VAT 021 Series Instrucciones de montaje

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 1/12

Rectangular Gate Valve MONOVAT classic

•with pneumatic actuator

double acting

The respective product identification is marked on each valve in the following or in a similar way :

made in Switzerland

Fabrication No.: patented . .

021 . .

- . . . . - . . . . / . .

A - . . . . . .

Read these «Installation, Operating and Maintenance Instructions» and the enclosed

«General Safety Instructions» carefully before you start any other action.

Actuator:

24 ... w/o solenoid

44 ... with solenoid

Size

10 ... 46 x 236

12 ... 50 x 336

01 ... 25 x 160

02 ... 25 x 210

03 ... 25 x 265

04 ... 25 x 420

05 ... 51 x 160

06 ... 51 x 210

07 ... 51 x 265

08 ... 51 x

420

09 ... 32 x 222

Body material:

A ...

aluminum

E ...

stainless steel

4 character

option code

0 2 1 1 0 - B A 2 4 - 0001

Flange type

... Same size of opening on seat side and rear side.

With bonnet flange, gate service via bonnet flange.

... Opening on rear side larger than on seat side.

With bonnet flange, gate service via bonnet flange.

View our inventory

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 2/12

Intended Use of Product

Use product for vacuum applications under the conditions indicated in chapter «Technical data» only!

Other applications are only allowed with the written permission of VAT.

Description

Flange see dimensional drawing

Actuator pneumatic, double acting, with position indicator,

mechanically locked in closed position

Feedthrough welded metal bellows *)

Technical Data

Leak rate (FKM seals)

- valve body < 1

.10-9 mbar l s-1

- seat < 1

.10-9 mbar l s-1

Leak rate (FFKM seals)

- valve body < 1

.10-8 mbar l s-1

- seat < 1

.10-7 mbar l s-1

Pressure range 1 .10-9 mbar to 1.2 bar (abs)

Differential pressure on the gate

- in either direction 1.2 bar *)

Differential pressure at opening ≤30 mbar *)

Cycle life between maintenance

- actuator 2 million *)

- bellows (under clean vacuum conditions) 2 million *)

- gate seal FKM (under clean vacuum conditions) 2 million

- gate seal FFKM (under clean vacuum conditions) 1 million

Operating temperatures

- valve body aluminum <150°C

- valve body stainless steel <200°C

- pneumatic actuator <150°C

- position indicator <80°C

- solenoid <50°C

Temperature difference between seat and gate ≤40°C

Heating and cooling rate ≤40°C h-1

Material

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 3/12

- valve body, gate aluminum 3.2315, AA6081, AlMgSi1

- valve body, gate stainless steel 1.4435, AISI 316L

- bellows end pieces 1.4435, AISI 316L

- bellows AISI 633 (AM 350)

- bonnet seal FKM (VITON®) *)

- gate seal FKM (VITON®) *)

Mounting position any

Position indicator

- Contact rating 3 A / 50 V DC

Compressed air pressure 4 - 7 bar / 55 - 95 psig (overpressure)

Compressed air connections internal threads M5 *)

- without solenoid : connections „open“ and „closed“

- with solenoid : connection „P“ for air supply

connection „R“ for exhaust

Action at power failure

- valve closed depends on type of solenoid

- valve open depends on type of solenoid

Action at compressed air failure

- valve closed valve remains closed

- valve open undefined

Closing time < 1 s *)

Opening time < 1 s *)

*) Standard specification. Specifications for optional features are provided on the

dimensional drawing of the product.

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 4/12

Installation

Leave the blue foil on the valve body openings as long as possible in order to protect the valve interior from dust and

particles. The valve and seals must not be cleaned before installation. The valve is assembled at VAT in a clean

environment and sealed in a plastic bag.

Attach the valve to a clean system only. The screws on the flanges have to be tightened uniformly in crosswise order.

Connect compressed air and electrical power only if

−valve is installed into the vacuum system

−moving parts cannot be touched

Do not touch electrical parts under voltage.

Admissible forces

The dimensions and tolerances specified on the dimensional drawing must be met under all operating conditions.

Compressed air connection

Compressed air pressure

(min. - max. overpressure)

4 - 7 bar / 55 - 95 psi

Use only clean, dry or slightly oiled air.

Connections: Internal threads M 5

with solenoid : connection „P“ for air supply

connection „R“ for exhaust

without solenoid : connections „open“ and „closed“, quick connect fitting for 4 mm tube

Electrical connection

Sockets for position indicator and solenoid are supplied with the valve. Verify that control voltage matches voltage

indicated on the solenoid.

Wiring diagrams :*)

Solenoid for impulse

actuation Standard position

indicator Position indicator

„open/close“ (Opt.) Standard position

indicator 1xLo / 2xLg

Position indicator

1xLo / 2xLg (Opt.)

4321

9101112131415

Lo1

Lg1

Lg2

Lg1

power

open

MV = coil of solenoid

Min. pulse duration:

50 ms Lo = position indicator „open” Lg = position indicator „close“ Voltage max. 50 V DC

*) Standard specification. Specifications for optional features are provided on the dimensional drawing of the product.

