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VAT 642 GP Series Installation, Operating, & Maintenance Instructions

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Installation, Operating &
Maintenance Instructions
Control gate valve
with DeviceNet interface
Series 642
DN 63- 400 mm (I.D. 2.5" - 16")
This manual is valid for the valve ordering number(s):
642 . . - . .GP- . . . .
642 . . - . .GQ- . . . .
642 . . - . .AP- . . . .
642 . . - . .AQ- . . . .
642 . . - . .HP- . . . .
642 . . - . .HQ- . . . .
642 . . - . .CP- . . . .
642 . . - . .CQ- . . . .
SPS = Sensor Power Supply
configured with firmware 600P.1G.00.08 and 375487 (DeviceNet
Sample picture
605593EC
(1 sensor input)
(2 sensor inputs)
(1 sensor input / ±15V SPS)
(2 sensor inputs / ±15V SPS)
(1 sensor input / PFO)
(2 sensor inputs / PFO)
(1 sensor input / ±15V SPS / PFO)
(2 sensor inputs / ±15V SPS / PFO)
PFO = Power Failure Option
Edition 2017-11-24
®
)

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Summary of Contents for VAT 642 GP Series

  • Page 1 Installation, Operating & Maintenance Instructions Control gate valve with DeviceNet interface Series 642 DN 63- 400 mm (I.D. 2.5” - 16") This manual is valid for the valve ordering number(s): 642 . . - . .GP- ..(1 sensor input) 642 .
  • 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 642 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 642 DeviceNet interface commands ..................58 4.8.1 Assembly objects .................... 58 4.8.2 Assembly object bit map ................. 59 4.8.3 Explicit messaging control commands ............61 4.8.4 Explicit messaging inquiry commands ............. 63 4.8.5 Explicit messaging setup commands .............. 69 Operation ...................

  • Page 5: Description Of Product

    This product is a control gate valve with isolation functionality. It is intended to use for downstream pressure control applications. 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 642 Technical data 1.6.1 Control and actuating unit Description Power input (α) +24 VDC (±10%) @ 0.5 V pk- [connector: POWER] pk max. [642 . . - . . A . - ../ 642 . . - . . G . - ..] 50 W max.

  • Page 7: Valve Unit

    Series 642 DESCRIPTION OF PRODUCT 1.6.2 Valve unit Description Pressure range at 20°C (unheated on delivery) • 1 × 10E-8 mbar to 2.0 bar (abs) DN63…200 • 1 × 10E-8 mbar to 1.2 bar (abs) DN250…400 1 × 10E-9 mbar ls Leak rate to outside / seat at 20°C (unheated on delivery) Differential pressure on the gate •...

  • Page 8: Safety

    SAFETY Series 642 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 642 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 605593EC...

  • Page 10: Design And Function

    Actuation is performed with a stepper motor and controller. The stepper motor/controller version ensures accurate pressure control due to exact gate positioning. For leak tight closing the VATLOCK principle is applied. For details refer to VAT catalog. 10/113 Edition 2017-11-24...

  • Page 11: Pressure Control System Overview And Function

    Series 642 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 642 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 642 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 642 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. (sample picture) Overview table: DN to required distance (d) for maintenance. 80 / 100 320 / 350 605593EC Edition 2017-11-24 15/113...

  • Page 16: Connection Overview

    INSTALLATION Series 642 4.2.2 Connection overview System: Valve Process chamber Gas inlet Pressure sensor(s) Sensor cable(s) Cable to remote control unit Cable to power supply Controller Connection cable controller / actuator Actuator Pump Actuator Controller 16/113 Edition 2017-11-24 605593EC...

  • Page 17: Installation Procedure

    Refer also to «Safety mode». 8. 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 642 Tightening torque 4.3.1 Mounting of CF-F flanges Tightening torques for CF-F flange connections depends on the type of seal which is used. Follow recommendations of seal manufacturer. The torque values below are dependent on many factors, such as materials involved, surface quality, surface treatment, and lubrication.

