CEGS Creation

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To create a Carbon Extraction and Graphitization System (CEGS), proceed through the outlined phases, following the instructions for each in turn.

Design

1. Plan the system with the desired features and options.
2. Design and model the system in Onshape.
3. Create the system in the IDB.
4. Reconcile the Onshape and IDB BOMs.

Get Materials

1. Check inventory against the IDB eBOM.
2. Order sourced parts and materials to ensure sufficient stock as soon as possible. Order items with long lead times first.

Make Parts

Make all of the parts required for the system (see the eBOM for a comprehensive list and exact counts). As a rule, make parts required by lower-level sub-assemblies first. The linked lists of parts by production method are ordered approximately that way. Parts listed first are generally needed before those further down the list.

Parts are created using one or more production methods. There are several major types:

3D Printed Parts

These include 3D filament- and 3D resin-printed parts, and also laser-etched and laser-cut parts. Lasered parts aren't truly 3D, nor printed, but the production mechanics are so similar that it is convenient to manage them together. Most of these parts are needed later in the manufacturing process, so working on them early is an exception to the normal production order. However, these parts and machines usually require very little active attention. This gives rise to the sensible practice of keep a running tab of everything that will be ultimately be required from each of these machines. Then, throughout the day, periodically spare a few minutes to keep the 3D printing machines busy before returning to your primary production efforts.

• List of 3D Printed and Lasered Parts

Machined Parts

Machined parts are crafted from base materials in the form of a sheet, rod, tube, bar or block, collectively known as stock. This stock is purchased in bulk and pre-cut into rough blanks. Machining precisely removes excess material to shape the final part. Common tools for this are mills, lathes, drills, saws, and grinders, with specialized machines also available for specific tasks (not required to make CEGS parts). A machine which uses a computer to deliver precise dimensions and controlled sequences of operations is, for archaic reasons, called a CNC (Computer numerical control) machine. CNC enhances dimensional accuracy and part consistency by automating the process. CNC mills, often called "machining centers", and CNC lathes, referred to as "turning centers", are particularly versatile. The distinction between a mill and a lathe is what is placed in the spindle. When the workpiece moves into a spinning tool, it's a mill; when the tool moves into a spinning workpiece, it's a lathe.

Preliminary operations like sawing produce blanks for further machining. Drilling is most often accomplished on the mill or the lathe, although a drill press or hand drill can be used where precision is not required. Grinding is usually a finishing or secondary operation. For these reasons, such parts are usually classified by the other machining required. Parts shaped solely by sawing, drilling or grinding are classified simply as "Other Machined Parts."

• List of Milled Parts

• List of Turned Parts

• List of Other Machined Parts

Fabricated Parts

Fabricated parts are created by shaping or combining materials into their final forms, using methods that do not remove material. Common processes include bending, stamping, punching, forging and welding, where bending is the simplest example and welding joins pieces together. Heat is often employed in fabrication. It can make materials more pliable for bending and is essential for welding, glasswork and thermo-forming plastics.

• List of Fabricated Parts

Modified Parts

Contracted parts—custom components outsourced to specialized suppliers—frequently require further processing after we receive them, including operations like bending, drilling, tapping, and surface finishing.

Additionally, Aeon uses commercial and commodity parts whenever feasible, due to their cost-effectiveness and broad availability. By leveraging economies of scale from external suppliers, we capitalize on existing engineering and reduce our dependence on custom manufacturing. Nonetheless, to meet functionality and compatibility requirements, modifications are often necessary. These range from simple enhancements, such as surface polishing, to comprehensive alterations, including disassembly, machining, and replacement of internal components.

• List of Modified Parts

Construct Sub-assemblies

Build as many as are required of the following assemblies. This list is approximately ordered according to the assembly tree. Assemblies further down the list may depend on assemblies above.

• Circuit Card Assemblies (CCAs)
• Actuator Controller Stack
• Heater Controller Stack
• Switchbank Stack
• Data Acquisition Electronics (DAQ)
• Servos
  • Servo CPW
  • Servo Serial
• Valve Actuators (do not mate them to valves)
• Port Pressure Sensor
• Graphite Reactor
• Breakseal
• Inline LN Phase Separator
• Ceramic Fiber Furnaces
  • GR Furnace (Graphite Reactor Furnace)
  • CCS Furnace (Combustion Chamber Sample Furnace)
  • CCQ Furnace (Combustion Chamber Quartz Media Furnace)
• FTC (Freeze-Thaw Coldfingers)
  • Measurement Chamber FTC (MC FTC)
  • Graphite Reactor FTC (GR FTC)
• Coil Trap
• VTC Heater (Variable Temperature Coldfinger heater)
• VTC (Variable Temperature Coldfinger)

Assemble the CEGS

The remaining major sub-assemblies are specific to the CEGS model. Refer to the Onshape 3D model and Item Manager for model-specific details. Beginning with the CEGS Frame, assemble these items in coordination with the others. The following list shows the approximate order in which each major sub-assembly is started. The steps below the list explain how to advance the construction of the sub-assemblies to complete them as the CEGS comes together as a whole.

CEGS major sub-assemblies

• CEGS Frame
• Main Plumbing Sections
  • Inlet Manifold Section
  • Process Section
  • Graphite Manifold Section
  • Vacuum Section
  • Optional Plumbing Sections
    • Tube Furnace Outlet
    • FLow Through Gas
• IP furnace carriages
• GR Swing Sets
• Air Manifold
• Liquid Nitrogen Manifold (LN Manifold)
• LN + air section
• LN supply plumbing
• Control Section
• Vacuum Stations
• In Situ Extraction Line

CEGS Assembly Sequence

1. Begin assembling the CEGS Frame according to the 3D model.
   • Omit the IP carriages and GR swings.
   • Make sure all captured tee-nuts have been inserted into each strut before its ends are blocked by other frame elements.
   • Tighten the outermost struts in position according to the model dimensions.
   • Position interior bars, ribs and other framing elements approximately according to the model, but leave their fasteners loose so that later they can be re-positioned accurately as the plumbing is attached.
2. Assemble each main plumbing section in sequence, and attach it to the frame.
   1. Assemble the plumbing valves and fittings together according to the CEGS-specific model.
      • Tighten each tube connection while securing the fitting or valve it goes to, preferably in the brass-jawed plumbing assembly vise.
        • Tighten all connections strictly according to the Swagelok instructions posted at the vise.
      • Use only modified valves.
      • Omit actuators from all valves.
      • Port screens must be inserted before tightening the tube connections into port valve inlets.
        • These port tubes must be plain, that is, they must not include ferrule grooves.
      • Install port filters into all ORS fittings on main plumbing sections except
      1. the HV connection on the Vacuum Section
      • Straighten and square up the plumbing section on a solid, flat work surface.
        • Apply bending forces across only one pair of adjacent fittings at a time.
        • Use 1-2-3 blocks, machinist squares and other spacers to check alignment.
        • Sight along the axial lengths of the plumbing to ensure valve bodies are all parallel.
        • Adjust the ports to achieve a 2-1/8 spacing between them.
   2. Mount the plumbing section to the frame.
      • The IM is installed first.
        • Attach all of the fitting hanger hooks to the correct IM fittings and tighten their screws.
        • Determine the reference fitting hanger and its location from the 3D model. It is given by the fixed dimension to the left- or right-most fitting hanger of the IM.
        • Place the IM Section onto the frame, adjust the reference hanger's mount to its location, and tighten its screw to secure it to the frame.
        • Then secure the remaining IM fitting hanger mounts, working in sequence away from previously tightened mounts.
      • As each subsequent plumbing section is completed, connect it to the previously-mounted plumbing before tightening any new section's mounts to the frame.
        • Always secure the fitting hanger hook to the plumbing first, then its mount to the frame, and work in sequence away from previously tightened mounts.

   3. Install the plug valve stems and actuators into the plug valves in the section.
      • Attach plug valve actuators onto plug valve stems and secure them in place by driving the spring pin through the coupling and stem.
        • Pay close attention to the valve and actuator orientations in the 3D model. The stem can go into the coupling in two opposite orientations. Choose the orientation that puts the face O-ring toward the valve's inlet when the actuator is oriented according to the model. The face O-ring is the one on the side of the stem. The valve's inlet is the fitting toward the base of the arrow imprinted on the side of the valve. The arrow points from the inlet to the outlet.
      • Clean the valve stem and valve body interior (the "barrel") using clean, dry compressed air.
        • If new, baked-out O-rings have not yet been installed into the valve stem, install them now.
        • Make sure there is no debris (dust or fibers) on the three valve stem O-rings. Used compressed air again if necessary.
      • Use a small probe-like tool (not a cotton swab!) to dab a little High Vacuum grease all along the exposed O-ring surfaces.

      Note: No grease is needed on the O-ring surfaces that contact the valve stem. Those areas are best left dry.

      • With a very slight twisting motion, insert the valve stem + actuator assembly straight into the valve body according to the 3D model. Avoid scraping the barrel with the metal edge of the valve stem.
      • Secure the stem to the valve body by installing the circlip into the groove at the end of the valve stem.
   4. After the last section is completed and on the frame, install all of the bellows-sealed valve actuators.
      • Engage the coupling set screw onto the center of correct flat of the BSV stem, making very sure it is tight.
      • Tighten a locking set screw into the coupling set screw.

   Note: Do not install any flow valve actuators. Those are installed during Integration.

3. Install a cold trap at each Inlet Port (IP)
4. Install and align the IP furnace carriages, ensuring smooth movement.
5. One inlet port at a time, align the IP furnaces.
6. Install the IP fans, centering its middle opening on on the appropriate cold trap as shown in the model.
7. Install the GR swings, aligning the arms with the reactors. Adjusting each furnace for optimal alignment with the Fe tube.
8. Install the LN+air module(s).
9. Install the LN valve actuators.
10. Install the FTCs and VTC.
11. Install the tMC thermistor.
12. Install the tGM thermocouples.
    • Position these thermocouples on the frame side of the plumbing to avoid warm air rising from the GR furnaces.

