LEYBOLD LEYCON BAV P AL Series User manual

LEYCON
User manual 17200295_002_C0/2016
High Vacuum Angle Valve BAV
DN 16–50 ISO-KF
 with pneumatic actuator P
single acting with closing spring (NC)
 with electropneumatic actuator EP
single acting with closing spring (NC)
 with electropneumatic actuator EP
single acting with opening spring (NO)
(DN 16 - 40 ISO-KF, version AL)
 aluminum version AL
 stainless steel version VA
High Vacuum Inline Valve BIV
DN 16–50 ISO-KF
 with pneumatic actuator P
single acting with closing spring (NC)
 with electropneumatic actuator EP
single acting with closing spring (NC)
 aluminum version AL
 stainless steel version VA
Part numbers
215130 215339 – 215345 215359 – 215361 215367 – 215369 215391 – 215393
215314 – 215337 215347 – 215357 215363 – 215365 215371 – 215373 215394V01
–
215395V01

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Imprint
Manufacturer Leybold GmbH, D-50968 Cologne, Germany
Website:
Phone:
Fax:
Email:
www.leybold.com
[phone]
[phone]
[email protected]
Publisher Leybold GmbH, D-50968 Cologne, Germany
Editor Leybold GmbH, D-50968 Cologne, Germany
Print Leybold GmbH, D-50968 Cologne, Germany
Copyright © Leybold GmbH 2016
No part of this user manual 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 Leybold. Offenders are liable to pay damages.
The use of trade names, brand names, trademarks, etc. in this user manual
does not entitle third parties to consider these names to be unprotected
and to use them freely.
Original
document
The German language version of this user manual is the original
document. All other languages are a translation of the original user
manual. In case of deviations the information within the original user
manual is valid.

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Table of contents
1 Description of product ........................................................................ 5
1.1 Important information .......................................................................................... 5
1.2 Identification of product ....................................................................................... 5
1.3 Validity of the user manual .................................................................................. 6
1.4 Technical data ..................................................................................................... 8
1.5 Components delivered with the valve ............................................................... 13
1.6 Warranty ............................................................................................................ 13
2 Safety ................................................................................................. 14
2.1 Compulsory reading material ............................................................................ 14
2.2 Danger levels .................................................................................................... 14
2.3 Purpose of use .................................................................................................. 15
2.3.1 Permitted use ........................................................................................ 15
2.3.2 Adverse use .......................................................................................... 15
2.4 Obligations / area of responsibility .................................................................... 15
2.4.1 Manufacturer ......................................................................................... 15
2.4.2 Operator ................................................................................................ 15
2.5 Personnel qualifications .................................................................................... 16
2.6 General Safety Instructions ............................................................................... 16
2.7 Safety labels ...................................................................................................... 16
3 Design and Function ......................................................................... 17
3.1 Design ............................................................................................................... 17
3.2 Function ............................................................................................................ 17
4 Installation ......................................................................................... 18
4.1 Unpacking ......................................................................................................... 18
4.2 Installation into the system ................................................................................ 19
4.3 Compressed air connection .............................................................................. 21
4.4 Electrical connection ......................................................................................... 21
4.4.1 Valve with position indicator .................................................................. 22
4.4.2 Valve with pilot valve and position indicator ......................................... 22
5 Operation ........................................................................................... 23
5.1 Normal operation ............................................................................................... 23
5.2 Operation under increased temperature ........................................................... 23
5.3 Behavior in case of air pressure drop ............................................................... 23
5.4 Behavior in case of power failure ...................................................................... 23
5.5 Operation of the NO model ............................................................................... 24
6 Maintenance ...................................................................................... 25
6.1 Exchange of vacuum seals ............................................................................... 26
6.1.1 Dismount actuator / plate assembly ...................................................... 27
6.1.2 Replacement of plate seal .................................................................... 27
6.1.3 Mount actuator / plate assembly ........................................................... 27
7 Repairs ............................................................................................... 28

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8 Dismounting and Storage ................................................................ 29
8.1 Dismounting ..................................................................................................... 29
8.2 Storage ............................................................................................................. 29
9 Packaging and Transport ................................................................. 30
9.1 Packaging ......................................................................................................... 31
9.2 Transport .......................................................................................................... 31
10 Disposal ............................................................................................. 32
11 Spare parts and accessories ........................................................... 33
12 Appendix ........................................................................................... 35
12.1 Safety information on contamination ................................................................ 35
12.2 Declaration of chemical contamination ............................................................ 36
12.3 Declaration of incorporation ............................................................................. 37

DESCRIPTION OF PRODUCT
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1 Description of product
1.1 Important information
This symbol points to a very important statement that requires particular
attention.
Example:
Leybold disclaims any liability for damages resulting from inappropriate
packaging.
1.2 Identification of product
The fabrication number and part number are fixed on the product directly or by means of an
identification plate.

