffusion Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 480V Wiring Diagram – NHS-35 Diffusion Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sight Glass Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Element Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Fittings – Cold Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1-2 1-4 1-6 1-9 1-10 1-11 1-12 1-15 3-3 3-5 List of Tables Table 4-1 Title Page Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 SECTION I INSTALLATION 1-1 GENERAL Upon receipt, inspect the container for evidence of damage in shipment. Do not discard any evidence of rough handling. Factory packing provides for maximum protection during shipment. However, the pump should be inspected immediately and any damage should be reported to the carrier without delay. Before unpacking and installing the pump, the user should thoroughly familiarize himself wiith the contents of this instruction manual, particularly the physical and operating specifications listed in the following paragraphs, in order to gain a better understanding of the operating principles, limitations, correct application of the diffusion pump, the hazards involved, and what to do and what not to do in order to avoid these hazards. 1-2 OPERATING SPECIFICATIONS Model NHS-35 Diffusion Pump with ASA flanges & standard cold cap with ASA flanges and halo baffle with ISO flanges & standard cold cap with ISO flanges and halo baffle Part Number 240 V 480 V F1730308 F1730318 L5924308 L5924318 F1730309 F1730319 L5924309 L5924319 380/415 V 400 V F1730326 F1730362 F1730336 F1730363 L5924326 – L5924336 – 440 V F1730364 F1730365 – – Optimum Operating Range 6 x 10-4 torr to < 5 x 10-8 torr (8 x 10-2 Pa to < 7 x 10-6 Pa) (8 x 10-4 mbar to < 7 x 10-8 mbar) Maximum Pumping Speed (See Figure 1-1) 50,000 liters/sec for air 62,500 liters/sec for helium Maximum Throughput 35 torr-liters/sec at 10-2 torr 4655 Pa - liters/sec @ 1.33 Pa 46.5 mbars - liters/sec @ 0.013 mbar Maximum Forepressure No Load – 0.55 torr (73.2 Pa) (0.73 mbar) Full Load – 0.40 torr (53.2 Pa) (0.53 mbar) Backstreaming Rate at Pump Inlet 0.0005 mg/cm2/min (with cold cap) Power Required (approximately) 24 KW, 240/380/415/440/480V, 50/60 Hz, 3-phase Warmup Time 60 hour Cooldown Time (using quick cool) 180 minutes (60 minutes) Fluid Charge 3 gallons Cooling Water Requirements 4 gpm at 60°F to 80°F inlet temperatures Backing Pump Size Recommended 300 cfm for optimum throughput 1-1 Installation Figure 1-1. Speed and Throughput Curves – NHS-35 Diffusion Pump 1-2 Installation 1-3 PHYSICAL SPECIFICATIONS (See Figure 1-2) Flange dimensions (inches): ASA OD ID Thickness Bolt Circle No. of Holes Size of Holes Orientation Gasket Groove ID wide deep Inlet Foreline 35"ASA 6"ASA 41.75 11 35 7.72 1.12 0.75 38.5 9.5 28 8 0.87 0.81 Straddle center line 35.37 8.20 0.56 0.17 0.25 0.09 Inlet ISO-1000-F 44.09 35.00 1.12 42.913 32 0.550 Foreline ISO-200-K* 9.45 7.72 0.47 – – – 40.75 0.56 0.25 – – – Height 72.13 inches; allow additional 8 inches (min) for heater removal Jet Assembly 5-stage, Self-aligning, fractionating design with four diffusion stages and one ejector stage Foreline Baffle Stacked disk and ring Cold Cap Water-cooled Water Connections 3 Thermal Switches Upper set at 200°F (92°C) Lower set at 600°F (315°C) Materials Body Flanges Jet Assembly Foreline Baffle ⁄8 FPT for pump body and quick-cool coils Mild steel Mild steel Stainless Steel Mild Steel Weight 1220 pounds (pump) 250 pounds (jet assembly) Shipping Weight 1550 pounds (705 kg) * Requires NW-200 centering ring (not included with pump) 1-3 Installation (optional) Figure 1-2. Physical Specifications – NHS-35 Diffusion Pump (with ASA Flanges) 1-4 Installation 1-4 UNPACKING Pumps are factory-packaged to permit prolonged storage in suitably protected areas without special precautions. WARNING When lifting some Varian diffusion pumps, use power-assisted equipment and trained moving/installation personnel to avoid dropping, slipping, and/or overturning the pump and severely injuring personnel. Check weight of equipment before lifting and do not stand under equipment being moved. a. Remove flange covers, blank plugs, protective plugs from water connections, etc. Be careful not to scratch or otherwise damage or mar the sealing surface. b. Carefully remove the outer shipping container and save it for evidence if damaged. Notify the carrier immediately. Visually inspect the pump for damage that may have occurred during shipping. Discard any internal packing which may have been used to protect the internal components. c. For non-critical work, after making sure that there are no foreign materials inside the pump, it may be charged with fluid and used without disassembly. Otherwise, it should be disassembled and cleaned. In general, cleaning may be required if the expected vacuum level is to be below the 10-6 Torr (.000133 Pa) range. d. Check the internal jet assembly. It should be concentric and firmly seated on the bottom of the pump. Using a flashlight, check to make sure that the ejector nozzle is opposite the foreline (the pump outlet connection). The jet assembly should not rotate because of an indexing pin at the bottom. 