VAT 09.1 Series Assembly instructions

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
1/15
HV Gate Valve
with pneumatic actuator
This manual is valid for the valve ordering number(s):
09134-_E14/24/34/44
09136-_E14/24/34/44
09138-_E14/24/34/44
09140-_E14/24/34/44
09144-_E14/24/34/44
The fabrication number is indicated on each product as per the label
below (or similar):
made in Switzerland
Fabrication No.:
patented
04
091..–....–..../....
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!

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
2/15
Contents:
1Use of product .......................................................................................................................................................... 3
1.1 Technical data.................................................................................................................................................... 3
2Installation................................................................................................................................................................. 3
2.1 Unpacking.......................................................................................................................................................... 3
2.2 Installation into the system................................................................................................................................. 3
2.3 Admissible forces............................................................................................................................................... 4
2.4 Tightening torque for mounting screws on flanges ............................................................................................ 4
2.5 Compressed air connection ............................................................................................................................... 5
2.6 Electrical connection.......................................................................................................................................... 5
2.6.1 Electrical connection solenoid valve ........................................................................................................ 6
2.6.2 Electrical connection position indicator.................................................................................................... 6
3Operation.................................................................................................................................................................. 7
3.1 Normal operation................................................................................................................................................ 7
3.2 Admissible temperature ..................................................................................................................................... 7
3.3 Compressed air or power failure........................................................................................................................ 7
3.4 Power failure ...................................................................................................................................................... 7
3.5 Emergency operation at power failure ............................................................................................................... 7
4Trouble shooting....................................................................................................................................................... 8
5Maintenance & repairs.............................................................................................................................................. 8
5.1 Cleaning of the sealing surface.......................................................................................................................... 9
5.2 Exchange of gate o-ring and gliders ................................................................................................................ 10
5.3 Exchange of bellows feedthrough unit ............................................................................................................. 11
6Drawing................................................................................................................................................................... 13
7Spare parts ............................................................................................................................................................. 14
8Warranty................................................................................................................................................................. 15

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
3/15
1 Use of product
Use product for clean and dry indoor vacuum applications under the conditions indicated in chapter «Technical data» only!
Other applications are only allowed with the written permission of VAT.
1.1 Technical data
Pressure range 1 x 10-9 mbar to 1.2 bar (abs)
Differential pressure on the gate 1.2 bar in either direction
Differential pressure at opening 1.0 bar
Admissible temperature: Valve 120°C
Pneumatic actuator 80°C
Position indicator 80°C
Solenoid 50°C
Position indicator: contact rating 12 - 30 V DC, max. 500mA, max. 10W
Solenoid see tag on solenoid
2 Installation
2.1 Unpacking
Make sure, that the the delivered components are according to order. Visually check the quality of the components. If
something of the delivery is not as expected please immediately contact VAT.
Notice:
Please do not throw away the original packaging. It might be useful in a case of service to return the components to VAT
2.2 Installation into the system
The valve seat side is indicated by the symbol " " on the connection flange.
1. Clean the sealing surface and the O-ring seal of the mating flange.
2. Move the valve in the correct mounting position. ATTENTION: Do not hit the sealing surfaces during manipulation!
3. Set 2 screws in one line
4. Set two additional two screws 90° to the line which is build by the first two screws.
5. Fasten the 4 screws crosswise until the O-ring seal gets in contact with the valve sealing surface.
6. Apply all remaining screws
7. Fasten all screws gradually in crosswise order.

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
4/15
2.3 Admissible forces
Forces from evacuating the system, from the weight of other components, and from baking 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
50
2
500
112
30
22
63
21/2
1960
440
78
58
80
3
2450
560
98
72
100
4
2450
560
98
72
160
6
2940
660
147
108
If a combination of both forces («FA» and «M») occurs, the values mentioned
above are invalid. Please contact VAT for more information.
2.4 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
ISO-F
50
2
N/A
N/A
63
21/2
8 –10
6 –8
80
3
8 –10
6 –8
100
4
8 –10
6 –8
160
6
13 - 15
9 –11
Table 1

