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VAT 642 Series Installation, Operating, & Maintenance Instructions

Control gate valve with rs485 interface
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Installation, Operating &
Maintenance Instructions
Control gate valve
with RS485 interface
Series 642
DN 63- 400 mm (I.D. 2.5" - 16")
This manual is valid for the valve ordering number(s):
642 . . - . .GJ - . . . .
642 . . - . .GK - . . . .
642 . . - . .AJ - . . . .
642 . . - . .AK - . . . .
642 . . - . .HJ - . . . .
642 . . - . .HK - . . . .
642 . . - . .CJ - . . . .
642 . . - . .CK - . . . .
SPS = Sensor Power Supply
configured with firmware 600P.1G.00.06...07...08
Sample picture
605622EE
(1 sensor input / analog outputs)
(2 sensor inputs / analog outputs)
(1 sensor input / analog outputs / ±15V SPS)
(2 sensor inputs / analog outputs / ±15V SPS)
(1 sensor input / analog outputs / PFO)
(2 sensor inputs / analog outputs / PFO)
(1 sensor input / analog outputs / ±15V SPS / PFO)
(2 sensor inputs / analog outputs / ±15V SPS / PFO)
PFO = Power Failure Option
Edition 2017-11-24

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  • Page 1 Installation, Operating & Maintenance Instructions Control gate valve with RS485 interface Series 642 DN 63- 400 mm (I.D. 2.5“ - 16") This manual is valid for the valve ordering number(s): 642 . . - . .GJ - ..(1 sensor input / analog outputs) 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 ................ 6 Identification of product ....................6 Use of product ......................... 6 Used abbreviations ......................6 Related documents......................6 Important information....................... 6 Technical data ......................... 7 1.6.1 Control and actuating unit ................. 7 1.6.2 Valve unit ......................
  • Page 4 Series 642 4.7.2 Tuning of control performance with fixed PI pressure controller ...... 54 4.7.3 Tuning of control performance with soft pump pressure controller ....57 RS485 interface commands ..................59 4.8.1 RS485 command syntax ................. 59 4.8.2 Addressed communication ................59 4.8.3 Control commands ..................
  • Page 5 Series 642 Appendix ..................116 605622EE Edition 2017-11-24 5/117...

  • Page 6: 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 7: Technical Data

    Series 642 DESCRIPTION OF PRODUCT 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 8 DESCRIPTION OF PRODUCT Series 642 Control and actuating unit (continuation) Sensor input Signal input voltage 0-10 VDC / Ri>100 kΩ [connector: SENSOR] ADC resolution 0.23 mV Sampling time 10 ms Digital inputs ±24 VDC max. [connector: INTERFACE] Digital outputs [connector: INTERFACE] Input voltage 70 VDC or 70 V peak max.

  • Page 9: 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 10: 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 11: 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 605622EE...

  • Page 12: 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. 12/117 Edition 2017-11-24...

  • Page 13: 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 14: 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 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 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 17: 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 605622EE Edition 2017-11-24 17/117...

  • Page 18: Connection Overview

    INSTALLATION Series 642 4.2.2 Connection overview System: Valve Process chamber Gas inlet Pressure sensor(s) Sensor cable(s) Cable to RS485 remote control unit Cable to power supply Controller Connection cable controller / actuator 10 Actuator 11 Pump Actuator Controller 18/117 Edition 2017-11-24 605622EE...

  • Page 19: 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 20: 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 21: 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 605622EE Edition 2017-11-24 21/117...

  • Page 22: 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. 22/117 Edition 2017-11-24 605622EE...

  • Page 23: 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 24: 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 25: 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 26: Power And Sensor Connection (+24 Vdc Sensors)

    An optional switch would allow for motor interlock to prevent valve from moving. • VAT fuse recommendation: (a) 5AF, (b) min. 3A • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources. •...
  • Page 27 S C1 091 A • VAT fuse recommendation: (a) 5AF, (b) min. 3A • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources. •...