1-5 CLEANING A NEW PUMP (Refer to Section 3, MAINTENANCE) a. Read cold cap maintenance and installation data which will be found in Section III, para. 3-4, of this manual. Remove the cold cap in accordance with these instructions. b. Disassemble the internal jet system from the body of the pump. See Figure 1-3 for a section drawing of a typical jet assembly. c. Remove fill and drain plugs and gaskets if supplied. d. Thoroughly clean all components of the jet assembly and pump casing interior (but not O-ring gaskets) with acetone followed by an alcohol rinse. e. Remove all traces of the cleaning fluid by carefully drying with clean, dry, oil-free compressed air. 1-5 Installation Figure 1-3. Section Drawing – NHS-35 Diffusion Pump 1-6 Installation WARNING Diffusion pumps are typically cleaned with acetone, alcohol, or other solvents. When heated, sprayed or exposed to high temperature equipment, these solvents become flammable and explosive, causing serious injury or death. Do not use near a high-temperature source. Ventilate working area with a blower and use in large, well-ventilated room. When heated or sprayed, solvents also become 4 to 5 times heavier than air and will flow down, settling in tanks, pits, and low areas, thus displacing air which can kill by asphyxiation. Use in a large, well-ventilated room. Use of a self-contained breathing apparatus may be necessary. Acetone, alcohol, and other solvents are irritants, narcotics, depressants, and/or carcinogenics. Their inhalation and/or ingestion may produce serious effects. Prolonged or continued contact with the skin will result in absorption through the skin and moderate toxicity. Always ensure that cleaning operations are carried out in large, well-ventilated rooms, and wear eyeshields, gloves, and protective clothing. f. For reassembly, reverse the above procedure. g. Clean the flanges and O-ring grooves thoroughly with alcohol, using clean, lint-free rags. CAUTION Acetone, alcohol, and other solvents degrade O-ring materials reducing their ability to hold a vacuum. Do not use solvents on O-rings. If necessary to clean O-rings, wipe with lint-free, clean cloth, wash in detergent and water, or use a small amount of pump oil. h. Remove all traces of acetone or alcohol by carefully drying with clean, dry, oil-free compressed air. Install O-ring gasket. 1-7 Installation 1-6 UTILITY AND SYSTEM CONNECTIONS 1-6-1 Safety Considerations and Interlocks a. Large pumps are equipped with two thermal switches. One is mounted at the body cooling coils, the other at the center of the boiler plate (at the bottom of the pump). These thermal switches are supplied normally closed. The thermal switches have been designed so that a cooling water failure or low oil level in the boiler will result in an increase in temperature, causing the normally closed contacts of the switches to open. When the problem has been corrected and the temperature lowered, the thermal switch will automatically reset itself. WARNING _____________ Utility failure can cause damage to the equipment, overheating, and possible explosions. Designers of the equipment using diffusion pumps must design their system to protect personnel and property from possible hazards. b. A small lamp of the same voltage as the diffusion pump heater may be connected across the terminals of the thermal switch. The lamp will normally be shunted by the contacts. However, when the contacts open, the lamp will receive full line voltage and give a visual trouble indication. 1-6-2 Vacuum Connections a. The pump must be installed with the body vertical and plumb. Check that the mating flange on the system (to the pump inlet) is horizontal within plus or minus 1 degree. If this condition is not met, correct the system before installing the pump. The boiler of the pump (especially for large pumps) must be horizontal to prevent uneven fluid level and avoid local overheating where the fluid level would be too shallow. b. Prepare inlet O-ring seals by wiping them with a clean cloth. Do not use solvents. Use a small amount of diffusion pump oil to wet the cleaning cloth. Install the O-ring in the groove being careful not to damage the sealing surface with cuts, nicks, or scratches. c. Using appropriate lifting apparatus, align the bolt holes of the flanges and assemble the bolts. Tighten the bolts evenly to compress the O-ring seal until light contact is achieved between metal flanges. d. Check fill and drain plugs for tightness. Apply light to medium torque, enough to compress gaskets. Minute leaks through the gaskets may develop with use in this location. They may be detectable with very sensitive mass spectrometer leak detectors. 