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VAT 612 Series Installation, Operating, & Maintenance Instructions

Butterfly pressure control valve with rs232 interface, dn 50 mm i.d. 2"
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Installation, Operating &
Maintenance Instructions
Butterfly Pressure Control Valve
with RS232 interface
Series 612
DN 50 mm (I.D. 2")
This manual is valid for the following product ordering numbers:
61234-KEAG-0002
Configured with firmware: 612P.1E.D4
Sample picture
298317EB
Edition 2013-02-19

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  • Page 1 Installation, Operating & Maintenance Instructions Butterfly Pressure Control Valve with RS232 interface Series 612 DN 50 mm (I.D. 2") This manual is valid for the following product ordering numbers: 61234-KEAG-0002 Configured with firmware: 612P.1E.D4 Sample picture 298317EB Edition 2013-02-19...
  • Page 2 The VAT firmware may not be used for purposes other than those intended nor is it permitted to make copies of the VAT firmware. In particular, it is strictly forbidden to give copies of the VAT firmware to other people.

  • Page 3: Table Of Contents

    Series 612 Contents Description of product ................ 5 Identification of product ....................5 Use of product ......................... 5 Used abbreviations ......................5 Related documents......................5 Important information....................... 5 Technical data ......................... 6 1.6.1 Control and actuating unit ................. 6 1.6.2 Valve unit ......................
  • Page 4 Series 612 4.8.5 Error messages ....................59 Operation ................... 60 Normal operation ......................60 5.1.1 Local operation ....................61 5.1.2 Remote operation .................... 62 Close valve ........................63 Open valve........................63 Position control ......................63 Pressure control ......................63 Display information ......................64 5.6.1 Power up ......................

  • Page 5: Description Of Product

    Use of product This product is a Butterfly control valve for downstream pressure control in vacuum systems. Use product for clean and dry vacuum applications only. Other applications are only allowed with the written permission of VAT. Used abbreviations Abbreviation...

  • Page 6: Technical Data

    DESCRIPTION OF PRODUCT Series 612 Technical data 1.6.1 Control and actuating unit Describtion Input voltage +24 VDC (±10%) @ 0.5 V pk-pk [connector: POWER] max. Power consumption 74 W [connector: POWER] Sensor power supply output ±15 VDC (±5%) / 1000 mA max. [connector: SENSOR] Sensor input [connector: SENSOR]...

  • Page 7: Valve Unit

    Series 612 DESCRIPTION OF PRODUCT 1.6.2 Valve unit Data 1 × 10E-8 mbar to 1.2 bar (abs) Pressure range at 20 C Leak rate to outside at 20 C 1 × 10E-9 mbar l/s 2‟000‟000 (unheated and under clean conditions) Cycles until first service Admissible operating temperature +10°C to +150°C...

  • Page 8: Safety

    SAFETY Series 612 Safety Compulsory reading material Read this chapter prior to performing any work with or on the product. It contains important information that is significant for your own personal safety. This chapter must have been read and understood by all persons who perform any kind of work with or on the product during any stage of its serviceable life.

  • Page 9: Personnel Qualifications

    Series 612 SAFETY Personnel qualifications WARNING Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Safety labels Label Part No. Location on valve On protective foil covering of T-9001-156 valve opening 298317EB...

  • Page 10: Design And Function

    DESIGN AND FUNCTION Series 612 Design and Function Design Double seal of rotary feedthrough Integrated controller Double seal Coupling Plate Bearing Valve body Function The valve plate (5) acts as a throttling element and varies the conductance of the valve opening. The integrated controller (1) calculates the required plate position to achieve the setpoint pressure.

  • Page 11: Pressure Control System Overview And Function

    Series 612 DESIGN AND FUNCTION 3.2.1 Pressure control system overview and function Vacuum pressures are always absolute pressures unless explicitly specified as pressure differences. Valve Process chamber Gas inlet Pressure sensor(s) Sensor cable Controller and actuator Seff Cable to remote control unit Cable to power supply HV Pump Q / p...