  • Page 28: Power (+24 Vdc) And Sensor Connection (±15 Vdc Sensors) With Opt. Sps Module

    SC 1090 A • VAT fuse recommendation: (a) 5AF, (b) min. 3A • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources. •...
  • Page 29 SC 1092 A • VAT fuse recommendation: (a) 5AF, (b) min. 3A • Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources. •...

  • 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 Series 642 INSTALLATION a) Configuration with switches for digital inputs: SC1045B Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 605622EE Edition 2017-11-24 31/117...
  • Page 32 INSTALLATION Series 642 b) Configuration with voltage source for digital inputs: SC1046B Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 32/117 Edition 2017-11-24 605622EE...

  • Page 33: Digital Inputs

    Series 642 INSTALLATION 4.5.7 Digital inputs Signal Function Description Priority type 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 RS485 control command have been received Digital CLOSE...

  • Page 34: Rs485 Network Topology

    INSTALLATION Series 642 4.5.8 RS485 network topology In the picture above, the general network topology of RS485 is shown. N nodes are connected in a multipoint RS485 network. A termination resistance is necessary on both ends of the line to eliminate reflections. Use 120Ω resistors (R) on both ends.

  • Page 35: 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 4.6.1 RS485 Interface configuration Interface configuration must be adapted according to application needs.

  • Page 36: Valve Configuration

    INSTALLATION Series 642 • Pressure and position range for RS485 communication must be selected. Default for pressure is 0 - 1’000’000. Default for position is 0 - 100’000. Local operation: Remote operation: (‘Control Performance Analyzer’ or Service Box2) (Refer to chapter «setup commands» for details) •...

  • Page 37: Sensor Configuration

    Series 642 INSTALLATION Remote operation: Local operation: (Refer to chapter «Setup commands» for (‘Control Performance Analyzer’ or ‘Service Box 2‘) details) With CPA: • Do valve configuration in menu ‘Valve / Setup’. With SB2: Send VALVE CONFIGURATION • Do power up configuration in menu ‘Setup / Valve’.

  • Page 38: Learn (Adaptive)

    INSTALLATION Series 642 warm up time. • Do not perform ZERO, if the base pressure of your vacuum system is higher than 1‰ of sensor full scale. We recommend disabling ZERO function in this case; refer to «Valve and sensor configuration» of the setup procedure. Otherwise incorrect pressure reading is the result.
  • Page 39 Series 642 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. At first it is necessary to find out about the required control range respectively its conductance values.

  • Page 40: Pressure Control Configuration

    INSTALLATION Series 642 4.6.6 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 41 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 4.6.6.2 With CPA 3.0 direct setup (standard)
  • Page 42 INSTALLATION Series 642 4.6.6.3 Pressure control parameter Local operation: Remote operation: (‘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 command) Describtion s:02abbc...

  • Page 43: Pressure Control Algorithem

    Series 642 INSTALLATION 4.6.7 Pressure control algorithem • Remote operation: Refer to chapter «RS485 interface commands» • 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.

  • Page 44: Gain Factor

    INSTALLATION Series 642 ramp time slope is SFS (10V) in 10 Seconds. 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.
  • Page 45 Series 642 INSTALLATION 4.6.7.2 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 46 INSTALLATION Series 642 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 47: Tuning Of Control Performance

    Series 642 INSTALLATION 4.6.7.4 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:02D01 i:02D01c s:02D02c c = 0…1 s:02 0 = constant time RAMP MODE UINT 1 = constant slope i:02D02c...

