Replacing Shutter Bellows

Make sure all necessary tools are in the glovebag prior to beginning loading procedure (refer to GlovebaggingPreview ).

The full set of pictures is also in the gallery below

• P1: Removes/replaces/aligns cells and shutter bellows.

• P2: Assists P1 (removes/places bolts, hands and opens clean tool boxes to P1, handles clean foil, loosens mount for rotation, removes/places transit case).

• P3: Assists P1 and P2.

• P4: Maintains glovebag pressure and operates chamber N2.

1. Everyone should put on gloves.

2. P1: Remove the nut/washer combo on the shutter bellows.

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      Location of nut/washer on shutter bellows

3. P1: Start loosening bolts on the cell whose shutter you'll be replacing. You'll need room to work, and this also allows you to be able to align the shutter by looking through the port.

   1. P2: Hold the bolt bag for P1 to place bolts in.

   2. P3: Get the transit case for the cell ready, which includes removing foil from case, making sure the seal stays in place.

4. P1: Hold the cell while P2 or P3 places the transit case and bolts it to the cell with 4 bolts.

5. P2 or P3: Hand P1 some clean foil to foil the open port.

6. Repeat the above process for any more cells that need to be removed.

7. P1: Use a ratchet wrench with a 1/4 bolt head extension/attachment to loosen the four bolts (1/4-28 x 1 1/4) on the shutter bellows actuator.

8. While P1 is loosening the four actuator bolts, P2 or P3 should begin getting a new shutter bellows ready by removing it from the transit case, clean the knife edge with clean gloves, and placing a new silver gasket on.

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      New shutter bellows with new silver gasket

9. While P3 is holding the bellows (on the out-of-vacuum side), P2 should get a long and thin piece of clean foil and fold it in half lengthwise (hot dog style) with the clean side on the outside. P2 needs to be careful to only touch the edges of this foil as it will be used as a "gasket clip."

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      Clean foil folded in half "hot dog" style to be used as "gasket clips"

10. P2: Hand the foil to P1 and put on clean gloves to handle the clean foil/shutter bellows.

11. P2: While P1 is holding the foil, tear off edges to an appropriate length to fit around shutter bellows and remove any dirty sections.

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       P2 tearing the ends off of the clean foil “gasket clip”

12. P2: Gently fold the foil around the shutter bellows to hold down the gasket. Leave one bolt visible for alignment.

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       P2 carefully placing clean foil around shutter bellows

13. P3: Hold the clean-foiled shutter bellows in a clean-gloved hand until it is ready to be placed on the system.

14. P1: Place some foil under the shutter to catch anything that may fall out. Put on multiple pairs of clean gloves. P1 in this tutorial was right handed, located on the Sb side of Bravo, and used 3 clean gloves on his left hand and 4 on his right (one extra on each hand). P2 or P3 will need to take off the top glove each time it gets dirty before using another clean tool or touching an in-vacuum component.

15. P1: Loosen and remove the bolts on the shutter bellows (both top gloves now dirty). P2 (or the person not holding the new shutter bellows) should collect the bolts in a bolt bag.

16. P1: Gently pull the bellows back. With one hand holding the shutter bellows back, have P2 take off the top dirty glove on the other hand.

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       P1 with the shutter bellows pulled back and P2 taking off P1's top dirty glove

17. P1: Using the clean-gloved hand, hold the shutter rod past the collar on the in vacuum side. Have P2 or P3 remove the top dirty glove on the other hand.

18. P1: With your free hand, grab the UHV clean allen after P2 or P3 opens the box. Use the allen to loosen the set screw on the collar. This will allow you to pull out the old shutter bellows.

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       P1 loosening the collar set screw while holding onto the shutter rod (both gloves clean)

19. P2 or P3: Get some clean foil ready to place the old shutter bellows in.

20. P1: Pull shutter bellows out of shutter rod while keeping the shutter rod as steady as possible. Some gentle twisting may be necessary to get the bellows loose. Try to also get the gasket off with the bellows. Once free, place the old shutter bellows in clean foil. Reminder: the hand used to pull shutter bellows off is now dirty.

21. P2 or P3: Take off P1's top glove.

22. P1: Grab the new shutter bellows (covered in clean foil) with your free hand and place on shutter rod. Try to align the bellows as best you can with the visible bolt hole, but a few iterations may be necessary.

23. P1: Have P2 or P3 open up the appropriate clean tool box and grab the UHV clean allen. Hold the rod with one clean hand and tighten down the set screw with the other. Note: tighten just enough to keep the shutter bellows in the shutter rod, but loose enough to be able to twist during alignment.

24. P1: Take off the foil covering the cell port so you can see the shutter and align properly. With one hand, take the foil off shutter bellows while keeping the gasket in place with the hand holding onto the shutter rod.

25. P1: Place the shutter bellows onto the flange, and make sure the gasket is seated properly and no glove got stuck between the gasket. Look into the cell port and make sure the shutter is aligned. If not, move the shutter bellows back out and rotate the rod as necessary.

26. P1: Once you're satisfied with the alignment, bolt the shutter bellows in place but only fingertight! When the actuator nut and washer are tightened down, the shutter will be pushed slightly farther into the system than without it. If you tighten the bolts down fully, but then realize the shutter is not aligned, you'll need a new gasket.

27. P1: Now that the shutter bellows is on the system and aligned, you should replace the cell. Place gasket clips on the flange. With a clean glove, wipe the knife edge.

28. P1: With the same clean glove, carefully place the gasket on the flange.

29. P1: Remove the cell from the transit case and cover with clean foil. Depending on the transit case, you may need to remove a gasket with clean gasket pullers.

30. P2: With a clean glove, wipe the knife edge on the cell.

31. P1: Carefully put the cell back into place, making sure the water feedthroughs are in the correct orientation. (If placing a cracker, use studs to keep the cell from moving around and ease of alignment).

32. P2 and P1: Put bolts in place (fingertight).

33. P1: Tighten down all bolts that haven't been tightened and start pumping down!

• Note: The Sb shutter rod on Bravo is slightly bent due to difficulty placing the new shutter bellows. It may be a good idea to replace this altogether during the next full maintenance.

Shutter maintenance gallery