Ion Pump Operation & Trouble Shooting Guide

Provided as a Service by Duniway Stockroom Corp.

Compiled by Sherman Rutherford 7/97

Table of Contents
Introduction

Problems & Troubleshooting

Won’t Start
Won’t Pump Down
No Current
Excessive Current
Current not Proportional to Pressure
Contamination
Argon Instability

Handy Tips

Appendix I: How an Ion Pump Works

Geometry, Materials, High Voltage, Magnetic Field and Pressure Range
Pumping Mechanisms for Various Gases
Types of Pumps

Appendix II: Starting Sputter-Ion Pumps

Introduction
Pre-Start Checking
Preparation
Control Unit/Power Supply
Roughing/Trapping
Starting
Operation/Protection
Attachments: Ion Pump Control Units 1961-1992, 1992-1997

Appendix III: Magnet Orientation in Sputter-Ion Pumps

Appendix IV: Cleaning & Rebuilding Sputter-Ion Pumps

DUNIWAY STOCKROOM CORP.

Phone: 800/446-8811 & 650-969-8811 FAX:
650-965-0764 email: info@duniway.com

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 Ion Pump Operation & Trouble Shooting Guide
Introduction:

Ion Pumps (Sputter-Ion Pumps, Getter-Ion Pumps, Penning Pumps) provide a clean,
simple, low maintenance alternative for producing and maintaining high and ultra-high
vacuum. Occasionally, questions or problems about performance may arise and this
document is meant to help with resolving those issues. In solving problems with ion pumps, it
may be helpful to review information on how they work and normal operating procedures. In
that interest, this document includes appendices on principles of operation, starting and
magnet circuits. Please review this information if you are not already familiar with ion pumps.

Problems & Troubleshooting

WARNING! Both line voltage used to power the

control units and the voltages developed in these units
and applied to the ion pumps are dangerous and
exposure could be lethal. Proper grounding and high
voltage connections are vitally important.

Problem: Pump Won’t Start (Starting is the process of going from roughing pressures, Zone
2 in the diagram in Figure 1, to the normal operating pressure, Zone 1)

Pressure - Torr
-8
10 10-4 10-2 760

Pressure Zone

Figure 2

Indication: No Pump Current: If the control unit shows that no current is being drawn
by the ion pump which is being started, even though the meter shows the proper
voltage, it could be caused by one of the following:

 Check that the polarity of the control unit high voltage is correct for the
pump being used. Diodes, noble diodes and DI (Differential Ion) pumps
require positive high voltage. Triodes and StarCell pumps require negative
high voltage.
 Check to be sure that the magnets are installed, and that they are installed
correctly. (See later section on magnet circuits).

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  Check to be sure that the high voltage cable is properly connected to both
the pump high voltage feedthrough and the control unit.
 Be sure that any safety features, such as ground protection relays, are
operating properly.
 Verify that the pressure is within the Zone 1 or Zone 2 range - not either in
Zone 3 where no discharge will occur or in Zone 4 where the pump current
will be too low to indicate.
 As a last resort, check that the internal connections between the high
voltage feedthrough and pumping elements are intact. Visual inspection
and electrical continuity meter checking (keep things clean!) should be
performed.

Indication: Excessive Heat During Starting. Some heating during starting of ion
pumps is normal and in fact, beneficial in removing adsorbed gases. However, if
during a prolonged starting process the pump becomes excessively hot, it could be
due to the following:

 There could be a leak in the system, which is keeping the pressure from
falling into Zone 1.
 The control unit could be over-powered for the pump being started. See
Appendix II, below on Starting Ion Pumps for matching of pump models with
control unit models.
 Excessive water vapor may have become adsorbed onto the pump
elements and system surfaces during exposure to atmosphere, either at
high humidity or over extended exposures. Bakeout of the pump and
system is recommended.

Indication: The pump starts, but it won’t pump down to expected base pressures.

 There could be a leak in the system, which is keeping the pressure from
falling to acceptably low base pressures. The ion pump current can be used
as a gross leak check; spraying helium or an acceptable liquid can give ion
current fluctuations as gas composition changes or leaks become
temporarily blocked.
 The system may be contaminated with a high vapor pressure material. The
most common contaminate is water vapor, but other liquids, oils, fingerprints
or high vapor pressure metals can clamp the pressure and stall a pump
down. If contamination is indicated, thorough dis-assembly and cleaning of
all interior surfaces with solvent and light abrasion is required.
 Are the magnets installed correctly and is the field strength up to
specification for the pump?

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Problem: Excessive Pump Current: The ion pump draws current substantially in excess of
expected values based on the pressure in the system, or suddenly becomes higher than
previously experienced.
Indication: The control unit current is at or approaching its rated short circuit current,
and the voltage is substantially below its open circuit value.
 The pressure in the system has risen due to a leak or due to a process
generating a high gas load.
 An electrical short has developed in the ion pump, due to a metallic object,
such as a flake, becoming lodged in the pumping element or in the high
voltage feedthrough. After turning off the control unit and removing the high
voltage cable, use a Volt-Ohm-Meter to check the electrical resistance
between the center conductor of the high voltage feedthrough and the metal
jacket of the pump. The normal condition is open circuit, any indication of
resistance is abnormal and may require rebuilding of the pump or elements.
 Electrical leakage due to conductive coatings has developed inside the
pump; either due to heavy sputtering, generally at elevated temperatures or
from other evaporative sources in the system. See previous point for
diagnosis.
 Electrical leakage outside the pump, in the control unit, cables or connectors
has developed. Check the control unit and cable independently of the ion
pump to see if leakage current persists. Replace or repair faulty
components.

Problem: Current not Proportional to Pressure. The system pressure is at the low levels
expected, but the ion pump current remains at a higher value than expected from the pump
specifications. There may be random spikes and variations

Indication: After considerable use, leakage current may develop in the ion pump. The
current is unrelated to pressure in the system and persists even if the pump magnets
are removed.

 No resistance can be measured even on the highest (Meg-ohm) scale of a multi-

meter. This indicates field emission leakage current, which is due to buildup of
sputtered material points or flakes. This effect can be removed or at least reduced
by applying an over-voltage to the pump, for example, from a neon sign
transformer at 15KVAC rated at a few milliamps. This process is called “hi-potting”,
and other high voltage supplies can be used, as long as the current is limited to a
few milliamps to avoid excessive heat.

WARNING! Both line voltage used to power the

control units and the voltages developed in these units
and applied to the ion pumps are dangerous and
exposure could be lethal.

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 If the problem persists, a rebuild of the pump and elements is indicated.

 Resistance can be measured on the meg-ohm scale of a multimeter. This is

probably due to buildup of conducting films on some of the high voltage stand-off
insulators. The conductive films may come from sputtering within the pump,
extended operation at high pressures (more than 0.1 micron) or deposits of
conductive contaminants. If cleaning of the outside ceramic of the high voltage
feedthrough does not solve the problem, a rebuild of the pump and elements is
indicated.