13. Install the Control Box.
14. Plan and route cables from every device into the control box.
    • Determine the cable lengths in advance, cut them to length, and wire the device connectors.
    • Connect the cables to all devices before routing any of them.
    • Begin routing from the farthest devices first and work toward the control box.
    • Before routing a cable, determine its optimal orientation, either "ground up" or "ground down."
      • This varies according to the cable's destination in the control box. Every cable has a ground wire, identified by color.
        • In flat rainbow-colored cables, the ground wire is black, brown, green, or gray, and it is always on an outside edge.
        • Thermocouple cables always have exactly two wires, each with a distinctive color. The ground wire is either entirely red or red-striped. The other wire color indicates the type of thermocouple (yellow for Type K, blue for Type T).
        • Switchbank wires are ground down.
        • AC2 wires are ground up.
        • AC1 wires are ground down.
        • Heater Controller wires are ground down.
        • DAQ wires are ground up.
    • Use frequent cable ties to bundle the cables into groups and cable mounts to secure them to the frame.
      • Space the cable ties as evenly as possible, with 1 to 2 inches between them.
      • Locate cable mounts strategically and as evenly as possible, with a 4 to 6 inch spacing.
      • As the harness advances toward each device, merge the device's cable into the outside of a compatible bundle, orienting it "ground up" or "ground down" as appropriate.
        • Be sure to reserve an adequate, uniform service relief, or slack, so the cable and connector will never suffer strain in use. Extra long strain relief is required for heaters, FTCs and VTCs because these devices must be moved in normal operation or for shipping. FTCs and VTCs need enough slack to lower them completely free of their coldfingers.
    • Use cable sleds to keep bundles of related devices collected and orderly, and to prevent tangling.
    • There are two incompatible types of cables: quiet and noisy. Keep incompatible cables separated as much as possible, especially over long stretches.
      • Quiet: Thermocouples, pressure sensors, thermisters, and actuators. These can be freely bundled together.
      • Noisy: Heaters and Solenoid valves. These can be bundled together also.
      • Join incompatible bundles only when necessary and separate them wherever possible.
    • Certain cables are easily overlooked, especially when their devices may not be present. Route these cables as soon as possible so they can be merged gracefully into appropriate bundles.
      • Route the GR pressure sensor cables from the graphite reactors. The GR pressure sensors are not present at this point. Refer to the CEGS model to determine the correct cable orientation for the sensors. Provide sufficient and consistent strain relief.
        • Pay close attention to these sensor connector pin-outs as they do not follow Aeon conventions.
      • Route the MC Thermister when the harness reaches the measurement chamber.

        Note: this sensor connector pin-out does not follow Aeon conventions.

      • Route the backing and roughing valve cables (vB and vR) from the Low Vacuum fitting.
      • Route the LN Supply solenoid valve cables from the appropriate location on the CEGS Frame.
      • Route the frame ground wire from a convenient fitting hanger near the Control Box.
      • Merge the tGM thermocouples into the GR thermocouple bundle.
      • Route the LN overflow thermocouple from a central area on the table beneath the LN Manifolds. Leave at least six inches of the end free at the table top.
    • Route the LN and air manifold cables before the harness reaches their merge point.
      • Route the LN Manifold level sensor thermocouples at the same time.
      • Pay special attention to the proper "ground-up/down" orientation for the LN+air cables; it often differs from other same-colored cables, with which they may be bundled.
    • Organize the bundles as they pass through the opening in the back of the control box, maintaining "ground up/down" orientations while avoiding cross-overs and tangles.
15. Complete the control box wiring. Finish and connect the cables to one destination at a time. The order is not critical, but it may be easier to work on destinations with fewer connections first and the most connections last.
    • U6IFC/DAQ
    • Switchbank
    • Actuator Controller 2 (if present)
    • Heater Controller heaters
    • Heater Controller thermocouples
    • Actuator Controller 1.

16. Fabricate and install the FTC LN tubes.
17. Install the FTC air lines.
18. Install the air filter/regulator. Set the PSI to 15.
19. Assemble and connect the Vacuum Station.
20. Install the UPS, mains detect, and host computer.

Inspection

1. Make sure the system is complete, with all components installed
   • Power supply terminal guards
   • FTCs
   • pressure sensors
   • FTC and VTC air lines
   • FTC and VTC LN lines
   • FTC and VTC drains
   • LN supply plumbing
   • All TCs (tGM, tOverflow, etc.)
   • LN and air plumbing
   • LN supply lines
   • Air supply lines
   • MCP1&MCP2, tMC
   • pVM.IG
2. Make sure the flow valve actuators are NOT installed, but stored in the system's part box.
3. Make sure all of the screws and nuts are properly torqued
   • Frame and structural components
   • Valve couplings
   • Valve bearings
   • Power supply terminals
   • System ground lug
   • Frame bonding point
4. For BSV valve couplings, make sure the locking set screw is installed.
5. Make sure the GR ports are in the proper positions as well.
   • They should be facing square to the front of the CEGS and vertical from all angles, at an equal distance from the frame.
   • They should be 2.125" apart as well, use a ruler to verify.
   • Also check that when the GR furnaces are in place, the hole of the furnace aligns with the port.
     • Prioritize adjusting the furnaces and bandclamps for this step rather than the ports.
   • LN Manifold snubbers installed into LN manifolds and phase separators
   • Clamps and rods installed on the LN manifolds and phase separators

Integration

Integration is the stage that transforms the CEGS assembly into a functional instrument. It occurs after the system is completely assembled, including all actuators, manometers, thermometers, control electronics, etc. This stage of production includes quality and safety checks, software configuration and settings, initial power-up, calibration, and comprehensive testing of each individual component device and the system as a whole.

Configure the Host Computer

The host computer is a specially configured Windows laptop. Many default Windows features and settings interfere with the intended purpose of this computer as a hardware controller. A major obstacle is Microsoft's policy for Windows Updates. For good reason, Microsoft stridently works to enforce update policies that disregard the system's need to operate continuously and to prioritize CEGS operation over inconsequential Microsoft and Windows services. Thus, careful preparation is required to maximize performance and to enable the computer to serve its intended function without disruption.

As any such configuration can increase vulnerability to certain types of malware attacks, it is important that the end user institute a policy of frequent backups and regular manual software updates.

See Configuring a HACS Host Computer for the latest procedure that Aeon follows to prepare the laptop for operation as a HACS host.

Record the model and serial numbers for the CEGS, the host computer, each serialized pressure sensor and vacuum station in the system configuration documentation.

Create the CEGS Application

1. Fork a similar AeonHacs repository on GitHub and download it to the host computer.
2. Edit the settings.json file to define the new CEGS configuration. Edit / enter as much information as possible before attempting to run the application for the first time. The following items usually require system-specific edits.
   • Name: Enter the name of the system.
   • AlertManager
     • Enter SiteName and (optionally) PhoneNumber
     • The AlertRecipients list should contain only one entry: the CEGS' own email address
       • <UniqueSystemName>@aeonhacs.com // self
   • DeviceManagers (enter COM port, populate Devices list)
     • Daq
     • Heater Controllers
     • ActuatorControllers
     • Switchbank
     • Other things?
   • ManagedDevices (primarily DAQ-managed devices; ID.Enables, fans, MFCs)
   • Meters (Can include any device that implements the Meter interface.)
     • Pressure sensors (pIM, pGR1, etc)
     • Thermocouples (tVTC, tGR1, tLN_MC, tLN etc.)
     • Thermisters (tMC)
     • ugCinMC
     • TubeFurnaces
     • LN tank scale
     • DCV supply monitors
     • Flow rate monitors (e.g., MFC feedback)
   • Valves
   • Switches
   • Heaters (Can be anything that implements the Heater interface, but usually only contains those managed by a HeaterController.)
   • LNManifolds
   • Coldfingers (FTCs)
   • VTColdfingers (VTCs)
   • VacuumSystems
   • Chambers (completely define these)
   • Sections (completely define these)
   • GasSupplies
   • FlowManagers
   • VolumeCalibrations
   • Logs
   • HacsComponents (left-overs, components that don't fit neatly into a specific component category)
   • Power
   • CegsPreferences (if the application requires something unusual)
3. Validate the settings.json structure.
4. Rename the solution and main project to express the new CEGS identity.
5. Adapt the main project class to match the features of the new CEGS.
6. Adapt the UI to represent the new CEGS layout.

Pre-power Safety Inspection

This must be done before First Time Power. Carefully check every item in this list before applying power to the system for the first time.

1. Make sure all of the safety grounds are correctly wired.
   • At least one green frame ground wire is securely clamped to the vacuum plumbing near the Control Box.
   • A green frame ground wire is connected to the U6IFC Frame pin.
   • A green ground wire is connected to the earth/ground terminal of the IEC C14 power inlet.
   • The other ends of all the wires above connect to the earth terminal on a DC power supply.
   • Green frame ground wires connect all of the the earth terminals on the DC power supplies together. These connections may be daisy-chained.
2. Ensure that the Black-White-Gray cables to the 3-pin sensors are wired and connected correctly.
   • Check all port pressure sensors.
     • Pin 1: Gray; Pin 2: Black, Pin 3: White

       Note: this sensor connector pin-out does not follow Aeon conventions.

     • The connector's pin 1 mates to the sensor's pin 1, which is on the left when viewing the sensor's port face with the pins pointing down. In other words, the connector's pin 1 triangle faces the same direction as the sensor's port. The port is the tube that protrudes from the sensor.
     • Be sure to check the GR pressure sensor cables; they are easily overlooked as the sensors are not yet installed.
   • Check the MC thermistor
     • Pin 1: Black; Pin 2: Gray, Pin 3: White

       Note: this sensor connector pin-out does not follow Aeon conventions.

     • The connector's pin 1 mates to the sensor pin 1 which is at right when viewing the sensor's flat face with the pins pointing down. The sensor pin 1 should be marked with a dot.
     • In other words, the connector's pin 1 triangle faces the same direction as the sensor's curved face.
3. Verify that the power wires in the control box are connected correctly
   • • The white wires at the +5 VDC power supply connect to the V+ terminal. Black goes to V-.
     • If present, +5V Boost connects to U6IFC PBC, and NOT to the adjacent tail end of PBB.
       • Black goes to GND (at the U6IFC CCA edge), red to +5V (toward the center of the U6IFC).
     • The +5 VDC cables at U6IFC PBD (HC and SB power) are oriented correctly: black toward the CCA edge.
     • The brown wire at the +15 VDC power supply connects to the V+ terminal. Black goes to V-.
     • The +15V brown wire goes to the +15V pin on the U6IFC's PBA bus, and NOT to the GND pin beside the PBA bus.
     • If a -15 VDC power supply is present:
       • The yellow wire at -15 VDC power supply connect to V-. Black goes to V+.
         • Note! These connections are the opposite of the +15V connections.
       • The -15 VDC yellow wire goes to the -15V bus on the U6IFC, and NOT to the OC outputs on the other end of the CCA.
4. Verify the U6IFC ambient pressure sensor is oriented correctly.
   • Sensor pin 1 = BARO, pin 2 = GND, pin 3 = VS. Sensor pin 1 is at left when viewing the sensor's port face with the pins pointing down.
5. The enable wires (yellow or green) of ion gauges (AIMs) connect to U6IFC OC pins (OC0, OC1, etc.), and NOT to PBD.
6. The black fan wires are connected to the U6IFC OC outputs, and NOT to PBD.