  • Page 12: Principle Of A Pressure Control System

    DESIGN AND FUNCTION Series 612 3.2.1.1 Way of operation The controller compares the actual pressure in the process chamber given by the pressure sensor with the preset pressure. The controller uses the difference between actual and set pressure to calculate the correct position of the control valve. The controller drives the control valve into the correct position and the actual pressure again equals the set pressure.

  • Page 13: Installation

    Make sure that the supplied products are in accordance with your order. Inspect the quality of the supplied products visually. If it does not meet your requirements, please contact VAT immediately. Store the original packaging material. It may be useful if products must be returned to VAT.

  • Page 14: Installation Into The System

    INSTALLATION Series 612 Installation into the system WARNING Valve opening Risk of serious injury. Human body parts must be kept out of the valve opening and away from moving parts. Do not connect the controller to power before the valve is installed complete into the system.

  • Page 15: Installation Space Condition

    Series 612 INSTALLATION 4.2.1 Installation space condition Install the valve with integrated controller with space for dismantling and air circulation as shown in figure below. 70 mm 298317EB Edition 2013-02-19 15/92...

  • Page 16: Connection Overview

    INSTALLATION Series 612 4.2.2 Connection overview System: Valve Process chamber Gas inlet Pressure sensor(s) Sensor cable(s) Controller and actuator Cable to remote control unit Cable to power supply Pump Controller: Ground connection 16/92 Edition 2013-02-19 298317EB...

  • Page 17: Installation Procedure

    Refer also to chapter «Safety mode». This valve may optionally be equipped with a heating device. Connect VAT heating device according to manual of respective heating device.

  • Page 18: Tightening Torque

    INSTALLATION Series 612 Tightening torque Tightening torques for KF-F flange connections depend on the type of seal which is used. Follow recommendations of seal manufacturer. 4.3.1 Admissible forces NOTICE Force at valve body Forces from the weight of other components can lead to deformation of the valve body and to malfunction of the valve.

  • Page 19: Admissible Forces At Controller

    Series 612 INSTALLATION 4.3.2 Admissible forces at controller NOTICE Force at pedestal In case higher force is applied, the pedestal could be permanently damaged. – Do not pushing, shocking load, or stressing the valve controller – Do not deposit anything at valve controller The admissible force at valve controller in regards to the pedestal is shown in table below Overview...

  • Page 20: Requirements To Sensor Connection

    INSTALLATION Series 612 Requirements to sensor connection To achieve fast and accurate pressure control a fast sensor response is required. Sensor response time: < 50ms. The sensor is normally connected to the chamber by a pipe. To maintain that the response time is not degraded by this connection it needs to meet the following requirements: Inner diameter of connection pipe: >...

  • Page 21: Ground Connection

    Series 612 INSTALLATION 4.5.1 Ground connection Recommendation for ground strap between controller and system (chassis) Material L (Length max.) B1 (min.) B2 (min.) d1 ( ) d2 ( ) copper tinned 200 mm 25 mm 25 mm 4.5 mm customized Recommended torque: 1,3…1,7Nm System Ground strap...

  • Page 22: Sensor Supply Concepts

    INSTALLATION Series 612 4.5.2 Sensor supply concepts This valve offers 3 alternative concepts to supply the sensor(s) with power. This depends on the sensor type and valve version that is used. This valve is available with an optional sensor power supply module (SPS) that converts 15 VDC from the 24 VDC.

  • Page 23: Power And Sensor Connection ( 15 Vdc Sensors) With Opt. Sps Module

    Series 612 INSTALLATION 4.5.3 Power and sensor connection ( 15 VDC sensors) with opt. SPS module [612 . . - . . G . - ../ 612 . . - . . H . - ..versions recommended] 298317EB Edition 2013-02-19 23/92...
  • Page 24 INSTALLATION Series 612 4.5.3.1 Sensor power wiring via controller Pins 4 and 8 must be bridged for operation. An optional switch would allow for motor interlock to prevent valve from moving. Low range sensor may be connected to sensor 1 or sensor 2 input.