1-6-3 Cooling Water Connections (See Figure 1-4) The following method of external connections is recommended. a. Water connections are designed for 3⁄8 FPT fittings. The cold cap cooling coil and all of the body and foreline cooling should be connected in series. A cooling water supply of 3 to 4 gpm at 60°F to 80°F (16°C to 27°C) should be adequate. A higher flow than this will not be harmful. If the pump is to be operated continuously at pressures below 1 x 10-6 Torr, the cooling coil on the bend of the foreline may be bypassed. This surface will then operate hot and therefore provide additional degassing. 1-8 Installation Water Requirements 4 gallons per minute at 60° to 80°F inlet temperature pressure drop across series curcuit of cold trap and body – 40 PSI. Figure 1-4. Water Cooling Connections If the water supply pressure is low, it may be necessary to connect the different sections of cooling coils in parallel. This should be done if the cooling water discharge temperature exceeds 130°F (54°C). The cooling water discharge should, if possible, be connected to an open drain so that cooling water flow can readily be checked. b. If the quick-cool coil is required, it must be connected to an open drain and the feed line controlled by a separate water 3-way valve (open, closed, and vent to atmosphere). The drain must be below the boiler level so that it is drained completely when the quick-cool coil water supply is shut off and the pump is operating. 1-6-4 Electrical Connections (See Figure 1-5, 1-6, or 1-7, Diffusion Pump Wiring Diagram) WARNING _____________ High voltages (up to 480V) can kill. Always break the primary circuit to the pump before starting to work on the heater and/or its wiring. a. The pump heater has been designed to operate at a certain voltage. Check the heater for correct supply voltage and, in the case of multiphase connections, for load balance by measuring the resistance of each branch. (See page 1-10, 1-11, 1-12 for proper resistance.) 1-9 Installation Figure 1-5. 240/400/440V Wiring Diagram – NHS-35 Diffusion Pump 1-10 Installation Figure 1-6. 380/415V Wiring Diagram – NHS-35 Diffusion Pump 1-11 Installation Figure 1-7. 480V Wiring Diagram – NHS-35 Diffusion Pump 1-12 Installation b. Make connections to the terminals in the junction box (at the foreline). The use of flexible conduit is recommended to facilitate removal of the pump for service. The pump should not be operated at more than 5% over the rated voltage. Make connections in accordance with the wiring diagram provided with each pump. 1-6-5 Thermal Switches The thermal switches have been pre-set at the factory and should not require adjustment. The lower thermal switch is set at 600°F; the upper switch is set at 200°F. Should any thermal switch be thrown out of adjustment, it can be adjusted as follows: 1. Boiler thermal switch The boiler thermal switch is mounted on a brass block at the center of the boiler. The thermal switch should be adjusted, with the pump operating, as follows: a) b) c) 2. After several hours operation, disconnect the lead wires and place an ohmmeter across the terminals of the thermal switch. Turn the adjusting screw until 1⁄16 of a turn either way will make the contact open or close. Turn the adjusting screw clockwise 1⁄4 turn. Cooling water thermal switch The cooling water thermal switch is located inside the small junction box. The switch should be adjusted with the pump in operation as follows: a) b) c) Disconnect the lead wires and place an ohmmeter across the terminals of the switch. Turn the switch adjusting screw until 1⁄16 of a turn either way will make the contact open or close. Turn the adjusting screw clockwise 1⁄ 4 turn. Thermal switches are to be operated on AC power only and should be connected in series with the coil of the diffusion pump heater contactor. See Figures 1-5, 1-6, or 1-7, Diffusion Pump Wiring Diagram. 1-6-6 Initial Vacuum Test The purpose of this test is to establish the leak tightness of the system, specifically the vacuum connections to the diffusion pump. (To eliminate misleading indications and the masking of leaks by the fluid, the tests should be carried out with the diffusion pump “dry”, i.e., before it is charged with the pumping fluid.) WARNING _____________ Pumps and their components are designed for vacuum service; they are not designed to be pressurized which could cause them to burst possibly expelling shrapnel at lethal velocities. Serious accidents have been caused by intentional pressurization of vacuum systems and their components. Never pressurize any part of a vacuum system for test or any other purpose. Always provide pressure relief when designing diffusion pumps into systems and ensure that pressure relief motion is limited to safe envelopes. 