  • Page 48: Tuning Of Control Performance With Adaptive Pressure Controller

    INSTALLATION Series 642 4.7.1 Tuning of control performance with adaptive pressure controller 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 49 Series 642 INSTALLATION Control a typical pressure / flow situation Repeat from step 2 with lower (higher) gain factors until optimal pressure response is achieved and stability is ok. Normally adjustments down to gain factors of 0.42 should lead to good results. Otherwise you may need to improve sensor connection.
  • Page 50 INSTALLATION Series 642 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 51 Series 642 INSTALLATION 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 52 INSTALLATION Series 642 Local operation: Remote operation: (‘Control Performance Analyzer’ or ‘Service Box 2‘) (Refer to chapter «Pressure control algorithm» > «Adaptive control algorithm» for details) With CPA: • Do the ‘Ramp Time’ and ‘Ramp Mode’ adjustment in menu ‘Pressure Control’ / ‘Setup’...
  • Page 53 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 605622EE Edition 2017-11-24 53/117...

  • Page 54: Tuning Of Control Performance With Fixed Pi Pressure Controller

    INSTALLATION Series 642 4.7.2 Tuning of control performance with fixed PI pressure controller 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 55 Series 642 INSTALLATION 1.2 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 56 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 56/117 Edition 2017-11-24 605622EE...

  • Page 57: Tuning Of Control Performance With Soft Pump Pressure Controller

    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 58 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 58/117 Edition 2017-11-24 605622EE...

  • Page 59: Rs485 Interface Commands

    Series 642 INSTALLATION RS485 interface commands 4.8.1 RS485 command syntax Commands and values are case sensitive. Acknowledgement within 10ms after reception of command. Wait for acknowledgement before sending a new command. Command termination of each command is CR and LF. CR = Carriage Return (0D hexadecimal), LF = Linefeed (0A hexadecimal) 4.8.2 Addressed communication...

  • Page 60: Control Commands

    INSTALLATION Series 642 4.8.3 Control commands Command Acknowledgement Control function Description CLOSE VALVE Valve will close. OPEN VALVE Valve will open. This function stops the valve at the current position. It is effective in PRESSURE HOLD CONTROL and POSITION CONTROL. The function can be revoked by a POSITION CONTROL, PRESSURE CONTROL, OPEN VALVE or CLOSE VALVE command.
  • Page 61 Series 642 INSTALLATION Command Acknowledgement Inquiry function Description A:aaaaaa data length 6 characters aaaaaa position, return value depends on configuration, refer to «RS485 setup commands, COMMUNICATION RANGE» POSITION for details This function returns the current valve position. Remark: 999’999 is returned when the position is unknown, for example after power up during synchronization P:saaaaaaa data length 8 characters...

  • Page 62: Device Status

    INSTALLATION Series 642 Command Acknowledgement Inquiry function Description i:30 i:30abcdefgh data length 8 characters 0 = local operation Access Mode 1 = remote operation 2 = locked remote operation 1 = synchronization Control Mode 2 = POSITION CONTROL 3 = CLOSED 4 = OPEN 5 = PRESSURE CONTROL 6 = HOLD...
  • Page 63 Series 642 INSTALLATION Command Acknowledgement Control function Description i:32 i:32abcdefgh data length 8 characters 0 = No Running 1 = Yes Data set present 0 = Ok 1 = No (Learn necessary) Abortion 0 = Ok, Learn completed 1 = Abort by user 2 = Abort by control unit 0 = Ok Open pressure...
  • Page 64 INSTALLATION Series 642 Command Acknowledgement Inquiry function Description i:51 i:51abcdefgh 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 65: Hardware Configuration

    Series 642 INSTALLATION Command Acknowledgement Inquiry function Description i:76 i:76xxxxxxsyyyyyyyabc data length 17 characters xxxxxx position, return value depends on configuration, refer to «RS485 setup commands, COMMUNICATION RANGE» for details sign, 0 for positive pressure readings, - for negative pressure readings yyyyyyy pressure, return value depends on configuration, refer to «RS485 setup commands, COMMUNICATION RANGE»...
  • Page 66 INSTALLATION Series 642 Command Acknowledgement Inquiry function Description i:84 i:84aaaaaa FIRMWARE data length 20 characters NUMBER aaaaaa Firmware number e.g. 700989 This function returns the VAT Firmware number. 66/117 Edition 2017-11-24 605622EE...

