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VAT 615 Series Installation, Operating, & Maintenance Instructions

Butterfly control & isolation valve with extended control range with logic interface, dn 40-50 mm i.d. 1.5"-2"
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Installation, Operating &
Maintenance Instructions
Butterfly control & isolation valve
with extended control range
with Logic interface
Series 615
DN 40-50 mm (I.D. 1.5" - 2")
This manual is valid for the valve ordering number(s):
615 . . - . .GC- . . . .
615 . . - . .GE- . . . .
615 . . - . .AC- . . . .
615 . . - . .AE- . . . .
615 . . - . .HC- . . . .
615 . . - . .HE- . . . .
615 . . - . .CC- . . . .
615 . . - . .CE- . . . .
SPS = Sensor Power Supply
configured with firmware 600P.1G.00.06...07...08
Sample picture
605435EC
(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 2014-07-10

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Summary of Contents for VAT 615 Series

  • Page 1 Installation, Operating & Maintenance Instructions Butterfly control & isolation valve with extended control range with Logic interface Series 615 DN 40-50 mm (I.D. 1.5“ - 2") This manual is valid for the valve ordering number(s): 615 . . - . .GC- ..(1 sensor input) 615 .
  • 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 615 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 615 4.7.3 Tuning of pressure control with soft pump ............58 Operation ................... 61 Normal operation ......................61 5.1.1 Local operation ....................62 5.1.2 Remote operation .................... 63 Close valve ........................64 Open valve........................64 Position control ......................64 Pressure control ......................

  • Page 5: Description Of Product

    This product is a Butterfly control valve with isolation functionality 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 615 Technical data 1.6.1 Control and actuating unit Describtion Power input (α) +24 VDC (±10%) @ 0.5 V pk-pk [connector: POWER] max. [615 . . - . . A . - ../ 615 . . - . . G . - ..] 38 W max.
  • Page 7 Series 615 DESCRIPTION OF PRODUCT Control and actuating unit (continuation) Sensor input Signal input 0-10 VDC / Ri>100 kΩ [connector: SENSOR] ADC resolution 0.23 mV Sampling time 10 ms Digital inputs 3) ±24 VDC max. Digital outputs Input voltage 70 VDC or 70 V peak max. Input current 0.5 ADC or 0.5 A peak max.

  • Page 8: Valve Unit

    DESCRIPTION OF PRODUCT Series 615 1.6.2 Valve unit Description Pressure range at 20°C - Aluminum hard anodized (615 . . - . H. . - ..) 1 × 10E-6 mbar to 1.2 bar (abs) - Stainless steel (615 .
  • Page 9 Series 615 DESCRIPTION OF PRODUCT Valve unit (continuation) DN 40 DN 50 1½" 2" (61532 - ..) (61534 - ..) Max. differential pressure on plate 1000 mbar 1000 mbar Min. controllable conductance (C 0.05 l/s 0.1 l/s molecular flow] Conductance in open position [N molecular flow] 60 l/s 120 l/s...

  • Page 10: Safety

    SAFETY Series 615 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 11: Personnel Qualifications

    Series 615 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 605435EC...

  • Page 12: Design And Function

    DESIGN AND FUNCTION Series 615 Design and Function Design Sample picture XY: Double excentric bearing: prevents wearing of the o-ring and particle generation Controller Double seal Coupling Plate Bearing Body 12/102 Edition 2014-07-10 605435EC...

  • Page 13: Function

    Series 615 DESIGN AND FUNCTION Function The valve plate acts as a throttling element and varies the conductance of the valve opening. The integrated controller calculates the required plate position to achieve the setpoint pressure. Actuation is performed by a stepper motor. An encoder monitors the position. This principle ensures fast and accurate process pressure control even in demanding contaminating processes.

  • Page 14: Principle Of A Pressure Control System

    DESIGN AND FUNCTION Series 615 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 15: 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 16: Installation Into The System

    INSTALLATION Series 615 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 17: Installation Space Condition

    Series 615 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 605435EC Edition 2014-07-10 17/102...