 PN: Part number
SN: Fabrication number
Figure 1-1
In all communications with Leybold, please specify the information on the
product nameplate.
PN . . . . .
SN . . . . . . . . . .
Build . . . .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
....... . . .
Leybold GmbH
Bonner Str. 498, D-50968 Köln, Germany

DESCRIPTION OF PRODUCT
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1.3 Validity of the user manual
This document applies to products with the part numbers below-mentioned.
List of part numbers
Type Part number Type Part number
BAV . . P AL BAV . . P VA
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215315
215316
215317
215318
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215335
215336
215337
-
BAV . . EP AL 24 VAC BAV . . EP VA 24 VAC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215319
215320
215321
215322
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215339
215340
215341
215342
BAV . . EP AL 24 VDC BAV . . EP VA 24 VDC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215323
215324
215325
215326
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215347
215348
215349
215350
BAV . . EP AL 115 VAC BAV . . EP VA 115 VAC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215327
215328
215329
215330
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215351
215352
215353
215354
BAV . . EP AL 230 VAC BAV . . EP VA 230 VAC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215331
215332
215333
215334
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215343
215344
215345
-
BAV . . EP AL 24 VDC 1
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215395V01
215394V01
215130
-
1 currentless open (NO model)

DESCRIPTION OF PRODUCT
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Type Part number Type Part number
BIV . . P VA BIV . . EP VA 24 VAC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215355
215356
215357
-
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215359
215360
215361
-
BIV . . EP VA 24 VDC BIV . . EP AL 24 VDC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215367
215368
215369
-
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215314
215391
215392
215393
BIV . . EP VA 115 VAC BIV . . EP VA 230 VAC
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215371
215372
215373
--
ISO KF 16
ISO KF 25
ISO KF 40
ISO KF 50
215363
215364
215365
-
Table 1-1
Descriptions and illustrations within this user manual refer to the currentless
closed valves (NC).
In large parts this is valid for the currentless open valves (NO) as well.
Differences are identified and highlighted, if existing.

DESCRIPTION OF PRODUCT
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1.4 Technical data
Standard valves see chapter «1.3 Validity of the user manual».
For special valves which are not listed in chapter «1.3 Validity of the user manual» the
product data sheet is applicable in addition.
Material
Material
Item Aluminum version Stainless steel version
Body Aluminium (AIMgSi) Stainless steel (AISI 304)
Actuator Aluminium Aluminium
Valve plate AISI 316L AISI 316L
Bellows AISI 316L (1.4404, 1.4435)
AISI 316 Ti (1.4571)
AISI 316L (1.4404)
AISI 316 Ti (1.4571)
Bonnet seal, plate seal Viton® Viton
®
Cover of position indicator Plastic Plastic
Table 1-2
General technical data
Value / description
Type / Item DN 16 DN 25 DN 40 DN 50
Leak rate [mbar l/s] ≤ 1 · 10-9
Pressure range: valve open
[mbar], absolute 1 · 10-8 to 5000
Differential pressure on the
plate [bar]
In opening direction 2 ≤ 2
In closing direction 2 ≤ 5
Differential pressure at
opening [bar] ≤ 2 in either direction
2 see «Figure 3-1»

DESCRIPTION OF PRODUCT
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Value / description
Type / Item DN 16 DN 25 DN 40 DN 50
Switching times [ms]
Opening time
(4 bar pneumatic pressure) < 100 < 120 < 250 < 400
Closing time
(8 bar pneumatic pressure) < 100 < 210 < 550 < 650
Weight [kg]
Angle valve: aluminum 0.24 0.36 0.92 1.34
Angle valve: stainless steel 0.3 0.47 1.08 1.52
Inline valve: aluminum 0.32 0.49 1.3 2.19
Inline valve: stainless steel 0.74 0.47 1.16 –
Volume of air cylinder [l] 0.004 0.011 0.035 0.047
Connection: hose plug-in
connector, Ø [mm] 4
Compressed air pressure
(min. – max. overpressure)
[bar / psi]
4 – 8 / 58 – 116
Molecular flow conductance
[l/s] 5 14 45 80
Mounting position any
Switching frequency [1/min] ≤ 100 ≤ 50
Admissible temperature [°C]
Valve body aluminium 0 to 120
Valve body stainless steel 0 to 150
Actuator 0 to 120
Cover of position indicator 0 to 80
Pilot valve 0 to 80
Cycles until first service
10 millions
(except wearing parts such as sealing elements and
position indicators)
under clean, static conditions and at max. 80°C