  • Page 19: Mounting With O-Ring In Grooves

    Series 642 INSTALLATION 4.3.3 Mounting with O-ring in grooves max. torque t max. torque Max. hole depth [d] (Nm) (lbs . ft) (mm) inch ISO-F ASA-LP ISO-F ASA-LP ISO-F ASA-LP 605593EC Edition 2017-11-24 19/113...

  • Page 20: Admissible Forces

    2½ 1960 1960 2450 2940 2940 3430 3920 3920 7840 1760 In case of both kind of forces are occurring («FA» und «M»), the above shown values are invalid. Please contact VAT in this case. 20/113 Edition 2017-11-24 605593EC...

  • Page 21: Requirements To Sensor Connection

    Series 642 INSTALLATION 4.4.1 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: •...

  • Page 22: Ground Connection

    INSTALLATION Series 642 4.5.1 Ground connection Recommendation for ground strap between controller ground 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 Chassis (PE) (Protective Earth)

  • Page 23: Sensor Supply Concepts

    Series 642 INSTALLATION 4.5.2 Sensor supply concepts Those valves offer 4 alternative concepts to supply the sensor(s) with power. This depends on the sensor type and valve version that is used. Concepts: • External +24 VDC supplied to POWER connector is feedthrough to SENSOR connector to supply 24 VDC sensors.

  • Page 24: Power And Sensor Connection (+24 Vdc Sensors)

    • VAT fuse recommendation: (a) 5AF / (b) Safety switch 3A min. • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources.
  • Page 25 S C1 091 A • VAT fuse recommendation: (a) 5AF, / (b) Safety switch 3A min. • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources.
  • Page 26 SC 1090 A • VAT fuse recommendation: (a) 5AF, / (b) Safety switch 3A min. • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources. •...
  • Page 27 SC 1092 A • VAT fuse recommendation: (a) 5AF, / (b) Safety switch 3A min. • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources. •...

  • Page 28: Devicenet® Interface Connection

    INSTALLATION Series 642 4.5.5 DeviceNet® interface connection Connector type: Micro-style male (5 pin), connector is shown on panel refer to chapter «Installation into the system». At valve controller DeviceNet® cable Name Wire color Description Drain Bare Shield DeviceNet® power supply + Black DeviceNet®...

  • Page 29: Logic I/O

    Series 642 INSTALLATION 4.5.6 LOGIC I/O This interface allows for remote operation by means of a command set based on the DeviceNet protocol. In addition there is a digital input and a digital output. Digital input may only be operated by a switch. Active digital input has: higher priority than DeviceNet commands higher priority than Local commands...

  • Page 30: Service Port Connection

    You can use our Software (freeware) 'Control Performance Analyzer' which can be downloaded from: http://www.vatvalve.com/customer-service/informations-and-downloads/control-performance-analyzer. Alternatively the VAT Service Box2 can be connected to the service port for setup and local operation. The service port is not galvanic isolated. Therefore we recommend using this only for setup, testing and maintenance and not for permanent control.

  • Page 31: Initial Operation

    • For ease setup (in Local mode) of ‘Interface’, ‘Valve’, ‘Sensor’, ‘Senor ZERO’, ‘LEARN’ and ‘PRESSURE CONTROL COFIGURATION’ it is possible to use the CPA 3.0, The free download is available on the VAT homepage: http://www.vatvalve.com/customer-service/informations-and-downloads/control- performance-analyzer ®...
  • Page 32 ® VAT offers valve-related but not general DeviceNet support. Contact us under: devicenet- support@vat.ch 1. The node number is the device address and can be selected by two rotary switches which are on the valve controller panel.
  • Page 33 Series 642 INSTALLATION Assembly object change procedure: Local operation: Remote operation: (‘Control View’, ‘Control Performance Analyzer’ (Refer to chapter «Explicit messaging setup or ‘Service Box 2‘) commands» for details) Select POLL CONNECTION OUTPUT assembly Select POLL CONNECTION INPUT It’s not possible to make assembly assembly object configuration in local operation.

  • Page 34: Logic I/O Configuration

    INSTALLATION Series 642 4.6.3 LOGIC I/O configuration Default configuration for LOGIC I/O is: Function Mode Input Digital input close valve non inverted enabled Function Mode Output Digital output close non inverted enabled The «LOGIC I/O» Digital input and Digital output can be adjusted. Local operation: Remote operation: (‘Control View’, ‘Control Performance Analyzer’...