  • Page 18: Connection Overview

    INSTALLATION Series 615 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 4.2.3 Installation procedure All numbers in brackets refer to chapter: «Connection overview». Remove protective covers from body flanges.

  • Page 19: Tightening Torque

    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 20: Admissible Forces

    INSTALLATION Series 615 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. Do not higher force the valve body as specified. The following forces are admissible.

  • Page 21: Admissible Forces At Controller

    Series 615 INSTALLATION 4.4.1 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 22: Requirements To Sensor Connection

    INSTALLATION Series 615 4.4.2 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 23: Ground Connection

    Series 615 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 200 mm 25 mm 25 mm 4.5 mm customized...

  • Page 24: Sensor Supply Concepts

    INSTALLATION Series 615 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 25: Power And Sensor Connection (+24 Vdc Sensors)

    Series 615 INSTALLATION 4.5.3 Power and sensor connection (+24 VDC sensors) [615 . . - . . G . - ../ 615 . . - . . H . - ..versions recommended] 4.5.3.1 Sensor power wiring via controller Pins 4 and 8 must be...
  • Page 26 INSTALLATION Series 615 4.5.3.2 Sensor power wiring external 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 27: Power And Sensor Connection (±15 Vdc Sensors) Without Opt. Sps Module

    Series 615 INSTALLATION Power and sensor connection (± ± ± ± 15 VDC sensors) without opt. SPS module 4.5.4 [615 . . - . . G . - ../ 615 . . - . . H . - ..versions only] 4.5.4.1 Sensor power wiring via controller Pins 4 and 8 must be...
  • Page 28 INSTALLATION Series 615 4.5.4.2 Sensor power wiring external 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 29: Power And Sensor Connection (±15 Vdc Sensors) With Optional Sps Module

    Series 615 INSTALLATION Power and sensor connection (± ± ± ± 15 VDC sensors) with optional SPS module 4.5.5 [615 . . - . . A . - ../ 615 . . - . . C . - ..versions only] Pins 4 and 8 must be bridged for operation.

  • 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: Functions And Wiring

    Series 615 INSTALLATION 4.5.7 Functions and Wiring Logic interface allows for remote operation by means of digital and analog signals. Digital inputs may be operated either by switches or by voltage sources. a) Configuration with switches for digital inputs: SC1096 A Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 605435EC...
  • Page 32 INSTALLATION Series 615 a) Configuration with voltage source for digital inputs: SC1097A Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 32/102 Edition 2014-07-10 605435EC...

  • Page 33: Digital Inputs

    Series 615 INSTALLATION 4.5.8 Digital inputs Function Signal Description Priority type This pin selects the control mode. This valve may either be operated as pressure controller or as position controller. PRESSURE CONTROL is activated as long as optocoupler is ‘on’. CONTROL Digital The PID controller controls the chamber pressure according to...
  • Page 34 INSTALLATION Series 615 Function Signal Description Priority type This function compensates the pressure gauge offset voltage and sets the pressure value to zero. In case of a 2 sensor system both sensor inputs will be adjusted. This function is initiated by the ‘off’ to ‘on’ transition of the optocoupler.

  • Page 35: Digital Outputs

    Series 615 INSTALLATION 4.5.9 Digital outputs Function Signal Description type This output is active in all operation modes and indicates either that the valve is open or that a service is requested. VALVE A service request is indicated when the valve requires cleaning due OPEN Digital to contamination.

  • Page 36: Analog Inputs And Outputs

    INSTALLATION Series 615 4.5.10 Analog inputs and outputs Function Signal Description type The meaning of the setpoint input depends on the operation mode. LEARN: A voltage of 0-10V shall be applied to this input as pressure limit for learn. The limit pressure is in linear relation to the applied voltage. 10V relates to sensor full scale.

  • Page 37: 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 To enable the valve for pressure control setup steps 1 to 6 must be performed.