1-13 Installation a Confirm the vacuum ultimate pressure characteristics of the mechanical pump. This should closely approximate the value quoted in the manufacturer’s data, if the mechanical pump is correctly installed, adjusted, and filled with clean oil. Pressure measurements should be made with a continuously indicating total pressure gauge, such as a thermocouple gauge. This test can be performed to evaluate either valved or unvalved systems. Connect the outlet or foreline of the diffusion pump to the inlet of the mechanical backing pump, using appropriate vacuumtight connections. b In the case of a valved system, close the roughing valve and main isolation valve ahead of the diffusion pump. In the case of unvalved systems, the entire work chamber volume must be included in the test. Evacuate the entire system with the mechanical pump only. Let the mechanical pump reach an ultimate pressure in the system. This reading should approximate the value obtained in step a above (usually 10 to 50 microns (1.33 to 6.65 Pa)). If it does not, examine for leakage. If leakage is suspected, follow standard procedures for leak testing. These will depend on the type of vacuum gauges and/or leak detection equipment available. The most effective are Varian’s helium leak detectors. 1-7 ADDING PUMP FLUID WARNING _____________ The risk of explosion in large pumps is increased by hydrocarbon oils, low fuel levels, or opening either fill or drain plugs during operation. Never operate diffusion pumps larger than 6 inches with hydrocarbon oils without a complete safety analysis for the specific system and application. Hydrocarbon oils are more prone to explode than synthetic silicone-based oils, similarly the larger the diffusion pump the greater the risk of explosion. Running the pump with low oil level causes hot surfaces and the oil to be decomposed and very toxic. Such decomposed oil and any residue from toxic/corrosive materials pumped will be present on the dipstick when the fluid level is measured. NOTE ________ Fluids must be stored in clean, tightly closed containers and should be clearly identified in accordance with their type. Do not mix pumping fluids of different types and origins. Generally, it is not a good idea to mix used and new fluid for a pump charge. a. The recommended fluid charge for the pump is three gallons. The fluid charge will gradually be depleted through use, but the pump will continue to operate normally. When the charge is reduced to approximately 60% of the initial amount, the boiler temperature may begin to rise and under this condition the thermal switch is designed to open the heater circuit. b. This diffusion pump is furnished with fill and drain fittings with special Viton elastomer sealed plugs. 1-14 Installation c. If the pump is hot, wait until the pump has cooled then vent it to atmosphere. Remove the plug from the filling port of the pump and install the specified quantity of fluid up to the FULL COLD level indicator on the sight glass (see Figure 1-8). The fluid can also be poured in from the pump inlet or foreline. d. Replace the fill plug with a new Viton gasket. Tighten the fill plug using moderate torque (75 inch-pounds maximum). Lubricate the O-ring with pump fluid before installation. e. Once the pump is running, the oil level should be in the FULL HOT operating range as indicated on the sight glass assembly. f. It is not recommended that Santovac 5 Diffusion Pump Fluid be used with the NHS-35. Figure 1-8. Sight Glass Assembly 1-15 Installation 1-16 SECTION II OPERATION During initial installation, the newly installed pump fluid may be subjected to a degassing process. This may result in foreline pressure fluctuations and “bursts”. Such fluctuations are considered normal. 2-1 START-UP PROCEDURE WARNING _____________ The following conditions increase the risk of explosion: • any air leaks into the system; • roughing through a hot diffusion pump may cause some hot hydrocarbon fluids to ignite or explode when exposed to air; • air release or admitting air to a pump with a hot boiler, permit a strong oxidizer to contact the hot pump oil; • high (above 1 micron (.133 Pa)) inlet pressure; • insufficient (or low level of) pump fluid; • running pump without cooling water circulating to main water cooling coils; • trapping water between closed isolation valves at inlet and discharge of quick cool coils and running diffusion pump; • foreign matter in the pumping fluid which changes its viscosity and obstructs flow passages. CAUTION ________ • Do not turn on the heater without fluid in the pump. This may ruin the heaters and damage the pump. • Do not air-release the pump while the boiler is hot. Most diffusion pump fluids are heat-sensitive and will break down under these conditions. • Do not operate the pump without the foreline baffle. This may cause a greater than normal fluid loss. • Do not operate the pump for extended periods at an inlet pressure above 1 micron (.133 Pa). High pressure operation may cause excessive backstreaming. • Do not operate the pump heater unless the cooling water is circulating. It will cause the pump and fluid to overheat. a. Evacuate the diffusion pump by means of the mechanical roughing pump to a pressure level below 0.5 Torr (66.5 Pa). The diffusion pump will not function unless the discharge pressure is less than the tolerable forepressure (approximately 0.5 Torr (66.5 Pa)). b. Turn on the cooling water supply to the pump body and check that adequate flow is provided by examining the amount of water discharged at the visual drain points. 