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VMD900DL Instruction Manual Page 2

VMD900DL

Vacuum Metal Deposition System

For Latent Fingerprint Development

Operating Instructions

VMD900DL Instruction Manual Page 3

Contents

1. Health & Safety Notices

2. Description

3. Technical Data

4. Services Required

5. Installation.

6. Layout of Components

7. Operation

8. Recommended Servicing Requirements

9. Recommended Spares List

VMD900DL Instruction Manual Page 4

1. Health & Safety Notices

WARNING!

 Please read these instructions and all the associated manufacturers instruction

manuals before attempting to use this equipment

 This system operates automatically. System vacuum pumps and valves can operate

without warning.

 Caution should be used if disconnecting the compressed air supply pipework

 Isolate the system from the electrical mains supply before attempting any

maintenance

 Caution should be used when operating this system

 Operators should fully familiarise themselves with all relevant Operating and

Health & Safety procedures before attempting to use this system

 Please carefully read this manual before attempting to carry out any cleaning or

maintenance on this system.

 Always where the recommended PPE when carrying our cleaning or maintenance

on this system

VMD900DL Instruction Manual Page 5

2. Description

The VMD900DL Vacuum Metal Deposition System is designed to be used for the Vacuum

Metal Deposition fingerprint detection technique.

The system is designed to be used primarily for the coating of flexible packaging plastic,

such as polythene bags and sacks, although provision is also made to coat articles made of

solid plastic, glass, firearms and many other non‐porous samples.

The process will be carried out in accordance with procedures developed by the Centre for

Applied Sciences and Technology (CAST) and documented in the Fingermark Visualisation

Manual 2014.

General

This system is designed in accordance with all British standards and is manufactured using

new CE marked components.

The system is suitable for use by staff in an operational Police or Forensic laboratory with

the minimum of training and will require the minimum of maintenance.

Components, controls and design is such as to minimise hazards to the health and safety of

the operator and other personnel.

The system has been designed to give rapid pump down times, ease of evaporation and air

admittance such that cycle times are minimised.

Chamber

The system is capable of coating the surface of flexible polythene sheet material up to 800

mm x 1214 mm, in one evaporation, without the substrate overhanging the work holder jig.

The chamber is a horizontal cylinder, with an internal diameter of 770 mm and an internal

useable depth of approximately 900 mm.

A simple method for the loading and unloading the chamber with samples is provided (see

work holder specification below).

The chamber is fitted with one 200 mm diameter clear aperture window for easy viewing of

the sample surfaces to be coated. This window provides a clear view diagonally upwards to

the surface being coated.

VMD900DL Instruction Manual Page 6

The chamber has been design so that an operator of average height can readily look through

the viewing port and view the upper interior surface of the chamber.

Four low voltage LED lamps (a minimum of 20 watts each) are provided, two either side of

the filament bar, at positions of approximately one third, and two thirds along the filament

bar assembly. These lamps can be easily replaced by the operator.

The design of the lamp holder is such as to shield the viewer from the direct glare of the

filament, but to maximise illumination of the sample surfaces being coated. The lights can

be turned on and off during proccessing of the specimen and the development of the marks

These lamps can be easily replaced by the operator.

A metal grid is fitted into the mouth of the pumping port to prevent material, such as

polythene sheeting, from being sucked down into the pumps , and to prevent potential

damage to the high vacuum valve.

Work Holder

A simple method of loading the articles to be treated is provided.

A 750 mm diameter semi‐cylindrical workholder is fitted (approximately 25 mm less that the

internal radius of the chamber, and 50 mm shorter than the useable internal length of the

chamber). Thin polythene sheeting can be attached to it securely by means of small 10 mm

diameter x 10 mm long high power Bromag magnets.

The workholder is a magnetic grade of stainless steel. It is resistant to cleaning with weak

alkalis or acids.

The workholder is mounted on a system of support slides so that it may be withdrawn fully

from the chamber, locked in the withdrawn position at positions of 45, 90 and 180 degrees.

The workholder is designed so as to eliminate the possibility of independent movement of

the two support slides and the locking systems for the work holder withdrawal and rotation

are quick reliable and safe in operation.

The design incorporates both friction stops and mechanical stops for maximum operator

safety.

Please Note: Care should always be taken when rotating the work holder system and the

operator should ensure that out of balance loads are not fitted to the work holder.

VMD900DL Instruction Manual Page 7

The work holder also has three parallel lines of small holes of 3 to 5 mm diameter above the

filament bars so that bulky exhibits may be attached to the work holder for processing.