  • Page 25: Rs232 Interface Connection

    The service port (connector: SERVICE) allows to connect the valve to a RS232 port of a computer. This requires a service cable and software from VAT. You can either use our freeware 'Control View', which can be downloaded from www.vatvalve.com or purchase our 'Control Performance Analyzer'.

  • Page 26: Functions And Wiring

    INSTALLATION Series 612 4.5.6 Functions and Wiring This interface allows for remote operation by means of a command set based on the RS232 protocol. In addition there are 2 digital inputs and 2 digital outputs. Digital inputs may be operated either by switches or by voltage sources.
  • Page 27 Series 612 INSTALLATION b) Configuration with voltage source for digital inputs: Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 298317EB Edition 2013-02-19 27/92...
  • Page 28 INSTALLATION Series 612 4.5.6.1 Digital inputs Function Signal type Description Priority This function will close the valve. Valve will be in interlock mode as long as function is activated. After deactivation of function it will remain effective until - OPEN valve digital input is active - converse RS232 control command have been received Digital The function is activated when optocoupler is „on‟...

  • Page 29: Initial Operation

    Series 612 INSTALLATION Initial operation 4.6.1 Setup procedure To enable the valve cluster for pressure control setup steps 1 to 6 must be performed. In case position control is required only it‟s sufficient to perform steps 1 to 4. Setup step Description Turn on external + 24VDC power supply (and external 15 VDC for sensor power supply if required).

  • Page 30: Valve Configuration

    INSTALLATION Series 612 4.6.3 Valve configuration Basic valve configuration must be adapted according to application needs. Definition of valve plate position in case of: After power up, default is „close„. Power failure, default is „not defined„. Only for versions that have Power Fail Option equipped [612 . . - .

  • Page 31: Sensor Configuration

    Series 612 INSTALLATION *) description of synchronization methods and mode synchronization method: standard if the valve is closed the next movement command (except of close) will start the synchr. if the valve is not closed the synchronization starts immediately open command the synchronization is only made when the command open is sent all movement commands only a movement command (including close) will start the synchronization...

  • Page 32: Zero

    INSTALLATION Series 612 4.6.5 ZERO ZERO allows for the compensation of the sensor offset voltage. When ZERO is performed the current value at the sensor input is equated to pressure zero. In case of a 2 sensor system both sensor inputs will be adjusted. A max. offset voltage of +/- 1.4 V can be compensated.

  • Page 33: Pressure Control Configuration

    Series 612 INSTALLATION 4.6.6 Pressure control configuration Local operation: Remote operation: („Control View‟ or „Control Performance Analyzer‟) Open CV or CPA Go to «Tools» > «Terminal» and send setup command s:02 according to application needs. (possibility of adjustment see below) Acknowledgement Command (within 10ms after reception of...
  • Page 34 INSTALLATION Series 612 a (control mode) parameter description b, c are not used. Set 00 Fixed PI downstream d Setpoint Ramp Time (s): control 0 = 0.0, 1 = 0.5, 2 = 1.0, 3 = 1.5, 4 = 2.0, 5 = 2.5, 6 = 3.0, 7 = 3.5, 8 = 4.0,9 = 4.5, A = 5.0, B = 5.5, C = 6.0, D = 6.5, E = 7.0, F = 7.5, G = 8.0, H = 8.5, I = 9.0, J =9.5, K = 10.0 Fixed PI...
  • Page 35 Series 612 INSTALLATION 4.6.6.1 LEARN (adaptive downstream) LEARN adapts the PID controller of the valve to the vacuum system and its operating conditions. LEARN must be executed only once during system setup. The LEARN routine determines the characteristic of the vacuum system. Based on this, the PID controller is able to run fast and accurate pressure control cycles.
  • Page 36 INSTALLATION Series 612 Gasflow calculation for LEARN: Do not apply a different gasflow for learn than determined below. Otherwise pressure control performance may be insufficient. Required pressure / flow regime must be known to calculate the most suitable learn gas flow for a specific application. 1.