2-1 Operation c. Switch on the power to the diffusion pump heater. d. Check inlet and forepressure performance by means of the system instrumentation. e. During operation, the gas load at the inlet of the diffusion pump should not exceed the maximum throughput capability of the pump. This means that the pressure at the inlet flange should not (except in transient conditions) exceed approximately 1 x 10-4 Torr .0133 Pa. During operation, the discharge or fore pressure must be below the specified tolerable forepressure. 2-2 SHUTDOWN PROCEDURE WARNING _____________ Boiler temperatures reach 530°F (275°C) which can cause serious burns when touched. Always ensure surfaces have cooled near room temperature before touching them. Air release or admitting air to a pump with a hot boiler, especially when it is under vacuum, permits a strong oxidizer to contact the hot pump oil and thereby increases the risk of an explosion. CAUTION ________ Do not operate the quick-cool coil when the pump is c old or out of service to prevent harmful collection of condensation on the boiler plate, heater, and heater terminals. a. Switch off the power to the diffusion pump heaters. b. Admit cooling water to the quick-cool coil if necessary and continue to circulate it until the pump body just above the boiler heat shield can be touched (approximately 130°F or 54°C). In valved systems which have tight inlet and foreline connections, it is possible to close valves to isolate the diffusion pump at inlet and discharge, to air-release the remainder of the system, shut off the heat to the diffusion pump, and stop the mechanical pump. With this method, the quick-cool coil does not have to be used. However, the water flow through the pump must be maintained until the boiler cools down below approximately 300°F (150°C). 2-2 SECTION III MAINTENANCE 3-1 GENERAL Diffusion pumps generally require little attention when correctly operated. However, it is advisable to perform some periodic checks to insure continued trouble-free operation. By simple preventive maintenance, costly down-time and cleaning procedures can be avoided. A day-to-day log of pump and system performance will indicate the condition of the pump and marked variations will show the need for corrective action. 3-2 PERIODIC INSPECTION The frequency of inspection will depend on the type of system, its operation and utilization. The maximum interval between inspections is established on the basis of experience. It is recommended that the following items be regularly examined. WARNING _____________ High voltages (up to 480V) can kill. Always break the primary circuits to the power supply before starting to work on the heater and/or its wiring. Make sure that the pump is at room temperature before attempting service. Serious burns can result if this Warning is not heeded. Depending on system process, poisonous or corrosive compounds may be present when opening the fill or drain. Always wear appropriate gloves and clothing and use a self-contained breathing apparatus. An explosion could occur if the fill or drain is opened when the pump is running or when it is hot. Check oil level only when the pump is cold. a. When the pump is cold, check the condition and level of fluid. These can be inspected by withdrawing a sample through the drain and by visually checking the level of fluid through the sight glass respectively. (Use new O-ring gaskets when replacing fill and drain plugs.) Slight discoloration of the fluid does not affect performance. b. Loss of the fluid can be caused by the following: c. 1. incorrect air admittance procedures and/or admittance of excessive air or other gas to a hot pump, 2. inadequate water cooling 3. continuous operation at inlet pressures above 10-3 Torr (.133 Pa) 4. failure to reinsert the foreline baffle in the pump assembly When the pump is cold, check that the heaters are bolted snugly to the boiler plate and that all heater terminal connections are tightly fastened inside the junction box. 3-1 Maintenance d. Check the total heater input and balance of load if a multi-phase heater is used. e. Check to insure that cooling water flow is unobstructed and not below specified quantities. 