Special Considerations

The system is capable of handling typical amounts of water vapour and other contaminants,

such as hydrocarbon oils and organic compounds generated from the samples. It can also

handle the other significant source of contamination caused by the zinc evaporation.

Please Note: A dust mask, gloves and safety glasses should be used when cleaning chamber

furniture.

Pumping System

The pumping group that has been supplied is well proven in this application and is

exceptionally robust and reliable with high pumping speed/performance and is highly

tolerant to the contaminants found in this process.

The roughing pumps consist of an Edwards E2M80 (rotary pump)/Edwards EH500

(mechanical booster) combination that has a pumping speed of approximately 80m3hr‐1 at

atmospheric pressure, and 400 m3hr‐1 at 10‐1 mbar. The E2M80 rotary pump is fitted with a

MF100 oil mist filter to ensure a minimum discharge of oil mist via the pump exhaust.

ISO100 backing/roughing pipework is used to ensure optimum pumping speed at the

chamber without significant loss due to conductance limitations.

A Varian VHS‐10 water cooled diffusion pump (5300 ls‐1) is supplied, and is fitted with a

pneumatically operated high vacuum gate valve. The effective pumping speed at the

chamber is 3750 l s‐1. The diffusion pump is filled with a charge of Silicone 704 fluid.

The diffusion pump will tolerate inlet cooling water temperatures of up to 250C, and is fitted

with a thermal snap switch and water flow switch that is interfaced to the PLC control

system for alarm purposes and to provide an automatic fail‐safe condition.

Pumping Performance and System Specification

The Edwards E2M80 (rotary pump)/Edwards EH500 (mechanical booster) combination with

the Varian VHS‐10 high throughput diffusion pump, ensures that very fast pump down times

are achieved.

Without the Polycold cold finger running an empty, dry chamber evacuation time to process

pressures for Gold or Silver ( 1x10‐5 mbar) is typically 6‐7 minutes.

VMD900DL Instruction Manual Page 8

Under normal working parameters, with a trained operator, it is possible to complete a

process in less than 12 minutes.

Filament Support and Power Supply

The evaporation filaments are dispersed along a line running from front to back of the

chamber approximately 100 mm from the bottom of the chamber.

The location of filaments with respect to the surface being coated is such as to create, as far

as possible, a uniform coating of the surface during the evaporation of gold and zinc.

There are three independently selectable sets of evaporation sources.

The filament bars are designed so that there can be flexibility in the location of particular

sources.

Sources are mounted at approximately 1/4, 1/2, and 3/4 distance along the length of the

chamber.

The filament clamp fixings to the source bus bars has been designed so that changing the

filament cannot result in accidental misalignment of the mounting.

The filament bar assembly is designed for straightforward removal and dismantling to

enable cleaning, and is of a robust construction. The insulator design minimises the

potential problems of 'bridging' by zinc deposits.

The power supply and control system is ideally suitable for raising the temperature of a pair

of filaments for gold evaporation to white heat and two boats used for zinc to red heat in a

controlled manner.

Instrumentation and Control System

The control system is straight forward to use and all regularly used controls are readily

accessible from the operators position in front of the chamber whilst observation is made

through the chamber view port .

The Mitsubushi FX series programmable logic controller (PLC) and E1101 touch panel alpha

numeric display (HMI). The control system provides a simple semi‐automatic operation of

the vacuum system.

The PLC controls the running of the vacuum pumps and the evacuation of the chamber from

atmospheric pressure to the process ready pressure using single button operation.

VMD900DL Instruction Manual Page 9

The HMI display has a simple system mimic and is mounted within the control unit to allow

the operator to easily identify system status. All controls are clearly labelled.

The control system provides evaporation control via a ‘SOURCE’ . The PLC controls the

chamber pressure to within the following parameters:

GOLD Better than 2 X 10‐4 mbar

ZINC Between 3 x 10‐4 and 5 x 10‐4 mbar

Vacuum Gauges

The vacuum gauging consists of two ATC‐M active thermocouple gauge heads (one in the

regeneration line and the other on the chamber) and one AIM‐S Active inverted magnetron

gauge head on the chamber.

The AIM‐S active inverted magnetron gauge head is automatically switched on and off at an

optimum pressure (measured by the chamber ATC‐M) to protect it from operation at

unsuitably high pressures.

