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Related Manuals for VAT 64251-JEAC-0001
Summary of Contents for VAT 64251-JEAC-0001
- Page 1 Installation, Operating & Maintenance Instructions Control gate valve with Logic interface Series 642 DN 350 mm (I.D. 14") This manual is valid for the following product ordering numbers: 64251-JEAC-0001 Configured with firmware: 600P.1H.00.03 Sample picture 1011029EA.DOCX Edition 2019-12-19...
- Page 2 The VAT firmware may not be used for purposes other than those intended nor is it permitted to make copies of the VAT firmware. In particular, it is strictly forbidden to give copies of the VAT firmware to other people.
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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 Close valve ........................45 Open valve........................45 Position control ......................45 Pressure control ......................45 Display information ......................46 5.6.1 Power up ......................46 5.6.2 Operation ......................47 5.6.3 Errors ......................47 5.6.4 Safety mode ....................47 5.6.5 Service indication ....................
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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 Describtion Input voltage +24 VDC (±10%) @ 0.5 V pk-pk max. [connector: POWER] Power consumption 50 W [connector: POWER] Sensor power supply output +24 VDC / 1500 mA max. [connector: SENSOR] Sensor input Signal input voltage / Input resistance... -
Page 7: Valve Unit
Series 642 DESCRIPTION OF PRODUCT 1.6.2 Valve unit Valve unit 1 × 10E-8 mbar to 1.2 bar (abs) Pressure range at 20°C 1 × 10E-9 mbar l/s Leak rate to outside at 20°C 1 x 10E-9 mbar l/s Leak rate valve seat at 20°C Cycles until first service - Throttling cycles (open - max. -
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 1011029EA.DOCX... -
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. 10/74 Edition 2019-12-19... -
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 1011029EA.DOCX Edition 2019-12-19 15/74... -
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 Logic remote control unit Cable to power supply Controller Connection cable controller / actuator Actuator Pump Actuator Controller 16/74 Edition 2019-12-19 1011029EA.DOCX... -
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 The torque values below are dependent on many factors, such as materials involved, surface quality, surface treatment, and lubrication. The torques below are valid if immersion depth of the mounting screws is at least once the thread diameter (min. 1d), and the friction coefficient of the screw-flange + µ... -
Page 19: Admissible Forces
» lbf. 3500 For a combination of both forces (F and M) the values are invalid. Verify that the depth of the mounting screws is min. 1 × thread diameter. Please contact VAT for more information. 1011029EA.DOCX Edition 2019-12-19 19/74... -
Page 20: Requirements To Sensor Connection
INSTALLATION Series 642 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 21: Ground Connection
Series 642 INSTALLATION 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 22: Sensor Supply Concepts
INSTALLATION Series 642 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. Concepts: • External +24 VDC supplied to POWER connector is feedthrough to SENSOR connector to supply 24 VDC sensors. -
Page 23: Power And Sensor Connection (+24 Vdc Sensors)
S C 1 083 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 24 S C 1 084 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. •...
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Page 25: Power (+24 Vdc) And Sensor Connection (±15 Vdc Sensors) With Opt. Sps
S C 1 085 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 26: 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 27: Functions And Wiring
Series 642 INSTALLATION 4.5.6 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: Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 1011029EA.DOCX Edition 2019-12-19... - Page 28 INSTALLATION Series 642 b) Configuration with voltage source for digital inputs: Do not connect other pins than indicated in the schematics above! Use only screws with 4-40UNC thread for fastening the DB-25 connector! 28/74 Edition 2019-12-19 1011029EA.DOCX...
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Page 29: Digital Inputs
Series 642 INSTALLATION 4.5.7 Digital inputs Function Signal type Description Priority 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’. Digital The PID controller controls the chamber pressure according to CONTROL MODE... -
Page 30: Digital Ground
INSTALLATION Series 642 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 31: Digital Outputs
Series 642 INSTALLATION 4.5.8 Digital outputs Function Signal type Description This output is active in all operation modes and indicates either that the valve is open or that a service is requested. A service request is indicated when the valve requires cleaning due to VALVE OPEN Digital contamination. -
Page 32: Analog Inputs And Outputs
INSTALLATION Series 642 4.5.9 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 33: Initial Operation
Series 642 INSTALLATION Initial operation To enable the valve for pressure control setup steps 1 to 6 must be performed. In case position control is required only it’s sufficient to perform steps 1 to 3. Setup steps Description Turn on external + 24VDC power supply of valve (and external ±15 Power up VDC for sensor power supply if required). -
Page 34: Valve Configuration
INSTALLATION Series 642 4.6.2 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 35: Learn
Series 642 INSTALLATION • Do not perform ZERO as long as pressure gauge voltage is shifting otherwise incorrect pressure reading is the result. Refer to manual of sensor manufacturer for warm up time. • Do not perform ZERO, if the base pressure of your vacuum system is higher than 1‰... - Page 36 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.