   Note: The 5V power to the fan connectors is supplied by the +5 VDC SPS or another supply.

7. The +5V power connectors are oriented correctly (Black = GND) at the HC, SB, and AC stacks.
8. The COM connectors are oriented correctly (Green = GND) at the HCs, SBs, ACs, and at the USB-serial adapters.

First Time Power

1. Complete Pre-power Safety Inspection
2. Prepare for First Time Power
   • Temporarily remove the AC stack power from the SB and HC stacks.
   • Disconnect the pVM_IG (AIM) enable wire (yellow or green) from the U6IFC OC0.
   • Disconnect the fans from U6IFC OC1..OC4.
   • Unplug the Control Box USB cable from the laptop/host computer.

     Note: Do not plug this cable back in until instructed to do so later.

   • Unplug the Vacuum Pump System from the UPS.
   • Unplug the Mains Detector power supply from the UPS.
   • Install a 10A slow-blow fuse into Control Box fuse holder.
   • Plug the Control Box power cord (from the IEC power inlet) into a BATT+SURGE outlet on the UPS.
   • Plug the UPS power cord into a 120 VAC facility wall outlet.
3. Apply power
   • Connect the UPS Battery
     • Follow the instructions on the yellow sticker on the UPS
     • In case the sticker is missing, the instructions are as follows:
       • Push down and slide the side panel off of the UPS.
       • Lift up the battery using the plastic straps.
       • Plug the red cable into the battery's red+ terminal (AFC side facing up)
       • Place the battery back into its resting spot and replace the cover.
   • Turn on the UPS.
   • Turn the Control Box power switch on.
   • Observe that the DC power supply LEDs illuminate.
   • Ensure all USB LEDs are lit. Toggle the push-button switches as needed.
4. Adjust DC power supplies
   • Probe V+ (red lead) to V- (black lead) on the +5 VDC power supply with a portable voltmeter.
     • Adjust the potentiometer beside the LED to set the +5 VDC output.
       • If this supply is used for IP fans, then set the output to +5.5 VDC; otherwise set the output as close to +6.0 VDC as possible.

         Note: Usually, the maximum possible is about +5.7 VDC.

   • Probe V+ (red) to V- (black) on the +15 VDC power supply with a portable voltmeter
     • Adjust the potentiometer beside the LED to set the output to between +15.0 and +15.2 VDC.
   • If the -15 VDC power supply is present, probe V- (red) to V+ (black) with a portable voltmeter
     • Adjust the potentiometer beside the LED to set the output to between -15.0 and -15.2 VDC.
5. Spot-check DC power at test points on U6IFC
   • Connect a temporary ground test lead to a GND pin on U6IFC PBD and clip the portable voltmeter's reference test lead (black) to it.
     • Probe the +5V bus at PBD, and confirm a reading of +5.0 ± 0.5 VDC.
     • Probe the +15V bus at PBA, and confirm a reading of +15.0 ± 0.2 VDC.
     • If -15 VDC power supply is present, probe the -15V bus (red lead), and confirm a reading of -15 VDC.

Disable Windows USB Power Management and assign COM port IDs

The host computer must provide USB power at all times when the CEGS is running. Some CEGS pressure sensors and other devices receive power from USB, but do not communicate with Windows. If Windows is allowed to manage USB power, these devices will stop working at indeterminate times. Therefore, Windows must not be permitted to manage USB power.

1. On the USB Hub in the control box, turn off all of the ports connected to serial devices (toggle the push-button switch beside a port so its LED is off).
2. Plug the Control Box USB cable into the laptop/host computer.
3. (WINDOWS 10 ONLY) Disable Windows' USB selective suspend feature.
   • Open Control Panel and choose Power Options
   • Click Change plan settings, then Change advanced power settings.
   • Expand USB settings, and USB selective suspend setting beneath it.
   • Click to change Setting to Disabled.
   • Click OK to close the Power Options window and close Control Panel.
4. Open Device Manager and expand the Universal Serial Bus controllers group
   • Open every Generic USB Hub and USB Root Hub, select the Power Management tab, and

     Uncheck [ ] Allow the computer to turn off this device to save power.

5. Register the CEGS serial devices into USB COM ports in sequence, starting with the one farthest from the USB power cable (COM5).
   • Plug two temporary USBs into the laptop in sequence, and check that they register as COM3 and COM4 respectively.
   • Turn the port power on for each USB device in sequence.
     • Check in Device Manager that each device is assigned to a new COM port.
     • The control box USB hub COM ports should be numbered COM5, COM6, etc., in their physical order on the hub.
   • For each device, in Device Manager, under Ports:
     • Open the newly added COM port
     • Select the Power Management tab, and

       Uncheck [ ] Allow the computer to turn off this device to save power.

   • In Device Manager, enable "Show Hidden Devices" to show the inactive COM3 and COM4 ports, and right-click -> Uninstall the device on each port.

First Application Startup

1. Ensure all firmware is up to date: AC, HC, SB

   In general, CCA firmware programming and calibration is part of the CCA's construction, not system integration. However, CCA firmware should be updated to the latest release during integration if any changes have been made in the intervening time.

2. Use Serial Port Terminal to determine the COM port for each serial device.
   • Edit settings.json and set the COM ports accordingly.
3. For each controller (Device Manager), use Serial Port Terminal to determine the channel for each connected device.
   • Edit settings.json and populate the Devices list for the controller accordingly.
     • Heaters
     • Thermocouples
     • Solenoid Valves
     • CPW and RS232 Valves
     • Pressure Sensors
4. Start the new CEGS application.

Plug Valve Positions

• Closed: Adjust Value so the orientation line on bottom of stem crosses valve flow direction at 90° (~1700).
  • On the High Vacuum, Backing, and Roughing valves (vHV, vB and vR), also set the Configuration Value time limit to "t1".
• High Vacuum, Backing, and Roughing valves only (vHV, vB and vR):
  • Opened: Adjust Value so the orientation line aligns with valve flow direction (~700).
  • Also set the Configuration Value time limit to "t1".
• All other plug valves:
  • Opened: Adjust Value so the orientation line crosses valve flow direction at 45° (~1200).

LN Valve Positions

• FullyOpened: Adjust Value for best alignment of passage holes (~1000)
• Closed: Set Value to FullyOpened + 820
• Opened: ~1400 (to be adjusted after LN testing begins.)
• ColdTrickle (VTCs only): ~1400 (to be adjusted after LN testing begins.)
• WarmTrickle (VTCs only): ~1300 (to be adjusted after LN testing begins.)

Bellows-Sealed Valve (BSV) Positions

Note: Current and time limits may require later adjustment; this is determined after vacuum is established.

• Closed: 192 (192 is for a 2-turn range; use 288 for a 3-turn range)
• Opened: 0
• Open the valve's context menu and select Calibration.

Manual Furnaces

Caution: Before turning any furnace on for the first time, make sure there is no debris inside and vacuum the dust out of it.

1. Connect a Type K thermocouple to an open channel on a heater controller (tCal).
2. Insert tCal into hot zone of heater
   • For CCQ heaters, center the thermocouple into the quartz sugar of a prepared combustion tube, and
     position the combustion tube in the inlet port heaters (CCS and CCQ), where it goes in normal operation.
3. Set the heater's max power level to an appropriate value for the heater type
   • 15% for standard furnaces (GR, inlet, etc.)
   • 4% for VTT
4. Edit Test() to calibrate all desired furnaces on the system and hot reload the software.
5. Set MaxPowerLevel equal to or slightly above the adjusted PowerLevel.

1. If the furnace is correctly calibrated, the following conditions should be satisfied:
   1. From room temperature, the heater exceeds its minimum temperature limit within 10 minutes.
      • For CCQ heaters, the minimum temperature limit is 725 °C.
   2. The heater temperature stabilzes below its maximum temperature limit or remains below it for 80 minutes of operation.
      • For CCQ heaters, the maximum tempertaure limit is 900 °C.

GR Furnaces

Caution: Before turning any furnace on for the first time, make sure there is no debris inside and vacuum the dust out of it.

Accurate control of the Fe powder temperature is very sensitive to the position of the furnace on the Fe tube. This makes performance tuning these heaters (hGRx) more involved than the others. Adjust and configure the furnace as follows:

• Connect a Type K thermocouple to spare TC channel (tCal) on a system heater controller.
• Familiarize yourself with the furnace positioning adjustments. There are two ways to adjust the position.
  • Caution: Wear heat-resistant gloves when adjusting the furnace position.
  1. "Slide:" Loosen the furnace clamp and slide the furnace away from or toward the reactor. Re-tighten the screw to secure the furnace after making the adjustment.
     • Move the furnace away from the reactor to reduce tCal with respect to tGR.
     • Move it toward the reactor to raise tCal with respect to tGR.
  2. "Pivot:" Slightly loosen the clamp and slightly pivot the furnace about the clamp screw, then re-tighten the screw.
     • This finer adjustment is appropriate only for very small temperature corrections. Avoid it if possible.
     • The ideal pivot angle results in the Fe tube aligning straight into the furnace.
     • If pivoting causes a large change in the offset (tCal - tGR), or if an excessive pivot angle is needed to minimize the offset, adjust the furnace by sliding it in or out, as described above.
• Throughout the procedure, monitor the tGR and tCal temperatures reported by the heater controller both in the CEGS application and in the Data Visualizer.

1. If present, first remove the graphite reactor pressure sensor from its port.
2. Feed the tCal thermocouple through the pressure sensor port into the Fe tube, so the tip rests where the Fe powder goes.
3. Lower the furnace into position on the graphite reactor.
4. Configure the furnace for Manual mode and set the PowerLevel so tCal stabilizes between 550 and 580 °C.
5. Adjust the position of the GR furnace to minimize the offset tCal - tGR.
   • Try to achieve this using only the sliding adjustment described above.
   • During this adjustment, keep tweaking the PowerLevel as needed to keep tCal between 550 and 580 °C.
   • If small furnace adjustments cause wild offset swings, bend the tip of the tGR thermocouple slightly farther from the furnace wall. It must remain closer than the Fe tube to the hottest area in the furnace chamber.
6. Adjust the PowerLevel so tCal is between 575 and 585 °C.
7. Confirm that tCal - tGR remains between -5 and 0 °C.
   • If not, refine the furnace position to make it so. Use the pivot adjustment if needed.
8. Set the temperature setpoint of the furnace to 580 °C and switch it to PID control by turning manual mode off.
9. Turn the furnace off and allow it to cool to below 80 °C.
   • You can work on other furnaces while waiting. Be sure to restore tCal to the current furnace when resuming work on it.
10. Conduct a Step Test using the PID tuning.ods spreadsheet and enter the calculated PidSetup parameters into the settings file.
11. Final Performance Test
    1. Make sure the furnace is off and its temperature is below 40 °C.
    2. Ensure the furnace is configured for for automatic control.
    3. Set the GR's SampleSetpoint to 580 °C and turn the furnace on using the CEGS user interface.
    4. Closely monitor tCal as the temperature rises.
       • If tCal reaches 590 °C, immediately raise the furnace clear of the Fe tube and turn it off.
    5. Check the results. The furnace configuration is acceptable if all of the following conditions are met. If any condition is not met, adjust the furnace position, PidSetup parameters, and/or SampleTemperatureOffset, and repeat the test.
       • tCal never exceeds 590 °C
       • SampleTemperature must reach the setpoint in about 10 minutes (less is ok).
       • SampleTemperature must remain within 3 °C of the setpoint after reaching it.
       • One hour after SampleTemperature reaches the setpoint, tCal > 575 °C.
12. Remove the tCal thermocouple from the pressure sensor port and install the pressure sensor.