The AIM‐S head is readily demountable and can be easily cleaned even by a relatively nontechnical

operator without a detrimental effect to calibration.

All pressures are displayed on the HMI display panel.

These are as follows:

BACKING PRESSURE – Displays the pressure in the backing line.

ROUGHING PRESSURE – Displays the pressure in the chamber during the initial ‘roughing’

phase of the evacuation.

HIGH VACUUM PRESSURE – Displays the pressure in the chamber during the ‘high vacuum’

phase of the evacuation.

Cold Finger (Optional Extra)

The vacuum chamber can be fitted with a cryogenically refrigerated cold finger with a

Polycold PFC552 cryogenic refrigeration system. The refrigeration system is connected to a

'cold finger' with a 250 cm2 minimum surface area. The cold finger is of circular cross section

and is self‐supporting. This system operates at <‐120 0C

Please Note: This option is highly recommended if processing exhibits with a high moisture

content. Also for general use the presence of the cold finger significantly reduces the

chamber evacuation time.

VMD900DL Instruction Manual Page 10

The location of the cold finger is such that regular cleaning by wiping the full length may be

easily carried out without obstruction, and without the need to remove any ancillary

components.

Please Note: The cold finger can still be at temperatures of –1000C with the chamber door

open. Care must be taken to prevent cold burns on exposed skin.

Health and Safety

Design and construction will ensure safe operation by non‐technical, trained staff.

Any potential hazards to health associated with the use of the machine are documented and

fully comply with the UK Health and ‘Safety at Work Act’, the ‘Control of Substances

Hazardous to Health Regulations’.

Electrical Loading

The VMD900DL system and water chiller require a 415V + neutral 3 ph, 50Hz, 63 Amp

electrical supply. So far as practical the loading will be equally distributed between phases.

Water Supply

The cooling water flow requirement is 3.0 l min‐1 for the VHS‐10 diffusion pump at the

maximum acceptable inlet temperature of 25oC. This can be either mains water or from a

free standing water chiller.

The cooling water flow requirement is 4.3 l min‐1 for Polycold PFC552HC system (if

purchased) at the maximum acceptable inlet temperature of 13oC. This can be either mains

water or from a free standing water chiller.

Pneumatic Supply

The compressed air requirement is 100 psi with virtually zero flow. This can be either factory

air supply or from a free standing pneumatic compressor.

Exhaust

The exhaust from the E2M80 pump is vented to atmosphere through an Edwards MF100 oil

mist filter

Please Note: It is recommend that this exhaust is piped away to either a fume extraction

point or through an external wall. This exhaust line must be left unobstructed at all times.

VMD900DL Instruction Manual Page 11

Siting

The ‘Standalone’ Vacuum Metal Deposition System would normally be positioned in the

laboratory with all pumps and accessories mounted into a separate service corridor or

outbuilding to help reduce noise levels and heat output into the room and the working

environment.

The depth of the system inside the laboratory will not be more than 3005 mm with the work

holder extended for loading, and the system will not be wider than 1200 mm including the

control panel assuming that the pumps and any ancillary equipment are positioned outside.

It is highly recommended that the E2M80/EH500 vacuum pump set is sited in a separate

room to the main system. This is because both generate a heat load that would be

unacceptable in a laboratory. For this reason the room that these units are sited in should

have adequate natural or forced ventilation.

The E2M80 vacuum pump has a noise level of 70 dB (A) and this should also be considered

when siting this pump.

Optional extras

The closed loop water chiller should be located on a plinth either in a suitably cool and well

ventilated service room or corridor, or alternatively it can be sited outside the building.

It is recommended that the Polycold 552HC system and the compressor should also be sited

in a suitably cooled and well ventilated service room or corridor.

Floor Loading

Approximate floor loading:

Main System (Chamber and Control) 1500 Kg over 970 mm x 860 mm

Vacuum Pump Set (E2M80/EH500) 220 kg over 400 mm x 250 mm

Optional Extras

Polycold PFC552HC 408 Kg over 953 mm x 660 mm

Closed Loop Water Chiller* 113 Kg over 652 mm x 575 mm

Closed Loop Water Chiller** 188 Kg over 652 mm x 575 mm

Closed Loop Water Chiller*** 316 Kg over 1310 mm x 660 mm

Pneumatic Compressor 50 Kg over 400 mm x 750 mm

*System without Polycold PFC552 and chiller located inside

**System without Polycold PFC552 and chiller located outside

*** System with Polycold PFC552 and chiller located inside

VMD900DL Instruction Manual Page 12

Building Works

All required services as indicated above should be provided within 2 metres from the chosen

location for the main system and associated equipment.