  • Page 35: Valve Configuration

    Series 642 INSTALLATION 4.6.4 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 [642 . . - .

  • Page 36: Zero

    INSTALLATION Series 642 4.6.6 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 37: Learn (Adaptive)

    Series 642 INSTALLATION 4.6.7 LEARN (adaptive) 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 38 INSTALLATION Series 642 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 39: Pressure Control Configuration

    Series 642 INSTALLATION 4.6.8 Pressure control configuration Select the configuration what your application needs. Constant gas flow available Constant gas flow not System Configuration available Tv*<= 500 sec Tv* > 500 sec Downstream Adaptive pressure Process controller Fixed pressure controller chamber (Refer to chapter: (Refer to chapter: Pressure controller)
  • Page 40 3 = Soft pump For easy setup (Local operation) of ‘Pressure controller’ and ‘Pressure control parameter’ please use the VAT “Control Performance Analyzer” CPA 3.0. There is a free download on the VAT home page, refer to: http://www.vatvalve.com/customer- service/informations-and-downloads/control-performance-analyzer 4.6.8.2 With CPA 3.0 direct setup (standard)
  • Page 41 Series 642 INSTALLATION 4.6.8.3 Pressure control parameter Local operation: Remote operation: (‘Control View’ or ‘Control Performance Analyzer’) • Open 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 42: Pressure Control Algorithem

    INSTALLATION Series 642 4.6.9 Pressure control algorithem • Local operation: With CPA direct setup, see chapter: With CPA 3.0 direct setup (standard). With CV or CPA, go to «Tools» > «Terminal» and send setup commands according to application needs. See next tables. 4.6.9.1 Adaptive control algorithm (downstream) Parameter...
  • Page 43 Series 642 INSTALLATION GAIN FACTOR The GAIN FACOTR is a control parameter to adapt the performance of the pressure control algorithm. A higher gain results in faster response, higher over- / undershoot of pressure. A lower gain results in slower response, lower over- / undershoot of pressure.
  • Page 44 INSTALLATION Series 642 4.6.9.2 Fixed 1 control algorithm Parameter Command Request Data Type Values s:02B01c s:02 c = 0.00…1 000.0 ’ ’ RAMP TIME FLOAT Default is: 0.00 i:02B01 i:02B01c c = 0 or 1 s:02B02c s:02 0 = constant time RAMP MODE UINT 1 = constant slope...
  • Page 45 Series 642 INSTALLATION Example: Set RAMP MODE of the Fixed 1 pressure controller to the value 0 (fixed time) Command Pressure Parameter selection variable Parameter value controller s:02 B (a) 02 (bb) 0 (c) s:02B020 To optimize Fixed 1 algorithm, refer to chapter «Tuning of control performance». 4.6.9.3 Fixed 2 control algorithm Parameter...

  • Page 46: Tuning Of Control Performance

    INSTALLATION Series 642 4.6.9.4 Soft pump control algorithm Parameter Command Request Data Type Values s:02D01c s:02 c = 0.00…1 000.0 ’ ’ RAMP TIME FLOAT Default is: 0.00 i:02D01c i:02D01 s:02D02c c = 0…1 s:02 0 = constant time RAMP MODE UINT 1 = constant slope i:02D02...

  • Page 47: Tuning Of Control Performance With Adaptive Algorithm

    Series 642 INSTALLATION 4.7.1 Tuning of control performance with adaptive algorithm Normally the default settings will result in good pressure control performance. For some applications tuning may be required to improve performance. The tuning procedures for each parameter (grey boxes) and its default values are described separately below.
  • Page 48 INSTALLATION Series 642 4.7.1.1 Gain factor adjustment The gain factor effects: Stability, Response time 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 49 Series 642 INSTALLATION 4.7.1.2 Sensor delay adjustment Sensor delay adjustment effects: Stability 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. But control response time will be slowed down by this measure.
  • Page 50 INSTALLATION Series 642 4.7.1.3 Setpoint ramp adjustment Setpoint ramp effects: Undershoot of pressure, Response time 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 51 Series 642 INSTALLATION 4.7.1.4 Valve speed adjustment Valve speed effects: Response time Adjustment range is from 1 to 1000. This parameter effects valve plate actuating speed. Speed adjustment is effective for PRESSURE CONTROL and POSITION CONTROL. Normally best pressure control response is achieved with max. valve speed. In particular applications it may be of advantage to have a slower valve response.