CCS Furnaces

Caution: Before turning any furnace on for the first time, make sure there is no debris inside and vacuum the dust out of it.

1. Conduct a Step Test using the PID tuning.ods spreadsheet and enter the calculated PidSetup parameters into the settings file.
2. Test the performance of the PID settings:
   1. Make sure the furnace is off and its temperature is below 40 °C.
   2. Ensure the furnace is configured for for automatic control.
   3. Set the furnace setpoint to 625 °C and turn the furnace on using the CEGS user interface.
   4. Monitor the temperature profile in the Data Visualizer.
3. Check the results. If all of the following conditions are met, the configuration is acceptable. Otherwise, adjust the parameters and repeat the test.
   • The furnace must reach the setpoint in about 10 minutes (less is ok).
   • The overshoot must not exceed 5 °C. (Zero overshoot is ideal.)
   • The indicated temperature must remain within 3 °C of the setpoint after reaching it.

VTC Warm Operation

1. Conduct a Step Test using the PID tuning.ods spreadsheet and enter the calculated VtcWarm PidSetup parameters into the settings file.
   1. Uncomment the VttWarmStepTest() in the Test() function, launch the software, and run Test(). Use the spreadsheet to calculate parameters from the output log
2. Test the Warm PID performance
   1. Make sure the heater is off and its temperature is below 40 °C.
   2. Ensure the heater is configured for for automatic control.
   3. Set the VTC setpoint to 50 °C and set the VTC to Regulate.
   4. Monitor the temperature profile in the Data Visualizer.
   5. Wait until five minutes after the VTC reaches setpoint.
3. Check the results. If all of the following conditions are met, the configuration is acceptable. Otherwise, adjust the parameters and repeat the test.
   • The VTC temperature must reach the setpoint in less than 5 minutes.
   • After reaching the setpoint, the temperature must not deviate from it by more than 1 °C.

Meters - Preliminary Settings

1. Determine each sensor's DAQ channel and update settings.json appropriately.
   • Most should already be done
2. Set the gain and offset for these pressure sensors to their nominal values:
   • pForeline
   • pVM_GP
   • pIM
   • pGM
3. Connect pCal to a spare DAQ channel and add it to the settings file, using an offset of 0, and setting the gain according to the meter calibration.ods spreadsheet.

   Note: pCal is a calibrated 0-1000 Torr capacitance manometer.

Establish Vacuum

1. Temporarily install pCal in place of pVM_LP.
2. Set pVM_LP to atmosphere by holding the "Play" button on the sensor until the sensor LED starts to flash.
3. Install culture tubes into every IP and GR.
4. Set the VacuumSystem to Standby, and manage the VacuumSystem valves manually until vacuum is established.
5. Start the Vacuum Station, and evacuate the entire line.
   • It may be necessary to begin with only the roughing pump.
   • It may be necessary to start with only the VM and expand the evacuated volume from there to identify and fix major leaks.
6. Find and fix any major leaks to achieve a pCal pressure of < 0.1 Torr (1e-1).
7. Manually zero (using Zero Now) these pressure sensors:
   • pForeline
   • pVM_GP
   • pIM
   • pGM
   • All pGRs
8. Isolate the VacuumSystem.
9. Isolate the Vacuum Manifold.
10. Re-install pVM_LP in place of pCal.
11. Set the VacuumSystem to Evacuate.
12. Wait for the pVM pressure to reach ≤ 0.1 Torr.
13. Set the VacuumSystem to Isolate.
14. Close all IP and GR ports and gas supply valves.
15. Manually open and join all sections to the vacuum manifold.
16. Set the VacuumSystem to Evacuate.
17. Wait for the pVM pressure to reach ≤ 0.1 Torr.
18. Find and fix any leaks to achieve pVM pressure of < 1e-2 Torr.
19. Connect pVM_IG Enable to its OC pin on the U6IFC.

Meters - Digital Filters

Examine each meter's settings and observe its displayed value. Refine the default settings as follows:

1. Ensure each meter's represented value is stable and within the sensor's range.

   Note: The represented value is the actual pressure, temperature, or whatever the sensor monitors. Make sure it is essentially unchanging. The observed voltage and indicated value may be fluctuating significantly, though.

2. Set Resolution to 1/100 to 1/10 the desired display resolution.
   • i.e., Resolution should have 1 or 2 more significant digits than the display

     Note: Filters need the fractional resolution to maximize effectiveness.

3. If the display value is exponential (e.g. "5.2e-3"), check ResolutionIsProportional (set true).
4. Set Sensitivity to the minimum deviation from zero that the sensor can reliably detect.

   Note: Sensitivity and Resolution are often equal.

5. Set MaxValue and MinValue to match the sensor's true output range.
6. Adjust the meter's digital filter. Use the weakest filtration that yields acceptable display flicker.
   1. Set Filter.StepChange to zero
      • [x] ResetSwing: SwingHigh and SwingLow should both change a bit.
   2. Wait 15-30 seconds.
   3. Set Filter.StepChange to two or three times the observed Swing value.
   4. Adjust the Filter properties to achieve adequate responsiveness with minimal display flicker:
      • ExponentialFilter (often best for significant high-frequency noise):
        • Adjust Power or StepChange
      • ButterworthFilter (may be better for signals with longer-term drift):
        • set Order to 2 and adjust CutoffFrequency

Meters - Voltage Correction and Unit Conversion

Factory-calibrated sensors

• General Procedure: Use the AIN Gain sheet of meter calibrations.ods to determine the divider-compensated voltage gain.
  1. Record the gauge's serial number in the spreadsheet.
     • Save the factory calibration data sheet for delivery with the system to customer.
  2. Use a precise voltmeter to measure divider input vs output, and enter them into the spreadsheet.
     • E.g., Measure the input voltage at "in" below for DAQ analog input 3 "ai3".

       

       Locations of the input and output voltages on the U6 interface.

       • Use the equivalent location for other DAQ channels.
  3. Enter the the filtered voltage from the meter's Properties panel into the spreadsheet.
  4. Note the "divider-compensated voltage gain" (CompensatedGain) calculated by the spreadsheet.
  5. In the settings file, enter or edit the Operation "CompensatedGain" in the meter's "VoltageCorrection" Conversion to multiply the DAQ input value by the CompensatedGain.
  6. Enter Conversion operations as needed to effect the sensor's transfer function and convert the output to the desired units.
     • Refer to the device's datasheet or other documentation to determine its transfer function.
• Measurement Chamber Pressure (pMC)
  1. Pressurize the sensor's chamber to ~90 Torr, according to pVM_GP.
  2. Configure pMC's gain using meter calibration.ods as described above.
• Coil Trap Pressure (pCT)
  1. Join sections CT..MC.
  2. Evacuate splits as needed to reduce the pressure to ~9 Torr, according to pMC.
  3. Configure pCT's gain using meter calibration.ods as described above.

Un-calibrated pressure gauges and thermisters

• Enter Conversion operations to effect each sensor's transfer function and convert the output to the desired units.

  Note: Voltage gain and unit conversion may be combined into a single Gain multiplier.

  • Determine the gain using 2-point "meter calibration" sheet of meter calibration.ods.
  1. Evacuate the sensor's chamber to < 0.01 Torr, then select Zero Now from the sensor's context menu.
     • It is ok to omit the GR pressure sensors (pGRx) from this evacuation and zeroing; keep the previously obtained offsets.
     • Enter 0 into the spreadsheet for both low true and indicated values.
  2. Open the sensor's chamber to atmosphere to observe its 'high indicated value' and use pCal as the 'high true value'.
     • Copy the existing offset and gain values from the sensor settings into the spreadsheet 'programmed values'.
  3. Copy the 'corrected values' gain and offset from the spreadsheet into the sensor settings.

• Ambient air pressure (pAmbient)

1. After calibrating another port pressure sensor in the system (e.g., pIM or a pGR), replace that calibrated sensor with a fresh one and use the calibrated one for pAmbient, instead. (I.e., move it onto the U6IFC BARO connector.)
2. Copy the gain and offset values for the 'stolen' calibrated sensor into pAmbient's settings.
3. Calibrate the replacement sensor as before.

• Ambient air temperature (tAmbient)

1. Use the nominal offset from the datasheet and set its gain so the actual lab air temperature is indicated.
   • Determine the lab air temperature using the NIST thermometer placed close to the sensor on the U6IFC CCA.

• Measurement Chamber Temperature (tMC)

1. Remove the thermistor from the CEGS and use the thermistor calibration station:
2. Insert the thermistor into the tester.
3. Adjust the excitation voltage to +5.000 VDC ± 2 mV.
4. Set the temperature to 15.0 °C (displayed on the reference thermometer), wait a moment for the thermistor output voltage to stabilize, and note the stabilized value, V15.
5. Similarly, set the temperature to 20.0, 27.0, and 35.0 °C, and note the stabilized voltages V20, V27, and V35.
6. Calculate the thermistor gain = (35 - 15) / (V35 - V15).
7. Calculate the thermistor offset = 15 / gain - V15.
8. Calculate the error E20:

   E20 = | (V20 - offset) * gain - 20 |

9. Calculate the error E27:

   E27 = | (V27 - offset) * gain - 27 |

10. Record the value of E20 or E27, whichever is greater.

    Note: The greater of E20 or E27 is the MC temperature uncertainty, which is needed for the Final Acceptance Test.

11. Reinstall the thermistor onto the CEGS Measurement Chamber.
12. Enter the calculated offset and gain and offset values into the sensor settings.