Problem: Contamination of the pump by some high vapor pressure material.

Indication: System pressure remains above desired levels in spite of prolonged

operation.

 Hydrocarbon contamination from oil or grease. This could be from an

untrapped mechanical or diffusion pump, residual from machining
operations, finger prints or organic sealing greases. For materials of this
kind, a pump and system bakeout will help remove the materials. Presence
of organic materials in the system may be detected as brownish or yellowish
deposits on the glass portion of an ionization gauge or by sooty deposits in
the ion pump.

 High vapor pressure materials, such as active metals (cesium, rubidium,
etc.). These materials may come from an experiment or oven source as
part of the process being performed in the vacuum chamber. Excess
material may deposit in the cool parts of the vacuum system due to
accidents or long term exposure. Such materials may be detected by a
metallic sheen on interior of glass parts such as ionization gauges.
Presence of such materials requires rebuilding of the ion pump and careful
cleaning of the interior of the vacuum system.

Problem: Argon Instability

Indication: Diode pump displays regular, periodic pressure spikes, with the pressure
gradually building up from the base pressure of the system to about 10-4 torr, slowly
falling into the upper 10-5 torr range, then rapidly falling to the system base pressure.
The period of the fluctuation is roughly proportional to the base pressure between
fluctuations; at 10-8 torr base pressure the period can be days, at 10-7 torr it can be
hours, at 10-6 torr in can be minutes.

 The pressure fluctuation is caused by re-emission of previously pumped

argon (or other heavy noble gas), due to sputtering of the covered over
areas. The instability disappears when the source of noble gas is
eliminated, either by correcting an air leak or removing the source of noble

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 gas. These fluctuations do not change the pumping mechanisms for
chemically active gases, in fact, the additional fresh sputtered titanium
actually increases the pumping speed, temporarily, for these gases.

 If sources of heavy noble gases cannot be eliminated from the system, the
configuration of the pump elements must be changed to allow stable argon
(heavy noble gas) pumping. See Appendix I for a more detailed discussion
of pumping elements and pumping mechanisms.

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Handy Tips

(Note: Always be sure to observe the safety precautions described in the ion
pump and control unit operating manuals. Proper grounding of the ion pump
and proper protection of the high voltage connections is mandatory. High
voltages and currents developed are hazardous and can be fatal if safety
precautions are not followed.)

Procedure for opening an Ion pump to atmospheric pressure:

Water vapor from the atmosphere, adsorbed onto the surfaces of an ion pump and system, is
normally the primary gas load encountered in starting the pump. Therefore, operators should
take whatever measures to limit exposure to moisture laden air. This includes:

Keeping the pump sealed under vacuum until connection to the system.

Using dry nitrogen or dry air when letting the pump and system up to atmospheric
pressure.

In general, limiting exposure of pump and system to the atmosphere, especially in

regions where humidity is high and where temperature fluctuations may lead to
condensation.

(Note: One layer of water molecules on the inside surface of a one meter cube, is
approximately 3 torr-liters of gas, and, if completely desorbed into the volume would
raise the pressure in the cube by 3x10-3 torr. In addition, surfaces in a vacuum system
can adsorb many layers of water vapor before they saturate.)

Procedure for baking an ion pump:

Since water vapor from the interior surfaces of the pump and system provide the
majority of the gas load during pumpdown, acceleration of the desorption of the water
layers will speed up the pumpdown. Ion pumps can normally be baked to 150oC while
operating with the magnets on, and to 450oC with the magnets and cables removed.
Heating tapes or special ovens can be used, taking precautions to avoid hot spots
which might damage the system.

During starting of an ion pump, the power dissipated by the pumping elements at
higher pressures (above 10-5 torr) causes heating of the elements and surrounding
pump structure. If the control unit is properly matched to the pump, this heating will
not be excessive; in fact, it can provide beneficial removal of adsorbed water vapor,
which will lead to faster pumpdown subsequently. (See Appendix II for more
information on starting ion pumps and matching control units to ion pumps.)

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 If the pump has been exposed to large amounts of water vapor, starting can take
extended time. Heating due to power dissipation keeps the operation of the pump in
the high power zone of the control unit, leading to water desorption, more heat, etc.
Manually shutting the pump control unit off-and-on to reduce the duty cycle and heat
dissipation, while still operating the roughing pump, can speed up the starting of the
ion pump. (See Appendix II for more information on starting ion pumps and matching
control units to ion pumps.)

Procedure for ‘Hi-Potting’ an Ion Pump

After extended operation of an ion pump, where sputtered material deposits may form
flakes with sharp points, field emission current leakage may occur. Field emission
current results from electrons being extracted from sharp points under high voltages.
The resulting high voltage gradients are high enough to draw electrons directly from
the metal points. The resulting current has a threshold and is exponentially related to
the applied voltage above the threshold. While very useful in some applications, this
current is annoying in ion pumps because it can mask the true ion current for purposes
of indicating the pressure in a pump.

Reduction of field emission leakage current is accomplished by a process called ‘hi-

potting’. Taking advantage of the exponentially increasing current with applied
voltage, the sharp points can be burned off by applying an over voltage to the point
where current flow causes melting of the tip. Hi-potting control units, with variable high
voltage and over-current protection are commercially available. Turning the control up
to 15 -20 KV usually does the job. Use of a neon sign transformer, with 15 KVAC and
a few milliamps of short circuit current has also been effective.

WARNING! Both line voltage used to power the

control units and the voltages developed in these units
and applied to the ion pumps are dangerous and
exposure could be lethal.

If hi-potting does not reduce leakage current to appropriately low values, then the
pump probably needs rebuilding due to conductive coating on insulator surfaces.

Some times, offending particles can be removed from critical positions by vibration.
For example, light tapping of the pump envelope with a soft-faced hammer or screw-
driver handle can cause the particles to break loose and move to less critical positions.
Use caution in the force used in this process; stay away from the cables and high-
voltage feedthroughs.

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Appendix I: How an Ion Pump Works:

Ion pumps work by using an electrical, ionizing discharge which is maintained under
vacuum conditions, and chemically active metals, such as titanium. The discharge is called a
Penning Discharge, after its discoverer, F.M. Penning in 1937.

Ion pumps require a correct combination of geometry, materials, high voltage,

magnetic field and pressure range to operate.

WARNING! Both line voltage used in control units

and the voltages developed in this unit and applied to
the ion pumps are dangerous and exposure could be
lethal.

Geometry and Material: Typical ion pumps consist of an anode structure (an array of
hollow cylindrical cells made of stainless steel tubing), suspended between a set of two
cathode plates (made of titanium). See Figure 1 below. The whole array is mounted in a
vacuum envelope, with good conductance access to the volume being pumped.