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 5/12

Operation

“Products without differential pressure tabs are specifically designed for operation under equal pressure

on either side. Application of differential pressure through such products may cause damage to the

product and serious injury of people!”

Please refer to the dimensional drawing of the product to ensure it is properly specified for the application.

Normal operation

Valve with pneumatic actuator : Valve is opened and closed pneumatically.

Admissible temperature

See chapter «Technical data».

Compressed air failure

Valve closed: Valve remains closed (mechanically locked).

Valve open: Valve position is undefined.

Power failure

Valve supplied with pneumatic connection (ordering code 021 . . - . . 24) :

Valve position depends on applied solenoid valve. VAT recommends to operate all transfer valves with impulse

actuated solenoids.

Valve supplied with impulse solenoid (ordering code 021 . . - . . 44) :

Valve closed: Valve remains closed (mechanically locked).

Valve open: Valve remains open.

A started movement will be completed.

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 6/12

Emergency operation at power failure

In case of power failure, valve can be actuated if compressed air is available.

To actuate valve in case of power failure :

−Press push-button : Valve opens

−Pull push-button : Valve closes

open

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 7/12

Preventive Maintenance

The italicized numbers refer to the detail drawings in this chapter and to the drawings in chapter «Spare parts».

Under clean operating conditions, the valve does not require any maintenance during the specified cycle life

(see chapter «Technical data»).

Preventive maintenance actions include replacing gate, bellows, and piston seals. Also, the pneumatic

parts are relubricated, and the valve body is cleaned. Other parts are checked and replaced if necessary.

For repair or case of emergency, VAT recommends to keep at least the following spare parts on site :

−1 MONOVAT gate

−2 bellows assembly

−1 complete gate/actuator assembly (minimizes MTTR)

Cleaning or Replacing Gate

1. Vent chambers and open valve

2. Disconnect valve from compressed air and electrical supply

3. Unfasten bonnet screws 65 and remove gate/actuator assembly carefully

4. Loosen screws 44 by 1 turn to withdraw gate from shafts

5. Clean or replace gate, reassemble in reverse direction. Tighten gate screws 44 with 5 Nm.

Replacing Bellows

1. Remove gate as described above

2. Remove cover sheets 15 (2x) with screws 47 (4x per sheet)

3. Remove circlip 53, distance rings 23 (2x), and bolt 11 (see detail)

4. Unfasten screws 40 (8x) and remove bonnet 64

5. Pull out bellows assembly 2carefully

Note : Do not contaminate O-rings 30 and tube 17 with any dirt or lubricant.

6. Mount new bellows assembly 2, O-rings 30 (2x per bellows) and tube 17 (1x per bellows)

Note : Handle new bellows assembly with gloves.

7. Reassemble in reverse direction

Please note :

−Do not contaminate the vacuum side of the bellows with any lubricant.

−The shaft of replacement bellows assembly is lubricated at the factory for the shaft bushing.

−Actuator has a leak detection port (marked on drawing) for the bellows assembly.

Replacing Piston seals:

1. Remove gate and cover sheets as described above

2. Unfasten screws 40 (8x) and remove bonnet 64

3. Remove nut 55 and lug 22, and pull out piston 14 and shaft 13

4. Replace piston O-ring 32 and shaft seal 33, replace static O-rings 31, 35, 36 if damaged

5. Lubricate cylinder and piston with VAT high temperature pneumatic grease

6. Reassemble in reverse direction

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 8/12

Replacing Position indicator

1. Disconnect valve from compressed air and electrical supply

2. Remove cover sheets 15 (2x) with screws 47 (4x per sheet)

3. Unfasten screws 77 (4x), wire wrap and screws 70 (2x per assembly)

4. Pull mounting bar downwards out of it’s slot in the actuator house.

5. Pull out insert 5 (to the left) and remove position indicator.

6. Reassemble in reverse direction

The switch point can be readjusted by loosening the screws of the switch

and moving the switch in the slotted holes of the mounting bar. The switch

point should be set 1 to 1.5 mm prior to the end positions.

Adjustment of Actuator

The compression of the gate seal is adjusted and tested at our factory and must normally not be readjusted.

Verification of Adjustment

−Gap «A» between gate and seat (see sketch beside) should be 3.0 mm ±0.15 mm

−Gate and seat should be parallel within 0.2 mm

−During closing the mechanical locking should occur between 1.0 and 1.2 bar air pressure

To check this : 1. Reduce air pressure below 0.5 bar

2. Command valve in closed position

3. Increase air pressure until a clicking sound indicates the mechanical locking

Adjustment of Compression and / or Parallelism

1. Open valve

2. Loosen screws 43 (2x per rack) of racks 12 (2x)

3. Adjust compression of gate seal by turning both screws 42 by the same angle

Note : Turning screws 42 by 30° results in 0.125 mm change of compression.

