Pfeiffer Vacuum BVML User manual

OPERATING INSTRUCTIONS
EN
Original
BALL VALVE
Valve

Dear customer,
Thank you for choosing a Pfeiffer Vacuum product. Your new Pfeiffer Vacuum valves should
support you in your individual application with full performance and without malfunctions. The
name Pfeiffer Vacuum stands for high-quality vacuum technology, a comprehensive and
complete range of top-quality products and first-class service. With this expertise, we have
acquired a multitude of skills contributing to an efficient and secure implementation of our
product.
Knowing that our product must not interfere with your actual work, we are convinced that our
product offers you the solution that supports you in the effective and trouble-free execution of
your individual application.
Please read these operating instructions before putting your product into operation for the
first time. If you have any questions or suggestions, please feel free to contact info@pfeiffer-
vacuum.de.
Further operating instructions from Pfeiffer Vacuum can be found in the Download Center on
our website.
Disclaimer of liability
These operating instructions describe all models and variants of your product. Note that your
product may not be equipped with all features described in this document. Pfeiffer Vacuum
constantly adapts its products to the latest state of the art without prior notice. Please take
into account that online operating instructions can deviate from the printed operating
instructions supplied with your product.
Furthermore, Pfeiffer Vacuum assumes no responsibility or liability for damage resulting from
the use of the product that contradicts its proper use or is explicitly defined as foreseeable
misuse.
Copyright
This document is the intellectual property of Pfeiffer Vacuum and all contents of this
document are protected by copyright. They may not be copied, altered, reproduced or
published without the prior written permission of Pfeiffer Vacuum.
We reserve the right to make changes to the technical data and information in this document.
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Table of contents
1 About this manual 5
1.1 Validity 5
1.1.1 Applicable documents 5
1.1.2 Products concerned 5
1.2 Target group 5
1.3 Conventions 5
1.3.1 Instructions in the text 5
1.3.2 Pictographs 6
1.3.3 Abbreviations 6
1.4 Trademark proof 6
2 Safety 7
2.1 General safety information 7
2.2 Safety instructions 7
2.3 Safety precautions 8
2.4 Limits of use of the product 8
2.5 Proper use 9
2.6 Foreseeable misuse 9
2.7 Personnel qualification 9
2.7.1 Ensuring personnel qualification 9
2.7.2 Personnel qualification for maintenance and repair 10
2.7.3 Advanced training with Pfeiffer Vacuum 10
3 Product description 11
3.1 Function 11
3.2 Scope of delivery 11
3.3 Identifying the product 11
3.3.1 Product types 12
3.3.2 Product features 12
4 Transportation and Storage 13
4.1 Transport 13
4.2 Storage 13
5 Installation 14
5.1 Preparatory work 14
5.2 Mounting orientation 14
5.3 Mounting the valve 14
6 Operation 15
7 Maintenance 16
7.1 General maintenance information 16
7.2 Replacing O-ring seal 16
7.3 Replacing or adding pilot valve 17
8 Decommissioning 18
9 Recycling and disposal 19
9.1 General disposal information 19
10 Malfunctions 20
11 Service solutions by Pfeiffer Vacuum 21
12 Spare parts - Ball valves 23
13 Technical data and dimensions 24
13.1 General 24
Table of contents
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13.2 Technical data 24
13.3 Dimensions 26
Table of contents
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1 About this manual
IMPORTANT
Read carefully before use.
Keep the manual for future consultation.
1.1 Validity
These operating instructions are a customer document of Pfeiffer Vacuum. The operating instructions
describe the functions of the named product and provide the most important information for the safe use
of the device. The description is written in accordance with the valid directives. The information in these
operating instructions refers to the product's current development status. The document shall remain
valid provided that the customer does not make any changes to the product.
1.1.1 Applicable documents
Document Reference
Declaration of conformity included with these operating instructions
1.1.2 Products concerned
This document applies to products with the following part numbers:
Part number Description
BVML-xxxxxx Models for manual ball valves
BVP-xxxxxx Models for pneumatic ball valves
1.2 Target group
These operating instructions are aimed at all persons performing the following activities on the product:
●Transportation
●Setup (Installation)
●Usage and operation
●Decommissioning
●Maintenance and cleaning
●Storage or disposal
The work described in this document is only permitted to be performed by persons with the appropriate
technical qualifications (expert personnel) or who have received the relevant training from Pfeiffer Vac-
uum.