  • Page 37: Tuning Of Control Performance

    Series 612 INSTALLATION Tuning of control performance Tuning of pressure control performance with adaptive control, refer to chapter: 4.8.1 Tuning of pressure control (adaptive) Tuning of pressure control performance with PI control, refer to chapter: 4.8.2 Tuning of pressure control performance with fixed PI control Tuning of control pressure performance with Soft pump , refer to chapter: 4.8.3 Tuning of pressure control (soft pump) 4.7.1...
  • Page 38 INSTALLATION Series 612 4.7.1.1 Gain factor adjustment The gain factor effects: Stability, Response time Default value is 1. Adjustment range is from 0.0001 to 7.5. Higher gain results in: faster response / higher over- / undershoot of pressure Lower gain results in: slower response/ lower over- / undershoot of pressure Adjustment procedure: 1.
  • Page 39 Series 612 INSTALLATION 4.7.1.2 Sensor delay adjustment Sensor delay adjustment effects: Stability Default value is 0 s. Adjustment range is from 0 to 1.0s. Pipes and orifices for sensor attachment delay response time and so badly impact pressure control stability. By adapting this parameter to the approximate delay time stability problems can be reduced.
  • Page 40 INSTALLATION Series 612 4.7.1.3 Setpoint ramp adjustment Setpoint ramp effects: Undershoot of pressure, Response time Default value for Setpoint Ramp is 0 s. Adjustment range for Setpoint Ramp is from 0 to 10 s. This parameter defines the time that is used to decrease / raise pressure between 2 setpoints. Especially in pressure decrease situations at low flows pressure response can be improved much by adapting setpoint ramp time.
  • Page 41 Go to „Tools / Create Diagnostic File‟ in „Control View‟ resp. „Control Performance Analyzer‟ and save file Pressure / flow / gas conditions to be controlled Chamber volume Pumping speed (l/s) and pump type (e.g. turbo pump) System description Problem description Send diagnostic file with and all required information to tuning-support@vat.ch 298317EB Edition 2013-02-19 41/92...

  • Page 42: Tuning Of Pressure Control Performance With Fixed Pi Control

    INSTALLATION Series 612 4.7.2 Tuning of pressure control performance with fixed PI control 4.7.2.1 Optimizing P gain and I gain This valve may be used for downstream or upstream pressure control depending on configuration. The PI parameters of the pressure controller require correct adjustment. These parameters must be set once during system setup and are stored in the device memory which is power fail save.
  • Page 43 Series 612 INSTALLATION Start optimization with P gain set to 1.0 and I gain set to 0.0. Set chamber pressure to SP2, wait until the pressure is stable. Set pressure to SP1. If the transition from SP2 to SP1 results in a significant pressure over shoot or even does not stabilize at all, the P gain is too high.
  • Page 44 Go to „Tools / Create Diagnostic File‟ in „Control View‟ resp. „Control Performance Analyzer‟ and save file Pressure / flow / gas conditions to be controlled Chamber volume Pumping speed (l/s) and pump type (e.g. turbo pump) System description Problem description Send diagnostic file with and all required information to tuning-support@vat.ch 44/92 Edition 2013-02-19 298317EB...

  • Page 45: Tuning Of Pressure Control (Soft Pump)

    The VAT soft pump controller requires a pump down time shorter than 10 sec. for good control results. If the required pump down time is longer than 10 sec., the pump down curve has to be partitioned into sections shorter than 10 sec.
  • Page 46 INSTALLATION Series 612 Optimizing P gain WE start by setting the P gain to 1.0 as a trial value and adjust according to the response. The pump down routine has to be controlled as follows: Move control valve into close position Start pump down by opening the pump isolation valve or starting the pump and sending the first pressure set point to the valve controller.

  • Page 47: Rs232 Interface Commands

    Pressure / flow / gas conditions to be controlled Chamber volume Pumping speed (l/s) and pump type (e.g. turbo pump) System description Problem description Send diagnostic file with and all required information to tuning-support@vat.ch RS232 interface commands 4.8.1 Command syntax [function][value][CR][LF] Each element is separated with square brackets for clarity.