  • Page 67: Setup Commands

    Series 642 INSTALLATION 4.8.5 Setup commands Command Acknowledgement Setup function Description c:01aa c:01 data length: 2 characters 00 = local operation (service port) 01 = remote operation, change to local enabled ACCESS MODE 02 = locked remote operation, change to local not possible via service port This function selects the access authorization to the valve.
  • Page 68 INSTALLATION Series 642 Command Acknowledgement Setup function Description s:01abcdefgh s:01 i:01 i:01abcdefgh 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 SENSOR...
  • Page 69 Series 642 INSTALLATION Command Acknowledgement Setup function Description s:05aaaaabcd s:05 i:05 i:05aaaaabcd data length 8 characters 00001…99999 (10000 = 1.0000) Value 0 = “-“, 1 = “+” Sign Exponent 0…4 Exponent Pressure Unit 0 = Pa 1 = bar SENSOR SCALE 2 = mbar 3 = ubar 4 = Torr...
  • Page 70 INSTALLATION Series 642 Command Acknowledgement Setup function Description s:18aaaabbbb s:18 i:18 i:18aaaabbbb data length 8 characters logarithmic resolution[ millivolt /decade] 0000 = linearizing off 0001 = min. value 9999 = max. value (default value: 0000 = linearizing off) SENSOR 2 full scale [millivolt] LINEARIZATION 0001 = min.
  • Page 71 Series 642 INSTALLATION Command Acknowledgement Setup function Description s:21abcdefgh s:21 i:21 i:21abcdefgh 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 ... 1000000 e.g.

  • Page 72: Interface Configuration

    INSTALLATION Series 642 Command Acknowledgement Setup function Description s:20abcdefgh s:20 i:20 i:20abcdefgh data length 8 characters baud rate: 0 = 600 1 = 1200k 2 = 2400 3 = 4800 4 = 9600 5 = 19.2k 6 = 38.4k 7 = 57.6k 8 = 115.2k parity bit: 0 = even...
  • Page 73 Series 642 INSTALLATION Command Acknowledgement Setup function Description ZERO This command initiates ZERO to compensate for offset of gauge(s). Remark: Refer to «ZERO» for correct zero procedure. c:6002aaaaaaaa c:60 data length: 8 characters aaaaaaaa System base pressure, value depends on configuration, refer to «RS485 setup commands, COMMUNICATION RANGE»...

  • Page 74: Pressure Controller

    INSTALLATION Series 642 Command Acknowledgement Setup function Description V:00aaaa i:68 i:680000aaaa data length 6 characters starting with double zero for writing 8 characters starting with quadruple zero for reading VALVE SPEED aaaa valve speed, 1 ... 1000 (1 = min. speed, 1000 = max. speed) This command allows changing the actuating speed of the valve plate.
  • Page 75 Series 642 INSTALLATION Command Acknowledgement Setup function Description s:02abbc s:02 configure parameter: set parameter bb of pressure controller a to value c i:02abb get value c of parameter bb of i:02abbc pressure controller a Pressure controller: A = Adaptive downstream pressure controller B = Fixed 1 pressure controller (downstream or upstream) C = Fixed 2 pressure controller (downstream or upstream) D = Soft pump pressure controller...

  • Page 76: Pressure Control Algorithem

    INSTALLATION Series 642 Command examples: Set GAIN FACTOR of the adaptive s:02A041.075 pressure controller to the value 1.075 GET GAIN FACTOR of adaptive i:02A04 Answer is i:02A041.075 Value = 1.075 pressure controller Set RAMP TIME of soft pump pressure s:02D01281 controller to the value 281 seconds Get RAMP TIME of soft pump pressure i:02D01...
  • Page 77 Series 642 INSTALLATION RAMP MODE Mode = 0 The RAMP TIME is dependent on the adjusted parameter ramp time and is always the same independent of the control deviation. That means the ramp Cocnstant Time time from the actual value to the setpoint value is the adjusted parameter ramp time value.
  • Page 78 INSTALLATION Series 642 4.8.6.2 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 79 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 control algorithm, refer to chapter «Tuning of control performance».
  • Page 80 INSTALLATION Series 642 4.8.6.4 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:02D01 i:02D01c s:02D02c c = 0…1 s:02 0 = constant time RAMP MODE UINT 1 = constant slope i:02D02c...