  • Page 38: Valve Configuration

    INSTALLATION Series 615 • Functionality of digital inputs CLOSE VALVE and OPEN VALVE must be selected. These may be configured as ‘not inverted‘ or ‘inverted‘. Default is ‘not inverted‘. • LEARN range configuration for remote operation must be selected. This may either be ‘full range’ or pressure limit according of analog SETPOINT input. Default is ‘full range‘.

  • Page 39: Sensor Configuration

    Series 615 INSTALLATION 4.6.4 Sensor configuration Basic sensor configuration must be adapted according to application needs. • ZERO function: This may be ‘disabled’ or ‘enabled’. Default is ‘enabled‘. Refer also to chapter «ZERO». • Sensor configuration with 2 sensor version [615 . . - . . . E - ..]. Refer also to chapter: «Pressure control operation with 2 sensors».

  • Page 40: Learn (Adaptive)

    INSTALLATION Series 615 4.6.1 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 41 Series 615 INSTALLATION 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. 10.

  • Page 42: Pressure Control Algorithem

    INSTALLATION Series 615 4.6.2 Pressure control algorithem Select the configuration what your application needs. Constant gas flow available Constant gas flow System Configuration not 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 43 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 4.6.2.2 With CPA 3.0 direct setup (standard)
  • Page 44 INSTALLATION Series 615 4.6.2.3 Pressure control parameter 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 45 Series 615 INSTALLATION Pressure control algorithem • Local operation only: With CPA direct setup, see chapter: With CPA 3.0 direct setup (standard). With CPA, go to «Tools» > «Terminal» and send setup commands according to application needs. See next tables. 4.6.2.5 Adaptive control algorithm (downstream) Parameter...

  • Page 46: Gain Factor

    INSTALLATION Series 615 In the adaptive pressure controller mode, the RAMP TIME parameter also can be a value to minimize over- / undershooting. The ramp could be used to harmonize the adaptive control algorithm. 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.
  • Page 47 Series 615 INSTALLATION 4.6.2.6 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 48 INSTALLATION Series 615 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 control algorithm, refer to chapter «Tuning of control performance».

  • Page 49: Tuning Of Control Performance

    Series 615 INSTALLATION 4.6.2.8 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:02D01 i:02D01c s:02D02c c = 0…1 s:02 0 = constant time RAMP MODE UINT 1 = constant slope i:02D02c...

  • Page 50: Tuning Of Pressure Control (Adaptive)

    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 50/102 Edition 2014-07-10 605435EC...
  • Page 51 Series 615 INSTALLATION 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:...
  • Page 52 INSTALLATION Series 615 4.7.1.2 Sensor delay adjustment Sensor delay adjustment effects: Stability Default value is 0sensorDeay0. 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 53 Series 615 INSTALLATION 4.7.1.3 Setpoint ramp adjustment Setpoint ramp effects: Undershoot of pressure, Response time Default value for Setpoint Ramp is 0. 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 54 INSTALLATION Series 615 4.7.1.4 Valve speed adjustment Valve speed effects: Response time Default value is 1000. 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.

  • Page 55: Tuning Of Pressure Control Performance With Fixed Pi Control

    Series 615 INSTALLATION 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 56 INSTALLATION Series 615 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 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 605435EC Edition 2014-07-10 57/102...

  • Page 58: Tuning Of Pressure Control With 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 59 Series 615 INSTALLATION 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 60 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 60/102 Edition 2014-07-10 605435EC...

  • Page 61: Operation

    Series 615 OPERATION 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 62: 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 63: Remote Operation

    Series 615 OPERATION 5.1.2 Remote operation This product is equipped with a Logic interface to allow for remote operation. See section «Logic 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 64: Close Valve

    OPERATION Series 615 Close valve Local operation: Remote operation: (‘Control View’, ‘Control Performance Analyzer’ or (Refer to chapter «Digital inputs» for details) ‘Service Box 2‘) Push CLOSE button Send CLOSE VALVE Open valve Local operation: Remote operation: (‘Control View’, ‘Control Performance Analyzer’ or (Refer to chapter «Digital inputs»...