Figure 1 - Diode, DI, and Noble Diode Ion Pumps

Voltage: A positive high voltage is established between the anode and the cathode
plates. The voltage typically is in the range of 3000 to 7000 volts DC. (see “Types of Pumps”
below for variations.) High voltage feedthroughs and stand-off insulators are used to isolate
the anode from the cathodes and the vacuum envelope.

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 Magnetic Field: A magnetic field is required, aligned with the axis of the anode cells.
The field is generally between 1000 and 2000 gauss; it should be parallel to the axis of the
anode cells and should be uniform across the array. See Appendix III for more information
about magnets and their circuits.

Pressure/Vacuum Range: Ion pumps are designed to operate continuously in the

range between 10-4 torr and to 10-8 torr and below. (Zone 1 in Figure 2 below). In Zone 1, the
electrical discharge is strong, efficient and confined to the anode cells. In this region, a cloud
of electrons circulates inside the anode cells, constrained by the combination of electrical and
magnetic fields. The circulating electrons collide with gas molecule to form positive ions and
secondary electrons. The secondary electrons help maintain the intensity of the circulating
electron cloud. The positive gas ions, are attracted to the cathode plate, and because they
have a much greater mass to charge ratio than the electrons, their path is much less curved,
and they collide with the titanium cathode.

At pressures between 10-4 and 10-2 torr (Zone 2), the pump operates, but in a less
efficient, unconfined discharge mode. In most cases, roughing pumps are used to lower the
pressure into the Zone 2 range, then the ion pumps is “started”.

At pressures from atmosphere (760 torr) down to several torr, no discharge will occur;
depending on the geometry. The unconfined glow discharge starts at the lower end of Zone
3 and extends through Zone 2.

In Zone 4, the ultra-high vacuum range below 10-8 torr, depending on the strength of
the magnetic field and diameter of the anode cells, the discharge intensity, and therefore
pumping speed can decline. This is because the discharge goes into a lower intensity mode
due to the loss of electrons from the discharge. The product (BxD) of magnetic field strength,
B and cell diameter, D determines the transition point from Zone 1 to Zone 4. High values of
BxD can push this transition point to below 10-11 torr.

Pressure - Torr
-8
10 10-4 10-2 760

Pressure Zone

Figure 2

Zone 1: 10-4 to 10-8 torr Normal Operating Range

Zone 2: 10-2 to 10-4 torr Starting Range
Zone 3: ~1 to 760 torr Non-Operating Range
Zone 4: 10-8 torr & below UHV Range

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Pumping Mechanisms for Different Gas Species

The combination of ionization, ion bombardment, sputtering and general collision of

gas molecules with the pump walls leads to pumping by a variety of mechanisms.

Chemically Active Gases: Most of the pumping in ion pumps takes place by direct
chemical combination between the active gas ions/molecules as they strike the chemically
active titanium surfaces. Oxygen and nitrogen form very stable compounds with titanium, so
once they are pumped they are permanently removed from the vacuum system.

Small Atoms: Small diameter atoms, such as hydrogen and helium, are pumped by
ionization, burial and subsequent diffusion into the cathodes. Hydrogen, especially, since
titanium has a very high affinity for dissolving hydrogen, can be pumped in very large
quantities. Unfortunately, under heating, it can also come out of solution and be re-emitted
into the system. Buried and diffused helium also can be re-emitted by heating.

Heavy Noble Gases: Since the noble gases are chemically neutral, they must be
pumped by burial and covering over by subsequently sputtered material. If the noble gas ion
is initially buried in an area of heavy subsequent sputtering, it can be re-emitted as it is
uncovered. This burial and re-emission, in some cases, can lead to a periodic pressure
fluctuation called argon instability. Since the atmosphere has about 1% argon as a
constituent, the desire for stable pumping of argon has led to alternate configurations in
which the areas of net build-up of sputtered material are enhanced.

Complex Molecules: Molecules such as water, methane, carbon dioxide, carbon

monoxide, ammonia and light hydrocarbons are dissociated in the discharge and their
chemical components are pumped by their normal mechanisms.

Types of Pumps

Diode: The earliest and most common type of pump is called the “Diode” configuration
and it is shown in Figure 1. Both cathode plates are made of titanium and the anode is
operated at positive high voltage. This configuration is simplest, least expensive and most
reliable for normal operation against outgassing loads and at low pressures.

Differential (DI) or Noble Diode: However, the need to operate against steady air
leaks and with artificial loads of heavy noble gases, especially argon, lead to new
configurations. In one such variation, the pump is the same as shown in Figure 1, except that
only one cathode is made of titanium, while the other is made of a substantially heavier
metal, such as tantalum. The slower sputtering rate of the heavier metal shifts the balance of
areas where there is a net buildup of buried atoms and sputtered material. This shift leads to
higher pumping speeds and stable pumping for noble gases.

Triode or StarCell: Another variation for stable noble gas pumping is the triode. In this
configuration, the anode is maintained at ground potential while the cathodes are operated at
a negative high voltage. The cathodes are constructed of strips of titanium, providing grazing

11
incidence sputtering. See Figure 3. In the StarCell variation, the anode-cathode voltage
relationship is the same as in the triode, but the cathode has open areas with star-shaped
slats arranged radially around the opening. In both these configurations, the cathode
geometry provides enhanced areas where there is a net buildup of buried atoms and
sputtered material. This shift leads to higher pumping speeds and stable pumping for noble
gases.

StarCell Triode

Figure 3

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 Appendix II: Starting Sputter-Ion Pumps

1. Introduction

Sputter-ion pumps have many advantages in simplicity, cleanliness and reliability for high and ultra-
high vacuum systems. The transition from the roughing pressure to independent operation at high
vacuum is referred to as “starting”. With some attention to preparation and operation during starting,
this transition can be made smoothly and with a minimum of problems.

2. Pre-Start Checking

Ion pumps are normally delivered under vacuum. They have been baked and processed, then
sealed with a copper pinch-off. Before opening the pump, it is a good idea to check the condition of
the vacuum in the pump. Visually check the pinch-off and high voltage feedthrough for integrity,
attach a ground connection to the pump and attach the high voltage connector to an appropriate control
unit. Put the meter scale to ‘Pressure’ or the lowest current range. Turn on the control unit. A brief
spike of current should occur, due to pressure build-up in the pump, then the current should fall into
the microamp range. In many cases the current will fall below the level readable on the current meter,
and in every case should fall rapidly to below 2 microamps.

3. Preparation

Before beginning the operation of a sputter ion pump, it is advisable to consider some system
and safety issues. If these issues are taken into account, both personal and equipment convenience will
be assured.

First of all, in order to take maximum advantage of the pumping speed available from the
sputter-ion pump, the conductance, or access for gas flow should be maximized. This means
decreasing the length and increasing the diameter of the tubing connecting the sputter-ion pump to the
system.

