Tag Archives: heat exchanger

16-020/050 Heat Exchanger Shuts Off

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The X-ray sources used on the older Physical Electronics (PHI) XPS systems use a heat exchanger which circulates air-cooled water to keep the X-ray source from overheating. 

If your 16-020 or 16-050 heat exchanger shuts down there are only a few things that can cause that issue.  This blog post will explain how to isolate the problem.

The 32-095/96 X-ray source control has two interlocks that will shut down the heat exchanger. The first is a vacuum interlock that connects from J2 interlock on the back of the 32-095/6 to setpoint 3 in the DGCIII ion gauge. That set point is typically set to 5 X 10-7 Torr.   To bypass the vacuum setpoint, turn off the 32-095/6 main power and remove the J2 cable on the back of the 32-095/6, then short out pin A to B on the connector (not the cable) with a small paper clip.   Note that with the vacuum interlock cable bypassed there is no protection for the x-ray source if the vacuum pressure gets too high (as in if the system vents).

If the 16-020/050 heat exchanger no longer shuts down then the issue is related to setpoint 3 on the DGCIII. It could be that the J2 cable is loose or that the setpoint relay in the DGCIII is dirty. Here is a blog post on how to clean the relays – https://www.rbdinstruments.com/blog/dgc-iii-digital-ion-gauge-control/

The second 32-095/96 interlock is the flow switch.   If the water flow is insufficient then the flow switch will turn off the 16-020/050 heat exchanger. It could be that the actual flow is low, or it could be that the flow switch is defective.  If your heat exchanger has a flow meter then you can see what the flow is. If you have an 04-548 source then the flow rate should be about 1.7 GPM (gallons per minute).  If your system has a 10-560 source then the flow rate should be about .9 to 1 GPM.  If you do not have a flow meter, then you need to remove the X-ray source lines from the source and run the water into a clean container (so that you can reuse the water) for a total time of 1 minute.  With the water lines disconnected from the X-ray source the heat exchanger will shut off after 9 seconds. You need to turn the 32-095/6 off and then back on to get the water flowing again.  One you have 1 minutes’ worth of water, measure it and then you will know the GPM.  Then put the water back into the heat exchanger.

If the GPM is low, then you may have some obstruction, or the deionizer cartridge or particle filter may need to be replaced (RBD Instruments provides them). If the water lines are green or black, they should be replaced. Here is a blog post that explains how to do that – https://www.rbdinstruments.com/blog/replacing-the-water-lines-in-a-16-050-heat-exchanger/

If the GPM is correct, then you can bypass the flow switch by turning off the 32-095/6 and shorting pins A to E on the Pump Control connector (not the cable).  You also need to move the Pump power cord on the back of the 16-020 to the HV power receptacle and then the pump will turn on when the circuit breaker in the back of the 16-020 is turned ON.   Remember that there would be no protection for the source if a water flow issue develops while the flow switch is bypassed.   If the heat exchanger does not shut with the flow switch bypassed then the issue is related to the flow switch.  It may need to be adjusted, or it may be defective.

To adjust the flow switch setpoint, turn the small, slotted screw that is inside the hole in the black housing 2 turns CW.  Then see if the heat exchanger stays on.  If not, try 4 turns in the other direction.  If the heat exchanger still turns off, then the flow switch is bad.

RBD Instruments provides a flow switch and a power converter. The original flow switch was powered by 120 or 220 VAC, the new ones are 24V DC.

To order a flow switch kit that includes the power converter contact us here –

https://rbdinstruments.com/phi/optics-parts.html

Here is a link to a procedure on how to replace the flow switch – https://www.rbdinstruments.com/blog/tag/replace-flow-switch/

16-020 heat exchanger 12″ deionizer cartridge issue

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The 16-020 heat exchangers are used with the older Physical Electronics (PHI) 5100 through 5400 X-ray photo-electron spectrometer (XPS) systems.The 16-020 has a built-in deionizer cartridge (and a particle filter) which keeps the water in the closed loop system clean and it also keeps the resistance of the water high. 

The original deionizer cartridges were blue and had a recess in the bottom of the filter that matched up with a plastic guide on the bottom of the Millipore housing.  Those blue deionizer cartridges are no longer available. The new replacement deionizer cartridges do not have a recess on the bottom.

When a new deionizer cartridge is used with the original Millipore housing the plastic guide on the bottom of the housing will push up on the bottom of the deionizer.  This makes it difficult if not impossible to fully screw on the housing.  It also puts pressure on the bottom of the deionizer cartridge which can rupture the bottom of the deionizer and cause the media particles to leak out, potentially causing an issue with the water flow and or damage the pump and lead to a catastrophic anode melt down. There are two ways to solve this fit issue. One is to cut and grind out the top part of the guide on the original Millipore housing. To do that you need to remove the plug on the bottom of the housing and then use a drill or cutting wheel that is mounted on a drill extension. The pictures below show a housing before and after modification.

 

The other option is to replace the original Millipore housing with new housing that correctly fits the new deionizer cartridge. But if you replace the housing you will also need to replace the manifold as the new manifold will not fit into the original Millipore manifold.

RBD Instruments provides both deionizer cartridges and housings. If you have the original Millipore housing on your 12” deionizer cartridge then I recommend that you inspect it to see whether the guide on the bottom has been cut down or not.  If not, you should cut it down or replace the housing.  

If the deionizer is ruptured then the entire cooling system (reservoir, pump, water lines and source) needs to be inspected and flushed out.This problem is an issue only with the 12″ deionizer cartridge on the 16-020 heat exchangers. 