  • Page 52: Tuning Of Control Performance With Fixed Pi Algorithm

    INSTALLATION Series 642 4.7.2 Tuning of control performance with fixed PI algorithm 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 53 Series 642 INSTALLATION Optimizing P gain While optimizing P gain, the gas flow determined above has to be constant all the time. 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 54 • 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 54/113 Edition 2017-11-24 605593EC...

  • Page 55: Tuning Of Control Performance With Soft Pump Algorithm

    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 56 INSTALLATION Series 642 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 57 • 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 605593EC Edition 2017-11-24 57/113...

  • Page 58: Devicenet Interface Commands

    INSTALLATION Series 642 DeviceNet interface commands 4.8.1 Assembly objects Factory default assemblies are: Input assembly 3 / Output assembly 8 Number Type Composition [number of data bytes] EXCEPTION STATUS Input PRESSURE [2] or [4] POSITION [2] or [4] EXCEPTION STATUS Input PRESSURE [2] or [4]...

  • Page 59: Assembly Object Bit Map

    Series 642 INSTALLATION 4.8.2 Assembly object bit map This is an example based on output assembly 8 and input assembly 3 to illustrate bit map. DATA TYPE in this example is signed integer. 4.8.2.1 Output assembly Assembly Type Byte Bit7 Bit6 Bit5 Bit4...
  • Page 60 INSTALLATION Series 642 4.8.2.2 Input assembly Instance Type Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 EXCEPTION STATUS PRESSURE low byte Input PRESSURE high byte POSITION low byte POSITION high byte EXCEPTION STATUS will respond with one out of below selections, see also «Explicit messaging inquiry commands».

  • Page 61: Explicit Messaging Control Commands

    Series 642 INSTALLATION 4.8.3 Explicit messaging control commands Service Service Command Service Code Class ID Instance ID Attribute ID data length data field ® (DeviceNet term (number of bytes) if deviant) Description This command changes the valve to executing state. EXECUTING must to be selected to enable for all executing commands such EXECUTING as control mode, close valve and open valve.
  • Page 62 INSTALLATION Series 642 Service Service Command Service Code Class ID Instance ID Attribute ID data length data field ® (DeviceNet term (number of bytes) if deviant) Description 2 or 4 2 or 4 POSITION SETPOINT position setpoint according to selected DATA TYPE, 0 (closed) … 10’000 (open) This command transfers/reads the position setpoint to/from the valve.

  • Page 63: Explicit Messaging Inquiry Commands

    Series 642 INSTALLATION 4.8.4 Explicit messaging inquiry commands Service Service Command Service Code Class ID Instance ID Attribute ID data length data field ® (DeviceNet term (number of bytes) if deviant) Description VALVE CLOSED This command returns: CHECK valve is not closed (discrete input 1) valve is closed VALVE...
  • Page 64 INSTALLATION Series 642 Example of PRESSURE and SENSOR READING allocation: High range sensor 1 Torr PRESSURE SENSOR 1 READING 0 – 10’000 0 – 10’000 Low range sensor 100 mTorr SENSOR 2 READING 0 – 10’000 0 mTorr Above picture shows a 2 sensor system. In this configuration sensor 2 covers low range (100 mTorr) and sensor 1 covers high range (1 Torr).
  • Page 65 Series 642 INSTALLATION Service Service Command Service Code Class ID Instance ID Attribute ID data length data field ® (DeviceNet term (number of bytes) if deviant) Description This command returns the status of the LEARN procedure. The status is binary coded. Explanation: (LSB) 0 0 = LEARN not running...
  • Page 66 INSTALLATION Series 642 Service data length Service Command Service Code Class ID Instance ID Attribute ID (number of data field (DeviceNet® term bytes) if deviant) Description self test idle DEVICE STATUS 1 self test exception executing abort This command returns the device status. This command returns the device status.
  • Page 67 Series 642 INSTALLATION Service Service Command Service Code Class ID Instance ID Attribute ID data length data field ® (DeviceNet term (number of bytes) if deviant) Description Table with EXCEPTION DETAIL ALARM resp. EXCEPTION DETAIL WARNING bits. Exception / Failure / Error (except for detail size bytes) Data Bit 7 Bit 6...
  • Page 68 INSTALLATION Series 642 Service data length Service Command Service Code Class ID Instance ID Attribute ID (number of data field (DeviceNet® term bytes) if deviant) Description THROTTLE CYCLE This command returns the number of throttle cycles. Data type is unsigned long integer. A COUNTER movement from max.

