Varian VHS-4 User manual

INSTRUCTION MANUAL
vacuum technologies
VHS-4, VHS-6 and
VHS-250
Diffusion Pumps
Part No. 699901024
Revision A
February 2005

Copyright 2005
Vacuum Technologies
VHS-4, VHS-6 and VHS-250
Diffusion Pumps

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
iii
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 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 replaced 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.
When products are used with toxic chemicals, or in an atmosphere that is dangerous to the health of humans, or is
environmentally unsafe, it will be the responsibility of the Customer to have the product cleaned by an independent
agency skilled and approved in handling and cleaning contaminated materials before the product will be accepted by
Vacuum Technologies for repair and/or replacement.
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.
Disclaimer
Operation and maintenance of this equipment involves serious risk. It is the responsibility of the user to maintain safe
operating conditions at all times. Vacuum Technologies assumes no liability for personal injury or damage resulting
from operation or service of the equipment.
Vacuum Technologies 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 the users of Vacuum Technologies 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.
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 Customer’s expense; in addition, a charge for testing and examination may be made on Products
so returned.
3/1/00

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Varian, Inc.
declare under our sole responsibility that the product,
erklären, in alleniniger Verantwortung, daß dieses Produkt,
déclarons sous notre seule responsabilité que le produit,
declaramos, bajo nuestra sola responsabilidad, que el producto,
verklaren onder onze verantwoordelijkheid, dat het product,
dichiariamo sotto nostra unica responsabilità, che il prodotto,
Declaration of Conformity
Konformitätserklärung
Déclaration de Conformité
Declaración de Conformidad
Verklaring de Overeenstemming
Dichiarazione di Conformità
to which this declaration relates is in conformity with the following standard(s) or other normative documents.
auf das sich diese Erklärung bezieht, mit der/den flogenden Norm(en) oder Richtlinie(n) übereinstimmt.
auquel se réfère cette déclaration est conforme à la (auz) norme(s) ou au(x) document(s) normatif(s).
al que se refiere esta declaración es conforme a la(s) norma(s) u otro(s) documento(s) normativo(s).
waamaar deze verklaring verwijst, aan de volende norm(en) of richtlijn(en) beantwoodt.
a cui se rifersce questa dichiarazione è conforme alla/e sequente/I norma/o documento/I normativo/i.
Frederick C. Campbell
Operations Manager
Vacuum Technologies
We
Wir
Nous
Nosotros
Wij
Noi
Lexington, MA, 02421-3133 USA
121 Hartwell Avenue
Vacuum Technologies
Lexington, Massachusetts, USA
Varian, Inc.
VHS-4, VHS-6 and VHS-250 Diffusion Pump
73/023/EEC . . . . . . . . . . . . . . . . . . . Low Voltage Directive
EN 61010-1. . . . . . . . . . . . . . . . . . . “Safety requirements for electrical equipment for measurement, control and
laboratory use”, incorporating amendments, numbers 1 and 2.
VMF-11 VHS-6 VHS-400 NHS-35
AX-65 VHS-250 HS-16
AX-150 VHS-4 HS-20
HS-2 VHS-10 HS-32
October 2000
Declaration
of
Conformity

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VHS-4, VHS-6 and VHS-250 Diffusion Pumps
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Contents
Introduction ............................................................................................................................... 1-1
Pump Specifications ........................................................................................................................... 1-1
Installation ............................................................................................................................... 1-10
Unpacking ........................................................................................................................................ 1-10
Pump Oil Installation ........................................................................................................................ 1-10
Vacuum System Connections ........................................................................................................... 1-11
Cooling Water Connections .............................................................................................................. 1-11
Electrical Connections ...................................................................................................................... 1-12
Thermal Switch ................................................................................................................................ 1-13
Startup ....................................................................................................................................... 2-1
Shutdown .................................................................................................................................. 2-2
General Maintenance ................................................................................................................ 3-1
Inspection Requirements ............................................................................................................ 3-1
Cleaning .................................................................................................................................... 3-2
VHS-4 and VHS-6 Cold Cap Removal/Installation ...................................................................... 3-3
VHS-250 Cold Cap Removal/Installation .................................................................................... 3-4
Jet Assembly Removal/Installation ..............................................................................................3-5
Heater Replacement .................................................................................................................. 3-8
Pump Fluid Charge .................................................................................................................. 3-10
Leakage ..................................................................................................................................... 4-1
Outgassing ................................................................................................................................. 4-1
Poor Pump or System Performance ............................................................................................ 4-2