1.3 Conventions
1.3.1 Instructions in the text
Usage instructions in the document follow a general structure that is complete in itself. The required ac-
tion is indicated by an individual step or multi-part action steps.
Individual action step
A horizontal, solid triangle indicates the only step in an action.
►This is an individual action step.
Sequence of multi-part action steps
The numerical list indicates an action with multiple necessary steps.
1. Step 1
2. Step 2
3. ...
About this manual
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1.3.2 Pictographs
Pictographs used in the document indicate useful information.
Note
Tip
1.3.3 Abbreviations
Abbreviation Meaning in this document
BV Ball valve
CDA Clean dry air
Delta P Delta pressure
DN Nominal diameter as size description
FKM Fluoropolymer rubber
HV High vacuum
IPA Isopropyl alcohol
ISO Flange: Connection in accordance with ISO 1609 and ISO 2861
PTFE Synthetic fluoropolymer of tetrafluoroethylene
UHV Ultra-high vacuum
Tbl. 1: Abbreviations used in this document
1.4 Trademark proof
●Apiezon® is a registered trademark of M&I Materials Ltd
●Allen® is a registered trademark of Apex Brands, Inc
●Loctite® is a registered trademark of Henkel IP & Holding GmbH, Germany
About this manual
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2 Safety
2.1 General safety information
The following 4 risk levels and 1 information level are taken into account in this document.
DANGER
Immediately pending danger
Indicates an immediately pending danger that will result in death or serious injury if not observed.
►Instructions to avoid the danger situation
WARNING
Potential pending danger
Indicates a pending danger that could result in death or serious injury if not observed.
►Instructions to avoid the danger situation
CAUTION
Potential pending danger
Indicates a pending danger that could result in minor injuries if not observed.
►Instructions to avoid the danger situation
NOTICE
Danger of damage to property
Is used to highlight actions that are not associated with personal injury.
►Instructions to avoid damage to property
Notes, tips or examples indicate important information about the product or about this docu-
ment.
2.2 Safety instructions
Risks during installation
WARNING
Risk of injury due to incorrect installation
Dangerous situations may arise from unsafe or incorrect handling
►Do not put hands or any other body part or objects in the valve.
WARNING
Risk of injury due to overpressure in the vacuum system > 1000 hPa
Released parts and escaped gases can result in injury.
►Do not open clamps while the vacuum system is pressurized.
►Use the clamp types that are suited for overpressure.
WARNING
Risk of injury due to overpressure in the vacuum system > 2500 hPa
KF flange connections with elastomer seals cannot withstand such pressures. Process media can
leak and cause potential damage to your health.
►Use O-rings provided with an outer centering ring.
Safety
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Risks during maintenance, decommissioning and disposal
WARNING
Health hazard through poisoning from toxic contaminated components or devices
Toxic process media result in contamination of devices or parts of them. During maintenance work,
there is a risk to health from contact with these poisonous substances. Illegal disposal of toxic sub-
stances causes environmental damage.
►Take suitable safety precautions and prevent health hazards or environmental pollution by toxic
process media.
►Decontaminate affected parts before carrying out maintenance work.
►Wear protective equipment.
2.3 Safety precautions
Duty to provide information on potential dangers
The product holder or user is obliged to make all operating personnel aware of dangers
posed by this product.
Every person who is involved in the installation, operation or maintenance of the product
must read, understand and adhere to the safety-related parts of this document.
Infringement of conformity due to modifications to the product
The Declaration of Conformity from the manufacturer is no longer valid if the operator
changes the original product or installs additional equipment.
●Following the installation into a system, the operator is required to check and re-evalu-
ate the conformity of the overall system in the context of the relevant European Direc-
tives, before commissioning that system.
General safety precautions when handling the product
►Observe all applicable safety and accident prevention regulations.
►Check that all safety measures are observed at regular intervals.
►Never put hands or any other object in the valve.
2.4 Limits of use of the product
Parameter Limit value
Installation orientation Product to be installed directionally, with flow indicated by a visible ar-
row
Allowable ambient humidi-
ty
0 - 95% non-condensing
Process temperature
range
20 °C - 150 °C
Heating capabilities Body can be heated up to 150 °C with optional heater kits
Maximum internal pres-
sure
1400 hPa
Maximum delta P before
opening
1400 hPa in open direction. 1400 hPa in closing direction.