  • Page 48: Rs232 Control Commands

    INSTALLATION Series 612 4.8.2 RS232 Control commands Acknowledgement Command Control function (within 10ms after reception of command) Description [R:][xxxxxx][CR][LF] [R:][CR][LF] [i:38][CR][LF] [i:38][00xxxxxx][CR][LF] data length 6 characters for writing 8 characters starting with double zero for reading xxxxxx position SETPOINT, value depends on configuration, POSITION CONTROL refer to «RS232 with analog output setup commands, RANGE CONFIGURATION»...

  • Page 49: Rs232 Inquiry Commands

    Series 612 INSTALLATION 4.8.3 RS232 Inquiry commands Acknowledgement Command (within 10ms after reception of command) Inquiry function Description [i:76][CR][LF] [i:76][xxxxxxsyyyyyyyabc][CR][LF] data length 17 characters xxxxxx position, return value depends on configuration, refer to «RS232 setup commands, RANGE CONFIGURATION» for details sign, 0 for positive pressure readings, - for negative pressure readings yyyyyyy pressure, return value depends on configuration,...
  • Page 50 INSTALLATION Series 612 Acknowledgement Command (within 10ms after reception of Inquiry function command) Description [i:64][CR][LF] [i:64][sxxxxxxx][CR][LF] data length 8 characters sign, 0 for positive readings, - for negative readings SENSOR 1 READING xxxxxxx sensor 1 reading, return value depends on configuration, refer to «RS232 setup commands, RANGE CONFIGURATION»...
  • Page 51 Series 612 INSTALLATION Acknowledgement Command (within 10ms after reception of Inquiry function command) Description [i:51][CR][LF] [i:51][abcdefgh][CR][LF] data length 8 characters 0 = no service required 1 = service request, it is indicated when the control unit detects that motor steps are apparently not effective. This may happen when the valve is heavily contaminated or the gate seal is heavily sticking.
  • Page 52 INSTALLATION Series 612 Acknowledgement Command Inquiry function (within 10ms after reception of command) Description [i:32][CR][LF] [i:32][abcdefgh][CR][LF] data length 8 characters 0 = LEARN not running, 1 = LEARN running 0 = LEARN data set present, 1 = LEARN data set not present 0 = ok 1 = last LEARN interrupted by user (control command) 2 = last LEARN interrupted by control unit...
  • Page 53 Series 612 INSTALLATION Acknowledgement Command Inquiry function (within 10ms after reception of command) Description [i:70][CR][LF] [i:70][xxxxxxxxxx][CR][LF] data length 10 characters xxxxxxxxxx number of throttle cycles THROTTLE CYCLE COUNTER This function returns the number of throttle cycles. A movement from max. throttle position to open back to max.