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VHS-4, VHS-6 and VHS-250 Diffusion Pumps
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Figures
1-1 VHS-4 Speed and Throughput Curves .................................................................................. 1-4
1-2 VHS-4 Wiring Information ................................................................................................... 1-4
1-3 VHS-6 Speed and Throughput Curves .................................................................................. 1-6
1-4 VHS-6 Wiring Information ................................................................................................... 1-6
1-5 VHS-250 Speed and Throughput Curves .............................................................................. 1-8
1-6 VHS-250 Wiring Information ............................................................................................... 1-8
3-1 VHS4 and VHS-6 Cold Cap Removal/Installation................................................................. 3-3
3-2 VHS-250 Cold Cap Removal/Installation.............................................................................. 3-4
3-3 VHS-4 Diffusion Pump Jet Assembly .................................................................................... 3-6
3-4 VHS-6 and 250 Diffusion Pump Jet Assembly ...................................................................... 3-7
3-5 VHS-6 and VHS-250 Heater Mounting ................................................................................ 3-8
3-6 VHS-4 Heater Mounting ...................................................................................................... 3-9

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VHS-4, VHS-6 and VHS-250 Diffusion Pumps
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Tables
1-1 Pump Operational Specifications ........................................................................................ 1-1
1-2 VHS-4 Dimensions ............................................................................................................. 1-5
1-3 VHS-6 Dimensions ............................................................................................................. 1-7
1-4 VHS-250 Dimensions ......................................................................................................... 1-9
4-1 Troubleshooting.................................................................................................................. 4-2
5-1 VHS-4 Models .................................................................................................................... 5-1
5-2 VHS-4 Replacement Parts ................................................................................................... 5-1
5-3 VHS-6 Models .................................................................................................................... 5-2
5-4 VHS-6 Replacement Parts ................................................................................................... 5-3
5-5 VHS-250 Models ................................................................................................................ 5-4
5-6 VHS-250 Replacement Parts ............................................................................................... 5-4

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VHS-4, VHS-6 and VHS-250 Diffusion Pumps
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Preface
Instructions for Use
This equipment is designed for use by professionals. Read this instruction manual and any
other additional information supplied by Vacuum Technologies before operating the
equipment. Vacuum Technologies will not be held responsible for any events that occur due
to non-compliance with these instructions, improper use by untrained persons,
non-authorized interference with the equipment, or any action contrary to that provided for
by specific national standards.
Documentation Standards
This manual uses the following documentation standards:
WARNING Warnings are for attracting the attention of the operator to a
particular procedure or practice which, if not followed
correctly, could lead to serious injury.
CAUTION Cautions are displayed before procedures, which if not
followed, could cause damage to the equipment.
NOTE Notes contain important information.

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xiv
Safety
Diffusion Pump Hazards
Designers of systems utilizing diffusion pumps must design out hazards wherever possible.
For hazards that cannot be designed out, warnings, procedures, and instructions on proper
use and servicing are provided. Please use guards, safety features, and interlocks as
recommended.
Refer to the following tables for a list of general hazards and recommended actions, a list of
prohibited actions that can result in explosions, and a list of pressurization hazards that can
result in damage to equipment.
THE INSTALLATION, OPERATION, AND SERVICING OF DIFFUSION PUMPS INVOLVES
ONE OR MORE OF THE HAZARDS LISTED IN THIS SECTION, ANY ONE OF WHICH IN
THE ABSENCE OF SAFE OPERATING PRACTICES AND PRECAUTIONS, COULD
POTENTIALLY RESULT IN DEATH OR SERIOUS HARM TO PERSONNEL.

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xv
General Hazards
Hazard Suggested Corrective Action
Loss of utility: water and/or electricity Provide sufficient backup water and power
supply as necessary 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 the
pressure in foreline is above 0.5 Torr (0.67 mbar).
Overtemperature Fit temperature sensors and pump fluid level
sensors with feedback to an interlock on the
heater power supply.
Insufficient water flow through main cooling coils Use water flow sensor and feedback to interlock
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 electrical 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 Prevent personnel contact with high voltages;
design and attach warnings.
Toxicity and 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” or larger in diameter.
Do not use hydrocarbon-based pumping oils.