Review

• Confirm that the Control Panel meter displays remain reasonably stable:
  • Include "hidden" devices in Device Settings.
  • Adjust Filter settings as needed to eliminate excessive jitter in the displayed value while minimizing its stabilization time.
  • Configure DataLog columns with appropriate Resolution values.
    • In DataLogs, Resolution is the value change that will trigger an new log entry. Use -1.0 to ignore a column for triggering purposes.
  • Ensure reports are not triggered by noise, but only by true value changes or timeouts.
  • Double-check that DataLog file sizes are not excessive.

Vacuum Quality Check

1. Set the VacuumSystem to Isolate.
2. Close all IP and GR ports and gas supply valves.
3. Manually open and join all sections to the vacuum manifold.
4. Set the VacuumSystem to Evacuate.
5. Use the Data Visualizer to monitor VM pressure.
6. Wait 4 to 12 hours for pVM to approximately stabilize.
7. Perform Rate of Rise (RoR) tests using approximate chamber volumes to test for leaks.
   • Use rate of rise.ods for the calculations.
8. Assess the results and take corrective action as needed.
   • RoR < 3e-6 Torr: Excellent. Clean and leak-free.
   • RoR 3e-6 to 1e-5 Torr: Ok. Slight out-gassing or perhaps very small leak; monitor for trouble.
   • RoR 1e-5 to 1e-4 Torr: Dirty. Significant outgassing or small leak; correction recommended.
   • RoR > 1e-4 Torr: Leaking. Probably a significant leak, but could be a major outgassing issue; system unreliable.

Meters - Refine Zeros

Vacuum Manifold Low Pressure (pVM_LP)

1. Make sure the system is in the following state:
   • VacuumSystem is in Evacuate mode.
   • All sections are opened and joined to the Vacuum Manifold.
   • All IP and GR ports are closed
   • All gas supply valves are closed.
   • The ion gauge reading (pVM_IG) is less than 1e-4 Torr.
2. Manually zero pMC and pCT.
3. Wait until pVM_IG indicates 1.0e-5 Torr.
   • If pVM_IG < 1.0e-5 Torr, then set the VacuumSystem to Isolate, wait for pVM_IG to rise slightly above 1.0e-5 Torr, and then set VacuumSystem to Evacuate.
4. When pVM_IG indicates 1.0e-5 Torr, set pVM_LP to 1e-5 by holding "Play" button on the sensor until the sensor LED starts to flash.
5. Manually zero pVM_LP using Zero Now.

Foreline Pressure (pForeline)

1. Isolate the VacuumManifold, set VacuumSystem to Evacuate and wait for pVM < 5e-3.
2. Disable Auto Manometer, ensure pVM_IG is On and set the VacuumSystem to Standby.
3. Close vR, vB, and then Open vLV.
4. Wait for the pVM to drop to its minimum, then select Zero Now from pForeline's context menu.
5. Once Zeroing has completed, Close vLV, and then Open vB and vR
6. Switch VS back to Evacuate, and enable Auto Manometer.

Gas Cylinder Regulators

Adjust the gas cylinder regulators, using pIM or pGM to check pressure.

• O2: 1400..1500 Torr
• H2: 1400..1500 Torr (must be sufficient for graphitization of max sample)
• He: 850..900 Torr
• CO2: 200-800 Torr (lower is better, even < 200 is ok)

Procedure:

1. Purge the gas lines, if not done already
2. Isolate the VM connected to desired gas supply
3. Isolate the GM or IM section, depending on where the gas lines are attached to the system, and connect it to the VM
4. Isolate the Vacuum System, and open the flow valve connected to the desired gas supply.
5. Open the desired gas supply shutoff valve (next to the flow valve)
6. Observe the pressure given by pIM or pGM, and compare to the desired pressure. Adjust the gas regulator valve on the tank accordingly
   • When adjusting the regulator valve, always finish by turning the valve very slightly open.
7. Evacuate the line for 2-5 seconds with the shutoff valve open to bring the pressure down, then isolate the vacuum system again
8. Repeat steps 6-7 until the pressure is within the desired range for the gas supply
9. Close the gas supply shutoff valve, and evacuate the open sections to ensure no contamination
10. Repeat for all gas supplies

Flow Valves

1. Make sure the actuator is not installed. If it is, remove it as follows:
   1. Unplug the cable.
   2. Loosen the coupling set screw (1/16 hex key). This set screw secures the actuator coupling to the valve knob.
   3. Remove the actuator.
2. Set the mechanical knob stop for minimum flow rate while monitoring gas flow into vacuum.
   1. Adjust the knob set screw so the knob can turn the stem without running into the bonnet.

      To achieve this, loosen the knob set screw the least amount required to allow the knob to slide up and down on the stem shaft.

      (M-series: 5/64 hex key; S-series: 1/16 hex key)

      The set screw must still engage the flat on the shaft sufficiently that the knob can turn the stem.

   2. GENTLY close the valve until the force required to turn it just begins to increase, where the needle barely contacts the orifice.
   3. Set the upstream gas supply to the maximum process pressure. (If in integration, this should have just been done)
   4. Isolate the VM and vacuum system, then open the gas shutoff valve and begin evacuating the gas through the flow valve.
   5. Adjust the valve so the vacuum manifold pressure (pVM) pressure stabilizes below the process-required minimum purge pressure, but do not allow the needle to bind in the orifice.
      • If the required pressure is not readily achieved with no hint of the flow valve binding or jamming, remove and service or replace the flow valve.

      Notes:

      • Typically < 0.2 Torr is readily achievable, but it is better to adjust for the highest pressure that permits the desired process control performance.
      • On vacuum systems backed by a diaphragm pump, the ultimate foreline pressure may be significantly higher than 1 Torr, especially when pumping H2 or He.
      • In cases where the required minimum process pressure is below the achievable foreline pressure, the vacuum system must be configured so the high vacuum mode can draw the process pressure down to the required level. Because of the turbo pump's higher pumping speed, the minimum purge pressure can be reduced. The objective is to adjust the minimum flow rate; the minimum purge pressure serves as a proxy for that.
      • The minimum purge pressure for a gas supply is generally lower than the minimum controlled pressure to be delivered by the gas supply. The purge pressure must be low enough that the flow manager has sufficient time, after vacuum is removed, to check conditions and stop the flow before the pressure exceeds the minimum process value.

   6. From the valve position determined above, open the stem ~1/16 turn (22.5 deg).

      M-series valve only:

      1. Remove the knob and install a positive stop spacer onto the stem.
         • Aeon plastic washer-like part 0.350 OD x 0.1875 ID x 0.0625 thick.
      2. Slide the knob back onto the stem, oriented so the knob set screw aligns with the flat on the shaft.

   7. Squeeze the knob firmly against the stop spacer (M-series) or bonnet (S-series) and securely tighten the knob set screw.

      M-series: 5/64 hex key; S-series: 1/16 hex key.

      Note: The set screw must engage the flat on the valve stem shaft.

3. Close the gas shutoff valve.
4. Install the actuator.
   1. Install the actuator bearing block if it is not already installed.
   2. Turn the valve stem in the open direction until its set screw is opposite the most convenient access to the actuator coupling set screw.

      Note: The actuator coupling set screw should engage the knob on the side opposite the knob's own set screw.

   3. Slide the assembled actuator onto the valve knob, so the frame engages the actuator bearing block and the actuator connector points in the right direction.

      Be particularly careful positioning the actuator onto the medium flow valve.

      The horizontal parts of the frame must not contact the bearing block even when the valve is completely closed.

   4. Tighten the actuator coupling set screw (1/16 hex key).
5. Execute the "Calibrate" option from the valve's context menu.

GasSupplies

1. Check the GasSupplies section in the settings file and make sure the gas supply presets are reasonable
   • PurgePressure = 10.0 and SecondsToPurge = 20 are reasonable values
2. Define a sample in the CEGS software if one isn't already defined
   • This can be done most easily through selecting the desired inlet port and clicking the "Edit Sample" option.
3. Test each gas supply at its process pressure extremes.
   • Run Test() with TestGasSupplies() enabled.
     • This runs TestAdmit() for GasSupplies without flow valves and TestPressurize() for those with flow valves:
     • Make sure to edit the parameters of the functions to select the proper pressures and chambers
4. Adjust GasSupply properties as needed to deliver the specified pressure of gas to the destination volume.
   • gs_H2_GM: 100 ± 2 Torr and 900 ± 9 Torr
     • also test Admit() (for systems that flush with H2 instead of He)
   • gs_He_MC: 80 ± 2 Torr -or- gs_O2_MC: 80 Torr (for volume calibrations)
   • gs_He_GM: 800 ± 2 Torr (not strictly required for systems with no vial ports)
   • gs_CO2_MC: 75 ± 3 ugC and 1000 ± 3 ugC

Chamber Volumes

1. Install a Known Volume chamber into an MC aliquot expansion port.

   Note: see the settings file for which one to use.

2. Run “Measure MC volume (KV in MC port)”.
3. Remove the Known Volume and replace it with a stainless steel plug.
4. Run "Measure valve volumes" (This adjusts MC volume and calculates OpenedVolumeDelta.)
5. Open the Sample Data.txt file.
   1. Copy the data from the two tests above into the chamber volumes.ods spreadsheet.
   2. Update the settings file with the OpenedVolumeDelta from chamber volumes.ods.
6. Remove the stainless steel plug and replace it with the expansion chamber.
7. Run "Measure remaining chamber volumes".

LN manifold

1. Remove the phase separator and LN manifold top.
2. Ensure the LN manifold spring is wedged between the back of the LN manifold body and frame.
3. Illuminating from below with a bright light, find the Fully Opened position for each valve.
4. This is the position where the top of the passage hole in the stem is best aligned with the bottom of the narrow passage hole in the LN manifold.
5. The orientation mark on the stem should be straight up, or nearly so, off only as much a needed to best align the stem and manifold passages.
6. Insert a rod (0.039 OD springback wire) through the manifold passage, well into the stem.
7. Pivoting on the stem, move the wire back and forth, longitudinally along the stem, to shape the manifold passage so it fully exposes the top of the stem passage.

LN valve flow rates

1. Set a coldfinger to "Freeze"
2. Wait for the LN manifold to fill (3-4 mins)
3. Once the coldfinger valve opens, closely monitor the FTC drain tube, making sure that LN doesn't drain too quickly
   • The ideal FTC behavior is the valve closing right as LN starts to drip out of the drain tube, so that the coldfinger fills as quickly as possible without overflowing significantly.
   • A few drops of LN leaking out is ideal, just not too many
4. Over a few cycles, monitor the Coldfinger Data temperature in the Data Visualizer
   • The waveform should look like a sawtooth, with the LN bringing the temperature down as fast as possible, then the temperature slowly rising until the valve opens again.
5. Adjust the valve open position to control the LN flow rate, and the coldfinger FrozenTemperature to control the temperature that the valve opens at.
   • Adjust these parameters so that the drain overflow and waveform guidelines are met as closely as possible.
6. Large changes in the Open operation's Value may require a software restart to take effect if the valve's center position is not dynamically updated.
7. VTC LN valve ColdTrickle must be sufficient to maintain a virtually continuous minimal trickle from the drain when the VTC heater is off; the LN level trace must stay at the bottom.