Second, cleanliness should be observed in handling and preparing both the system and the
sputter-ion pump. Exposure to oils, water vapor or dust can significantly add to the gas load, both
during starting and continued operation. Even fingerprints can be harmful in contributing to gas loads.
Sputter-ion pumps do not deteriorate just by being stored at atmospheric pressure, if they are kept
clean. Aluminum foil or a plastic cover on the inlet flange during storage will keep out dust, dirt and
debris.

Finally, for personal safety, always establish a definite electrical grounding connection from
the sputter-pump case to control unit ground. Sputter-ion pumps operate with high voltages and
current levels which can be fatal if accidental contact is made. By assuring proper grounding of the
pump, personal safety is greatly improved, and proper operation of control unit overload circuits is
provided.

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4. Control Unit/Power Supply

Each sputter-ion pump requires a control unit of an appropriate voltage level, polarity and
current capacity. These parameters are best determined by consulting the User Manual for the sputter-
ion pump and/or the control unit. If the original documents are not available, the manufacturer’s
catalog may have the information. In any case, you may call Duniway Stockroom, where a
comprehensive listing of this information is maintained. An example of the information available
“Varian and Perkin Elmer Ion Pump Control Units, 1961-1992, 1992-1996” is attached.
In general, the larger the pump rating in liters per second, the higher the required current
capacity. Also, triode configurations (triode or StarCell) require negative voltage polarity while diode
configurations (diode, noble diode, DI) require positive voltage polarity.

Voltage is usually rated as “open circuit voltage”, that is the voltage with no current load on the
control unit. Current is usually rated as “short circuit current”, that is the current drawn by the power
supply when the output is shorted to ground.

An example of voltage and power versus current for a typical sputter-ion pump control unit, a
Duniway Stockroom Corporation IPC-0066, is shown in the attached Figure 1.

In the plot in Figure 1, the voltage is represented on the vertical axis by the bars, the power is
represented on the vertical axis by the line plot and the current is represented on the horizontal axis.
The voltage rating of the power supply is shown by the maximum voltage plot at the upper left of the
graph, or approximately 7,200 volts; the current rating of the power supply is shown by the point in the
lower right of the plot where the power curve intercepts the lower axis, or .58 amps (580 ma); and the
power rating is shown by the top of the power curve, or 1200 watts.

The product of voltage and current at any point in the process gives the power going into the
sputter-ion pump. This information is displayed as plot of power versus current. This plot has a power
maximum near the middle range of the current capacity. This maximum is called the “power hill”,
because as the pump current moves either up or down (the same as the pressure moving up or down) it
must climb this “power hill”. Increasing power means increasing heat to be dissipated, which
normally means an increasing gas load due to outgassing. As we will see below (6. Starting), the
heating that takes place due to power dissipation has an effect on the starting of the pump.

Sputter-ion pump current is proportional to pressure, especially in the pressure ranges below
-5
10 torr. This relationship is expressed by the equation: I/P = constant. Thus, at lower pressures,
pump current can be used as an indicator of the pressure. An example of the relationship between
sputter-ion pump current and pressure is shown attached as Figure 2; in this case the pumps are Varian
8,20, 30 and 60 liter per second diodes. The slope of the upper I/P curve shown (for the 60 liter per
second pump) is 1000 amps per torr. (Calculated by choosing a typical point on the curve, say 10
milliamps at 1x10-5 torr, and dividing the current at that point by the pressure at that point).

14
5. Roughing/Trapping

Sputter-ion pumps operate by using a low pressure gas discharge called the Penning discharge.
Through a combination of magnetic field and electric field, gas ions are formed and captured on active
metal plates, such as titanium. The Penning discharge only operates at pressures below approximately
10-3 torr, so the pressure in the pump and vacuum system must be reduced by other means to reach that
pressure range.

A variety of rough vacuum pumps is available, including rotary mechanical pumps,

turbomolecular pumps and sorption pumps. Since the sputter-ion pump is inherently clean and
typically used in clean, ultra-high vacuum applications, it is important to use a clean technique for
rough pumping. Also, the roughing pump should have a valve to isolate it from the sputter-ion pump
after the starting phase, since the sputter-ion pump can operate independently on a closed system. In
addition to the gases contained in the volume of the system, the main gas load at the lower pressures is
represented by the water vapor that is adsorbed on all the surfaces of the system.

It is a good idea to check the base pressure obtained by the roughing pump to assure that the
pump is reaching a pressure adequately low for sputter-ion pump starting. A properly calibrated
thermocouple gauge will do the job, and a pressure below 10 millitorr indicates adequate roughing
pump performance. Lower pressure before starting will generally lead to quicker results.

The cleanest roughing pump technology is the sorption pump, which uses ultra-high surface
area materials such as molecular sieve, which are chilled to liquid nitrogen temperatures. Water vapor,
oxygen, nitrogen, argon and most organic vapors are pumped by sorption pumps, thus reducing the
pressure to a few millitorr. For small systems a single stage sorption pump is sufficient to reach the
starting pressure for sputter-ion pumps; for larger systems a sequenced, two stage sorption pump is
recommended. Prior to using a sorption pump, it is important to remove the previously absorbed
gases, particularly water vapor, by baking the pump.

Rotary mechanical pumps, which use oil-sealed vanes, can also be used for rough pumping;
however, an efficient trap must be provided between the mechanical pump and the sputter-ion pump.
Either a liquid nitrogen trap or a molecular sieve trap can be used to keep the mechanical pump oil
from migrating into the sputter-ion pumped system. In addition, the trap will help remove water vapor,
the major gas load during the later stages of rough pumping. Mechanical pumps are not efficient at
removing water vapor, since it just gets recycled through the oil on each rotation of the pump rotor.

Another good alternative for rough pumping is the turbomolecular pump. This pumping
technology is clean and provides a better pumping speed and lower roughing pressure than other
alternatives.

15
6. Starting

When the roughing pressure falls below 10 millitorr, the sputter-ion starting process can begin.
To review the precautions, be sure that the pump is properly grounded, that the control unit voltage
polarity and power rating are matched to the pump being started.

Verify that the control unit “Start-Protect” switch is set to the “Start” position, and that the
“Meter Range” switch is set to “Voltage”. Now turn on the “Power” switch. Immediately after
turning on the power switch, observe the voltage reading on the meter. In the starting mode, the
voltage should be in the 300-1000 volt range, and then gradually rise as the pump starts.

(If the voltage reading is either at zero or at the open circuit rating of the control unit when the
pump is turned on during starting, immediately turn the control unit off, because there is either an
electrical short in the pump or an open circuit which must be found and corrected before proceeding.)

Next, turn the meter switch to the highest current scale and verify that the current is near the
appropriate (near short circuit current) for the control unit.

