Rectangular Door L-VAT with pneumatic actuator double acting This manual is valid for the products: 0 7 5 1 0 U A 2 4 0 0 0 1 4 character option code Size 10... 46 x 236 12... 50 x 336 Actuator 24... without solenoid 44... with solenoid 01... 25 x 160 02... 25 x 210 03... 25 x 265 04... 25 x 420 Body material 05... 51 x 160 06... 51 x 210 07... 51 x 265 08... 51 x 420 0X... misc. A... aluminum H... aluminum hard anodized E... stainless steel Flange type U... Actuator mounted on same surface as opening V... Mounting surface for actuator and opening are perpendicular C... Body without bonnet flange, gate maintenance through body opening on rear The respective product identification is marked on each door in the following or similar way : made in Switzerland Fabrication No.:.. patented 075.. -.... -.... /.. A -...... 1/15
Explanation of symbols: Read declaration carefully before you start any other action! Keep body parts and objects away from the valve opening! Attention! Hot surfaces; do not touch! Product is in conformity with EC guidelines, if applicable! Loaded springs and/or air cushions are potential hazards! Disconnect electrical power and compressed air lines. Do not touch parts under voltage! Wear gloves! Read these «Installation, Operating & Maintenance Instructions» and the enclosed «General Safety Instructions» carefully before you start any other action! 2/15
Imprint: Manufacturer Website www.vatvalve.com Phone +41 81 771 61 61 Fax +41 81 771 48 30 Email CH@vatvalve.com Publisher Editor Print Copyright VAT Vakuumventile AG 2008 No part of these Instructions may be reproduced in any way (photocopies, microfilms or any other reproduction processes) nor may it be manipulated with electronic systems, duplicated or distributed without written permission from VAT. Offenders are liable to pay damages. The original VAT firmware and updated state of the art versions of the VAT firmware are intended for use with VAT products. The VAT firmware contains a limited, time unlimited user license. 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. The use of trade names, brand names, trademarks, etc. in these Instructions does not entitle third parties to consider these names to be unprotected and to use them freely. This is in accordance with the meaning of the laws and acts covering brand names and trademarks. 3/15
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. Technical specifications are defined in the Product data sheet 202559. Dimensions are defined in the corresponding dimensional drawings for each product Installation Leave the door in the sealed plastic bag as long as possible in order to protect it from dust and particles. The door and seals must not be cleaned before installation. The door is assembled at VAT in a clean environment and sealed in a plastic bag. Attach the door to a clean system only. Connect compressed air and electrical power only if door 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) : Connections: 4-7 bar / 55-95 psi Use only clean, dry or slightly oiled air. quick connect fittings for pneumatic tubing O.D. 4 mm without solenoid : connections open (blue) and P (black) on actuator body with solenoid : connection IN for air supply on solenoid mounting block connection EX for exhaust on solenoid mounting block IMPORTANT NOTE: OPEN port must be vented while door is closed and P port must be always pressurized with CDA to endure closing of valve. After installation and after compressed air failure, door command must be set to open before the first closing for proper function of the door. 4/15
Pneumatic and electrical connection Socket for solenoid is supplied with door, if equipped with solenoid (ordering code 075.. -.. 44). Solenoid wiring diagram see label attached to product. Verify that control voltage matches voltage indicated on solenoid. Pneumatic connection Position indicator Subminiatur D connector, 9 pin, male NOTE: Doors without solenoid: wiring is not part of the VAT product and must be setup in customer's system. Doors with solenoid: wiring is part of the VAT product. Recommended flow rate for the solenoid valve is > 150 l/min (at 6 bar). Lo = position indicator open Lg = position indicator close Solenoid for impulse actuation Electrical power may only be connected by an authorized expert! Do not touch parts under voltage! Connect solenoid only when - valve is installed into the vacuum system - moving parts cannot be touched Sockets for solenoid are supplied with the valve. Verify that control voltage matches voltage indicated on the solenoid. Wiring diagram: Solenoid for impulse actuation MV = coil of solenoid Min. pulse duration: 50 ms Pin assignment on the connectors: 5/15