  • Page 54: Rs232 Setup Commands

    INSTALLATION Series 612 4.8.4 RS232 Setup commands Acknowledgement Command (within 10ms after reception of command) Setup function Description [c:01][xx][CR][LF] [c:01][CR][LF] data length: 2 characters 00 = local operation (service port) 01 = remote operation, change to local enabled 02 = locked remote operation, change to local not possible via service port ACCESS MODE This function selects the access authorization to the valve.
  • Page 55 Series 612 INSTALLATION Acknowledgement Command (within 10ms after reception of command) Setup function Description [s:01][abcdefgh][CR][LF] [s:01][CR][LF] [i:01][CR][LF] [i:01][abcdefgh][CR][LF] data length 8 characters 0 = no sensor 1 = 1 sensor operation (sensor 1 input) 2 = 2 sensor operation with automatic changeover (low range = sensor 2 input, high range = sensor 1 input) 3 = 1 sensor operation (sensor 2 input) 4 = 2 sensor operation with automatic changeover...
  • Page 56 INSTALLATION Series 612 Acknowledgement Command (within 10ms after reception of command) Setup function Description [s:21][abcdefgh][CR][LF] [s:21][CR][LF] [i:21][CR][LF] [i:21][abcdefgh][CR][LF] data length 8 characters range for POSITION: 0 = 0 – 1‟000, 1 = 0 – 10‟000, 2 = 0 – 100‟000 bcdefgh upper value for PRESSURE and SENSOR READING: 1000 ...
  • Page 57 Series 612 INSTALLATION Acknowledgement Command (within 10ms after reception of command) Setup function Description [Z:][CR][LF] [Z:][CR][LF] ZERO This command initiates ZERO to compensate for offset of gauge(s). Note: Refer to «ZERO» for correct zero procedure. [c:6002][xxxxxxxx][CR][LF] [c:60][CR][LF] data length: 8 characters xxxxxxxx System base pressure, value depends on configuration, refer to «RS232 setup commands, RANGE CONFIGURATION»...
  • Page 58 INSTALLATION Series 612 Acknowledgement Command (within 10ms after reception of command) Setup function Description [s:02][abcdefgh][CR][LF] [s:02][CR][LF] [i:02][CR][LF] [i:02][abcdefgh][CR][LF] data length 8 characters 0 (reserved, do not change) gain factor: 0 = 0.10, 1 = 0.13, 2 = 0.18, 3 = 0.23, 4 = 0.32, 5 = 0.42, 6 = 0.56 7 = 0.75, 8 = 1.00, 9 = 1.33, A = 1.78, B = 2.37, C = 3.16, D = 4.22 E = 5.62, F = 7.50, G = 0.0001, H = 0.0003, I = 0.001, J = 0.003, K = 0.01, L = 0.02, M = 0.05...

  • Page 59: Error Messages

    Series 612 INSTALLATION 4.8.5 Error messages Description Error message Protocol Parity error [E:][000001][CR][LF] Framing error (data length, number of stop bits) [E:][000003][CR][LF] Input buffer overflow (to many characters) [E:][000002][CR][LF] Commands <CR> or <LF> missing [E:][000010][CR][LF] : missing [E:][000011][CR][LF] [E:][000020][CR][LF] Unknown command [E:][000021][CR][LF] [E:][000022][CR][LF] Invalid value...

  • Page 60: Operation

    OPERATION Series 612 Operation WARNING Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. WARNING Valve opening Risk of serious injury. Human body parts must be kept out of the valve opening and away from moving parts. Do not connect the controller to power before the valve is installed complete into the system.

  • Page 61: Local Operation

    Local operation means that the valve is operated via the service port using a computer or the Service Box 2. When using a computer, a service cable and a software from VAT are required. You can either download our freeware 'Control View' from www.vatvalve.comor purchase our 'Control Performance Analyzer'.

  • Page 62: Remote Operation

    OPERATION Series 612 5.1.2 Remote operation This product is equipped with a RS232 interface to allow for remote operation. See section «RS232 interface» for details. „Control View‟ software, 'Control Performance Analyzer' software or 'Service Box 2' may be used for monitoring during remote control. „Control View‟...

  • Page 63: Close Valve

    Series 612 OPERATION Close valve Local operation: Remote operation: („Control View‟, „Control Performance Analyzer‟ or (Refer to chapter: «Control commands» for „Service Box 2„) details) Push CLOSE button Send CLOSE VALVE Open valve Local operation: Remote operation: („Control View‟, „Control Performance Analyzer‟ or (Refer to chapter: «Control commands»...

  • Page 64: Display Information

    OPERATION Series 612 Display information There is a 4 digit display located on 1 2 3 4 the panel. It displays configuration, status and position information. For details refer to following tables. Display 5.6.1 Power up Description Digit 1 Digit 2 Digit 3 Digit 4 At first all dots are illuminated...

  • Page 65: Operation

    Series 612 OPERATION 5.6.2 Operation Description / Mode Digit 1 Digit 2 Digit 3 Digit 4 PRESSURE CONTROL mode POSITION CONTROL mode Valve closed Valve open Closed / open interlock (Valve closed / open 0…100 by digital input) = valve position (%, 0 = closed / 100 = open) HOLD (position frozen) activated ZERO running LEARN running...