VTC Cold Operation

1. Temporarily alter the settings as follows:
   1. Create a temporary Type T thermocouple "tCal" on a free TC channel of a convenient heater controller.
   2. Create a Temporary DataLog (e.g., Temporary data.txt):
      • Columns: tCal, tLN_VTC
      • ChangeTimeoutMilliseconds: 5000
   3. Change the VTC's heater from hVTC to another heater (e.g., hGR1)
   4. Adjust vLN_VTC's ColdTrickle Value by -50 (50 towards open).
   5. Change tVTC's Type to None.
   6. Change hVTC's' Manual Mode to true.
2. Move the tVTC connector to the tCal channel.
3. Set the VTC to Freeze.
4. Monitor the temperature profile in the Data Visualizer.
5. Wait 10 minutes after VTC's LN valve starts using the ColdTrickle setting.
6. Wait until the VTC temperature is below -180 °C.
7. Control hVTC manually to conduct a Step Test using the PID tuning.ods spreadsheet.
8. Make a note of the precise time CO is changed to the high value.
9. Use the Temporary DataLog.txt as the PID tuning.ods data source.
10. Restore the system to its original configuration.
11. Move the tVTC connector back to its configured channel.
12. Enter the calculated "VtcCold" PidSetup parameters into the settings file.
13. Adjust the VTC LN valve's WarmTrickle.

    The Value must be sufficient to maintain a virtually continuous minimal trickle from the drain when the VTC heater is regulating at -140 °C. The LN level trace must stay at the bottom.

14. Test the Cold PID performance
    1. Set the VTC to Freeze.
    2. Monitor the temperature profile in the Data Visualizer.
    3. Wait until the VTC temperature is below -180 °C.
    4. Set the VTC setpoint to -140 °C and set the VTC to Regulate.
    5. Wait until five minutes after the VTC reaches setpoint.
15. Check the results. If all of the following conditions are met, the configuration is acceptable. Otherwise, adjust the parameters and repeat the test.
    • The VTC temperature must reach the setpoint in less than 2 minutes.
    • After reaching the setpoint, the temperature must not deviate from it by more than 2 °C.

13C He pressure -- omit if there are no 13C ports

Run “Calibrate d13C He pressure”

GR H2 density ratios

1. Run "Check GR H2 density ratios"
2. Analyze the data from the "Sample data.txt" log and set the H2DensityAdjustment property to the average.
   • TODO: update code to automatically store calibration data (currently only collects data)

Software Testing

1. Make sure each ProcessDictionary entry has been run at least once.
   • (Processes that are used during FAT may be skipped.)
2. Make sure each sample Process sequence has been run at least once.
   • (Sequences that are used during FAT may be skipped.)

AC power transformer

(220V installations only) Ensure the AC transformer safely converts the delivery site mains power to 120 VAC with 0V between Neutral and Ground.

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Final Acceptance Test

Notes

• During the procedure, record the test data in a CEGS FAT data sheet.ods.
• Data collected during Integration may be used if all conditions that affect the recorded data are unchanged.
• If any observed value fails to meet the expected value, adjust or correct the faulty condition, and then re-test all affected specifications.
• Fix any incidental problematic issues that are discovered during FAT.
• A "reference thermometer" is any NIST-traceable, calibrated thermometer. Multiple thermometers of different types may be used. Throughout this procedure, a reading from a reference thermometer is denoted TREF.
• Throughout this procedure, a device's "indicated temperature" TIND is taken from a display for that device in the CEGS application. The value may be observed in the application's main user interface, a device's Properties page or state popup, or from a Device Settings page.

Factory configuration

• Inlet ports: Record the count.
• Graphite reactors: Record the count.
• Optional features: Record any significant optional features.

Measurement Chamber

• MC volume: > 13 mL
  • Record the average of 5 volume calibration runs with a known volume.
• MC volume uncertainty: < 0.1 mL
  • Record standard deviation of 5 volume calibration runs with a known volume.
• MC pressure sensitivity: < 1 Torr
  • Disable auto-zero.
  • Record zero drift (±) over 5 minutes under vacuum < 1e-4 Torr
  • Enable auto-zero.
• MC pressure uncertainty: < 0.2% of reading
  • Record the pressure sensor's uncertainty from the manufacturer's specification data.
• MC temperature uncertainty: < 1 °C
  • Record the value determined for the MC thermistor during System Integration.

Vacuum System

• Ultimate vacuum pressure: < 1e-4 Torr
  1. Record the ultimate vacuum pressure with the line evacuating fully open except for the inlet ports and graphite reactors, which should be closed.
  2. It may take 24 hours or more for the system to reach ultimate vacuum, especially if baked-out O-rings are not used.
  3. The ultimate vacuum pressure for a standard system will be significantly higher than that for a low-level system, strictly due to the total length of elastomer seals.
• Rate of rise: < 3e-5 Torr L / s
  1. Evacuate the IM..GM+VM section for 4 to 24 hours.
  2. Keep the IM and GM port valves closed.
  3. Observe the pIG pressure "P0".
  4. Set the vacuum system to Manual Manometer.
  5. Isolate the vacuum system and start a timer.
  6. After 120 seconds (or more), observe the pIG pressure "P1" and the elapsed time "dt".
  7. Set the vacuum system to Auto Manometer.
  8. Calculate CV, the total chamber volume in liters (sum of all the connected chamber volumes being evacuated).
  9. Calculate the change in pressure dP = (P1-P0).
  10. Calculate and record the rate-of-rise Q = V * dP / dt. (Torr L / sec)

Quartz furnace

• Maximum temperature: Record the value from the manufacturer datasheet provided with the furnace.
• Temperature at 10 minutes: > 725 °C
  1. Select a random inlet port.
  2. Insert a reference thermometer's Type K thermocouple into a prepared combustion chamber, so the thermocouple tip is approximately centered within the quartz sugar.
  3. Place the combustion chamber with the thermometer into the inlet port furnaces.
  4. Set the inlet port's CCQ PowerLevel to its previously calibrated value and turn the furnace on.
  5. Wait 10 minutes.
  6. Record the reference thermometer temperature.
  7. Turn the furnace off.

Combustion furnace

• Maximum temperature: Record the value from the manufacturer datasheet provided with the furnace.
• Temperature error at 150 °C: | e | < 10 °C
  1. Select a random inlet port.
  2. Set the CCS setpoint to 150 °C and turn it on.
  3. After the furnace reaches the setpoint, wait at least 10 minutes before continuing.
     • The delay allows the temperature gradient in the furnace insulation to normalize. The power level needed to maintain the setpoint temperature will fall during this time.
  4. Switch the furnace to manual mode.
  5. The CCS's indicated temperature may drift significantly; wait for it to stabilize again, then note the indicated temperature TIND.

- IMAGE -

• 1. Disconnect the heater's thermocouple from its heater controller, connect it to a Type K reference thermometer, and note the reference thermometer temperature TREF. Reconnect the heater's thermocouple to its heater controller.
  2. Calculate and record the temperature error:

     e = TIND - TREF

• Temperature error at 350 °C: | e | < 10 °C

  Follow the same procedure as for 150 °C, but with a setpoint of 350 °C.

• Temperature error at 625 °C: | e | < 10 °C

  Follow the same procedure as for 150 °C, but with a setpoint of 625 °C.

• Temperature error at 850 °C: | e | < 20 °C

  Follow the same procedure as for 150 °C, but with a setpoint of 850 °C.

• Temperature error at 625 °C (repeat): | e | < 10 °C

  Repeat the temperature error at 625 °C test.

• Stability at setpoint (625 °C): < ± 3 °C
  1. Check the Data Visualizer CCS traces from the two 625 °C temperature error tests.
  2. Observe the temperature fluctuations that occurred after the temperature stabilized at the setpoint.
  3. Record the absolute value of the most extreme deviation from setpoint.
• Repeatability at 625 °C: < 2 °C
  1. Record the absolute value of the difference between the two 625 °C temperature errors.

Variable temperature coldfinger

• Maximum temperature: 52 °C (record this fixed value)
• Minimum temperature: -195.8 °C (fixed value)
• VTC temperature error at ambient: | e | < 5 °C
  1. Set the VTC to Thaw. After, it automatically switchs to Standby, wait at least 10 minutes until its indicated temperature TIND stabilizes near room temperature.
  2. The delay allows the temperature gradient in the VTC insulation to normalize, reducing the error due to the time elapsed between the TIND and TREF observations.
  3. Disconnect the VTC's primary thermocouple from its heater controller, connect it to a Type T reference thermometer, and note the reference thermometer temperature TREF. Reconnect the VTC thermocouple to its heater controller.
  4. Calculate and record the temperature error:

     e = TIND - TREF

• VTC temperature error in liquid nitrogen: | e | < 5 °C
  1. Set the VTC to Freeze. Wait at least 5 minutes after its LN Level sensor stabilizes near -195.8 °C.
  2. Note the indicated temperature TIND for the VTC's LN Level sensor.
  3. Calculate and record the temperature error:

     e = TIND - (-195.8)

• VTC temperature in "Freeze" mode: < -180 °C
  1. Set VTC to Freeze.
  2. Wait 10 minutes after VTC's LN valve starts using the ColdTrickle setting.
  3. Record the indicated VTC coldfinger temperature.
• VTC regulating at -140 °C, stability: < ± 2 °C
  1. Set the VTC setpoint to -140 °C and set the VTC to Regulate.
  2. Wait at least 5 minutes after the temperature stabilizes.
  3. Check the Data Visualizer VTC temperature trace from the -140 °C test.
  4. Observe the temperature fluctuations that occurred after the temperature stabilized at the setpoint.
  5. Record the absolute value of the most extreme deviation from setpoint.
• VTC regulating at 50 °C, stability: < ± 1 °C
  1. Set the VTC setpoint to 50 °C and set the VTC to Regulate.
  2. Wait at least 5 minutes after the temperature stabilizes.
  3. Set the VTC to Standby
  4. Check the Data Visualizer VTC temperature trace from the 50 °C test.
  5. Observe the temperature fluctuations that occurred after the temperature stabilized at the setpoint.
  6. Record the absolute value of the most extreme deviation from setpoint.