3-3 CLEANING Complete cleaning of the pump may be periodically required because of the gradual deterioration of some pump fluids. Removal of the pump from the system is then necessary. WARNING _____________ If hazardous gas, vapors, chemicals, or combustible mixtures are pumped, sufficient quantities may exist during operation. This pump may contain decomposed and/or overheated pump oils or poisonous and/or corrosive process materials which are highly toxic and also can be an asphyxiant. Proper operation will not always ensure that all hazardous materials have been removed. Diffusion pumps are typically cleaned with acetone, alcohol, or other solvents. When heated, sprayed or exposed to high temperature equipment, these solvents become flammable and explosive, causing serious injury or death. Do not use near a high-temperature source. Ventilate working area with a blower and use in large, well-ventilated room. When heated or sprayed, solvents also become 4 to 5 times heavier than air and will flow down, settling in tanks, pits, and low areas, thus displacing air which can kill by asphyxiation. Use in a large, well-ventilated room. Use of a self-contained breathing apparatus may be necessary. Acetone, alcohol, and other solvents are irritants, narcotics, depressants, and/or carcinogenics. Their inhalation and/or ingestion may produce serious effects. Prolonged or continued contact with the skin will result in absorption through the skin and moderate toxicity. Always ensure that cleaning operations are carried out in large, well-ventilated rooms, and wear eyeshields, gloves, and protective clothing. CAUTION ________ Any solvents degrade O-ring materials reducing their ability to hold a vacuum. Do not use solvents on O-rings. If necessary to clean O-rings, wipe with a lint-free, clean cloth or use a small amount of diffusion pump oil. a. Disconnect all water cooling lines and break the primary circuit supplying power to the pump heater. b. Unbolt the inlet and foreline connections and remove the pump from the system. c. Drain the pump of all fluid. d. Remove the jet assembly following the procedures outlined. 3-2 Maintenance e. Thoroughly clean the pump body interior using acetone followed by an alcohol rinse. Dry with clean, dry, oil-free compressd air or heat gun. f. Thoroughly clean the jet assembly using acetone, wipe all surfaces with alcohol, and dry with clean, dry, oil-free compressed air or heat gun. g. Install the jet in the pump body. h. Check condition of O-rings and replace, if necessary. i. Reinstall the pump in the system. 3-4 DISASSEMBLING AND REASSEMBLING THE COLD CAP 1 To disassemble the cold cap: 2 a Remove the female coupling, nut, follower, and the gasket located at the end of the cold cap water line on the outside of the pump. b Remove the nut which secures the cold cap to the jet assembly. c Lift out the cold cap. To reassemble the cold cap: a Insert the end of the cold cap water line into the cold cap port opening at the side of the pump before setting the cold cap on top of the jet assembly. b Replace the nut which secures the cold cap to the jet assembly. Do not overtighten the nut. c Replace the gasket, the follower, the nut, and the female coupling to the side of the pump. Figure 3-1. Heater Element Assembly 3-3 Maintenance 3-5 DISASSEMBLING AND REASSEMBLING THE JET ASSEMBLY 1 To disassemble the jet assembly: 2. a Disassemble the cold cap water line feedthrough compression seals by removing the nut, follower, gasket, and female coupling located at the side of the pump. b Remove the nut which secures the cold cap to the jet assembly. c Lift out the cold cap. d Unscrew the hex nut above the top cap and remove it. e Lift the jet assembly out with a chain fall attached to the cross member now visible in the jet. f Once the jet is out of the pump, unscrew the two nuts on the cross member to release the lower jet stages. g Disassemble and clean as required. To assemble the jet assembly: a Reverse the steps outlined above. b When the jet is installed in the pump body, it is very important that the slot in the jet base is engaged in the locating pin in the boiler. Unless this is done, the pump will not function properly. WARNING _____________ High voltages (up to 480V) can kill. Always break the primary circuit to the power supply before starting to work on the heater and/or its wiring. CAUTION ________ Poor clamping resulting in inadequate thermal contact may result in reduced heater life and poor pump performance. Tighten nuts fingertight on clamping plate, then gradually and evenly tighten them to 250 in-pounds. 3-6 HEATER REPLACEMENT a Determine which heater element has failed at the junction box, then disconnect the two corresponding leads from the terminal strip. Pull the leads out of the terminal box then out the elbow cover plate. b Remove the heater cover and insulation from the bottom of the diffusion pump. c Remove the nuts holding the clamping plate. d Lower the entire heating unit (heater element, clamping plate and heater shield, see Figure 3-2) until it is off the mounting studs. 