  • Page 69: Explicit Messaging Setup Commands

    Series 642 INSTALLATION 4.8.5 Explicit messaging setup commands Service Service Command Service Code Class ID Instance ID Attribute ID data length data field ® (DeviceNet term (number of bytes) if deviant) Description signed integer DATA TYPE floating point This command defines the data type for PRESSURE, SENSOR READING, OFFSET and POSITION.
  • Page 70 INSTALLATION Series 642 Command Service Service ® (DeviceNet term Service Code Class ID Instance ID Attribute ID data length data field if deviant) (number of bytes) CHANGE OF STATE / CYCLING INPUT input assembly object number (3, 4, 5, 13, 14, 100, 101) This command configures resp.
  • Page 71 Series 642 INSTALLATION Command Service Service ® (DeviceNet term Service Code Class ID Instance ID Attribute ID data length data field if deviant) (number of bytes) no sensor 1 sensor operation (sensor 1 input) 2 sensor operation with automatic changeover (low range = sensor 2 input, high range = sensor 1 input) 1 sensor operation (sensor 2 input) 2 sensor operation with automatic changeover...
  • Page 72 INSTALLATION Series 642 Command Service Service ® (DeviceNet term Service Code Class ID Instance ID Attribute ID data length data field if deviant) (number of bytes) 2 or 4 LEARN learn pressure limit according to selected DATA TYPE, PRESSURE LIMIT nominal pressure range is 0 …...
  • Page 73 Series 642 INSTALLATION Command Service Service ® (DeviceNet term Service Code Class ID Instance ID Attribute ID data length data field if deviant) (number of bytes) 0 = 0.10, 1 = 0.13, 2 = 0.18, 3 = 0.23, 4 = 0.32, 5 = 0.42, 6 = 0.56 PID CONTROLLER 7 = 0.75, 8 = 1.00, 9 = 1.33, 10 = 1.78, 11 = 2.37, 12 = 3.16, 13 = 4.22 GAIN FACTOR...

  • Page 74: Operation

    OPERATION Series 642 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 75: 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 is required. You can use our Software (freeware) 'Control Performance Analyzer' which can be downloaded from: http://www.vatvalve.com/customer-service/informations-and-downloads/control-performance-analyzer.

  • Page 76: Remote Operation

    OPERATION Series 642 5.1.2 Remote operation This product is equipped with a DeviceNet interface to allow for remote operation. See section «DeviceNet interface» for details. 'Control Performance Analyzer' software or 'Service Box 2' may be used for monitoring during remote control. 'Control Performance Analyzer' software 'Service Box 2' In case ‘Control Performance Analyzer’...

  • Page 77: Close Valve

    Series 642 OPERATION Close valve Local operation: Remote operation: (‘Control View’, ‘Control Performance Analyzer’ or (Refer to chapter «Explicit messaging control ‘Service Box 2‘) commands» for details) Send EXECUTING (if not yet selected) Send SETPOINT TYPE Push CLOSE button = position control Send CONTROL MODE for position = close valve Open valve...

  • Page 78: Pressure Control

    OPERATION Series 642 Pressure control To prepare valve for PRESSURE CONTROL perform complete «Setup procedure». The valve has parameters that may be modified to tune pressure control performance. Refer to «Tuning of control performance». The included PID controller controls the chamber pressure according to the pressure setpoint by means of the valve position.