  • Page 65: Operation With 2 Sensors

    Series 615 OPERATION 5.5.1 Operation with 2 sensors [applicable with 612 . . - . . . E - ..version only] If 2 sensor operation is enabled, changeover between the sensors is done automatically during pressure control.

  • Page 66: Display Information

    OPERATION Series 615 Display information 1 2 3 4 Display There is a 4 digit display located on the panel. It displays configuration, status and position information. For details refer to following tables. 5.6.1 Power up Description Digit 1 Digit 2 Digit 3 Digit 4 ●...

  • Page 67: Operation

    Series 615 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 HOLD (position frozen) 0…100 activated = valve position (%, 0 = closed / 100 = open) ZERO running LEARN running Safety mode established.

  • Page 68: 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 69: Trouble Shooting

    TROUBLE SHOOTING Series 615 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 - Local operation via - Switch to remote operation.

  • Page 70: Pressure Control

    TROUBLE SHOOTING Series 615 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». - ZERO done? - Perform ZERO when base pressure is reached.

  • Page 71: 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 72: 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: heated ≤ ≤ ≤ ≤ 80 °C Replacement of unheated heated >...

  • Page 73: Replacement Of Plate O-Ring

    Series 615 MAINTENANCE 7.2.1 Replacement of plate o-ring 7.2.1.1 Required tools • • Allen Wrench 3mm Vacuum grease (see chapter spare parts) • • O-ring removal tool Cleanroom wipes (see chapter Accessories) Description Required tool 1. Vent vacuum system on both sides of the valve. 2.
  • Page 74 MAINTENANCE Series 615 Description Required tool 7. Remove the plate o-ring O-ring removal tool 8. Replace the plate if necessary Cleanroom wipes soaked with 9. Clean the plate and o-ring groove isopropyl alcohol 10. Lubricate the new o-ring with 0.0125 ml vacuum grease Vacuum grease For new o-ring refer to chapter spare parts.
  • Page 75 Series 615 MAINTENANCE Description Required tool 13. Move the o-ring in the o-ring groove on the other side 14. Push in the o-ring equally around the plate into o-ring groove 15. Plate with equal mounted o-ring 16. Place the plate on the shaft in the valve body 17.
  • Page 76 MAINTENANCE Series 615 Description Required tool 19. Connect electrical POWER connection Attention! at valve Attention! Valve does synchronize automatically and moves the plate into sit of valve body (close position). 20. Disconnect electrical POWER Keep fingers out of the valve opening connection during plate movement! 21.

  • Page 77: Replacement Of Shaft Feed Through Seals And Valve Cleaning

    Series 615 MAINTENANCE 7.2.2 Replacement of shaft feed through seals and valve cleaning 7.2.2.1 Required tools • • Allen Wrench 2mm / 2.5mm Isopropyl alcohol • • Allen Wrench 3mm Cleanroom wipes • • O-ring removal tool Vacuum grease (see chapter spare parts) (see chapter Accessories) Description Required tool...
  • Page 78 MAINTENANCE Series 615 Description Required tool Remove control and actuating unit from mechanical valve unit If clamp coupling is separated, assemble them at control and actuating unit. Unfasten and remove the 2 fastening Allen Wrench screws Push the plate a little down Remove the plate on the other side of shaft 10.
  • Page 79 Series 615 MAINTENANCE Description Required tool Cleanroom wipes 12. Clean the plate and o-ring groove soaked with isopropyl alcohol 13. Lubricate the new o-ring with 0.0125 ml vacuum grease Vacuum grease For new o-ring refer to chapter spare parts. 14. Pay attention that grease is distributed constantly over the whole circumference.
  • Page 80 MAINTENANCE Series 615 Description Required tool 17. Push in the o-ring around the plate into o-ring groove equally 18. Plate with equal mounted o-ring 19. Deposit the plate on a clean surface Allen Wrench 20. Unfasten both screws complete 21. Remove mechanical unit from valve body 80/102 Edition 2014-07-10...
  • Page 81 Series 615 MAINTENANCE Description Required tool Cleanroom wipes 22. Clean shaft soaked with isopropyl alcohol 23. Remove both o-rings Soft tool Cleanroom wipes 24. Clean shaft feed through soaked with isopropyl alcohol Cleanroom wipes 25. Clean the valve body soaked with isopropyl alcohol 26.
  • Page 82 MAINTENANCE Series 615 Description Required tool 27. Lubricate seal contact surface of shaft with a slight film of 0.0125 ml vacuum Vacuum grease grease 28. Lubricate each o-ring with a slight film of 0.0125 ml vacuum grease. Vacuum grease 29. Slide both o-rings onto shaft till the end Vacuum grease 30.
  • Page 83 Series 615 MAINTENANCE Description Required tool 34. Place the plate on the shaft in the valve body 35. Tighten plate screws to block. Allen Wrench 36. Loosen the plat screws a quarter turn counter clockwise so that plate is still movable at shaft.
  • Page 84 MAINTENANCE Series 615 Description Required tool 41. Assemble valve unit with control and actuating. Push axis (C) into clamp coupling Allen Wrench 42. Tighten mounting screws adequately Allen Wrench: 43. Tighten clamp coupling: elastic coupling • with elastic coupling 1.1 Nm 2 mm •...