Graphite reactor

• Maximum temperature: 900 °C (record this fixed value)
  1. Select a random graphite reactor.
  2. Remove the graphite reactor pressure sensor from its port.
  3. Pass a reference thermometer's Type K thermocouple through the pressure sensor port into the Fe tube, so the tip rests where the Fe powder goes.
  4. Lower the furnace into position on the graphite reactor.
  5. Temperature error at 400 °C: | e | < 10 °C
     1. Set the furnace to 400 °C and turn it on.
     2. Wait for the temperature to stabilize.
     3. Record the difference between the SampleTemperature TIND and the reference thermometer temperature TREF. (TIND - TREF)
  6. Temperature error at 580 °C: | e | < 10 °C
     1. Set the furnace to 580 °C and turn it on.
     2. After the furnace reaches the setpoint, wait at least 10 minutes before continuing.
     3. The delay allows the temperature gradient in the furnace insulation to normalize. The power level needed to maintain the setpoint temperature will fall as a result, and the reference thermometer temperature will fall due to the reduced radiant energy from the heating element.
     4. Record the difference between the SampleTemperature TIND and the reference thermometer temperature TREF. (TIND - TREF)
     5. Turn the furnace off.
  7. Temperature error at 580 °C (repeat): < 10 °C
     1. Wait for the furnace temperature to fall below 400 °C.
     2. Set the furnace to 580 °C and turn it on.
     3. After the furnace reaches the setpoint, wait at least 10 minutes before continuing.
     4. Record the difference between the SampleTemperature TIND and the reference thermometer temperature TREF. (TIND - TREF)
  8. Stability at setpoint (580 °C): < ± 3 °C
     1. Check the Data Visualizer GR SampleTemperature traces from the two 580 °C temperature error tests.
     2. Observe the temperature fluctuations that occurred after the temperature stabilized at the setpoint.
     3. Record the absolute value of the most extreme deviation from setpoint.
  9. Repeatability at 580 °C: < 2 °C
     1. Record the absolute value of the difference between the two 580 °C temperature errors.
  10. Remove the reference thermometer thermocouple and re-install the GR pressure sensor.

CO2 transfer efficiency

• Create a new Dead CO2 sample with Sample ID = 5 and Sample mass = 0.9 mg
• MC → VTT → MC extraction and transfer efficiency: > 97%
  1. Run "Measure Extraction efficiency".
  2. Record the transfer efficiency.
• MC → GR → MC transfer efficiency: > 97%

  Note the mass of the sample in the MC, m0.

  1. Run "Transfer CO2 from MC to GR".
  2. Run "Transfer CO2 from prior GR to MC".
  3. Run "Measure" to obtain the final mass, m1.
  4. Record the transfer efficiency, 100 * m1 / m0.
• MC → GR → IP → MC collection and transfer efficiency: > 97%
  1. Install a sample transport vessel into a graphite reactor.
  2. Open the transport vessel valve.
  3. Evacuate the graphite reactor.
  4. Open the path from the MC to the GR and evacuate it to OkPressure.
  5. Isolate the graphite reactor.
  6. Run "Admit Dead CO2 into MC" and note the mass measured after clean up, m0.
  7. Evacuate the GR to OkPressure.
  8. Isolate the path from MC to GR.
  9. Put LN on the transport vessel in the GR.
  10. Open the path from MC to GR.
  11. Wait 4 minutes for the CO2 to transfer into the vessel.
  12. Raise the LN level on the vessel ~ 1 inch.
  13. Wait for the LN to settle.
  14. Close the vessel valve.
  15. Isolate the graphite reactor.
  16. Remove the LN from the vessel.
  17. Remove the vessel from the graphite reactor.
  18. Install the vessel into an inlet port.
  19. Evacuate the inlet port to OkPressure.
  20. Isolate the inlet port.
  21. Open the vessel valve.
  22. Create a new sample at the inlet port:
      • Lab ID: IPCE test
      • Mass: <m0>
      • Port type: Manual
      • Process Sequence: Collect and Measure
  23. Run "Run Samples" and select the "IPCE test" sample.
  24. Note the measured final mass, m1.
  25. Record the transfer efficiency, 100 * m1 / m0.

FAT sample test suite

• Samples: Process the following samples in order.
  • AAG blank, 1 mg, "Graphite"
  1. Ox2, 15 mg, "Oxalic acid"; divide into 3 aliquots
  2. AAG blank, 2 mg, "Graphite"; divide into 2 graphites
  3. Empty organic blank (prepared combustion tube, no sample), "Combust, Measure"
  4. C7, 4.7 mg, "Oxalic acid"
  5. 90 mL volume of lab air, ~100 mg, "Collect, etc"
  6. Aeon 194.2, 2.6 mg, "Organic"; difficult sulfur sample, AMS not required
• Results assessment:
  • Empty blank level (equivalent µg C): < 1 µg C
    1. Record the carbon mass from the empty organic blank sample.
  • Highest mass C measured: > 2700 µg C
    1. Record the highest carbon mass measured of all test samples.
  • Highest mass C graphitized: > 900 µg C
    1. Record the highest carbon mass graphitized of all test samples.
  • Lowest mass C graphitized: < 50 µg C
    1. Record the lowest carbon mass graphitized of all test samples.
  • Lowest C yield: < 0.05%
    1. Record the lowest carbon yield of all test samples.
  • Highest 14C activity: ~ 1.3407 fM
    1. Record the average 14C activity of all Ox2 aliquots.
  • Average AAG 14 activity, above AMS blank: ~ 0.002 fM
    1. Record the average 14C activity of all AAG aliquots.
  • AAG standard deviation (N=3): < 0.002 fM
    1. Record the standard deviation of all AAG aliquot activities.
  • 14 activity of C7: ~ 0.4953 fM
    1. Record the 14C activity of the C7 sample.
  • Aeon 194.2 successfully graphitized in nominal time: PASS
    1. Record PASS if the sample successfully graphitized in about the same amount of time as the C7 sample.

Delivery

Cleanup HACS Host Computer / Laptop

1. Close all plug and bellows-sealed valves in the system.
2. Fully open all the flow valves.
   • Gas supply flow valves
   • CT Flow valve
   • FTG and TF Flow valves

Crate Creation

• Build the crate

Loose Item Removal

Prepare the system for transport:

1. Follow the shutdown procedure in the CEGS Manual
2. Follow the disconnection procedure in the CEGS Manual
3. Weigh the fully assembled system

Boxes

• Laptop box
  • Use the original equipment manufacturer (OEM) box that came with the laptop.
• (Optional) Mains Converter Box:
  • If applicable, use the OEM box provided with the mains power converter. Ensure the converter is well-padded for protection, as the OEM-provided packing may not be sufficient.
• UPS Box
  • Utilize the OEM box provided with the Uninterruptible Power Supply (UPS). Be cautious to prevent anything from touching the front display panel of the UPS to avoid marring it during transit.
• Standard Parts Boxes
  • Use 12x12x7 boxes as needed. Group similar or related items together whenever possible. Pack supplementary items together, which include tools, consumables, and spares that are not actual components of the CEGS.

Removal Procedure

• Wrap each item when removing it, but do not pack until all items are collected
  • To wrap, enclose the item(s) within protective material, such as bubble wrap or bags, to safeguard them during transport. Ensure that each wrapped item is labeled for easy identification.
• Remember to plug or cap any openings after something is removed from it.

1. Remove all culture tubes from GRs and IPs. Do not wrap or pack these items. Return them to in-house storage for future use.
2. Remove IP cold traps from IPs. Add them to "Inlet port kits".
3. Disconnect the Vacuum Pump System:
   1. Loosen the ORS fitting at the CEGS VM to detach the HV line (large bellows tube) from the CEGS. Keep the QF clamp and fitting assembled to the HV line.
   2. Loosen the ORS fitting at the CEGS VM and disconnect the two connectors to detach the Foreline and vBvR cable harness from the CEGS.
   3. Detach the HV line from the Vacuum Pump System:
      • Release and remove the smaller QF clamp and its centering ring from the top of the turbo pump. Bag the clamp and ring.
      • Cap both ends of the HV line.
      • Cap the QF adapter on top of the turbo pump.
   4. Loosen the ORS fitting at the Vacuum Pump System tee and disconnect the two connectors to detach the Foreline and vBvR cable harness from the Vacuum Pump System. These two items are removed and bagged as a unit. Plug the Vacuum Pump System's ORS fitting from which the foreline was removed.
   5. Release and remove the QF16 clamp and its centering ring from the turbo pump outlet. Cap the turbo pump's QF16 outlet.
   6. Release and remove the QF16 clamp and its centering ring from the roughing pump inlet. This frees the Vacuum Pump System's vBvR assembly. Wrap this for packing. Cap the roughing pump's QF16 inlet.
4. Remove the following cables:
   • Vacuum Pump System power cord
   • Control box power cord
   • USB 3.0 SS cable
   • LN supply cable harness
   • AIM-X cable adapter
5. Remove the mains detect power cube from the mains detect cable.
6. Coil the mains detect cable and secure it to the CEGS with a wire-tie.
7. Remove the heavy pressure sensors: pLP, pCT, pIG, pMC (and additional sensors on some systems: pIM, pGM, pForeline, and pHP).
   • Note: All 3-pin pressure sensors (pIM, pGM, pForeline, pGP) remain on the CEGS. For each removed sensor, secure its connector to the CEGS with a wire-tie.
8. Remove the CO2 cylinder and adapter assemblies MCP1 and MCP2. Take care not to mix them up. Ensure both are labeled "MCP1" or "MCP2" directly on the cylinder.
9. Remove the LN supply tube(s) and flow restrictors from the LN supply plumbing. Be careful to catch the flow restrictor, as it often falls free as the tube comes out of the fitting. Bag the flow restrictor(s), but set aside the LN supply tube(s) for wrapping later with the FTC LN tubes.
10. Loosen the 6-32 setscrew(s) that secure the phase separator rod(s). Remove the phase separator rod(s) and cross grip(s). Bag them assembled into "phase separator parts".
11. Remove the LN Phase separator(s) and phase separator pad(s). Add the pad(s) to "phase separator parts".
12. Temporarily remove the LN manifold top(s). The top is wrapped assembled to its manifold.
13. Remove the LN manifold TC locator and TC clip. Bag them together.
14. Put the LN manifold top(s) back on the LN manifold(s).
15. Identify each LN valve actuator with its position number (mark the number on tape).
16. Remove and separately wrap each LN valve actuator. Do not disassemble the valve stems or collars from the actuators. Be careful to catch all servo spacers and screws. Count the servo t-nuts, servo spacers, and screws, and bag them together by type (3 bags).
17. One by one, remove each LN manifold together with its top, tube retainer, and attached inline phase separator parts. Place the LN manifold upside down on a work surface.
18. Remove the LN tube retainer together with the attached tube+shroud+e-clip assemblies. Identify any special/non-interchangeable tube+shroud assemblies. Remove and bag these individually (still assembled). Remove the remaining (identical) tube+shroud assemblies and bag them together along with all of the e-clips (counted). Bag the LN tube retainers, keeping them flat.
19. Remove the FTC air tubes and bag them all together.
20. Remove the manual air shutoff valve and short tube from the inlet of the compressed air filter+regulator.
21. Remove the FTC LN tubes with inline phase separator funnel attached. Wrap them together with the LN supply tubes. These will be secured to the CEGS later.
22. Loosen the ORS fittings and remove the glass elements (MC, VTC, CT) together with their FTCs. Keep the glass inside its FTC. The FTC will remain tethered to the CEGS by thermocouple leads. Wrap each of these FTCs, ensuring the open glass ends are covered by the wrapping. Do not attach the FTCs to the CEGS at this time.