Return the meter range switch to the “Voltage” position to monitor the operation of the pump.
When it appears that the roughing system has reached its base pressure, close the valve between the
roughing system and the sputter-ion pump and observe the results on the “Voltage” scale of the control
unit. If the voltage falls, indicating a rising current (rising pressure), reopen the roughing valve. If the
voltage increases or remains the same, leave the roughing valve closed.

NOTE: with a sputter-ion pump, a modest rise in pressure is normal during the initial starting
phase. This is caused by heating of the pump components by the dissipated power and normally
precedes operation in the normal mode. Some heating during starting is beneficial because it causes
out-gassing of components which will not have to take place during later stages of the system pump
down. Excessive heating due to prolonged high pressure operation or a mismatched control unit can
damage a pump. Operation in the start mode should always be monitored.

The electrical discharge in a sputter-ion pump gives off a blue/purple glow due to the electron-
gas ionization process taking place. At starting pressures, above 10-4 torr, the discharge occurs
throughout the pump; in some cases it can extend into the system itself. If the presence of this
discharge in the system is a problem, a stainless steel, electrically grounded screen can be placed
across the mouth of the pump. As the sputter-ion pump starts, the discharge confines itself to the area
within the pump elements, and gradually becomes fainter as the pressure, and thus the rate of
ionization, falls.

16
7. Operation/Protection

After the sputter-ion pump starts, as indicated by the voltage rising toward the open-circuit
rating and current falling to below about 25% of the rated value on the control unit meter, normal
operation can commence.

In normal operation, the roughing pump valve is closed and the “Start/Protect” switch on the
control unit is placed in the “Protect” position. The pump is now protected against a pressure rise
above approximately 0.5 mTorr while unattended. Should such a pressure rise occur due to a leak or
other failure, the control unit will automatically turn off after a brief delay. This protects both the
pump and control unit against excessive current and heat conditions.

During normal operation, pump current is proportional to pressure over a wide operating range.
This is illustrated in the typical (Varian 8-60 l/s diodes) current vs. pressure curve shown below in
Figure 2. By knowing the current and using the correct curve for that pump and control unit, the
pressure can be calculated. In addition, most control units have a “Pressure” scale, which is a
logarithmic scale from below 10-9 torr to above 10-4 torr. Also, a recorder and control signal, with a
range from 0 to 100 mV, is normally available for monitoring the pump pressure.

17
 IPC-0066 Diode Power/Voltage vs. Current

8000 1400

7000 1200
Power
6000
1000
5000
Voltage 800
Voltage
4000
Power
600
3000
400
2000

1000 200

0 0
0 0.1 0.2 0.3 0.4 0.5
Current - Amps

Figure 1 - Typical Sputter-Ion Control Unit Voltage and Power vs. Current

Figure 2 - Typical Sputter-Ion Pump Current vs. Pressure

(Varian 8-60 liter per second diodes)

18
 DUNIWAY STOCKROOM CORP. 800-446-8811/650-969-8811 info@duniway.com
'Perkin Elmer/Ultek Ion Pump Control Units 1961-1992

Item Pump Speed Model Output Output H.V. Input Input Mounting Mounting Ship** Orig.
# liters/sec Number Volts* MA Cable Volts Hz Height Width Weight Year Description
1 Appendage 60-013 2900 3 yes 115 60 cabinet 13 1961 linear meter
2 Appendage 222-0330 4750 10 no 115 60 cabinet 15 1972
3 Appendage 222-0370 4750 10 no 115 60 5" 19" 15 1972
4 Appendage 222-0380 4750 10 yes 220 50 5" 19" 15 1972
5 Appendage 222-0350 4750 10 yes 220 50 cabinet 15 1972
6 Ionpak 200 222-0200 5500 2.5 yes 120 60/50 small box 5 1984
7 5-9 60-056 3200 150 yes 115 60/50 cabinet 37 1961
8 5-11-20-25 60-062 4750 150 yes 115 60 5.25" 19" 37 1964
9 5-11-20-25 222-0400 4750 150 yes 115 60 5.25" 19" 37 1968
10 5-11-20-25 222-0451 4750 150 yes 220 50 5.25" 19" 37 1968
11 5-11-20-25 222-0410 4750 150 yes 115 60 5.25" 19" 37 1972
12 5-11-20-25 222-0460 4750 150 yes 220 50 5.25" 19" 37 1972
13 1-5-11 222-0360 +/- 5500 60 yes 117/208/230 60 5.25" 38 1977 low power
14 20-25-60-80 222-0360 +/- 5500 100 yes 117/208/230 60 5.25" 38 high power
15 1-5-11 222-0365 +/- 5500 60 yes 100/200/220 50 5.25" 38 1977 low power
16 20-80 222-0365 +/- 5500 100 yes 100/200/220 50 5.25" 38 high power
17 40 60-103 3200 350 yes 115 60 cabinet 80 1961
18 50 60-104 4750 350 yes 115 60 8.75" 19" 70 1966
19 50 60-105 4750 350 yes 115 60 8.75" 19" 70 1967
20 50 222-0510 4750 350 yes 115 60 8.75" 19" 70 1972
21 50 222-0560 4750 350 yes 200 50 8.75" 19" 70 1972
22 60-150 222-0520 5500 350 yes 115 60 8.75" 19" 60 1974
7000 60
23 80-220 222-0530 +/- 5500 250 yes 115/208/230 60 6.5" 19" 70 1977
24 80-220 222-0580 +/- 5500 250 yes 200/220 50 6.5" 19" 70 1977
25 25-270 Digitel 500 +/- 5500 220 yes 110/220 6050 5.25" 19" 49 1982 microprocessor
26 Boostivac 60-650 4750 350 yes 115 60 10" 19" 125 1963 6.5 volts - 50 amps
27 Boostivac 60-655 4750 350 yes 115 60 10" 19" 125 1964 6.5 volts - 50 amps
28 Boostivac 224-0620 4750 350 yes 115 60 10" 19" 125 1974 8.0 volts - 55 amps
29 Boostivac 224-0650 4750 350 yes 208/230 50 10" 19" 125 1974 8.0 volts - 55 amps
30 Boostivac 224-0630 +/- 5500 250 no 117 60 7" 19" 125 1977 8.0 volts - 62 amps
31 Boostivac 224-0635 +/- 5500 250 no 220 50 7" 19" 125 1977 8.0 volts - 62 amps
32 90-450 60-153 3200 1000 no 110 60 cabinet 140 1961
33 100-1200 60-154 4750 1000 no 208/230 60 8.75" 19" 148 1963
34 100-1200 60-154-01 4750 1000 no 208/230 60 8.75" 19" 148 1964 with meter relay
35 100-1200 60-160 4750 1000 no 208/230 60 8.75" 19" 130 1967
36 100-1200 60-160-01 4750 1000 no 208/230 60 8.75" 19" 130 1967 with meter relay
37 100-600 222-0600 4750 1000 no 208/230 60 8.75" 19" 131 1972
38 100-600 222-0650 4750 1000 no 208/230 50 8.75" 19" 131 1972
39 120-500 222-0630 +/- 5500 720 no 208/230 60 6.5" 19" 130 1977
+/- 7000 600 60
40 120-500 222-0680 +/- 5500 720 no 200/230 50 6.5" 19" 130 1977
+/- 7000 600 50

*Output Volts - Positive unless labelled otherwise **Ship Weight in Pounds

H.V. Cable - Yes means included, hardwired in place; No means not included, demountable, order separately.
PE/Ultek Ion Pumps can be operated on Varian Ion Pump Control Units.
Call for information on operating multiple ion pumps from a single control unit.