  • Page 85: Replacement Of Option Board

    Series 615 MAINTENANCE 7.2.3 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 86 MAINTENANCE Series 615 7.2.3.1 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 87 Series 615 MAINTENANCE 7.2.3.2 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! 605435EC...
  • Page 88 MAINTENANCE Series 615 7.2.3.3 Required 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, SENSOR and INTERFACE Open end wrench 4.5 mm connectors.
  • Page 89 Series 615 MAINTENANCE 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 5). Insert option board at correct position (see step 7) 10.

  • Page 90: Repairs

    Series 615 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 91: Dismounting And Storage

    Series 615 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 92: Storage

    DISMOUNTING AND STORAGE Series 615 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 93: 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 94: 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. 94/102 Edition 2014-07-10 605435EC...

  • Page 95: Disposal

    Series 615 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. 605435EC Edition 2014-07-10 95/102...

  • Page 96: 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 97: Drawing

    Series 615 SPARE PARTS 12.1 Drawing Sample picture Plate screws Body with mechanism Lever complete Body complete Adapter flange, rod with bearing Plate Rotary feedtrough seals Plate o-ring 605435EC Edition 2014-07-10 97/102...

  • Page 98: Iso-Kf Valve Unit - Aluminum Hard Anodized, Without Heating

    SPARE PARTS Series 615 All “Item“ refer to chapter «Drawing» 12.1.1 ISO-KF valve unit – aluminum hard anodized, without heating Item Description DN 40 / 1½” DN 50 / 2” Valve size Product ordering number 61532 - KH . . 61534 - KH .

  • Page 99: Seals And Grease

    12.1.4 Control and actuating unit Description Part number Control and actuating unit Too many to list. Please contact VAT. Option board with SPS module 378000 (±15 VDC Sensor Power Supply) Option board with PFO module 378002...

  • Page 100: Accessories

    SPARE PARTS Series 615 12.1.5 Accessories Description Part number 24 VDC power supply unit 249775 (input: 100 – 240 VAC) free download from: ‘Control Performance Analyzer’ ® http://www.vatvalve.com/customer-service/informations-and- package for Windows downloads/control-performance-analyzer Service cable 230327 (PC to valve Service connector) free wiring information available for download from: http://www.vatvalve.com/customer-service/informations-and- downloads/control-performance-analyzer...

  • Page 101: Appendix

    Series 615 APPENDIX Appendix No information entered on time. 605435EC Edition 2014-07-10 101/102...
  • Page 102 Series 615 This page left blank intentionally. 102/102 Edition 2014-07-10 605435EC...

This manual is also suitable for:

615-gc series615-ge series615-ac series615-ae series615-hc series615-he series ... Show all

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