MBA Series64
User Manual: Pdf series64
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Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 Control Gate Valve with Direct Drive This manual is valid for the valve ordering numbers: 642..-.E52 The respective product identification is given on each valve in the following way (or similar): made in Switzerland Fabrication No.: .. patented 642 . . – . . . . – . . . . / . . . . A –...... Fabrication number 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! VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 1/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 Imprint: Manufacturer VAT Vakuumventile AG, CH-9469 Haag, Switzerland Website www.vatvalve.com Phone +41 81 771 61 61 Fax +41 81 771 48 30 Publisher VAT Vakuumventile AG, CH-9469 Haag, Switzerland Editor VAT Vakuumventile AG, CH-9469 Haag, Switzerland Print VAT Vakuumventile AG, CH-9469 Haag, Switzerland Copyright © VAT Vakuumventile AG 2013 Email CH@vatvalve.com 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. VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 2/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 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. Corrosive process gases may impact the performance of the product. Please contact VAT to assure that the product is compatible with the process gases used in your application. Technical data Pressure range DN 160 - 200: 1 x 10-8 mbar to 2 bar (abs) DN 250 - 400: to 1.2 bar (abs) Differential pressure on the closed gate DN 160 - 200: 2 bar in either direction DN 250 - 400: 1.2 bar in either direction Max. differential pressure at opening 30 mbar Admissible temperature: Valve Actuator < 150°C < 50°C Operation only with VAT PM-4/5 controller and connection cable Further data according to VAT catalogue «Vacuum Valves 2016». Installation into the vacuum system The valve seat side is indicated by the symbol " " on the connection flange. Tightening torque for mounting screws on flanges 1. Mounting with centering ring Tighten mounting screws of the flanges uniformly in crosswise order. Observe the maximum torque levels in the following table. Higher tightening torques deform the valve body and can lead to an improper function of the valve. DN max. tightening torque (Nm) max. tightening torque (lbs . ft) mm inch ISO-F JIS ASA-LP ISO-F JIS ASA-LP 63/100 4 8 – 10 8 – 10 8 – 10 6–8 6–8 6–8 160 6 13 – 15 13 – 15 20 – 30 9 – 11 9 – 11 15 – 22 200 8 13 – 15 13 – 15 20 – 30 9 – 11 9 – 11 15 – 22 250 10 17 – 20 17 – 20 40 – 60 13 – 15 13 – 15 30 – 44 320 350 12 14 17 – 20 17 – 20 40 – 60 13 – 15 13 – 15 30 – 44 400 16 17 – 20 30 – 35 55 – 80 13 – 15 22 – 26 41 – 59 VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 3/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 2. Mounting with O-ring in groove Tighten mounting screws of the flanges uniformly in crosswise order. Observe the maximum torque according to the grade of screws and depth of thread you use. Admissible forces Forces from evacuating the system, from the weight of other components, and from heating can lead to deformation of the valve body and to malfunction of the valve. The stress has to be relieved by suitable means, e.g. bellows sections. The following forces are admissible: DN (nom. I.D.) Axial tensile or compressive force «FA» Bending moment «M» mm inch N lbf Nm lbf ft 63 1 2 /2 1960 440 78 58 100 4 2450 560 98 72 160 6 2940 660 147 108 200 8 2940 660 147 108 250 10 3430 770 196 145 320 / 350 12 / 14 3920 880 294 217 400 16 7840 1760 980 722 FA M If a combination of both forces (FA and M) occurs, the values mentioned above are invalid. Please contact VAT for more information. VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 4/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 Electrical connection Do not touch electrical parts under voltage! This control valve may only be operated with a VAT PM-4 or PM-5 Adaptive Pressure Controller and the corresponding cable supplied by VAT. The PM-4 or PM-5 control unit has to be turned off for at least 60 seconds before connecting or disconnecting the cable to the valve. Operation Operation is allowed only after the installing procedure. Differential pressure Do not open the valve, if the differential pressure on the gate is equal or larger than 30 mbar. Power