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xvi
Explosion
Operation of the diffusion pump without continuous evacuation below 0.5 Torr (0.67 mbar)
or without coolant, and then introducing a strong oxidizer (such as air), explosive vapors,
powders, or materials which may react with pumping fluids in a hot pump (above 300 °F or
150 °C) can cause an explosion. Such an explosion would 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 could result from expelled
parts, doors, shrapnel, and shock waves.
Avoid the implementing the following three elements that could result in an explosion:
❑Fuel
❑Oxidizer
❑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. The oxidizer can be air, which is a strong oxidizer
that is introduced by a leak, deliberately brought in via a process, or inadvertently admitted
by an operator or by a process controller error.
Explosion and Fire from Acetone and Alcohol
Diffusion pumps are typically cleaned with acetone and alcohol. When combined with
air, oxygen, and other oxides, alcohol and most other solvents are very flammable and
explosive. Never permit any trace of these cleaners to remain in or on the pump. Remove
all traces of alcohol and acetone and other cleaners with clean, dry, oil-free compressed air.
Oxygen and other strong oxidizers are even more dangerous than air. 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
injury. Never operate large diffusion pumps utilizing hydrocarbon oils without a complete
safety analysis for the entire system and for the application.
Never operate a large diffusion pump under the conditions listed in the following table.
Any of these situations increases the probability of an explosion.

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xvii
Explosive Conditions
Prohibited Action Explosion-Causing Condition
Do not run pump without cooling water. Overtemperature
Do not run pump with low level of pump fluid. Overtemperature
Do not run pump without proper backing or holding pump. Overpressure
Do not run pump when not evacuated below 0.5 Torr
(0.67 mbar).
Overpressure
Do not admit air to, or rough through, a pump with hot boiler. Overpressure plus strong oxidizer
Do not open drain or fill plug while pump is under vacuum,
especially when it is hot.
Overpressure plus strong oxidizer
Do not contaminate pump with explosive vapors. Lower explosive threshold
of gas mixtures
Do not remove, defeat, or override safety counter-measures such
as pressure and thermal switches and valve sequencer interlocks.
Overtemperature, overpressure,
more combustible mixtures
Do not machine or weld any part of the pump without removing
all oil or solvent residue in pump in large pumps.
Source of ignition
Do not use unsuitable pumping fluid, especially hydrocarbon oil. Lower explosive threshold
of gas mixture

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xviii
Pressurization Hazards
Large vacuum pumps and their components are designed for vacuum service. They are not
designed to be pressurized, which can cause them to burst and possibly expel 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 any of the hazards in the table below to develop.
Pressure Relief Devices
Systems larger than 10”, such as this pump, 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.
Pressurization Hazards
Prohibited Action Result
Do not block inlet or vent of liquid nitrogen trap and lines. LN2trap and/or lines burst
Do not close isolation valves at inlet and discharge of main
water cooling coils when pump is reheated.
Water turns to steam and bursts coils
Do not pressurize the pump body. Body of pump bursts
Do not make a hole through the vacuum wall. Loss of structural integrity of wall

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xix
Dangerous Substances
Chemical Dangers of Acetone and Alcohol
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.
Ensure that cleaning operations are always performed in large, well-ventilated rooms. The
use of a self-contained breathing apparatus may be necessary depending upon the solvent
type and vapor concentration in surrounding air.
Poisonous and Corrosive Compounds
When pumping poisonous, reactive, and/or corrosive gas, vapors, or chemicals, proper
operation and regeneration do 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.
Pump Fluids
Overheating the pump fluid, exposing it to air or reactive materials, or overpressurizing it
above the normal operating range (approximately 1 x 10−3Torr / 1.3 x 10−3mbar)
decomposes the fluid and possibly makes 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.
Process Gasses
These gasses are frequently toxic, flammable, corrosive, explosive, or otherwise reactive.
Vacuum Technologies has no control over the types of gasses passing through your diffusion
pump as these are entirely under the control of the process user and/or the hardware
systems integrator. Since these gasses 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 and similar components to ensure that the
exhaust meets all air and water pollution control regulations.

VHS-4, VHS-6 and VHS-250 Diffusion Pumps
xx
High Temperatures
Hot Surfaces
Boiler temperatures reach 530 °F (275 °C) which can cause serious burns. Always ensure
that surfaces have cooled to near room temperature before touching them.
Hot Cooling Water and Steam
The water used to cool the pump can reach scalding temperatures. Touching or rupturing
the cooling surface can cause serious burns. Water left inside Quick Cool Coils from
previous use turns to steam when the pump is reheated. This steam must be allowed to
escape without coming into contact with 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 the Quick Cool Coils).
High Voltages
Diffusion pump heaters operate at voltages high enough to kill. Design systems to prevent
personnel contact with high voltages. Securely attach prominent hazard warnings. Always
break the primary circuit to the power supply when direct access to the heater or wiring is
required.