Equipment Documentation

The system will be supplied with:

1. One copy of a simple to follow user guide.

2. One copy of a comprehensive operating manual detailing all aspects of operation,

care and maintenance.

3. Technical Data

Rotary Pump : Edwards E2M80 (80 m3hr‐1)

Mechanical Booster : Edwards EH500 (500 m3hr‐1)

Diffusion Pump : Varian VHS‐10

Noise Level : Less than 75 dB

Dimensions : 1800 mm wide x 1920 mm high x 2200 mm

deep

Finish : Light grey leatherette

4. Services Required

Electrical : 414V 3ph 50 Hz neutral + earth

Current Rating : 63 Amp maximum

Pneumatic Air Supply : 80‐100 PSI

Water Cooling (VHS‐10) : Flow 3.0 L min‐1 @ 25 oC max.

Water Cooling (PFC552HC) : Flow 4.3 L min‐1 @ 13 oC max.

Exhaust from Rotary Pump : Suitable extraction point to atmosphere

5. Installation

The system will be fully installed by West Technology Systems Limited engineers into a

prepared site.

Site the system in a clean location and level the unit to the using the levelling jacks provided

on the base. Connect all services as per instruction manual.

IMPORTANT NOTICE: Failure to reconnect all services correctly could be dangerous for both

the system, system components and operator.

VMD900DL Instruction Manual Page 13

IMPORTANT NOTICE: Check direction of all motors to ensure that the 3 phase connections

are correct.

IMPORTANT NOTICE: Service or reconnection work after relocation should only be carried

out by qualified personnel.

Please consult West Technology Systems Limited for any technical queries.

6. General Layout

The ‘VMD 900DL’ has been ergonomically designed to fit into most laboratory situations.

All the mains services are located on a fixed panel at the rear of the machine, these include

water, pneumatics, power and vacuum pump exhaust lines.

The other panels are removable to allow easy access for maintenance purposes where

required.

The design of the system has taken into account that most operators will have no or limited

knowledge of vacuum systems with most operations controlled via the PLC.

The operator panel has all the controls for system start up and close down, chamber pump

down and vent and sequential deposition. Vacuum pressure adjustment (for zinc layer) and

source evaporation current control are located near to the HMI.

The source transformers are located behind the removable panel on the right hand side of

the main enclosure.

VMD900DL Instruction Manual Page 14

The Programmable logic controller and all contactors and control wiring are located behind

the removable panel to the left hand side of the main enclosure.

7. Operation

Starting the System

Please Note: Before operating this equipment please read all of the instructions provided.

Please Note: Care should always be taken when rotating the work holder system and the

operator should ensure that out of balance loads are not fitted to the work holder.

First check that ‘EMERGENCY STOP’ button is not operational by turning it anti‐clockwise to

release it.

Next turn ‘ON’ the Mains supply at the wall.

Then turn the power on by operating the switch located on the left hand side panel of the

VMD900DL.

The HMI will start its test routine and after approximately 15 seconds will display the ‘WEST

TECHNOLOGY WELCOME SCREEN’.

Pressing anywhere on this screen will take the operator to the ‘PUMP OPERATION SCREEN’

Pressing on the ‘INFORMATION’ button will take the operator to the ‘INFORMATION

SCREEN’ (see later).

VMD900DL Instruction Manual Page 15

To start the system the operator presses the ‘START SYSTEM’ button.

Please Note: If the ‘SAFETY RESET’ button is red then the system must be rest. To do this the

operator presses the ‘SAFETY RESET’ button. After a short delay this button changes to

‘SAFETY HEALTHY’.

Once the ‘SAFETY HEALTHY’ legend appears the operator can start the system by pressing

the ‘START SYSTEM’ button. This button then changes to display ‘STOP SYSTEM’.

VMD900DL Instruction Manual Page 16

The system takes 30 minutes to start up and the time is displayed as a count down in the

‘READY IN’ box.

Control Screen

Pressing the ‘CONTROL’ button on the System Mimic takes the operator to the ‘CONTROL

SCREEN’.

This is the main control screen for the system. The ‘CONTROL SCREEN’ is where the operator

carrys out the sequential deposition process.

Pressing the ‘PUMP DOWN’ buttong starts the evacuation of the chamber. As it is pressed

the lengend on the button briefly changes to ‘PUMPING’ then returns to display ‘PUMP

DOWN.