Open / close speed 1.0 s to open/close
Pneumatic supply 4000 - 7000 hPa
Solenoid electrical specifi-
cations
120 V AC
24 V DC
240 V AC
24 V AC
4.5 W
Position indicators Optical: NPN
Optical: PNP
Safety
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Parameter Limit value
Reliability 20,000 cycles in a clean environment
Leak rate High Vacuum: 1 x 10-7hPa l/s
Tbl. 2: Limits of use for ball valves
2.5 Proper use
►Use the valve only for isolating in a vacuum system.
►Use the valve only in closed indoor areas.
2.6 Foreseeable misuse
Improper use of the product invalidates all warranty and liability claims. Any use that is counter to the
purpose of the product, whether intentional or unintentional, is regarded as misuse, in particular:
●Use outside the mechanical and electrical application limits in accordance with the technical data
●Use with corrosive or explosive media, if this is not explicitly permitted
●Use outdoors
●Use with bare hands or with powder gloves
●Use after unauthorized technical changes (on the inside or the outside of the product)
●Use with replacement or accessory parts that are unsuitable or are not approved
2.7 Personnel qualification
The work described in this document may only be carried out by persons who have appropriate profes-
sional qualifications and the necessary experience or who have completed the necessary training as
provided by Pfeiffer Vacuum.
Training people
1. Train the technical personnel on the product.
2. Only let personnel to be trained work with and on the product when under the supervision of
trained personnel.
3. Only allow trained technical personnel to work with the product.
4. Before starting work, make sure that the commissioned personnel have read and understood
these operating instructions and all applicable documents, in particular the safety, maintenance
and repair information.
2.7.1 Ensuring personnel qualification
Specialist for mechanical work
Only a trained specialist may carry out mechanical work. Within the meaning of this document, special-
ists are people responsible for construction, mechanical installation, troubleshooting and maintenance
of the product, and who have the following qualifications:
●Qualification in the mechanical field in accordance with nationally applicable regulations
●Knowledge of this documentation
Specialist for electrotechnical work
Only a trained electrician may carry out electrical engineering work. Within the meaning of this docu-
ment, electricians are people responsible for electrical installation, commissioning, troubleshooting, and
maintenance of the product, and who have the following qualifications:
●Qualification in the electrical engineering field in accordance with nationally applicable regulations
●Knowledge of this documentation
In addition, these individuals must be familiar with applicable safety regulations and laws, as well as the
other standards, guidelines, and laws referred to in this documentation. The above individuals must
have an explicitly granted operational authorization to commission, program, configure, mark, and earth
devices, systems, and circuits in accordance with safety technology standards.
Safety
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Trained individuals
Only adequately trained individuals may carry out all works in other transport, storage, operation and
disposal fields. Such training must ensure that individuals are capable of carrying out the required activi-
ties and work steps safely and properly.
2.7.2 Personnel qualification for maintenance and repair
Advanced training courses
Pfeiffer Vacuum offers advanced training courses to maintenance levels 2 and 3.
Adequately trained individuals are:
●Maintenance level 1
─Customer (trained specialist)
●Maintenance level 2
─Customer with technical education
─Pfeiffer Vacuum service technician
●Maintenance level 3
─Customer with Pfeiffer Vacuum service training
─Pfeiffer Vacuum service technician
2.7.3 Advanced training with Pfeiffer Vacuum
For optimal and trouble-free use of this product, Pfeiffer Vacuum offers a comprehensive range of
courses and technical trainings.
For more information, please contact Pfeiffer Vacuum technical training.
Safety
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3 Product description
3.1 Function
Fig. 1: Manual ball valve overview
1 Optional locking latch 5 Teflon seat
2 Bushing 6 End plate / body seal
3 Bushing 7 Shaft seals
4 Pumping port
The manual ball valve's simple, robust design provides high reliability in "dirty" applications. A quarter
turn of the handle quickly moves the valve from open to closed.
3.2 Scope of delivery
●Valve
●Quick-start guide
3.3 Identifying the product
►To ensure clear identification of the product when communicating with Pfeiffer Vacuum, always
keep all of the information on the model number and serial number on hand.
Product description
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3.3.1 Product types
The product designation of Pfeiffer Vacuum ball valves from the BVML (manual valve) and BVP (pneu-
matic valve) series is composed of the family name, the size and, if required, an additional feature de-
scription.