Connections on Solenoid for impulse actuation Solenoid Valve to OPEN Solenoid Valve to CLOSE EX Port for Air Connection 1/8 ISO/NPT IN Port for Air Connection 1/8 ISO/NPT Operation Normal operation Door with pneumatic actuator : Door is opened and closed pneumatically. Admissible temperature See chapter «Technical data». Compressed air failure Door closed: Door remains closed for 72 h (integrated check valve). NOTE: Proper check valve function depends on fast air pressure decrease in the pneumatic supply line to the actuator port marked with "P". Slow pressure drop in this line will not trigger the check valve and the door position is undefined at compressed air failure. The check valve only works properly if the following conditions are met for the pneumatic supply line to port "P" between actuator port and T connection as shown in the wiring diagram (see chapter "Pneumatic and electrical connection"): Tubing O.D. Length of pneumatic supply line "P" 4 mm 1.5 m 6 mm 6.0 m Door open: Mounting position actuator downward and sideward: Door remains open. Mounting position actuator upward: undefined IMPORTANT NOTE: After installation and after compressed air failure, door command must be set to open before the first closing for proper function of the door. 6/15
Power failure Door supplied with pneumatic connection (ordering code 075.. -.. 24): Door position depends on applied solenoid valve. VAT recommends to operate all transfer doors with impulse actuated solenoids. Door supplied with impulse solenoid (ordering code 075.. -.. 44): Door closed: Door remains closed Door open: Door remains open; an already started movement will be completed Emergency operation at power failure In case of power failure, door can be actuated if compressed air is available. To actuate door in case of power failure: To open door: Press push-button on side of port "EX" To close door: Press push-button on side of port "IN" open close 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 door does not require any maintenance during the specified cycle life (see chapter «Technical data»). Preventive maintenance actions include replacement of the gate seal (or complete gate in case of bonded gate seal) as well as replacement and relubrication of the pneumatic seals according to the detail instruction below. Also, all outer surfaces on the complete door are 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 pc. L-VAT Gate 1 pc. Actuator Service Kit Lubrication of Door 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 the gate seal Lubricate pneumatic cylinder and piston seals with VAT high temperature pneumatic grease; other lubricants may not meet the VAT cycle life specification Lubricate screws outside the vacuum with Molykote 321R or equivalent; Screws supplied by VAT are lubricated 7/15
Cleaning or Replacing L-VAT Gate 1. Vent chambers and command door to the open position 2. Disconnect door from compressed air and electrical supply 3. Remove the 4 set screws 68 on the back of the pressure plate 4. While withdrawing the pressure plate from the shafts make sure that the 2 O-rings 70 stay on the shaft or put them back in position right after removing the plate 5. Loosen the 3 screws 75, and remove L-VAT gate. Never use the old screws again. Attention! Never use the old, used screws 75 again. If a screw is removed it has to be exchanged by a new one with fresh safety coating, otherwise no safe lock is guaranteed. 6. Clean or replace L-VAT gate 7. Use only the new screws supplied with the spare gate or ordered separately (part# 233635) to reassemble the gate. 8. Before reassembling the L-VAT gate to the pressure plate make sure that all the pistons and washers are at the correct position according to the assembly drawing 9. Tighten the 3 screws 75 with a torque of 9 Nm 10. Before putting the pressure plate back onto the shafts make sure that the 2 O-rings 70 are in the correct position. 11. Tighten the 4 set screws 68 with a torque of 4.5 Nm; These 4 screws have to be tighten step by step, crosswise to similar torque at a step. Make sure that the tips of the set screws fit into the 90 countersunks in the shafts. Recommendation! During system maintenance it is advised to check if the 3 screws 75 are still tightened properly according point 9. 8/15