The chamber pressure is displayed on the screen.

Pressing the ‘LIGHTS OFF’ button switches on the chamber LED lamps to illuminate the

inside of the vacuum chamber. When pressed the legend ‘LIGHTS OFF’ changes to ‘LIGHTS

ON’. Pressing the button again switches the LED lamps off (legend changes back to ‘LIGHTS

OFF’).

To vent the vacuum chamber the operator simply presses the ‘VENT’ button. Once pressed

the chamber is automatically vented back to atmospheric pressure.

Pressing the ‘MENU’ button takes the operator to the ‘MENU SCREEN’.

Pressing the ‘LIGHT BOX’ changes the HMI screem to a white light box screen. This is useful

for a quick check of the process exhibit to evaluate the finermarks developed. Pressing the

‘MENU’ button takes the operator back to the ‘MENU SCREEN’.

Pressing the ‘SEAL’ button will seal the chamber i.e. the high vacuum valve will close. This

feature is useful for ‘holding an exhibit at high vacuum overnight.

VMD900DL Instruction Manual Page 17

Gold/Zinc Evaporation

Once the chamber vacuum pressure reaches high vacuum pressure better than 1 x 10‐4

mbar the evaporation sources become active.

To start the gold deposition process press the ‘SOURCE OFF’ button.

After a short time delay the right hand legend ‘SOURCE OFF’ changes to ‘SOURCE 1’ and the

left hand ‘SOURCE OFF’ legend changes to ‘GOLD LAYER 1’.

At this point the operator can slowly adjust the located below the HMI screen and increase

the evaporation current until the boat glows a dull red colour and gold wire melts and

‘wets’ the evaporation boat.

Source Activation

Button

VMD900DL Instruction Manual Page 18

Please Note: If the evaporation currents is ramped up too quickly then the gold wire may

‘jump’ out of the boat.

When the gold has ‘wetted’ the evaporation boat the operator can slowly increase the

evaporation current via the current potentiometer until the boat glows white hot and the

gold will then evaporate. The evaporation should take no more than 3‐5 seconds. At the end

of the evaporation the operator winds down the evaporation current to zero using the

current potentiometer.

Pressing the ‘SOURCE 1’ button then selects the second set of gold evaporation boats, if

fitted.

In normal operation this evaporation source is not used but there can be circumstances

where the additional evaporation of gold is required. Alternatively this evaporation source

can be used for the process where the sequential evaporation of silver after the zinc

evaporation is required.

When pressed the ‘SOURCE 1’ legend changes to ‘SOURCE 2’ and the ‘GOLD Layer 1’ legend

changes to ‘GOLD Layer 2’. The evaporation sequence for gold is then repeated.

Current

Potentiometer

VMD900DL Instruction Manual Page 19

If a second deposition of gold is not required then by pressing the ‘Source 1’ button twice

the operator is taken to ‘SOURCE 3’ and the GOLD Layer 1’ legend changes to ‘ZINC LAYER’.

The system will automatically adjust the chamber pressure for the evaporation of zinc, this

normally takes a few seconds to stabilise at which point the legend ‘ ZINC LAYER’ will

appear.

Before slowly adjusting the current potentiometer, it is recommend that the operator

switches the chamber lights off by pressing the ‘LIGHTS ON’ button.

To evaporate the zinc the same process applies that was used to evaporate the gold i.e. the

operator can slowly adjust the current potentiometer and increase the evaporation current

until the boat glows a dull red colour and the zinc foil (or granules) source material melts

and ‘wets’ the evaporation boat.

At this point quickly turn the chamber lights on by pressing the ‘LIGHTS OFF’ button and

observe the surface of the exhibit being processed. The zinc will start to deposit on to the

surface of the exhibit developing the fingermark by slowly increasing the current.

This will allow the operator to watch and assess the deposition of the zinc to obtain the

optimum fingerprint image.

The deposition of the zinc on to the sample material requires experience to deposit

sufficient zinc to produce the fingerprint image but not too much zinc to decrease the

sharpness of the fingerprint image.

Please Note: If the evaporation currents is ramped up too quickly then the zinc may ‘jump’

out of the boat.

VMD900DL Instruction Manual Page 20

Please Note: If the chamber pressure is too low for the zinc deposition process then then

the ‘ZINC LAYER’ legend will not be displayed and the legend ‘PRESSURE LOW’ will appear

on the screen.