DESCRIPTION OF PRODUCT
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Value / description
Type / Item DN 16 DN 25 DN 40 DN 50
Position indicator: contact
rating
Voltage [V AC/DC] 5 to 50
Current [mA] 5 to 100
Power [W] 1.0
All valves with position indicator
Pilot valve
Voltage see specification on pilot valve (range ±10%)
Power
DC [W] ≤ 2.5
AC [VA] ≤ 4.8 starting / 3.6 holding current
Protection class IP50
Table 1-3

DESCRIPTION OF PRODUCT
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Drawings / Dimensions
Angle valve: aluminum and stainless steel
DN
Pos. 16 25 40 50 mm
A 40 50 65 70 mm
B 40 48 65 77 mm
D 16 25 40 50 mm
L 65.2 60.6 87.7 96 mm
L1 67.7 64 90.7 99 mm
Q 46 44 73.5 85.5 mm
F 9 13 19 20 mm
Z 2 4 9.5 10.5 mm
E 35.6 30.6 51.6 58.4 mm
E1 38.1 34 54.6 61.4 mm
L/E = aluminum version
L1/E1 = stainless steel version
Valve seat side
Required for dismantling
Mechanical position indication
Leak detection slot
Electrical connection
Compressed air connection
Figure 1-2
Inline valve: aluminum and stainless steel
DN
Pos. 16 25 40 50 mm
A 80 100 130 178 mm
B 40 48 65 77 mm
D 16 25 40 50 mm
L 91.5 100.3 140.9 170.1 mm
L1 93 108.9 150 – mm
Q 46 44 73.5 85.5 mm
E 29.6 30 36.1 37.6 mm
Z 2 4 9.5 10 mm
M 120 129.6 160 184.6 mm
M1 120.2 135 168.7 – mm
L/M = aluminum version
L1/M1 = stainless steel version
Valve seat side
Required for dismantling
Mechanical position indication
Leak detection slot
Electrical connection
Compressed air connection
Figure 1-3

DESCRIPTION OF PRODUCT
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Angle valve: aluminum, NO model
DN
Pos. 16 25 40 mm
A 40 50 65 mm
B 40 48 65 mm
D 16 25 40 mm
L 78.9 79.1 110.2 mm
Q 46 44 73.5 mm
F 9 59.4 19 mm
Z 2 3.4 9.5 mm
E 49.3 48.3 74.4 mm
L = aluminum version
Valve seat side
Required for dismantling
Mechanical position indication
Leak detection slot
Electrical connection
Compressed air connection
Figure 1-4

DESCRIPTION OF PRODUCT
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1.5 Components delivered with the valve
In addition to the attached hose connector Ø 4 mm, a hose connector Ø 6 mm is supplied
separately.
Maximum torque to fasten the hose connector fitting: 0.16 Nm.
Protective covers on both flanges.
Valves with an electrical position indicator are provided with a 7-pole Amphenol connector
(see Figure 11-1) ausgestattet. The connector is enclosed.
The original document of this user manual in German language is also enclosed.
1.6 Warranty
Leybold assumes no liability if the end-user or third parties:
• disregard the information in this document
• use the product in a non-conforming manner
• make any kind of interventions (modifications, alterations etc.) on the product
• use the product with accessories, options, and add-ons not listed in the corresponding
product documentation.
Failures due to contamination or wear and tear, as well as expendable parts (e.g. seals),
are not covered by the warranty.
Improperly accomplished maintenance work may reduce the safety, lifetime and
performance of the product and lead to refusal of warranty claims.
Maintenance work not described in this user manual may only be carried out
by the Leybold service staff or by specialists trained and authorized by
Leybold.

SAFETY
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2 Safety
2.1 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.
NOTICE
Lack of knowledge
Failing to read this manual may result in property damage.
Firstly, read manual.
This user manual is an integral part of a comprehensive documentation
belonging to a complete technical system. It must be stored together with the
other documentation and accessible for anybody who is authorized to work
with the system at any time.
2.2 Danger levels
DANGER
High risk
Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
Medium risk
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Low risk
Indicates a hazardous situation which, if not avoided, may result in minor or
moderate injury.
NOTICE
Command
Indicates a hazardous situation which, if not avoided, may result in property
damage.