Replacing of actuator pneumatic seals 1. Vent chambers and command door to the open position 2. Disconnect door from compressed air and electrical supply 3. Remove the 4 set screws 68 on the back of the pressure plate (see on page 11) 4. Remove pressure plate assembly from the actuator shafts, also remove the 2 O-rings 70 from the actuator shafts; place these parts in an area where they are protected from contamination and damage 5. Loosen the fixation screws 99 and remove the actuator assembly from the system 6. Remove the 4 roll pins (2 per actuator shaft) and pull the bushing out of the actuator body (see drawing below) Note : Make sue that the bushings do not get damaged during this action. 7. Remove the actuator shafts from the actuator body 8. Remove seals 10, 11, 12, 14, 15, 18 from their position, see drawing below for details 9. Clean and relubricate all grooves for the with step 8 removed seals 10. Put new seals 10, 11, 12, 14, 15, 18 from the Actuator Service Kit in the respective positions 11. Clean and relubricate the pneumatic cylinder walls in the actuator body 12. Reassemble the door in reverse direction Note : Make sure that the 2 O-rings 70 are in the correct position before reassembly of the pressure plate to the actuator shafts 13. Tighten the 3 (Type U) or 4 (Type V) set screws 99 with 6Nm Replacing the position indicator 1. Loosen the two fixation screws which hold the position indicator 42 (see on page 11). 2. Replace the position indicator. 3. Take the two fixation screws to attach the position indicator and tighten them properly. 9/15
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Spare Parts Attention! VAT has released a retrofit kit in order to provide proper function and safety with the product. This retrofit kit contains 3 pcs. of coated screws (75) and 3 pcs. of washers (61) 4mm thick. Never use old or used screws (75) again. If a screw is removed it has to be exchanged by a new one with fresh safety coating, otherwise no safe lock is guaranteed. If your product is already equipped with washers (61) of 4mm thickness you need to exchange the gate fixation screws (75) with every gate exchange only. Lubricants Description VAT high temperature pneumatic grease (for piston), 12g Ordering no. N-6951-403 Retrofit Kit with spare screws with washers for gate fixation. Description Ordering no. Retrofit kit: contains 3 pcs. coated screws (75) and 3 pcs. washers (61) of 4mm thickness 233635 Spare screws for gate fixation Description Countersunk head screw with safety coating (75) Note: 3pcs. are required for 1 valve Ordering no. N-6013-476 Spare gates with vulcanized Viton seal DN Description Ordering No. (Aluminum) Ordering No. (Stainless Steel) 46 x 236 Gate with vulcanized Viton seal. 205965 206413 50 x 336 Gate with vulcanized Viton seal. 205959 206415 Please refer to attention note above! Not indicated sizes, materials, and surface treatments on request Spare gates with assembled O-ring DN Description Ordering No. (Aluminum) Ordering No. (Stainless Steel) 46 x 236 Gate with assembled Viton O-ring 365 202482 200168 50 x 336 Gate with assembled Viton O-ring 375 202483 - Please refer to attention note above! Not indicated sizes, materials, and surface treatments on request Spare O-ring for gate seal DN Description Ordering No. 46 x 236 O-ring Viton N-5100-365 46 x 236 O-ring Chemraz N-5106-364 50 x 336 O-ring Viton 225630 11/15
Solenoid Item Description Qty Ordering No. - Solenoid kit (consisting of all parts according to drawing) Specify voltage! 1 214971 1 Adapter plate 1 202391 2 Solenoid 24 V/DC (other voltages on request) 1 N-7557-016 5 Screw (hollow) 2 N-5062-005 6 Screw 2 N-5018-005 7 Sealing 2 N-7016-010 8 Sealing 2 N-7015-015 Actuator assembly, without position indicator and solenoid The item number refers to the drawing on page 13 Item Description Qty. Ordering no. 26 Actuator assembly 1 205858 Position indicator Item Description Qty. Ordering no. 42 Position indicator 1 205861 42 Position indicator with mounting screws (complete kit) 1 313052 Pressure plate assembly The item numbers refer to the drawing on page 13. Item Description Qty. Ordering no. 60 Pressure plate 1 201917 61 Washer with countersink 3 233252 64 Piston shaft 3 94029-01 65 Piston 3 203272 66 Piston 3 N-7050-008 68 Hex-socket set-screw 4 N-6072-053 70 O-ring seamless 3 N-7100-112 75 Countersunk head screw 3 N-6013-476 Actuator installation parts Item Description Qty. Ordering no. 90 O-ring Viton, Type V only 2 N-7100-222 99 Installation kit, Type U 1 99412-R1 99 Installation kit, Type V 1 97141-R1 12/15