Please Note: If the chamber pressure is too high for the zinc deposition process then then

the ‘ZINC LAYER’ legend will not be displayed and the legend ‘PRESSURE HIGH’ will appear

on the screen.

In either this case it is not possible to evaporate the zinc until the pressure condition has

been rectified. This is done by carefully and gradually adjusting the leak valve located on the

right hand side of the chamber.

VMD900DL Instruction Manual Page 21

At the end of the zinc evaporation pressing the ‘SOURCE 3’ button will switch all

evaporation sources off.

Pressing the ‘VENT’ button returns the chamber to atmospheric pressure so the the

processed exhibit material can be removed. Once pressed the legend changes briefly to

‘VENTING’ before returning to ‘VENT’.

Venting the chamber takes approx 2 minutes.

Menu Screen

This screen allows acces to all the other system screens.

Control Screen – Pressing this button takes the operator to the ‘CONTROL SCREEN’ (see

above)

System Start – Pressing this buton takes the operator to the ‘PUMP OPERATION SCREEN’

(see above).

Pressure – Pressing this button takes the operator to the ‘PRESSURE SCREEN’ (see below).

Mimic – Pressing this takes the operator to the ‘SYSTEM MIMIC SCREEN’ (see below).

VMD900DL Instruction Manual Page 22

Data – Pressing this takes the operator to the ‘DATA SCREEN (see below).

Information – Pressing this takes the operator to the ‘INFORMATION SCREEN (see below).

Alarms – Pressing this takes the operator to the ‘ALARMS SCREEN’ (see below).

Chinese/English – Pressing this button changes the languge used in the HMI screens from

English to Chinese or vice versa.

Pressure Screen

This screen shows the backing, roughing and high vacuum gauge pressures.

System Mimic Screen

This screen provides information on the operational status of the system e.g. in the above

example both vacuum pumps are running and the high vacuum valve and backing valve are

open. The legend ‘HIGH VACUUM’ shows that the system is at high vacuum. The pressure

display is showing 3.5 x 10‐5 mbar.

VMD900DL Instruction Manual Page 23

Pressing the ‘LIGHTS OFF’ button switches on the chamber LED lamps to illuminate the

inside of the vacuum chamber. This is is useful when loading the gold wire into the

evaporation boats and also when initially applying current to the zinc boats during process

deposition.

Pressing the ‘MENU’ button takes the operator to the ‘MENU SCREEN’(see later).

Pressing the ‘CONTROL’ button takes the operator to the ‘CONTROL SCREEN’

Pressing the ‘OUTSIDE’ button takes the operator to the ‘SERVICES SCREEN’.

This screen shows the operational status of the water chiller (if fitted) and pneumatic

compressor (if fitted). It also shows the operator whether the water supply and pneumatic

air supplies are within operational parameters.

Pressing the ‘INSIDE’ button return the operator to the ‘SYSTEM MIMIC SCREEN’.

Data Screen

This screen displays data on all the critical operational system parameters including the

backing, roughing and high vacuum gauge pressures. The operational status of major

VMD900DL Instruction Manual Page 24

components (e.g. rotary vacuum pump, mechanical booster pump etc.) and the series of set

points used in the automatic control programme.

Please Note: It is possible to change the set points, however, it is strongly recommended

that the operator does not changes any set points without first discussing with West

Technology.

Information Screen

This screen has a number of buttons that allows the operator to find out further information

about the system:

Start Pumps – this gives a descirption of the operational sequence of the vacuum pumps

when the system is started.

Alarms – this takes the operator to the ‘ALARMS SCREEN’ (see below).

Pressure – this takes the operator to the ‘PRESSURE INFORMATION SCREEN’ (see below).

Service – this takes the operator to the ‘SERVICE INFORMATION SCREEN’ (see below).

Trends ‐ this takes the operator to the ‘PRESSURE TREND SCREEN’ (see below).

Maintenance – this takes the operator to the ‘MAINTENANCE SCREEN’(see below).

Timers – this takes the operator to the ‘TIMERS SCREEN’ (see below).

I/O List – pressing this takes the operator to the ‘I/O LIST SCREEN ( see below).

VMD900DL Instruction Manual Page 25

Pressure Information Screen

This screen gives a description of how the backing, roughing and high vacuum pressure

gauges work and display vacuum pressures.

Service Information Screen

This screen gives contact detail for West Technology. Contact us for service support

contracts.

Trends Screen

This screen shows the pressure trends for the roughing and high vacuum gauges.