  • Page 81: Error Messages

    Series 642 INSTALLATION 4.8.7 Error messages Description Error message Protocol Parity error E:000001 E:000002 Input buffer overflow (to many characters) E:000003 Framing error (data length, number of stop bits) Overrun (Service interface: Input buffer register overflow) E:000004 Commands <CR> or <LF> missing E:000010 : missing E:000011...

  • Page 82: 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 83: 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 84: Remote Operation

    OPERATION Series 642 5.1.2 Remote operation This product is equipped with a RS485 interface to allow for remote operation. See section «RS485 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 85: Close Valve

    Series 642 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 86: Pressure Control Operation With 2 Sensors

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

  • Page 87: Display Information

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

  • Page 88: Operation

    OPERATION Series 642 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 by digital input) 0…100 HOLD (position frozen) = valve position (%, 0 = closed / 100 = open) activated ZERO running...

  • Page 89: Service Indication

    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 90: Operation Under Increased Temperature

    OPERATION Series 642 Operation under increased temperature CAUTION Hot valve Heated valve may result in minor or moderate injury. Do not touch valve and heating device during operation. Once heating is switched off (valve and system) await until the valve is cooled down complete before doing any work.

  • Page 91: 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. Remote operation does not work - Local operation via service port active - Switch to remote operation.
  • Page 92 TROUBLE SHOOTING Series 642 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 93 TROUBLE SHOOTING Series 642 Failure Check Action PRESSURE CONTROL not optimal - Setup done completely? - Perform «Setup procedure» completely. - LEARN done? - Perform LEARN. Refer to «LEARN» for details. - ZERO performed before LEARN? - Perform ZERO then repeat LEARN. Refer to «Setup procedure»...

  • Page 94: 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 95: 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 96: 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 97 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 98 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 99 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 100 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 101: 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 102 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 103: Retrofit / Replacement Procedure

    Series 642 MAINTENANCE 7.2.3 Retrofit / replacement procedure Top view on control and actuating unit with panel removed: Master board Connector board Option board Interface 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 Required tools...
  • Page 104 MAINTENANCE Series 642 Description Required tools Remove this screws and the cover. Screw driver size 2 Remove female screw locks from Open end wrench 4.5 mm connectors. Lift controller panel carefully. (sample picture) Remove or replace option board. (sample picture) 104/117 Edition 2017-11-24 605622EE...
  • Page 105 Series 642 MAINTENANCE Description Required tools Reassemble all parts in reverse order (see steps 6…3). Tighten panel screws with 1.1 Nm (see step 3). Pozidriv screw driver size1 Connect all electrical connections. Open end wrench 7 mm If you need any further information, please contact one of our service centers. You can find the addresses on our website: www.vatvalve.com.

  • Page 106: 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 107: 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 108: 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 109: 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 110: 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. 110/117 Edition 2017-11-24 605622EE...

  • Page 111: 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. 605622EE Edition 2017-11-24 111/117...

  • Page 112: 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 113: Drawing

    Series 642 SPARE PARTS 12.1 Drawing Sample picture 605622EE Edition 2017-11-24 113/117...

  • Page 114: 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 115: 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 116 APPENDIX Series 642 Appendix No information entered on time. 116/117 Edition 2017-11-24 605622EE...
  • Page 117 Series 642 This page left blank intentionally. 605622EE Edition 2017-11-24 117/117...

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