3-4 Maintenance e Coat the boiler studs with anti-seize compound such as FEL-PRO-C-5A or common milk of magnesia. f Assemble the new unit (heater element, clamping plate, and heater shield). g. Support the heating unit by the clamping plate, line up the holes with the boiler studs, and push the unit up against the boiler plate. Use two nuts finger-tight to hold it in place. h. Screw on the remainder of the nuts finger-tight, then tighten the nuts evenly up to 250 inchpounds of torque. i Label the heater leads according to the schematic diagram, then run the wires around the periphery of the pump, under the wire retaining clips, into the conduit, and up into the junction box. Connect the leads to the terminal strip then replace the elbow cover plate. j Replace the heater cover and insulation. CAUTION ________ Should it be necessary to use a new wire in the following step, it is important that no. 10 stranded nickel wire with high-temperature insulation is used. The terminal lugs must be solid nickel. If copper or copperplated wire and/or lugs are used, they will oxidize rapidly because of the high temperature and the terminals will overheat and fail. Figure 3-2. External Fittings – Cold Cap Assembly 3-5 Maintenance 3-7 REPLACEABLE PARTS The following is a list of replaceable parts for the Varian NHS-35 Diffusion Pump. Part Number Description 81437301 Cold cap assembly (includes No.10-32 SST Rd Hd screw and No. 10-32 hex nut) SST Cold cap gasket (see Figure 3-2) Cold cap follower (brass) Cold cap nut Cold cap female coupling, 1⁄2-inch OD tube x 3⁄8-inch FPT, Imperial Flexfitting No. 66-FL Jet Assembly Foreline baffle assembly Sight glass service kit (includes glass tube, O-rings, and fittings; valves not included) (for pumps built prior to October 1995) Threaded plug, fill and drain Upper thermal switch, 200°F Lower thermal switch, 600°F Heater element with leads (4000 W, 240V, 380V, 480V) Heater element with leads (4000 W, 400V) Heater element with leads (4000 W, 440V) Clamping plate (no crushplate in NHS-35) Insulation for heaters – Cerablanket 0.50 inch thick Sight glass (for pumps built after October 1995) O-ring kit; includes: 1 butyl inlet flange O-ring (78536001) 1 butyl foreline flange O-ring (2-267) 8 Viton fill and drain O-rings (2-213) 1 Sight glass O-ring (2-240) 1 Graphite sight glass gasket (L9228001) 4 O-ring Viton (2-221) DC-702 diffusion pump fluid (one-gallon container) DC-704 diffusion pump fluid (one-gallon container) DC-705 diffusion pump fluid (one-gallon container) O-ring for ISO inlet flange 660811494 F2622001 75786001 622445026 F1971302 F1744301 F6097301 77261001 K9050005 K9050006 647335010 L6383010 L6383011 F1749001 L6514001 L9223001 K0377169 695472008 695474008 695475008 78536002 3-6 SECTION IV TROUBLESHOOTING 4-1 LEAKAGE Analysis of general operational experience with diffusion pumps indicates that certain locations are more prone to the incidence of leaks. The following locations should be checked first if leakage is the suspected cause of poor system performance. a. Inlet and foreline connections. b. Drain and fill plugs. c. Other compression fittings, such as high-vacuum gauges in the system. d. Threaded connections, such as a foreline gauge. 4-2 OUTGASSING High-vacuum systems, even without external leakage, can have high gas loads due to outgassing from internal surfaces or processes. The pressure in the system is a result of gas load divided by pumping speed (p = Q/S). If the gas load (Q) exceeds the maximum throughput capability of the diffusion pump, the diffusion pump will not function and the pumping action will essentially be due to the mechanical backing pump. To estimate the gas load, isolate the system from all pumps after evacuation and measure the rate of pressure increase. The gas load can be estimated as follows: V x ∆P Q = ______ ∆t where V is the isolated volume, ∆P is the pressure rise, and ∆t time period of measurement. 4-3 POOR PUMP OR SYSTEM PERFORMANCE Before proceeding with a program of step-by-step troubleshooting, check the performance and accuracy of the vacuum gauges used on the system. Table 4-1 shows common faults, and lists the probable cause and corrective actions to correct for poor performance. 