failure with power-fail option without power-fail option Valve closed Valve open or control position no change will close no change undefined VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 5/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 Preventive maintenance The numbers in brackets refer to the drawing on page 9 Note! The process environment of your application (i.e. corrosive gases, deposition on parts inside valve body) may require more frequent preventive maintenance intervals than suggested below. Heating of the valve is highly recommended for contaminating processes. VAT offers customized heater boxes for series 64.2 valves. For quick maintenance, VAT recommends to exchange the complete gate assembly in order to reduce downtime of the system. Warning! Never remove striking plate (20) from the mechanism (16)! Recommended maintenance after every 100'000 cycles (25’000 for DN 400 vertical mounting only): - Clean gate O-ring, clean inside surfaces - Inspect the bonnet seal, ball bearings and crank bolt. - Replace items (Spare part kit ‘C’), if corrosion or deposition of process by-products occured. - In corrosive processes: Relubricate locking balls with VAT Vacuum grease. Replace and lubricate locking balls, if corrosion has occured. Recommended maintenance after every 200'000 (50’000 for DN 400 vertical mounting only) cycles: In additional to the 100'000 cycles maintenance interval, VAT recommends to clean and lubricate the ball bearings (replace, if necessary), replace the locking balls, replace the crank bolt, inspect, clean and re-lubricate the ball guide plate (replace, if friction increased), inspect, clean and re-lubricate the feedthrough O-ring (replace it if necessary) The following table refers to the items on page 4 and the spare parts list on page 6. Cycles *) Procedures Recommended spare parts kits Every 100’000 1., 2., 3. A, E Every 200’000 1., 2., 3., 4., 5., 6., 7. For individual items see spare parts list on page 6 B, C, E For individual items see spare parts list on page 6 *) Definition of cycle: Movement of the gate from open to closed or control position and back to open position Procedures 1. Precondition for all maintenance work - Vent both valve chambers - Give ‘OPEN’ command on PM-4 or PM 5 control to open gate valve - Turn off power to PM-4 or PM-5 control unit. If power-fail option is installed, press ‘F2’ key to disable power-fail option temporarily and turn off power to PM-4 or PM-5 control unit within following 60 seconds - Wait for another 60 seconds, then disconnect cable to valve actuator 2. Removal of the gate assembly (4) / Replacement of the crank bolt (6) / Replacement of the bonnet seal (3) - Unfasten the bonnet screws (1) - Remove the bonnet plate (2) and the bonnet seal (3) - Pull the lever (15) a little bit out of the bonnet opening - Loosen the hexagonal socket-head bolt (7) for the crank bolt (6) - Remove the crank bolt (6), while lifting the gate assembly (4) a little bit if necessary VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 6/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 - Slide out the gate assembly (4) carefully from the body and put it on a clean workshop place - Re-assemble in reverse direction - Fasten the screws (1) crosswise with equal torque: 14 Nm (10 lbf ft) with DN 63 - 100 18 Nm (13 lbf ft) with DN 160 – 400 3. Replacement of the gate O-ring (5) - Remove O-ring carefully and avoid any damage to the groove sealing sureface - Clean groove and sealing surface - Install new O-ring by pressing it crosswise uniformly into the groove. Make sure, the O-ring is not twisted (pay attention to the seam of the O-ring) 4. Replacement of the ball bearings (22) - DN160 - 200: Replace complete ball bearing assembly (2 pcs) - DN250 - 400: Replace each individual ball bearing (4 pcs) 5. Replacement of the locking balls (19) - Put the gate assembly (4) carefully on a clean workshop place with the O-ring side to the bottom - Remove the 6 hexagonal nuts (17) - Lift off counter plate (18) and ball guide plate (16) - Replace locking balls (19), lubricate balls with VAT vacuum grease (E) before installation - Reassemble in reverse order, lubricate weld bolts on plate with VAT vacuum grease (E) before mounting hexagonal nuts 6. Removal of actuator (10) for change of rotary seal (included in seal kit ‘A’) - Remove gate assembly as per items 1 and 2 - Move the actuator to position 800 (PM control: Position mode, select 800) - Press 'F2', if power-fail option is installed to disable the power fail option - Turn off power to PM control unit. - Remove roll pin (8) out of the shaft feedthrough. Use VAT assembling tool or a punch - Remove lever (15). Note the marking "A" to be on top side when reinstalling - Remve 4 hexagonal socket-head bolts (9) on top of the direct drive actuator (10) - Remove complete direct drive actuator assembly (10) - Install in reverse order VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 7/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 Spare parts The item numbers refer to the assembly drawing on page 9 Item Description Part No. 160 200 250 320 400 350 3 Bonnet seal 77781-R1 77784-R1 N-5100-378 N-5100-382 N-5100-383 4 Gate assembly 84275-R1 84608-R1 83481-R1 209812 517637 5 Gate O-ring N-5102-364 N-5100-372 N-5102-453 N-5102-457 N-5100-461 6 Crank bolt 79090-R1 79090-R1 85783-R1 85783-R1 87749-R1 7 Crank bolt mounting screw with spring washer N-6005-458 N-6162-405 N-6005-458 N-6162-405 N-6005-502 N-6162-407 N-6005-502 N-6162-407 N-6005-502 N-6162-407 8 Feedthrough connection pin N-6097-480 N-6097-480 N-6097-509 N-6097-509 N-6097-509 Actuator A-side B-side 247102 247103 247102 247103 232850 232851 232850 232851 232850 232851 Actuator with interm. Pump. A-side B-side 247104 247105 247104 247105 232852 232853 232852 232853 232852 232853 10 11 Actuator seal N-5100-225 N-5100-225 N-5100-228 N-5100-228 N-5100-228 19 Locking balls N-6121-051 (18 pcs) N-6121-081 (18 pcs) N-6121-081 (24 pcs) N-6121-097 (32 pcs) 22 Ball bearing assembly 84326-R1 (2 pcs) N-6121-051 ( 24 pcs) 80642-R1 (2 pcs) 99205-R1 (4 pcs) 99205-R1 (4 pcs) 77286-01 (4 pcs) 246755 246756 246757 246760 245476 260150 260151 260152 260153 260154 88725-R1 88726-R1 88727-R1 88728-R1 88729-R1 A B Seal kit Actuator replacement kit, C Gate spare parts kit, D Feedthrough assembling tool VAT vacuum grease (40 g) E consisting of: actuator seal, bonnet seal, feedthrough connection pin consisting of gate O-ring, crank bolt, crank bolt connection screw, ball bearings, locking balls 240451 97381-R1 N-6951-012 VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 8/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 1 2 22 21 3 4 20 19 18 5 6 7 17 16 15 8 14 OPTION: R1/8" port 9 13 10 12 11 VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 9/10 Installation, Operating, and Maintenance Instructions Series 64.2, DN 160 - 400 Trouble shooting Valve does not close/open/control Pressure control does not work properly Leak at gate Leak at body - Is differential pressure < 30 mbar? - Do not operate valve, while differential pressure is > 30 mbar. Equalize pressure first. - Is PM control unit activated (hooked up to power, switched on)? - Is valve cable connected properly? - Please refer to Trouble Shooting section of PM contol unit (operation instruction M64005EB) - Clean valve seat and gate! - Check surface of seat and O-ring - Change O-ring, if necessary - Flange seals leaktight? - Bonnet seal leaktight? - Screws at bonnet tightened properly? Repairs Contact VAT for repairs or maintenance. The fabrication No. marked on the valve body has always to be specified. It has to be individually decided whether the work can be performed by the customer or has to be carried out by VAT. Power to the control unit has to be switched off and the cable to the valve has to be disconnected (wait at least 60 seconds) before removal/installation of the valve from/into the system. Keep fingers and objects away from the valve opening! Products returned to VAT for repair have to be free of harmful substances such as e.g. toxical, caustic or microbiological ones. For radioactively contaminated products the customer has to fill in the VAT form «Contamination and Radiation Report» and to send it with the product. The form is available at VAT. The maximum permissible values indicated in the form must not be exceeded. 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. VAT Vakuumventile AG, CH-9469 Haag, Switzerland Tel +41 81 771 61 61 Fax +41 81 771 48 30 CH@vatvalve.com www.vatvalve.com 219036EJ 2013-03-04 10/10
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