Family Size/model
BVML DN 16 to 50
BVP DN 16 to 50
Tbl. 3: Product designation of Pfeiffer Vacuum ball valves
3.3.2 Product features
Feature Description Valve Version
Valve body material 316L stainless steel BVML and BVP
Ball material 316L stainless steel BVML and BVP
Stem seal FKM elastomer BVML and BVP
Ball seal PTFE BVML and BVP
Tbl. 4: Ball valve features
Product description
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4 Transportation and Storage
4.1 Transport
WARNING
Danger of serious injury due to falling objects
Due to falling objects there is a risk of injuries to limbs through to broken bones.
►Take particular care and pay special attention when transporting products manually.
►Do not stack the products.
►Wear protective equipment, e.g. safety shoes.
We recommend
Pfeiffer Vacuum recommends keeping the transport packaging and original protective cov-
er.
Instructions for safe transport
►Transport the valve only within the permissible temperature limits.
►Where possible, always transport or ship the valve in its original packaging.
►Always carry the valve with both hands or use adequate equipment to transport the valve.
►Remove the protective cover only immediately prior to installation.
►Transport the valve in the closed position.
4.2 Storage
We recommend
Pfeiffer Vacuum recommends storing the products in their original transport packaging.
Storing the valve
1. Seal all flange openings with the original protective caps.
2. Seal all other connections (e.g. venting connection) with the corresponding original parts.
3. Store the valve only indoors within the permissible temperature limits.
Transportation and Storage
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5 Installation
5.1 Preparatory work
WARNING
Risk of injury due to incorrect installation
Dangerous situations may arise from unsafe or incorrect handling
►Do not put hands or any other body part or objects in the valve.
General notes for the installation of vacuum components
►Choose an installation location that permits access to the product and to supply lines at all times.
►Observe the ambient conditions given for the limits of use.
►Provide the highest possible level of cleanliness during assembly.
►Ensure that flange components during installation are grease-free, dust-free and dry.
Required tools and materials
●Lint-free, dry wipe
●Powder-free latex gloves
●Vacuum grease
Pre-installation
1. Observe the instructions for transport to the installation location.
2. Determine that the valve and adjacent plumbing in the vacuum system will be adequately support-
ed when installed.
3. Make sure the mating flanges are in line, flat, parallel, and the correct distance aparty to minimize
straining of the valve body.
4. Remove the flange cover and wipe the flange and gaskets with a lint-free, dry wipe.
5. If installing an o-ring seal flange, apply a light film of vacuum grease to the o-ring and install in the
flange groove.
5.2 Mounting orientation
►Install the product directionally, with flow indicated by a visible arrow.
5.3 Mounting the valve
Required tools and materials
●Clamps
●Lint-free gloves
Prerequisites
●Make sure no foreign particles enter the valve
●Leave protective caps in place until the product is ready to be installed
Procedure
1. Remove protective flange caps from the valve.
2. Connect the valve to the vacuum system using the clamps.
Installation
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6 Operation
●For continued trouble-free operation, keep the valve clean and free of contaminants.
●Use powder-free latex gloves to avoid contaminating the valve with finger oils.
●Work in a clean environment to avoid other contamination.
Operation
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7 Maintenance
7.1 General maintenance information
Required spare parts
1. To order replacement parts or repair kits, contact Pfeiffer Vacuum service.
2. Please provide the model number and serial number when ordering replacement parts.
Serviceable parts
►Contact Pfeiffer Vacuum service for repair of non-user-serviceable parts.
7.2 Replacing O-ring seal
●Always wear powder-free latex gloves when servicing the valve
●Be careful not to scratch o-ring groove
●Avoid twisting, stretching, or deforming the o-ring
●Avoid damaging the materials
●Heat gun may be required to melt any Loctite on jam nut threads
Required tools and materials
●3/16" hex key - DN40 and smaller
5/16" hex key - DN50
●Lint-free gloves
●Replacement o-rings
●Krytox grease
●Fomblin 25/6 oil
Prerequisites
●Dismount valve from the vacuum system
●Remove air fitting, if installed
Remove and clean o-rings
1. Remove flange from one side using hex key.
–4 fasteners and lock washers per side
2. Remove and discard o-rings and Teflon seats.
–Avoid scratching the seal surfaces by using a plastic o-ring pick to remove the o-rings.
Reassemble valve
1. Clean the o-ring grooves and valve seat using IPA soaked cleanroom wipe.
2. Clean seals using IPA soaked cleanroom wipe.
3. Blow-dry o-ring with CDA.
4. Wipe Teflon seat with IPA.
5. Evenly apply a light sheen of Fomblin to ID of Teflon seat.
6. Evenly apply a light sheen of Krytox to o-ring.
7. Orient the body with the stem bore at the top and flow arrow facing up away from the assembly
table.