Call Duniway Stockroom for help in BUYING, SELLING & REPAIRING:

Ion Pumps and Control Units from all Manufacturers

19
DUNIWAY STOCKROOM CORP. 800-446-8811/650-969-8811 info@duniway.com

Varian Ion Pump Control Units 1961-1992

Item Pump Speed Model Output Output H.V. Input Input Mounting Mounting Ship** Orig.
# liters/sec Number Volts* MA Cable Volts Hz Height Width Weight Year Description
1 Appendage 921-0006 3200 40 yes 115/230 60 cabinet 20 1961
2 Appendage 921-0015 3200 40 no 115/230 60/50 cabinet 20 1963
3 Appendage 921-0014 3200 40+40 no 115/230 60/50 7" 19" 50 1963 Multiple Pump
4 8 or 10 921-0011 3200 150 yes 115/230 60/50 7" 19" 52 1961
5 Leak Det. 975-0000 3200 150 yes 115/230 60 10 1/2" 19" 60 1962
6 15 921-0013 7200 70 yes 115/230 60/50 10 1/2" 19" 53 1963
7 40-50 921-0012 3750 425 yes 115/230 60 10 1/2" 19" 65 1960
8 75-80 921-0007 7200 190 yes 115/230 60 10 1/2" 19" 97 1960
9 75-80 921-0027 7200 190 yes 115/230 50 10 1/2" 19" 97 1960
10 140 921-0004 7200 235 yes 115/230 60 10 1/2" 19" 97 1960
11 140 921-0024 7200 235 yes 115/230 50 10 1/2" 19" 97 1960
12 280 921-0008 3200 900 yes 115/230 60 10 1/2" 19" 112 1960
13 280 921-0028 3200 900 yes 115/230 50 10 1/2" 19" 112 1960
14 400-500 921-0005 7200 750 yes 208/230 60 10 1/2" 19" 135 1961
15 400-500 921-0025 7200 750 yes 208/230 50 10 1/2" 19" 135 1961
16 11(Hi-Q) 921-0018 7200 750 yes 208/230 60 10 1/2" 19" 135 1961
17 1000 921-0000 7200 1900 yes 230/280 60 525 1961
18 140 921-0034 7200 300 yes 115/230 60/50 10 1/2" 19" 90 1966
19 270 921-0036 7200 600 yes 115/230 60 10 1/2" 19" 100 1966
20 270 921-0035 7200 600 yes 115/230 50 10 1/2" 19" 100 1966
21 500 921-0038 7200 1250 yes 208/230 60 10 1/2" 19" 125 1966
22 500 921-0037 7200 1250 yes 208/230 50 10 1/2" 19" 125 1966
23 1000 921-0040 7200 1800 yes 208/230 60 10 1/2" 19" 160 1966
24 1000 921-0039 7200 1800 yes 208/230 50 10 1/2" 19" 160 1966
25 110 921-0041 -5200 400 yes 115/208/230 60 10 1/2" 19" 90 1966
26 110 921-0041 -5200 480 yes 115/208/230 50 10 1/2" 19" 90 1966
27 220 921-0043 -5200 800 yes 115/208/230 60 10 1/2" 19" 100 1966
28 220 921-0042 -5200 800 yes 230 50 10 1/2" 19" 100 1966
29 400 921-0045 -5200 1600 yes 208/230 60 10 1/2" 19" 125 1966
30 400 921-0044 -5200 1600 yes 208/230 50 10 1/2" 19" 125 1966
31 8 921-0062 3300 120 no 120/240 60 7" 8.31" 40 1970
20,30 -5200 200 no 120/240 60
60 3300 100 no 120/240 50
-5200 167 no 120/240 50
32 110, 140 921-0066 7500 465 no 208/240 60 7" 19" 80 1970
220, 270 -5200 670 no 208/240 60
400, 500 7500 560 no 208/240 50
-5200 800 no 208/240 50

*Output Volts - Positive unless labelled otherwise **Ship Weight in Pounds

H.V. Cable - Yes means included, hardwired in place; No means not included, demountable, order separately.
Varian Ion Pumps can be operated on PE/Ultek Control Units.
Call for information on operating multiple ion pumps from a single control unit.

Call Duniway Stockroom for help in BUYING, SELLING & REPAIRING:

Ion Pumps and Control Units from all Manufacturers

20
DUNIWAY STOCKROOM CORP. 1800-446-8811/650-969-8811 info@duniway.com
Addendum: Ion Pump Control Units 1992-1997 (rev. 7/97)
Speed Model Notes Output H.V. Input Mounting (in.) Weight Orig. 1996
l/s Number Volts Ma. Cable Volts Hz. Height Width # Year Status
VARIAN
2,8 921-2001 VacIon Pump Control 3.5kv 1.6 no 115/220 50/60 3.8 3.8 6 1988 current
30,45,60 929-0080 Starcell -7kv 200 no 120 60 48 1986 obsolete
20 929-0081 Starcell -7kv 90 no 120 60 48 1986 obsolete
30-60 929-0170 Starcell -7kv 170 220/240 50 7 8.3 64 1988 obsolete
20 929-0171 Starcell -7kv 80 220/240 50 7 8.3 64 1988 obsolete
120-400 929-0172 Starcell -7kv 300 22/240 50 7 19 88 1988 obsolete
30-60 929-0180 Starcell -7kv 200 100/120 60 7 8.3 64 1988 obsolete
20 929-0181 Starcell -7kv 95 100/120 60 7 8.3 64 1988 obsolete
120-400 929-0182 Starcell -7kv 240 208 60 7 19 88 1988 obsolete
8-400 929-8000 µ8000- w. displ +/- 3 to 7.5kv 800 no 110 & 220 50/60 7 8.3 28 1991 obsolete
8-400 929-8100 µ8000- no displ +/- 3 to 7.5kv 800 no 110 & 220 50/60 7 8.3 28 1991 obsolete
2,8 929-0190 MiniVac +/- 5kv 15 no 120 47-63 4.2 5.1 5 1995 current
all 929-0191 MiniVac +/- 5kv 15 no 120 47-63 4.2 5.1 5 1995 current
all 929-0196 MiniVac +/- 5kv 15 no 24 47-63 4.2 5.1 5 1995 current
2, 8 929-0197 MiniVac +/- 5kv 15 no 24 47-63 4.2 5.1 5 1995 current
all 929-0290 MiniVac +/- 5kv 15 no 220 47-63 4.2 5.1 5 1995 current
2,8 929-0291 MiniVac +/- 5kv 15 no 220 47-63 4.2 5.1 5 1995 current
Base Unit 929-400X Multivac Base na na no 180-265 47-63 7 8.3 8 1995 obsolete
Base Unit 929-401X Multivac Base na na no 90-130 47-63 7 8.3 8 1995 obsolete
20-75 929-40X5 HV Cards +/- 3, 5, 7kv 250 no na na na na 7 1995 obsolete
20-500 929-40X0 HV Cards +/-1 to 7kv 10-400 no na na na na 7 1995 obsolete
20-60 929-5000 MidiVac X1 Neg neg 3, 5, 7kv 100 no 90-130 47-63 7 8.3 10 1997 current
20-60 929-5001 MidiVac X1 Pos pos 3, 5, 7kv 100 no 90-130 47-63 7 8.3 10 1997 current
20-60 929-5002 MidiVac X1 Neg neg 3, 5, 7kv 100 no 180-265 47-63 7 8.3 10 1997 current
20-60 929-5003 MidiVac X1 Pos pos 3, 5, 7kv 100 no 180-265 47-63 7 8.3 10 1997 current
20-60 929-5004 MidiVac X2 Neg X2 neg 3, 5, 7kv 100 no 90-130 47-63 7 8.3 10 1997 current
20-60 929-5005 MidiVac X2 Pos X2 pos 3, 5, 7kv 100 no 90-130 47-63 7 8.3 10 1997 current
20-60 929-5006 MidiVac X2 Neg X2 neg 3, 5, 7kv 100 no 180-265 47-63 7 8.3 10 1997 current
20-60 929-5007 MidiVac X2 Pos X2 pos 3, 5, 7kv 100 no 180-265 47-63 7 8.3 10 1997 current
20-500 929-6000 Multivac X1 Neg neg 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 15 1997 current
20-500 929-6001 Multivac X2 Neg X2 neg 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 22 1997 current
20-500 929-6002 Multivac X1 Neg Dig neg 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 15 1997 current
20-500 929-6003 Multivac X2 Neg Dig X2 neg 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 22 1997 current
20-500 929-6004 Multivac X1 Pos pos 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 15 1997 current
20-500 929-6005 Multivac X2 Pos X2 pos 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 22 1997 current
20-500 929-6006 Multivac X1 Pos Dig pos 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 15 1997 current
20-500 929-6007 Multivac X2 Pos Dig X2 pos 3, 5, 7kv 10-400 no 90-130 47-63 5.75 7.9 22 1997 current
20-500 929-6008 Multivac X1 Neg neg 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 15 1997 current
20-500 929-6009 Multivac X2 Neg X2 neg 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 22 1997 current
20-500 929-6010 Multivac X1 Neg Dig neg 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 15 1997 current
20-500 929-6011 Multivac X2 Neg Dig X2 neg 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 22 1997 current
20-500 929-6012 Multivac X1 Pos pos 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 15 1997 current
20-500 929-6013 Multivac X2 Pos X2 pos 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 22 1997 current
20-500 929-6014 Multivac X1 Pos Dig pos 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 15 1997 current
20-500 929-6015 Multivac X2 Pos Dig X2 pos 3, 5, 7kv 10-400 no 180-265 47-63 5.75 7.9 22 1997 current

PERKIN ELMER
2-80 2220240 IONPAK plus 5.6KV 8.6 direct 110/230 50/60 3.1 7.2 10 1984 current
2-80 2220242 IONPAK plus 5.6KV 8.6 yes 110/230 50/60 3.1 7.2 10 1984 current
2-80 2220245 IONPAK minus 5.6KV 8.6 yes 110/230 50/60 3.1 7.2 10 1984 current
2-80 2220272 DIGI-PAK plus 5.6KV 8.6 no 110/230 50/60 3.25 6 10 1984 current
2-80 2220275 DIGI-PAK minus 5.6KV 8.6 no 110/230 50/60 3.25 6 10 1984 current
25-270 2220400 DIGITEL +/- 5.5kv 250 no 110/230 48-62 5.75 19 44 1982 obsolete
120-700 2221500 DIGITEL +/- 5.5kv/7kv 750 no 230 48-62 7 19 105 1982 obsolete
8-80 635941 DIGITEL-MPC +/- 5.6kv & 7kv 100 no 115/230 50/60 5.25 19 36 1997 current
120-500 635942 DIGITEL-MPC +/- 5.6kv & 7kv 500 no 115/230 50/60 5.25 19 37 1997 current
8-80 635943 DIGITEL-MPC +/- 5.6kv & 7kv 2X100 no 115/230 50/60 5.25 19 56 1997 current
120-500 635944 DIGITEL-MPC +/- 5.6kv & 7kv 2X500 no 115/230 50/60 5.25 19 57 1997 current
8-500 635945 DIGITEL-MPC +/- 5.6kv & 7kv 100+500 no 115/230 50/60 5.25 19 56 1997 current
120-500 635946 DIGITEL-MPC +/- 5.6kv & 7kv 2X500 no 115/230 50/60 5.25 19 57 1997 current

21
Ion Pump Control Units -- 2010 Catalogs

Agilent (Varian) Typical

MODEL MAX
NAME # HV pos/neg SS CURRENT POWER
MiniVac 929-200 5KV 15 mA 21 W
Dual 929-000 3-7KV 100-400mA 100-400W
MidVac 929-000 3,5,7KV 100mA 150W

Gamma (PE) Digitel SPC 3.5-7.0KV 15mA 20w

Digitel LPC 500 5.6 OR 7.0KV 250mA 500W
1500 5.6 OR 7.0KV 720mA 1500W
1X 100 or
Digitel MPC -1 5.6 OR 7.0KV 500mA 500W
2X 100 or
-2 5.6 OR 7.0KV 500mA 1000W Total

Duniway Terranova 751A 3.5-7.0KV 50mA 50W

Terranova 752A 2x 3.5-7.0KV 50mA Total 50W Total
Classic VA 921-
Style 0062 3.3KV(+) or 5.2KV(-) 200mA 250W
Classic VA 921-
Style 0066 3.3KV(+) or 5.2KV(-) 675mA 700W

22
 Appendix III: Magnet Orientation in Sputter-Ion Pumps

Introduction:

For an ion pump to operate properly, it must have a magnetic field which meets or exceeds a
minimum value and which is precisely oriented parallel to the axis of the anode cells. The
magnetic field, in conjunction with the high voltage applied to the pump, causes the electrons
inside the anode cells to travel in curved orbits which are smaller in diameter than the anode
cells.