Type U Type V 13/15
Trouble Shooting Door does not close / open : Power available? Check voltage. Compressed air available? Check air pressure. Solenoid defective? Check solenoid (manual emergency operation). Leak at gate : Dirty? Clean door seat sealing surface and gate. Gate or gate seal damaged? Replace gate O-ring assembly or O-ring if damaged. Seal compression weak? Check air pressure and replace O-ring if necessary. Gate slides along chamber wall: Installation and initial command The correct installation is as follows: 1) move the door into open position 2) attach the door to the chamber 3) connect the air tubing to the "OPEN" port only 4) bend the tubing for the "P" port so that the tube is locked and no CDA (compressed dry air) can leave this tube 5) command the solenoid valve switch to the open position and apply CDA to the "OPEN" port only 6) connect air tubing to the "P" port 7) open the tube for the "P" port and apply CDA to this port 8) command the solenoid valve switch to the close position Compressed air? Check the pressure of the compressed air to be between 4 and 7 bars (55 95 psi). Air tubing? Check the correct length and diameter of the tubing for air supply. See details in chapter Compressed air failure. Air connection? Verify pneumatic connection between solenoid valve and actuator and the correct type of solenoid. Refer to chapter Pneumatic and electronic connection. Repairs Contact VAT for repairs or maintenance. Please advise the serial No. (075...- /.... ) marked on the actuator. It is individually decided whether the repair can be performed by the customer or has to be carried out by VAT. Disconnect all supplies (e. g. compressed air, electrical power) for removal/installation of the door from/into the system before doing any repair. Even with disconnected supply, loaded springs and/or air cushions in cylinders are potential hazards. Keep fingers and objects away from the door openings! Products returned to VAT for repair have to be free of harmful substances such as e.g. toxic, caustic or micro-biological ones. For radioactive contaminated products fill in the VAT form «Contamination and Radiation Report» and send it with the product. The form is available at VAT. The maximum permissible values indicated in the form must not be exceeded. 14/15
Warranty Each product sold by VAT Vakuumventile AG (VAT) is warranted to be free from the manufacturing defects that adversely affect the normal functioning thereof during the one-year period immediately following delivery thereof by VAT, provided that the same is properly operated under conditions of normal use and that regular, periodic maintenance and service is performed or replacements made, in accordance with the instructions provided by VAT. The foregoing warranty shall not apply to any product or component that has been repaired or altered by anyone other than an authorized VAT representative or that has been subject to improper installation or abuse, misuse, negligence or accident. VAT shall not be liable for any damage, loss, or expense, whether consequential, special, incidental, direct or otherwise, caused by, arising out of or connected with the manufacture, delivery (including any delay in or failure to deliver), packaging, storage or use of any product sold or delivered by VAT shall fail to conform to the foregoing warranty or to the description thereof contained herein, the purchaser thereof, as its exclusive remedy, shall upon prompt notice to VAT of any such defect or failure and upon the return of the product, part or component in question to VAT at its factory, with transportation charges prepaid, and upon VAT's inspection confirming the existence of any defect inconsistent with said warranty or any such failure, be entitled to have such defect or failure cured at VAT's factory and at no charge therefor, by replacement or repair of said product, as VAT may elect. VAT MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND, EXPRESS OR IMPLIED, (INCLUDING NO WARRANTY OR MERCHANTABILITY), EXCEPT FOR THE FOREGOING WARRANTY AND THE WARRANTY THAT EACH PRODUCT SHALL CONFORM TO THE DESCRIPTION THEREOF CONTAINED HEREIN, and no warranty shall be implied by law. Furthermore, the «Terms of sale» at the back of the price list are applicable. 15/15