VMD900DL Instruction Manual Page 26

Maintenance Screen

This screen gives gives a weekly, monthly, 3 monthly and annual maintenance schedule for

the system.

Timers Screen

This screen gives information about the diffusion high vacuum pump warm up timer (active

during stsem start up) and the diffusion pump cool down timer ( active during system shut

down).

I/O List Screen

VMD900DL Instruction Manual Page 27

This screen is password protected and can only be accessed by authorised service engineers.

Once accessed this screen allows the engineer to select manual control of the system plus a

range of other features.

Process Cycle

Loading Samples

To load sample materials into the chamber the operator must first release the door catch

and open the door.

Please Note: If the chamber has been in operation or left in a ‘sealed’ state then the

operator must press the ‘VENT’ button on the ‘Control Screen’ to return the chamber to

atmospheric pressure.

The operator then withdraws the workholder (using the handle) from the chamber. With

the workholder in the fully extended position the operator then pulls the small catch pin

located on the right hand side and slowly rotates the workholder backwards.

Please Note: The catch pin must be pulled out to fully rotate the work holder to its set

position.

The workholder has a three position latch assembly ‐ normal position, 90 degrees, 45

degrees and fully inverted. Once the work holder is in its required position the catch pin can

be released to lock the work holder in position.

The sample material is attached, making sure that it is smooth, to the workholder using the

small high powered magnets. Once attached the workholder is rotated back to its normal

position.

Please Note: Care should always be taken when rotating the work holder system and the

operator should ensure that out of balance loads are not fitted to the work holder.

Finally the operator pushes the workholder back into the chamber and closes the door.

Chamber Evacuation

To evacuate the chamber the operator must press the ‘PUMP DOWN’ button in the

‘CONTROL SCREEN’.

The sequence of events are as follows:

1. Roughing valve opens.

VMD900DL Instruction Manual Page 28

2. Pressure within chamber reduces to a preset level (crossover pressure).

3. Roughing valve closes. Backing valve opens.

4. High vacuum valve opens.

5. Chamber is evacuated to high vacuum pressure

Deposition Process

1. The operator first ensures that the current potentiometer is set at zero (fully clockwise).

2. If not already in the ‘CONTROL SCREEN’ the operator then selects this screen via the

‘SYSTEM MIMIC SCREEN’ or the ‘MENU SCREEN’.

3. In the ‘CONTROL SCREEN’ the operator presses the left hand ‘SOURCE OFF’ button, the

button legend changes to ‘SOURCE 1’ and the right hand ‘SOURCE OFF’ legend below

changes to ‘GOLD LAYER 1’.

4. The operator then slowly turns the current potentiometer knob anticlockwise until the

desired degree of evaporation is obtained. (See notes in ‘CONTROL SCREEN’ above).

Please Note: Do not apply power to the gold source too rapidly, as thermal shock will

take place and cause the gold to jump out of the evaporation boat. Apply power to the

evaporation boat slowly until the gold first wets the boat, then increase the power for

full evaporation. The gold will be fully evaporated by increasing the power until the boat

glows white hot.

Please Note: During gold evaporation it is best to have the chamber lights turned off.

5. Once evaporation is completed the operator must return the current potentiometer

knob fully clockwise to ensure that it is off.

6. The operator then either selects to carry out a second gold evaporation by pressing the

‘SOURCE 1’ button once or proceeds with the zinc evaporation by pressing the ‘SOURCE

1’ button twice and the legend changes to ‘SOURCE 3’.

There will be a short pause whilst the system automatically adjust the pressure in the

chamber to around 3.0 x 10‐4 mbar. Once the vacuum pressure is within the defined

range for the zinc deposition then the right hand legend changes to ‘ZINC LAYER’.

VMD900DL Instruction Manual Page 29

The zinc evaporation pressure can be adjusted within predefined limits via the LV10K

fine needle valve located just below the vacuum chamber on the RHS. Turning the valve

knob clockwise increases the vacuum pressure (e.g. from 6.7 x 10‐4 to 3.3 x 10‐4 mbar),

whilst anticlockwise decreases the vacuum pressure (e.g. from 3.3 x 10‐4 to 6.7 x 10‐4

mbar).

When evaporating the zinc evaporation boat it is recommended that the chamber lights

are initally turned off.

Apply the power gently until the ends of the evaporation boat starts to glow a dull red

color, and allow to the zinc to soak at this level for a short period of time before applying

more power to start the evaporation.