  • Page 66: Service Indication

    OPERATION Series 612 5.6.5 Service indication This product is able to indicate that the valve unit needs to be cleaned, or an obstruction is present. A service request is indicated when the control unit detects that motor steps are apparently not effective. This may happen when the valve unit is heavily contaminated.

  • Page 67: Trouble Shooting

    TROUBLE SHOOTING Series 612 Trouble shooting Failure Check Action No dots lighted on display 24 V power supply ok? Connect valve to power supply according to «Electrical connection» and make sure that power supply is working. Remote operation does not work - Local operation via service port active - Switch to remote operation.
  • Page 68 TROUBLE SHOOTING Series 612 Failure Check Action CLOSE VALVE does not work - Safety mode active, check for D on - Provide power to motor to allow for display? operation. - Refer to «Electrical connection» for details. - Refer to “Display shows «M C»” in this - Maintenance mode active table OPEN VALVE does not work...
  • Page 69 If you need any further information, please contact one of our service centers. You will find the addresses on our website: www.vatvalve.com. If you need any further information, please contact one of our service centers. You can find the addresses on our website: http://www.vat.ch 298317EB Edition 2013-02-19...

  • Page 70: Maintenance

    Before carrying out any maintenance, please contact VAT. It has to be individually decided whether the maintenance can be performed by the customer or has to be carried out by VAT. Please write down the fabrication number of the valve before contact VAT. Refer to chapter «Identification of product»...

  • Page 71: Maintenance Procedures

    Replacement of Option board. Refer to chapter: «Replacement of Option board» Required frequency of cleaning and replacement of seals is depending on process conditions. VAT can give the following recommendations for preventive maintenance: Replacement of unheated heated 80 °C heated >...

  • Page 72: Replacement Of Shaft Feedthrough Seals And Valve Cleaning

    MAINTENANCE Series 612 7.2.1 Replacement of shaft feedthrough seals and valve cleaning 7.2.1.1 Needed tools Allen Wrench 2mm feeler gauge Allen Wrench 3mm vacuum grease Description Required tool Depending on flange Vent vacuum system, screws, see disconnect electrical dimensional drawing. connections and remove valve from vacuum system.
  • Page 73 Series 612 MAINTENANCE Description Required tool Unfasten plate screws and Allen Wrench remove plate from shaft. Unfasten alternately the 2 Allen Wrench mounting screws little by little. Remove mechanical unit and clean shaft. Remove o-rings. Lint and dust free cloth soaked with Clean shaft feedthrough and isopropyl alcohol valve body.
  • Page 74 MAINTENANCE Series 612 Description Required tool Lubricate seal contact surface of valve body with a slight film of vacuum grease (0.025 ml). Vacuum grease 10. Lubricate new each o-ring with a slight film of vacuum grease (0.0125 ml). For new o-rings refer to chapter: «Spare parts»...
  • Page 75 Series 612 MAINTENANCE Description Required tool 18. Place the plate at shaft and Allen Wrench fasten plate screws a little. Allen Wrench 19. Center plate with feeler gauge 0.04 mm 20. Tighten plate screws with Adequate 2.5 Nm. feeler gauge 0.04 mm 0.04 mm 0.04 mm...