  • Page 79: Pressure Control Operation With 2 Sensors

    Series 642 OPERATION 5.5.1 Pressure control operation with 2 sensors [applicable with 642 . . - . . . Q - ..version only] If 2 sensor operation is enabled, changeover between the sensors is done automatically during pressure control.

  • Page 80: Display Information

    OPERATION Series 642 Display information There is a 4 digit display located on the panel. It displays configuration, status and position information. For details see following tables. Display 1 2 3 4 5.6.1 Power up Description Digit 1 Digit 2 Digit 3 Digit 4 ●...

  • Page 81: Operation

    Series 642 OPERATION SYNC indicates that powerup synchronization is running. 1) SPS = optional ±15 VDC Sensor Power Supply module 2) PFO = Power Failure Option 5.6.2 Operation Description / Mode Digit 1 Digit 2 Digit 3 Digit 4 PRESSURE CONTROL mode POSITION CONTROL mode Valve closed Valve open...

  • Page 82: Devicenet® Leds

    OPERATION Series 642 5.6.4 DeviceNet® LEDs Description Module Status LED Network Status LED Module and Network Status LEDs at Power–Up A LED test is to be performed at power–up. To allow a visual inspection to be performed, the following sequence is to be followed: •...

  • Page 83: Safety Mode

    Series 642 OPERATION 5.6.4.2 Network Status LED This bi–color (green/red) LED indicates the status of the communication link. Table below define the Network Status LED states. State Description Not Powered/Not On–line Device is not on–line. - The device has not completed the Dup_MAC_ID test yet. - The device may not be powered, look at ‘Status LED’...

  • Page 84: Operation During Power Up

    1). Default is not defined. Display indicates F. 1) Provide that battery pack of the VAT controller is charged. Charging time after power up is 2 minutes max.. All parameters are stored in a power fail save memory.

  • Page 85: Trouble Shooting

    TROUBLE SHOOTING Series 642 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. ® ® Module Status LED is off - DeviceNet power supply...
  • Page 86 TROUBLE SHOOTING Series 642 Failure Check Action ® Remote operation (DeviceNet - Local operation via - Switch to remote operation. does not work service port active - Safety mode active, check - Provide power to motor to allow for operation. for D on display? - Refer to «Electrical connection»...
  • Page 87 TROUBLE SHOOTING Series 642 Failure Check Action Pressure reading is wrong - Sensor(s) connected? - Refer to «Electrical connection». - 2 sensor version present - Check valve version on page 1. Verify pressure reading is negative at valve controller? configuration. Refer to «Setup procedure». - Refer to «Pressure control operation with 2 sensors».

  • Page 88: 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 89: Maintenance Procedures

    Replacement of gate seal (gate and bonnet seal) and valve cleaning Required frequency of cleaning and replacement of seals is depending on process conditions. VAT can give the following recommendations for preventive maintenance: Replacement of Recommendation Gate seal (gate and bonnet seal) Every 100’000 cycles...

  • Page 90: Replacement Of Gate Seals And Valve Cleaning

    MAINTENANCE Series 642 7.2.1 Replacement of gate seals and valve cleaning 7.2.1.1 Required tools • • Allen Wrench 4 mm (Allen torque wrench 4 mm) Isopropyl alcohol • • 2 × Open end wrench 13 mm Vacuum grease (see chapter spare parts) •...
  • Page 91 Series 642 MAINTENANCE Description Required tool Pull out the gate until the crank bolt can be reached 10. Loosen and remove the crank bolt Allen wrench 4 mm screw 11. Remove the crank bolt from lever 12. Pull out the gate assembly complete Caution! Take care that gate is not scratching at lever while pulling out...
  • Page 92 MAINTENANCE Series 642 Description Required tool Clean room wiper a 15. Clean the o-ring groove and the gate little soaked with assembly isopropyl alcohol 16. Install the new o-ring equally in o-ring groove (for new o-ring refer to chapter: «Spare parts») Cleaning tool a little soaked with isopropyl alcohol...
  • Page 93 Series 642 MAINTENANCE Description Required tool 20. Insert the crank bolt at lever If necessary use a new crank bolt (for new crank bolt refer to chapter: «Spare parts»). 21. Fasten the crank bolt screw Allen torque wrench adequately 4 mm 22.
  • Page 94 MAINTENANCE Series 642 Description Required tool 26. Reassemble the bonnet and bonnet seal with valve DN 63 / 100 1 × Open end torque wrench 13 mm 1 × Open end wrench 13 mm 27. Fasten the bonnet screws with: •...