Please Note: When evaporating the zinc layer is is advisable to have the chamber lights

turned on so the development of the finger print can be observed.

Fingerprint development can be quite difficult to observe on certain materials. It is

therefore advisable to secure a small white plastic test piece to the work holder to aid

observation.

7. Once evaporation is completed the operator must return the current potentiometer

knob fully clockwise to ensure that it is off.

8. After finishing the zinc evaporation it is recommended that the operator switches back

to the ‘GOLD LAYER 1’ and winds the current up until the gold evaporation boats are

glowing white hot. This will remove any zinc contamination from the boats.

9. Once evaporation is completed the operator must return the current potentiometer

knob fully clockwise to ensure that it is off.

Chamber Venting

To vent the chamber back up to atmospheric pressure the operator must press the ‘VENT’

button in the ‘CONTROL SCREEN’.

The sequence of events are as follows:

1. High vacuum valve closes.

2. After a short time delay the air admittance valve opens.

VMD900DL Instruction Manual Page 30

3. Once chamber is at atmospheric pressure the air admittance valve closes and system

resets.

Chamber Cleaning

Please Note: A respiratory dust mask, rubber gloves and safety glasses should be used when

cleaning chamber furniture.

Please Note: WTSL recommend that the system is shut down prior to commencing any

cleaning.

Please Note: Regular cleaning of the chamber is essential to ensure that large deposits do

not build up. This will make routine maintenance easier and help to keep optimum

performance from the system.

To aid the cleaning process the chamber has been fitted with removable liners, once

removed from the chamber they should be wiped down with a suitable solvent. We would

recommend a light scouring pad for the more stubborn deposits.

With the liners removed the chamber should be vacuumed out with special attention being

taken around the bus bars to prevent build up of deposits that can lead to electrical

shorting.

Please Note: Spare liner sets can be ordered from West Technology.

The LED lamp surfaces will also require periodic cleaning.

We recommend that a putting a light smear of a suitable vacuum grease on the lamp so that

it will only require cleaning with a suitable solvent cleaner. This will prevent any scratching

of the lamp during cleaning.

VMD900DL Instruction Manual Page 31

8. Recommended Service Requirements

Weekly

 Check oil level in oil sight glass of all of the E2M80 and EH500 vacuum pumps.

Replenish as necessary.

 Check oil level in pneumatic compressor (if present). Replenish as necessary.

 Clean chamber and ‘O’ ring door seal.

Monthly

 Clean chamber and chamber furniture.

3 monthly

 Check o ring door seal.

6 monthly

 Check condition and level of diffusion pump fluid.

12 monthly

 Minor service E2M80 pump

 Change oil in EH500 mechanical booster (if necessary).

 Check diffusion pump fluid.

 Check seals on roughing, backing, air admittance and high vacuum valves.

 Clean and check vacuum gauges.

Caution: A respiratory dust mask, rubber gloves and safety glasses should be used when

cleaning the chamber, chamber furniture, vacuum valves, vacuum gauges etc.

Please Note: Gauges must be cleaned in accordance with the manufacturers instructions.

VMD900DL Instruction Manual Page 32

9. Recommended Spare Parts and Consumables

VMD900 Spares P/No.

Ultragrade 20 oil 1 litre WTS/11024015/1L

Ultragrade 20 oil 4 litre WTS/11024013/4L

DC704 Diffusion Pump Oil 1 litre WTS/704/1L

AIM‐S‐NW25 Active Inverted Magnetron

Vacuum Gauge Head

WTS/14641000

ATC‐M‐1/8” Active Thermocouple Vacuum

Gauge Head

WTS/35108000

Thyristor Fuse 16A WTS/THYFUSE

Spare Fuse Set WTS/FUSE

Tool Box WTS/TOOL

Pack of 10 Bremag Magnets WTS/NB012B‐M

LED Lamp WTS/MR16‐3CW‐XREP4‐C

Chamber Door Seal WTS/DOORSEAL

Set of ‘o’ Ring Seals WTS/SEALSET

VMD Consumables (All models)

Evaporation Boats P/No.

Gold (Pack of 10) WTS/GOLD/BOAT

Silver (Pack of 10) WTS/SILVER/BOAT

Zinc (Pack of 10) WTS/SILVER/BOAT

Evaporation Source Material

Gold Wire 1m WTS/GOLD/1M

Silver Wire 1 m WTS/SILVER/1M

Zinc Granules 250g WTS/ZINC/250G

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