The 16-050 heat exchanger that is used on the 5600 and up XPS systems has a 10″ deionizer cartridge.

Not sure if you need to replace your deionizer cartridge?  Just run up the high voltage on your X-ray source to 15kV but do not set an power to the X-ray source.   Observe the emission current reading on the HV supply.  If the deionizer is good the reading will be 1-2 mA.  Once the leakage current gets up to 3-4 mA at 15kV you should plan on replacing the deionizer cartridge and particle filter soon.  If the leakage current at 15kV is 5 mA or higher you should replace the deionizer and particle filter and also flush out the water with new distilled water from a grocery store.  Lab distilled water does not always work but grocery store distilled water works every time.

Contact RBD Instruments to order the deionizer and particle filter.

16-050 Heat Exchanger Flow Switch replacement procedure.

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The original flow switch for the 16-050 heat exchanger used 220 VAC for the input power.

About 10 years ago that flow switch was discontinued and was replaced with a similar model that used 120 VAC for the input power.  A 220 VAC to 120 VAC step down transformer was also needed.

Very recently, the 120 VAC input power flow switch was discontinued, and it has been replaced by another version that uses 24 VDC as the input power.  To provide 24V DC to the replacement flow switch a small 220VAC to 24 V DC power supply is needed.

This blog post will provide step by step instructions on how to install the new 24V DC flow switch and power supply into a 16-050 heat exchanger.

Step one is to drain the water from the heat exchanger.  The easiest way to do that is to remove the IN and OUT couplers from the X-ray source and then connect those to the IN and OUT lines. Mark the IN and OUT water lines to make sure that you do not get them mixed up.  Hold them over a clean container (such as a plastic waste basket) and then turn on the 32-095 or 32-096 X-ray source control. 

The 16-050 will turn on and water will come out of the source IN line.  After about 9 seconds the 32-095/96 will shut down the 16-050 heat exchanger due to insufficient flow.  Turn the 32-095/96 OFF for a few seconds, then back ON.  Repeat several times (it might take 10 to 15 times) until water stops coming out of the source IN line and the pump starts to make noise.  This will drain most of the water out of the 16-050.  You want to use a clean container for the water so that you can reuse the water.  Or you can replace the water after the flow switch has been replaced with distilled water from a grocery store.  Lab DI water does not always work.

After the water has been drained, turn the 16-050 heat exchanger front panel power switch to OFF.

Next, trace the power cord that is on the back of the 16-050 into the electronics console and unplug the power cord.  Make a note of where that power cord plugs into so that you can plug it into the same receptacle later.

Turn the 16-050 front panel power switch to ON just to make sure that the 16-050 power cord is unplugged.  Verify that the 16-050 motor does not turn on and then turn the 16-050 heat exchanger front panel power switch back to OFF. Do not work on the 16-050 if it is still plugged in!

Remove the top cover on the 16-050.

Remove the small cover that is located just behind the 16-050 power switch.  There are 4 nuts that need to be removed then the cover comes off.

Remove the wires that go to the flow switch.  Those will be TB1 sections 1, 2, 5 and 7.

Remove the old flow switch.  Use your phone to take pictures of where the IN and OUT lines connect on the flow switch.

Install the new flow switch making sure that it is connected EXACTLY the way that the old flow switch was.

Route the new flow switch wires up to where the old flow switch wires were.

The wires need to be connected as follows:

RAVCV04-24 power supply:

Blue to TB1 7

Brown to TB1 5

Red to Flow Switch Brown

Black to Flow Switch White

Flow Switch:

White to RACV04-24 Black (use twist nut)

Brown to RACV04-24 Red (use twist nut)

Red to TB1 2

Black to TB1 1

Green – Not used.

This drawing shows the connections –

Verify that the wires are all tight and then replace the little cover using the 4 nuts.

Reconnect the couplers and water lines to the X-ray source.  Make sure that you have the IN and Out going to the correct ports on the X-ray source.

Pour most of the water back into the reservoir or use 2-3 gallons of distilled water from a grocery store.

Plug the 16-050 power cord back in and then turn on the 16-050 front panel power switch.

Turn on the 32-095/96 and the 16-050 motor should turn on.  It will turn off after 9 seconds.  Turn the 32-095/06 off and then back on to reset the pump.  Do this a few times until the air bubbles work themselves out and the 16-050 pump motor stays on. 

You will need to top off the water reservoir once the water fills up the lines.  Do not overfill!

If the 16-050 will not stay on even when the water is full (close to the upper line on the water level indicator on the back of the 16-050) then the flow switch may need to be adjusted.

The flow switch adjustment potentiometer is on the back of the flow switch under a label. It is a small, slotted screw.

Try turning the flow switch a few turns CW and then turn on the 32-095/96.  If that does not work, try a few turns CCW plus a few more turns.  Once you get it to where the 16-050 pump stays ON then you can slowly turn the potentiometer the opposite direction until the red interlock light on the 32-095/96 turns ON, then adjust the potentiometer 1.5 turns the other direction until the red interlock light just turns off. The idea is that you want to set the potentiometer so that the 16-050 pump is ON when you have water flow, but you want to be somewhat close to the edge so that the 16-050 pump will shut off when the flow drops. 

Typical flow rates are 1.1 GPM for XPS systems with a 10-610 mono-chromator source and up to 1.8 GM for systems that have only a single 04-548 dual anode X-ray source.

The RBD Instruments Part number for the kit that includes the 24V flow switch and the power supply is FLOW-SWITCH-24-Kit.

For more information please contact RBD Instruments here – https://rbdinstruments.com/contact.html