  • Page 95: Replacement Of Option Board

    Series 642 MAINTENANCE 7.2.2 Replacement of Option board NOTICE Electrostatic discharge Electronic components could be damage. All work on the control and actuating unit has to be done under ESD protected environment to prevent electronic components from damage. NOTICE Burned connector pins (spark) Connector pins or electronic parts could damage, if plugged and unplugged under power.
  • Page 96 MAINTENANCE Series 642 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 97: Retrofit / Replacement Procedure

    Series 642 MAINTENANCE 7.2.3 Retrofit / replacement procedure Top view on control unit with panel removed: Master board Connector board Option board DeviceNet board Motor driver 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! 7.2.3.1 Needed tools...
  • Page 98 MAINTENANCE Series 642 Description Required tool Attention to ESD protection! Disconnect all electrical connections Pozidriv screw driver size1 at controller. Open end wrench 7 mm Write down the «NODE ADDRESS» and «DATA RATE» in case of Ballpoint Interface board replacement. Remove the panel screws.
  • Page 99 Series 642 MAINTENANCE Description Required tool Loosen and remove the LOCIC Open end wrench 10mm connector screw Lift controller panel carefully. Remove or replace option board. Remove or replace connector board. 605593EC Edition 2017-11-24 99/113...
  • Page 100 MAINTENANCE Series 642 Description Required tool 10. Remove or replace interface board. 11. Remove or replace master board. 12. Remove or replace motor driver board 13. Insert all boards in reverse order as they disassembled at correct positions (see steps 12 to 7). 14.
  • Page 101 Series 642 MAINTENANCE Description Required tool 16. In case of replacement Interface board, adjust the «NODE Screw driver size 00 ADDRESS» and «DATA RATE» (see step 2). Pozidriv screw driver size1 17. Connect all electrical connections. Open end wrench 7 mm If you need any further information, please contact one of our service centers.

  • Page 102: Repairs

    Series 642 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 103: Dismounting And Storage

    Series 642 DISMOUNTING AND STORAGE 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 104: Storage

    DISMOUNTING AND STORAGE Series 642 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 105: 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. 10.1...

  • Page 106: 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. 106/113 Edition 2017-11-24 605593EC...

  • Page 107: Disposal

    Series 642 DISPOSAL Disposal WARNING Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. 605593EC Edition 2017-11-24 107/113...

  • Page 108: 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 109: Drawing

    Series 642 SPARE PARTS 12.1 Drawing Sample picture All “Item“ refer to chapter «Drawing» 605593EC Edition 2017-11-24 109/113...

  • Page 110: Valve Unit With Seals And Grease

    97442-R1 225315 97446-R1 85047-R1 95939-R1 98472-R1 98474-R1 98476-R1 Feedtrough 91001-R1 227400 assembling tool VAT vacuum N-6951-012 grease (40g) 12.1.2 Controller Item Description Part number Too many to list. Please contact Control and actuating unit VAT. Option board with SPS module 371399 (±15 VDC sensor power supply)

  • Page 111: Accessories

    Service Box 2 601BS-29NN-000 Control panel (rack-mount version of 602BS-29LE-000 Service Box 2) O-ring removal tool 234859 VAT valve cleaning tool 305709 12.1.3.1 Centering ring with Viton o-ring DN 63 / 2½” DN 80 / 3” DN 100 / 4”...

  • Page 112: Appendix

    APPENDIX Series 642 Appendix No information entered on time. 112/113 Edition 2017-11-24 605593EC...
  • Page 113 Series 642 This page left blank intentionally. 605593EC Edition 2017-11-24 113/113...

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