4-1 Troubleshooting Table 4-1 Fault Probable Cause Corrective Action Poor system pressure Leaks in system, virtual or real Locate and repair. High process gas load Measure gas load, eliminate cause. System dirty Clean system to reduce outgassing. Contaminated pump fluid Examine and replace. Low heat input Check voltage. Check for continuity, burned-out element, poor thermal contact. Inadequate cooling water flow Check water pressure. Check tubing for obstructions and backpressure. Excessive or too cold cooling water Check temperature. Adjust flow. High forepressure Check for leak in foreline, poor mechanical pump performance, breakdown of mechanical pump fluid. Water in quick-cool coil Check and remove cause. Low heat input Check heaters. Low fluid level Add fluid. Malfunctioning pump assembly. Check and repair or replace. Poor ultimate pressure Low speed (prolongedcycle after checking gas load conditions) Improperly located jets. Damaged jet system. Inlet pressure surges High chamber contamination Pump will not start Incorrect heater input Check and correct. Fluid outgassing Condition fluid by operating the pump for a few hours. Leak in system ahead of pump inlet Check and correct. Forepressure too high Check for leak in foreline, poor mechanical pump performance, breakdown of pump fluid, and incorrect valve operation. Prolonged operation at high throughput at pressure above 10-3 Torr Review procedures. Improper system operation and air release procedures Review procedures. Safety circuits and/or protective devices prevent contactor from staying closed Check utilities, flow switches, interlocks. Check thermostat operation. 4-2 Health and Safety Clearance Return Authorization Policy In compliance with Federal OSHA Safety Standard 1910.1200, Hazard Communications “Right to Know”, Varian is enforcing that standard to preclude the potential health risk to its service personnel that can occur when receiving, disassembling, or repairing potentially contaminated products. Returned products not accompanied by this completed certificate will be held until the completed certificate is received; failure to provide this completed certificate within 30 days of notification will result in the return of held product(s) unprocessed. If a product is received at Varian in a contaminated condition, the customer will be held responsible for all costs incurred to ensure the safe handling of the product. Company Name: __________ Hereby certify that the product(s) listed below have been cleaned of all hazardous residue and that the residue remaining is of a non-hazardous nature. __________ Hereby certify that the product(s) listed below have been contaminated by the following toxic or hazardous materials: RA Number Model Number Serial Number ________________________ ______________________ ______________________ ________________________________________ Authorized Signature _______________________________ Title ___________ Date Note: Varian Service will only accept contaminated Turbo or Mechanical Pumps. All other products must be decontaminated by the customer before Varian Vacuum Products Lexington will assign a Return Authorization (RA) number and authorize the return of the product (refer to the attached Return Authorization Report on the next page). Note: Varian Vacuum Products Lexington cannot accept any biological hazards, radioactive material, organic metals, or mercury at its facility. Varian Vacuum Technologies 21 Hartwell Avenue Lexington Massachusetts 02421 Telephone (781) 861-7200 FAX (781) 860-5405 November 1995 VPD Service Operation Returned Material Report This report must accompany all products returned for repair, replacement, or warranty evaluation. Full information regarding reasons for return of the product will expedite repair or adjustment. Please fill in all blanks below and furnish any other information which will help identify the nature and cause of failure. Reason for Return (check appropriate box) ❒ Paid Repair ❒ Advance Exchange ❒ Shipping Error ❒ Warranty Evaluation ❒ Loaner Return ❒ Shipping Damage ❒ Credit Product Information (use separate forms if more than one model no.) Varian Model No. _______________________ Serial No. __________________ Quantity ___________________ Part Description Purchase Information (if product is being returned for warranty evaluation, show your original purchase order number and date purchased) Varian Sales Order No. (if available) ________________________ Machine # ___________________________ Original Purchase Order No. _________________________ Purchase Order Date _______________________ Company Name ___________________________________________ Contact _______________________________________ Address City ______________________________________________________________ State _________________ Zip _____________ Telephone Failure Report (describe in detail suspected cause or nature of malfunction) Returned Products All products returned to Varian/VPD Service Operation for warranty evaluation must be sent prepaid and customer must comply with the warranty replacement and adjustment provision set forth in the warranty. Ship directly to: Varian Vacuum Products Vacuum Products Service Center 121 Hartwell Avenue Lexington, MA 02421 All products sold by Varian and returned by customer are subject to Varian Vacuum Products standard terms and conditions of sale including, but not limited to, the warranty and damages and liability provisions set forth in the warranty. November 1995
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