  • Page 76: Replacement Of Option Board

    23. Reinstall valve into vacuum system according to chapter «Installation». If you need any further information, please contact one of our service centers. You can find the addresses on our website: http://www.vat.ch . 7.2.2 Replacement of Option board NOTICE Electrostatic discharge Electronic components could be damage.
  • Page 77 Series 612 MAINTENANCE 7.2.2.1 Durability of power fail battery The curves in the graph show the estimated life of Ultra Cap PFO in the worst condition (max. sensor load = 1 A, valve heating temperature = 150 °C). If the SPS is not fully loaded (< 1 A) or heating temperature of valve body is lower than 150 °C, the corresponding life time curve will be somewhere in between the upper and the lower curve.
  • Page 78 MAINTENANCE Series 612 7.2.2.2 Retrofit / replacement procedure Top view on control and actuating unit with panel removed: Master board Motor driver board Option board Interface board All boards have a fixed position into control and actuating unit. It is not possible to fit a board in other position as shown in picture above! Do not try out other positions, which maybe destroy the socket of boards! 78/92...
  • Page 79 Series 612 MAINTENANCE 7.2.2.3 Needed tools Pozidriv screw driver size 1 Open end wrench 4.5mm Description Required tool Pozidriv screw driver Remove the panel screws. size 1 Remove female screw locks from POWER, Open end wrench 4.5 mm SENSOR and INTERFACE connectors.
  • Page 80 MAINTENANCE Series 612 Description Required tool Remove the master board. Remove the interface board. Replace option board. Insert master board and interface board in reverse order as disassembled at correct positions (see steps 6 to Insert option board at correct position (see step 7) 10.

  • Page 81: Repairs

    Series 612 Repairs Repairs may only be carried out by the VAT service staff. In exceptional cases, the customer is allowed to carry out the repairs, but only with the prior consent of VAT. Please contact one of our service centers. You will find the addresses on our website www.vatvalve.com.

  • Page 82: Dismounting And Storage

    DISMOUNTING AND STORAGE Series 612 Dismounting and Storage WARNING Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. Dismounting NOTICE Contamination Gate and other parts of the valve must be protected from contamination. Always wear clean room gloves when handling the valve.

  • Page 83: Storage

    Series 612 DISMOUNTING AND STORAGE Storage NOTICE Wrong storage Inappropriate temperatures and humidity may cause damage to the product. Valve must be stored at: – relative humidity between 10% and 70% – temperature between +10 °C and +50 °C – non-condensing environment NOTICE Inappropriate packaging Product may get damaged if inappropriate packaging material is used.

  • Page 84: Packaging And Transport

    If products are radioactively contaminated, the VAT form «Contamination and Radiation Report» must be filled out. Please contact VAT in advance. If products are sent to VAT in contaminated condition, VAT will carry out the decontaminating procedure at the customer's expense.

  • Page 85: Transport

    10.2 Transport NOTICE Inappropriate packaging Product may get damaged if inappropriate packaging material is used. Always use the original packaging material and handle product with care. VAT disclaims any liability for damages resulting from inappropriate packaging. 298317EB Edition 2013-02-19 85/92...

  • Page 86: Disposal

    DISPOSAL Series 612 Disposal WARNING Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. 86/92 Edition 2013-02-19 298317EB...

  • Page 87: Spare Parts

    «Identification of product». This is to ensure that the appropriate spare parts are supplied. VAT makes a difference between spare parts that may be replaced by the customer and those that need to be replaced by the VAT service staff.

  • Page 88: Drawing

    SPARE PARTS Series 612 12.1 Drawing 88/92 Edition 2013-02-19 298317EB...

  • Page 89: Valve Unit

    Series 612 SPARE PARTS 12.1.1 Valve unit Item Description Part number Spare parts kit 485723 body with mechanism Spare parts kit shaft kit 471292 Spare parts kit valve body 237850 Spare parts kit plate 239549 Plate screw 353386 12.1.2 Seals and grease Item Description Part number...

  • Page 90: Accessories

    12.2 Accessories Item Description Part number 24 VDC power supply unit 249775 (input: 100 – 240 VAC) „Control Performance Analyzer‟ Free download on VAT homepage. http://www.vatvalve.com/customer- ® for Windows service/informations-and-downloads/control-performance-analyzer „Control View‟ software for 248126 ® Windows free download from www.vatvalve.com...

  • Page 91: Appendix

    APPENDIX Series 612 Appendix 298317EB Edition 2013-02-19 91/92...
  • Page 92 Series 612 This page left blank intentionally. 92/92 Edition 2013-02-19 298317EB...

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