1. All magnets, including the Earth, have a North pole and a South pole. A simple
compass can be used to determine the polarity of a magnet segment, however,
readings should be made away from iron pole pieces.

2. Like poles (N-N or S-S) repel each other and unlike poles (N-S or S-N) attract each
other.

3. In an Ion Pump magnet array, the magnet sections must be arranged in a magnetic
circuit; that is N-S-N-S-N-S…etc., all the way around the pump.

23
4. The magnetic field should be between 1000-1800 gauss for most sputter-ion
pumps. Higher magnetic fields give somewhat higher pumping speed, especially at
low pressure. If the magnetic field is below 800 gauss, performance will be poor,
especially at pressures below 10-8 torr. See the manufacturer’s specifications for the
rated magnetic field.

For example, typical Varian style pumps with magnet gaps of approximately 2.5
inches utilize magnetic fields of 1200 gauss.

Typical PE/Ultek style pumps with magnet gaps of approximately 1.5 inches
utilize magnetic fields of 1800 gauss.

If the measured value is less than 80% of that specified, you will probably get
poor pumping results, especially at low pressures.

5. When assembling an Ion Pump magnet array, the magnets will tend to ‘pull’ into a
correct circuit configuration and ‘push’ out of an incorrect circuit configuration.

6. In Figure 1, (a cross section of a pump such as a Varian 110 or 140 l/s model), as
long as the individual blocks on the magnet assembly are installed correctly, the
orientation of the magnet assembly does not matter.

7. In Figure 2, (a cross section of a pump such as the Varian 60 l/s model), the circuit
must be completed exactly as shown. If one of the magnet assemblies is installed
backwards, the pump will operate with some reduction in speed, but the stray
magnetic field will be excessively high, and may interfere with sensitive experiments.

8. In Figure 3, (a cross section of a pump such as a Varian 400 or 500 l/s pump), the
most critical of the arrangements is illustrated. If one of the center magnet
segments is reversed, so that it doesn’t make a proper magnetic circuit, the
pumping speed of the pump will be reduced by nearly 50%. If the two outside
assemblies are reversed with respect to each other, the pump will operate with
some reduction in speed, but the stray magnetic field will be excessively high, and
may interfere with sensitive experiments.

24
 Cleaning and Rebuilding Sputter-Ion Pumps
Introduction:
Duniway Stockroom Corporation rebuilds sputter-ion pumps and pump elements from
all original manufacturers as a service to our customers. The process involves removal,
cleaning/replacement of all parts and vacuum processing of the rebuilt pump. All deposits
are removed, material is outgassed and electrical leakage is minimized. The rebuilt pumps
have the same performance and warrantee as new pumps. The following information
describes the process we use.

Open Pump & Remove Elements

For large pumps, generally above 50 l/s pumping speed, the elements can be easily
removed through the throat of the pump. For smaller pumps, the pump body must be cut
open to remove the elements. Some small pumps have been designed with weld flanges
that permit multiple rebuilding processes. For most small pumps, however, rebuilding is
limited to 1-3 times, depending on the design, due to material removed during the opening
process.

Disassemble the Element Completely

Anode, cathodes, insulators and support structures are separated and inspected to
verify condition. The parts are then cleaned, replaced or treated, depending on their material
and condition.

Stainless Steel Parts

Body, anode and other stainless steel parts are glass-bead blasted and acid etched. It
is important to use clean, glass beads (not sand blasting). The acid etching is performed by
a certified chemical cleaning shop, since the acid, a 35%nitric/3-4% hydrofluoric mix is
extremely aggressive. It can attack welds if improperly used and must be handled and
disposed of properly. After etching, the stainless steel parts are thoroughly rinsed and
protected until re-assembly.

Replace Titanium and Tantalum Parts

Titanium and tantalum cathodes are replaced with new material in most cases. There
are a few exceptions to this, but customers will be advised if these materials are re-used.

Ceramic Parts
For Perkin-Elmer/Ultek style pumps and elements, the ceramics are always replaced
with new ceramics.
For other style pumps, such as Varian, the ceramics are inspected for damage and
replaced if necessary, air fired to remove surface deposits, and then vacuum fired.

Vacuum Degas all Element Parts

Stainless steel and ceramics are vacuum degassed at 1000oC.
Titanium and tantalum parts are vacuum degassed at 700oC.
Vacuum degassing removes both remaining surface contaminants and gasses from
the bulk of the material.

25
Reassemble Elements
The clean parts are reassembled in a laminar flow bench, using clean assembly
techniques. Assembled elements are checked for electrical leakage and hi-potted if
necessary.

Install the Elements in the Clean Body

The clean elements are installed in the clean pump body. For small pumps, the body
is welded back together. For all pumps, the cover flange, with copper pinch-off tube is
installed. The pump is checked for leaks on a helium leak detector.

Bake-Out on Vacuum Manifold.

The copper pinch-off is attached to a vacuum manifold, and the pump is baked out at
400oC for 16 hours.

Check for leakage current

While still on the vacuum manifold, the pumps are checked for leakage current and hi-
potted if necessary

Pinch off
The copper tube is pinched off with the proper tools. Magnets are installed and the
appropriate high voltage is applied. Residual current is checked, it must be below 2
microamps at this point. It is typically below 0.5 microamps.

Clean Exterior
The exterior of the ion pump is glass bead blasted to remove the yellow-brown chrome
oxide formed during baking. This step is strictly cosmetic.

Check for Leakage Current

The pump is checked again for residual current; first without the magnets for electrical
leakage; then with magnets for residual pressure. Residual current is checked; it must be
below 2 microamps at this point. It is typically below 0.5 microamps. Attach inspection tag
noting serial number, date, residual current and inspector.

Ship
Properly package pump and/or magnets to avoid damage during shipment.

26
Notes:

Installing new/rebuilt elements in an old body

If new or rebuilt elements are installed in a used pump body without cleaning the pump
body, only about half the improvement in performance will be achieved.

Unsuccessful Attempts to Clean the Pump Yourself

If you attempt to clean the pump and are unhappy with the results, send it to us for
rebuilding. We do not charge extra for rebuilding pumps where the user has attempted
unsuccessfully to do the job themselves.

Experience and Attention to Detail

The cleaning process is not inherently difficult, however, it does involve proper
equipment, facilities and attention to detail. Duniway Stockroom Corp. performs these
processes many times every day, so they are easy for us. We use the best materials and our
chemical cleaning shop supplier is licensed for proper handling and disposal of hazardous
chemicals.

Contacting Duniway Stockroom Corporation

We have multiple ways set up to contact us. We will be glad to answer your questions
and help you with your ion pump or other vacuum related questions.

Toll Free Telephone: 800-446-8811

Telephone: 650-969-8811
FAX: 650-965-0764
E-mail: info@duniway.com
Internet: http://www.duniway.com
Duniway Stockroom Corp.

27