4. Adjust parallelism by turning one screw 42

Note : Turning one screw 42 by 30° results in 0.125 mm change of compression on the respective side

5. Fasten screws 43 (4x)

6. Open and close valve, verify again compression and parallelism, repeat adjustment if necessary

Lubrication of Valve

−Gaskets in the vacuum area are not lubricated. Small amounts of a suitable high vacuum grease (VAT high

performance vacuum grease) may be used to lubricate O-rings or gate seal.

−Lubricate pneumatic cylinder and piston seals with VAT high temperature pneumatic grease. Other lubricants may not

meet our cycle life specification.

−Lubricate gears, racks, and lashes in the actuator with Rocol or equivalent.

−Lubricate screws outside the vacuum with Molykote 321 R or equivalent. Screws supplied by VAT are lubricated.

−Pneumatic cylinder and actuator parts must be relubricated after the specified cycle life (see chapter «Technical

data»). The shaft of new bellows assembly is lubricated at the factory.

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 9/12

Spare Parts

Seal kit, Actuator service kit, Lubricants

Description Ordering no.

Seal kit, consisting of 1 gate with vulcanized VITON® seal and 1 bonnet seal On request

Spare bellows assembly, 25 x .. / 32 x .. 94196-R1

Spare bellows assembly, 46 x .. / 51 x .. 76610-R1

VAT high temperature pneumatic grease (for piston), 12g N-6951-403

VAT high performance vacuum grease, 10g N-6951-011

Gate with vulcanized VITON® seal, Bonnet seal, Body O-ring at SEMI interface

DN Gate aluminium,

VITON® seal Gate stainless steel,

VITON® seal Bonnet O-ring

VITON® O-ring VITON® at

SEMI interface Bonnet VATSEAL

(optional, SS body only)

32 x 222 76168-R1 78175-R1 N-5100-266 N-5100-263 82180-01

46 x 236 77006-R1 78201-R1 N-5100-266 N-5100-263 82180-01

50 x 336 94027-R1 96031-R1 N-5100-275 N-5100-273 81697-01

25 x 160 91088-R1 81483-R1 N-5100-262 82588-01

25 x 210 - 81786-R1 N-5100-266 82180-01

25 x 265 - 77008-R1 N-5100-271 77951-01

25 x 420 85113-R1 80664-R1 N-5100-279 92075-01

51 x 160 78819-R1 78493-R1 N-5100-262 82588-01

51 x 210 77939-R1 78213-R1 N-5100-266 82180-01

51 x 265 79364-R1 78485-R1 N-5100-271 77951-01

51 x 420 76752-R1 77682-R1 N-5100-279 92075-01

25 x 254 - 77008-R1 N-5100-271 77951-01

32 x 336 92020-R1 - N-5100-275 N-5100-273 81697-01

Gate/actuator assembly, Valve body, Bonnet flange

Ordering numbers of gate/actuator assembly, valve body (Pos. 60), bonnet flange (Pos. 64), and flange O-ring of custom

made valve body (O-ring size indicated on dimensional drawing) are supplied on request. Please indicate fabrication

number or ordering number and drawing number of the product in question to help identify the required part.

ISO 9001

EN 29001

Installation, Operating, and Maintenance Instructions

Series 021

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel ++41 81 771 61 61 Fax ++41 81 771 48 30 Email recepti[email protected] http://www.vat.ch 205440EC

2003-04-14 10/12

Gate with special vulcanized sealing material and/or special surface treatment, SEMI sizes

Gate material Sealing material 32 x 222 46 x 236 50x336

Chemraz® 630 96072-R1 96073-R1 96074-R1

Chemraz® 513 92032-R1 85104-R1 205413

Chemraz® E38 100432-R1 100430-R1 100431

Parofluor® V8514-65 93098-R1 91154-R1 204662

Perfluoro black 81063-R1 78510-R1 -

Silicone red 79416-R1 82625-R1 -

Silicone transparent - 85630-R1 -

Aluminium

SC 1107 205580 205581 204585

VITON® 80499-01 82510-01 95842-R1

Chemraz® 630 - 99424-R1 101367-R1

Chemraz® 513 93096-R1 88100-R1 -

Aluminium hard anodized

Parofluor® V8514-65 96045-R1 - -

VITON® 96062-R1 92796-R1 97154-R1

Chemraz® 630 - 97147-R1 -

Aluminium nickel plated

Chemraz® 513 - 89375-R1 -

Chemraz® 630 - 94106-R1 97077-R1Stainless steel Chemraz® 513 90151-R1 92057-R1 -

Not indicated sizes, materials, and surface treatments on request.

Solenoid

Item Description Qty Ordering No.

- Solenoid kit

(consisting of all parts according to drawing)

1 206572

1 Solenoid - specify voltage! 1 N-7542-000

2 Plug 1 N-8501-402

3 Connection plate 1 206575

4 Seal 1 206576

9 Screw M3 x 12 4 N-6024-526

10 Seal flat 1 N-7501-012

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