Wrapping

To wrap, enclose the item(s) within protective material, such as bubble wrap or bags, to safeguard them during transport. Ensure that each wrapped item is labeled for easy identification.

Gather all remaining loose parts and wrap them as needed for packing:

• System documentation (manuals, calibration certificates, etc.)
• Laptop
• Laptop cord/charger
• Mouse (turn it off)
• UPS
• Remaining "Inlet port kits" parts:
  • Inlet port adapter sets (1 set per IP):
    • Breakseal
    • Needle port kit:
      • Adapter 3/8 Luer
      • Stopper white silicone #5
  • IP cold traps (collected above)
• VTC LN overflow cup
• Consumables starter kit (refer to IDB for itemized list)
• "Spare parts":
  • (3) 1/4 ORS seat
  • (1) 3/8 ORS seat
  • (1) 1/2 ORS seat
  • (2) LN+air+TC grip snap
  • (1) Cross grip 1/4
  • (1 or 2) FEP tubing 5 ft
  • (1 or 2) LN sleeving 5 ft
  • (2) Servo spacers
  • (4) Gas supply nut & ferrule sets
• "Special tooling set":
  • CC loading template
  • Blow gun with 1/8 OD x 8" nozzle
  • 1/4 push tee
  • PU tubing clear blue 1/4 x 5/32 x 6 ft
  • Fe powder pickup probe
  • Fe powder magnet
  • Fe powder magnet tall
  • Sample tube loading set:
    • (2) Sample loading funnel
    • Sample loading straw
    • To be added in the future:
      • Bead funnel (need source!?)
  • Not previously included, add:
    • (2) Bio Quip tweezers (perchlorate and sample)
    • Techni-tool 2AD flat tweezers
    • Bead screen for quartz sugar reclamation beaker
  • Special maintenance tooling required by installation team:
    • Special tools for installing LN valve actuators
    • LN manifold passage tool
• Optional:
  • LN tank scale
  • Maintenance tooling set
  • Hold-down bolt/nut hardware for frame

Packing

Pack the loose items into boxes; see checklists below for box suggestions. Review the box checklists to ensure that everything is present. Items may be packed in different boxes than suggested by the checklists, but they must be present unless specifically omitted by the system.

• Note: Quoted items in these lists are to be wrapped together and labeled with the quoted text.

Parts Box 1:

• System documentation (manuals, calibration certificates, etc.)
• LN manifold(s)
• LN phase separator(s)
• After packing UPS box, additional lightweight items may be added as may fit.
  • Avoid heavy items and those with hard protrusions.

Parts Box 2:

• Pack whatever fits after packing Parts box 1.
• HV line (with QF fitting assembled at CEGS end)
• Foreline with vBvR cable harness
• Vacuum Pump System inlet (QF25) clamp and ring
• TP inlet adapter
  • QF40 x QF25 adapter
  • QF40 centering ring (screened)
  • QF40 clamp
• vBvR assembly
  • TP outlet (QF16) clamp and ring
  • RP inlet (QF16) clamp and ring
  • vBvR cable harness
• LN supply plumbing
  • "LN supply parts":
    • Flow restrictor(s)
    • Compression insert(s)
• VTC LN overflow cup
• Pressure sensor pMC
• FTC air lines
• MCP1 and MCP2
• "Free spares"
• "Cables"
  • Control box power cord
  • USB 3.0 SS cable
  • Vacuum Pump System power cord
  • LN supply cable harness
  • Ion gauge cable adapter

Parts box 3:

• Pack whatever fits after packing Parts box 2.
• Pressure sensors pIG, pLP, pCT
• Mains detect power cube
• Air shutoff valve
• "Consumables starter kit"
• "Special tooling set"
• "Inlet port kits" (1 kit per IP)
  • IP cold trap
  • Inlet port adapter set
    • Breakseal
    • Needle port kit
      • Adapter 3/8 Luer
      • Stopper white silicone #5
• "LN manifold parts"
  • Tube retainer(s), TC locator, TC clip
  • LN actuators
  • LN actuator screws
  • Servo spacers
  • Servo t-nuts
• "Phase separator parts"
  • Phase separator rod(s) with cross grip(s)
  • Absorbent pad(s)
• "FTC inline phase separators"
  • Tube+shroud, e-clips only
  • Individually ID'd and bagged special/non-interchangeable ones

UPS Box:

• Take items planned for other boxes if doing so is helpful.
• Caution: Pack pre-padded items only, and only along the sides and back. Do not pack anything touching the front panel.
• UPS
  • Pressure sensors pLP, pCT
  • Mains detect power cube
  • Air shutoff valve
  • Control box power cord
  • USB 3.0 SS cable
  • "Phase separator parts":
    • Phase separator rod(s) with cross grip(s)
    • Absorbent pad(s)
  • "Special tooling set"

Laptop Box:

• Laptop
• Laptop cord / charger
• Mouse (turned off)

Mains Converter box

• Mains power converter (re-pad with resilient packing as needed)

Optional

• LN tank scale
• Maintenance tooling set
• Hold-down bolt/nut hardware for frame

CEGS Packing and Shipping

1. Plug openings checklist:
   • HV, LV connections
   • Pressure sensors:
     • pCT, pMC, pLP, pIG
   • Glass ports:
     • CT, VTT, MC
     • GRs: Fe, perchlorate
     • IPs: (if cold traps are not removed)
2. Cap openings checklist:
   • IPs: cap tubes
   • Turbopump inlet and outlet, roughing pump inlet
3. Secure & support movable CEGS components
   • IP furnaces
     • Lock furnaces in fully raised position
     • Prop support under carriage wheels, zip tie to glides
       • Measure distance H between top of foot bar and bottom of wheels
       • Cut 1 x 1 x H+1/4 sticks of blue foam (1 for each carriage end)
       • Wedge the sticks between the foot bar and wheels
       • Secure each stick to the adjacent glide with zip ties in two places
     • Pad between CCS, CCQ, secure with two pins per group of furnaces
       • Use 1/16 x 2 blue foam long enough to protect each group of furnaces
       • Use 0.025 x 6 SS spring wire for pins
       • Add a 1/2 x 1/2 "sugar cube" of blue foam onto the top of each pin
       • Wedge half of the cube into top of CCQ to secure the pin
   • GR furnaces
     • Cut 2 x 1 sticks of blue foam long enough to support each bank of furnaces
     • Use sticks to pad behind the GR furnace arms, with a 2-inch face touching the tops of the furnaces
     • Tightly zip-tie each arm to bottom stop bar
   • GR FTCs
     • Wire-tie the FTCs to magnet bar
   • Glass ports
     • Wire-tie the CT, VTC, and MC FTCs to CEGS frame
   • Wire-tie wrapped FTC LN and LN supply tubes to CEGS frame
4. Remove control box cover
   • Zip-tie stack mux's to stack hardware (AC's, SB) (these may be left in place permanently)
5. Re-install box cover
6. Strap box cover to horizontal mounting struts
7. Plan placement of system and other items to be strapped to floating base plate
   • Bottom strut under inlet ports is 1" from side edge of platform
   • Bottom strut under control panel is 6" from end edge of platform
   • Strap notes:
     • Locate straps to avoid ideal plank foam block locations if possible
     • Two parallel straps are better than two crossing orthogonally
     • (Two parallel + 1 cross is most secure, but overkill for cardboard boxes)
     • Mark the underside of the platform with the strap paths.
     • Find out how long the strap needs to be to hold an item down then add 14 inches so that the strap can be tightened using tools.
8. Drill strap holes
   • Always position the holes outside and tangent to the item outline
   • (Do not "split" the item outline with the hole, or the item will shift)
   • Clean the parts and area of sawdust.
9. Locate & mount plank foam blocks onto the bottom of floating base plate
   • Place blocks to effectively support and cushion the load
     • Locate blocks under:
       • Corners & edges of base plate
       • CEGS frame columns
       • Plus additional as needed to uniformly support plate
10. Strap anything difficult to strap that does not block placing the system in place
11. Strap the system to floating base plate
12. Strap "loose parts" packages to the base plate
    • (Some may be deferred, later strapped to shelf mounted on top supports)
13. Insert expanding foam packs
    • Between items likely to collide with parts above or below
    • In the event of a big bounce
    • (Typically under overhanging/heavy CEGS components like VM; above T-Station)
14. Cover the system with sheet plastic
15. Mount plank foam blocks on side panels to constrain the base plate
16. Install two adjacent side panels (a corner) on the skid
17. Place base plate with system onto the skid, into the corner formed by side panels
18. Clamp other two side panels in position (to slightly compress plank foam) and screw in place
    • Ensure base plate is horizontally constrained by plank foam in every direction
19. Install hold down bars to vertically secure CEGS at frame shoulder plates
    • Slightly compress foam plank blocks between bars & shoulder plates
    • While securing hold-down bars to crate sides
    • Always secure hold-downs to crate sides using support blocks above the bar
      • Also secure them from below if a shelf will be added to them for more boxes
      • (I.e., the screws go into support blocks, never screw into bar end grain)
20. Attach a plastic document envelope inside crate
    • Insert Aeon Invoice and Bill of Lading
21. Attach the top panel to the crate
22. Label the crate "FRAGILE"
23. Label the crate with:

    Aeon Laboratories

    5835 N Genematas Dr

    Tucson AZ 85704

    520-690-0012

24. Label the crate with Aeon's (shipper's) BOL number
25. Staple a plastic document envelope to the outside of the crate
    • Insert Bill of Lading into the envelope
26. Strap the crate (required only for air transport, but ok in any case)
27. Deliver crate to carrier