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Page 37: Tuning Of Control Performance
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 1011029EA.DOCX Edition 2019-12-19 37/74... - Page 38 INSTALLATION Series 642 4.6.6.1 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 39 Series 642 INSTALLATION 4.6.6.2 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 40 INSTALLATION Series 642 4.6.6.3 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 41 Series 642 INSTALLATION 4.6.6.4 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.
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Page 42: 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 43: 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 44: Remote Operation
OPERATION Series 642 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 45: Close Valve
Series 642 OPERATION 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 46: 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. 1 2 3 4 Display 5.6.1 Power up Description Digit 1 Digit 2 Digit 3 Digit 4 At first all dots are illuminated then... -
Page 47: Operation
Series 642 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 0 . . . 100 = valve position (%, 0 = closed / 100 = open) HOLD (position frozen) activated ZERO running LEARN running... -
Page 48: Operation During Power Up
OPERATION Series 642 Operation during power up Reaction of valve: Valve position Valve power up configuration = closed Valve power up configuration = open before (default) power up: Valve runs to max. throttle position to Closed (isolated) Valve remains closed. detect the limit stops to synchronize. -
Page 49: 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 - Local operation via - Switch to remote operation. -
Page 50: Pressure Control
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». - ZERO done? - Perform ZERO when base pressure is reached. -
Page 51: 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 52: 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 53: 7.2.1 Replacement Of Gate Seals And Valve Cleaning
Series 642 MAINTENANCE 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 13mm Vacuum grease (see chapter spare parts) •... - Page 54 MAINTENANCE Series 642 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 55 Series 642 MAINTENANCE 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 56 MAINTENANCE Series 642 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 with Allen torque wrench 5.7 Nm 4 mm 22.
- Page 57 Series 642 MAINTENANCE Description Required tool 26. Reassemble the bonnet and bonnet seal with valve 1 × Open end torque wrench 13 mm 27. Fasten the bonnet screws with 18 Nm 1 × Open end wrench 13 mm § 1011029EA.DOCX Edition 2019-12-19 57/74...
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Page 58: Replacement Of Option Board
MAINTENANCE Series 642 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 59 Series 642 MAINTENANCE 7.2.2.1 Durability of power fail battery The curves in the graph show the estimated life of Ultra Cap PFO in the worst condition (max. sensor load = 1 A, valve heating temperature = 150 °C). If the SPS is not fully loaded (< 1 A) or heating temperature of valve body is lower than 150 °C, the corresponding life time curve will be somewhere in between the upper and the lower curve.
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Page 60: Retrofit / Replacement Procedure
MAINTENANCE Series 642 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 61 Series 642 MAINTENANCE 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) 1011029EA.DOCX Edition 2019-12-19 61/74...
- Page 62 MAINTENANCE Series 642 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.
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Page 63: 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 64: Dismounting And Storage
DISMOUNTING AND STORAGE Series 642 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 65: Storage
Series 642 DISMOUNTING AND STORAGE Storage NOTICE Wrong storage Inappropriate temperatures and humidity may cause damage to the product. Valve must be stored at: – relative humidity between 10% and 70% – temperature between +10 °C and +50 °C – non-condensing environment NOTICE Inappropriate packaging Product may get damaged if inappropriate packaging material is used. -
Page 66: 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 67: 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. 1011029EA.DOCX Edition 2019-12-19 67/74... -
Page 68: Disposal
DISPOSAL Series 642 Disposal WARNING Unqualified personnel Inappropriate handling may cause serious injury or property damage. Only qualified personnel are allowed to carry out the described work. 68/74 Edition 2019-12-19 1011029EA.DOCX... -
Page 69: 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 70: Drawing
SPARE PARTS Series 642 12.1 Drawing 70/74 Edition 2019-12-19 1011029EA.DOCX... -
Page 71: Valve Unit With Seals And Grease
Crank bolt kit complete 205049 Crank kit complete 205057 Seal kit vacuum 246760 Feedthrough assembling tool 240451 VAT vacuum grease (40 g) N-6951-012 Use only spare parts manufactured by VAT to assure safe and reliable operation All “ 1011029EA.DOCX Edition 2019-12-19 71/74... -
Page 72: Controller
• DB-9 female POWER plug • DB-15 male SENSOR plug • DB-25 male INTERFACE plug 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 72/74 Edition 2019-12-19 1011029EA.DOCX... -
Page 73: Appendix
Series 642 APPENDIX Appendix No information entered on time. 1011029EA.DOCX Edition 2019-12-19 73/74... - Page 74 Series 642 This page left blank intentionally. 74/74 Edition 2019-12-19 1011029EA.DOCX...
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