–Install the seat with the radius side down.
–Install o-ring around the OD of the seat.
8. Wipe the end plate with cleanroom wipe and IPA.
9. Place end plate onto body assembly using the four fasteners and lock washers to hand tight.
10. Turn the body assembly over and repeat steps above by starting with removing the flanges from
the other side using the hex key.
11. Once hand tight, torque the fasteners; arrow side first .
–Using a star pattern torque the four fasteners approximately 1/4 of a turn at a time.
Then torque the four fasteners on the opposite side using the same method.
Maintenance
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7.3 Replacing or adding pilot valve
Required tools and materials
●Philips head screwdriver
●Lint-free gloves
●5/64" or 5/32" T handle
●Pilot vlave kit
Prerequisites
●Dismount valve from the vacuum system
Remove pilot valve
1. Remove the poly tubing from the air fitting of the valve and the air fitting of the pilot valve.
2. Use Philips head screwdriver to remove two pan head screws.
Install pilot valve
1. Use Philips head screwdriver to attach two pan head screws to body.
2. Insert the poly tubing into the air fitting of the valve and the air fitting of the pilot valve.
Pilot valve test
1. Insert air supply line into the straight fitting on the pilot valve.
2. Apply 4000 - 7000 hPa air pressure.
–Valve should not open until power is applied.
–Verify valve opens when power is applied and closes when power is removed.
Maintenance
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8 Decommissioning
Required tools and materials
●Lint-free gloves
●Protective covers for the valve flanges
Prerequisites
●Vacuum system vented
●Control system off
●Valve closed
Procedure
1. Loosen the power supply connector and unplug it.
2. Disconnect the air tube.
3. Remove the valve from the vacuum system.
4. Install the protective lids.
Decommissioning
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9 Recycling and disposal
WARNING
Health hazard through poisoning from toxic contaminated components or devices
Toxic process media result in contamination of devices or parts of them. During maintenance work,
there is a risk to health from contact with these poisonous substances. Illegal disposal of toxic sub-
stances causes environmental damage.
►Take suitable safety precautions and prevent health hazards or environmental pollution by toxic
process media.
►Decontaminate affected parts before carrying out maintenance work.
►Wear protective equipment.
Environmental protection
You must dispose of the product and its components in accordance with all applicable reg-
ulations for protecting people, the environment and nature.
●Help to reduce the wastage of natural resources.
●Prevent contamination.
9.1 General disposal information
Pfeiffer Vacuum products contain materials that you must recycle.
►Dispose of our products according to the following:
–Iron
–Aluminium
–Copper
–Synthetic
–Electronic components
–Oil and fat, solvent-free
►Observe the special precautionary measures when disposing of:
–Fluoroelastomers (FKM)
–Potentially contaminated components that come into contact with media
Recycling and disposal
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10 Malfunctions
Problem Possible causes Possible solution
Valve does not open Obstruction inside valve Clear/remove any obstructions
Degraded or inadequate lubrication Clean and relubricate appro-
priately
Blockage of the air vent Clear air vent
Faulty pilot valve Check/replace pilot valve
Valve does not close Inadequate air supply pressure Ensure there is at least mini-
mum pressure of 4000 hPa
Kink or blockage in pneumatic sup-
ply line or inlet fitting
Clear or replace line
Faulty pilot valve Check/replace pilot valve
Pneumatic air cylinder piston o-ring
leak
Replace piston o-ring
Piston stem seal leak Replace piston stem seal
Valve does not seal ade-
quately
O-ring is defective or contaminated Clean/replace o-ring
Valve is not closing fully Refer to section above regard-
ing valve not closing
Process contamination has caused
seal degradation
Replace seal(s)
Vacuum system will not
pump down to ultimate pres-
sure
Leaks due to damage of flanges or
o-rings
Repair flanges/replace o-rings
Valve body leaks due to severe
bending moments during installation
Look for signs of deformation
or cracking
Ambient air leak due to damaged
bellows
Check/replace bellows
Position indicators not send-
ing signals
Valve not opening or closing fully Refer to sections above re-
garding valve not opening or
closing
Sensor cable not connected properly Ensure cable is connected
Position indicator is broken or needs
replacement
Replace position indicator
Tbl. 5: Troubleshooting the valve
Malfunctions
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