SAFETY
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2.3 Purpose of use
2.3.1 Permitted use
• The high vacuum angle valve BAV as well as the high vacuum inline valve BIV acts as
venting and shut-off device within a vacuum system.
• The valve features ISO-KF flanges and is intended for mounting within clamping flange
systems.
• Use product for clean and dry vacuum applications only. Observe the specification in
chapter «1.4 Technical data».
2.3.2 Adverse use
• Use of the product for liquid gas.
• Use of the product without instruction or outside of the permitted limits.
• Detaching of hazard notices, disabling safety systems.
• Conducting any kind of interventions (modifications, alterations etc.) on the product.
• Use with accessories and options, which are not menitoned in the corresponding product
documentation.
• Either use, not explicitly mentioned as permitted use, applies as adverse use.
2.4 Obligations / area of responsibility
2.4.1 Manufacturer
Leybold GmbH as manufacturer is responsible for supplying the product, with its user
manual and original accessories, in a completely safe condition.
2.4.2 Operator
The operator is the person in charge of the product. The operator ensures
that the product is used in accordance with the instructions, and the safety of
the equipment in use. Training and deployment of personnel who use the
product is also the operator‘s charge.
The operator has the following duties:
• To know local, operative regulations regarding safety and accident prevention.
• To assure that the national laws and directives are respected.
• To understand safety indications on the product, and instructions in the user manual.
• To immediately inform the manufacturer, if safety shortcomings of the product or it‘s use
occur.
• To check the sound condition of the product regularly and to assure the execution of the
maintenance works mandated.
The end-user assumes the responsibility in conjunction with the process
media used.

SAFETY
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2.5 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.
2.6 General Safety Instructions
• Adhere to the applicable regulations and take the necessary precautions for the process
media used.
Consider possible reactions between the materials and the process media.
• Adhere to the applicable regulations and take the necessary precautions for all work you
are going to do and consider the safety instructions in this document.
• Before beginning to work, find out whether any vacuum components are contaminated.
Adhere to the relevant regulations and take the necessary precautions when handling
contaminated parts.
2.7 Safety labels
Label Part No. Location on valve
T-9001-155 On protective covers of flanges
253198 On valve body or actuators
Table 2-1

DESIGN AND FUNCTION
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3 Design and Function
3.1 Design
This illustration shows an angle valve (NC). The inline valve has a different body shape.
opening direction
closing direction
Figure 3-1
1 Body 42 Position indicator and
connector 61 Plate seal
15 Bellows 44 Pilot valve 62 Bonnet seal
26 Actuator complete 60 Screws 65 Pneumatic connection
3.2 Function
Valve is closed by a spring (NC) and opened pneumatically.
NO model:
Valve is closed pneumatically and opened by a spring (NO).

INSTALLATION
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4 Installation
The subsequent notes need to be observed for all installation works!
Disconnect compressed air and electrical power during installation and
configurations.
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
NOTICE
Contamination
Product may get contaminated because of inadequate handling.
Always wear cleanroom gloves when handling the product.
NOTICE
Inappropriate tools
Sealing surfaces may get damaged.
Do not use sharp-edged tools.
4.1 Unpacking
• Before unpacking, check whether the packaging shows transport
damages and the goods could be damaged.
• Check whether the goods are complete and in impeccable condition. If
you have any objections, please contact the local agency immediately;
see backside of the document.
• Store the original packaging material. It may be useful if products must be
returned.
Remove the protective covers from the valve only at the moment when the
valve is being installed into the system. Keep unprotected sealing surfaces
clean and do not damage them.

INSTALLATION
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4.2 Installation into the system
DANGER
Overpressure in the vacuum system >1 bar
Injury caused by released parts and harm caused by escaping process gases
can result if clamps are opened while the vacuum system is pressurized.
Do not open any clamps while the vacuum system is pressurized. Use the
type of clamps which are suited to overpressure.
DANGER
Overpressure in the vacuum system >2.5 bar
KF flange connections with elastomer seals (e.g. O-rings) cannot withstand
such pressures. Process media can thus leak and possibly damage your
health.
Use O-rings provided with an outer centering ring.

INSTALLATION
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1. Remove the protective lids.
2. Check and carefully clean sealing surfaces of valve flanges and counter flanges.
3. Install valve with connection components appropriate for ISO-KF flanges by taking the
specification in «Table 4-1» into account.
DN (nom. I. D.) Axial tensile or
compressive force «F
A
» Bending moment «M»
mm Inch N lbf Nm lbf · ft
16
5
/ 8 25 6 1 0.8
25 1 70 16 3 2.2
40 1½ 100 22 6 4.5
50 2 150 34 11 8
A combination of both forces «F
A
» and «M» is not allowed. Please contact Leybold.
Angle valve
Inline valve
Table 4-1
Keep the protective lids.
4. Check that the vacuum connections are leak tight.