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
5/15
2. Mounting with O-ring in groove
Tighten mounting screws on the flanges uniformly in crosswise order.
Observe the maximum torque according to the grade of screws and depth of
thread you use.
2.5 Compressed air connection
Connect compressed air only if
- valve has been installed into the vacuum system
- moving parts cannot be touched
With solenoid: Connect compressed air to IN (internal thread R 1/8“, 1/8“ NPT for USA)
Without solenoid: Connect compressed air to OPEN and CLOSE (internal thread M5)
Compressed air pressure (min. - max. overpressure): 4 - 7 bar / 55 - 100 psig
Use only clean, dry or slightly oiled air!
2.6 Electrical connection
Do not touch electrical parts under voltage!
Connect electrical power only if
- valve has been installed into the vacuum system
- moving parts cannot be touched
Verify that mains voltage matches voltage stated on the solenoid! Sockets for position indicator and
solenoid are supplied with the valve.
Wire solenoid and position indicator according to the following diagrams:

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
6/15
2.6.1 Electrical connection solenoid valve
2.6.2 Electrical connection position indicator
MV = coil of solenoid
Operating voltage range 12…..30V
AC / DC (=Vb)
Max. permitted residual ripple ±10% Vb
Max. permitted switching current 500 mA
Max. permitted switching output 10 W (Ohmic load)
Response time < 0.5 ms
Max. permitted switching frequency 800 Hz
Short-circuit –proof no
Polarity-reversal protection no
Electrical connection
bn: Brown
bk: Black
bu: Blue
Ambient temperature
(cable immobile) -20 °C….+60 °C
(cable moveable) -5 °C….+60 °C
Storage temperature -20 °C +60 °C
Protection class IP65/67 according
EN 60 529
Housing Material PC, PET,
Epoxy resin
Cable material PUR
Lo :Position indicator for valve gate in open position
Lg: Position indicator for valve gate in closed position

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
7/15
3 Operation
3.1 Normal operation
Valve is opened and closed by means of compressed air.
3.2 Admissible temperature
The maximum temperatures indicated in the technical data are only valid as long as the valves is in one of the end
positions. Cycling the valve at these temperatures may reduce the cycle life of the mechanism. See “1.1 Technical data”.
3.3 Compressed air or power failure
Valve closed: valve remains closed.
Valve open: valve position is undefined.
3.4 Power failure
Standard solenoid: valve closes.
3.5 Emergency operation at power failure
In case of a power failure, the valve can be actuated manually if compressed air is available.
Standard solenoid
Press push-button: valve opens
Release push-button: valve closes

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
8/15
4 Trouble shooting
Failure
Check
Action
Valve does not open or close
Compressed air pressure
Verify compressed air pressure
Valve does not open or close
Power at solenoid
Verify electrical power
Valve is no more leak thight at seat
Check cleanliness at seat surface
Check gate O-ring
Clean the sealing surface
Exchange the gate O-ring
Valve is no more leak thight to the
outside
Check bonnet cover O-ring
Check valve flange O-rings
Check the bellows feed through
Clean/Exchange the O-ring
Clean/Exchange the O-rings
Exchange the bellows feed through
If you need any further information, please contact one of our service centers. You can find the addresses on our website:
http://www.vat.ch
5 Maintenance & repairs
Under clean operating conditions, the valve does not require any maintenance during the specified cycle life.
Contamination from the process may influence the function and requires more frequent maintenance.
Before carrying out any maintenance or repairs, please contact VAT. It has to be individually decided whether the
maintenance/repair can be performed by the customer or has to be carried out by VAT. The fabrication number on the
valve
made in Switzerland
Fabrication No.:
patented
. .
. . . . . – . . . . – . . . . / . . . .
A – . . . . . .
Fabrication number
has always to be specified.
All supplies (e. g. compressed air, electrical power) must be disconnected for removal/installation of the valve from/into
the system and for maintenance work.
Even with disconnected supply, loaded springs and/or air cushions in cylinders can be potential hazards.
Keep fingers and objects away from the valve opening!
Products returned to VAT must be free of harmful substances such as e.g. toxical, caustic or microbiological ones. If
products are radioactively contaminated, fill in the VAT form «Contamination and Radiation Report» and send it with the
product. The form is available at VAT. The maximum values indicated in the form must not be exceeded.

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
9/15
5.1 Cleaning of the sealing surface
Please wear safety glasses if you start with any maintenance work on the valve.
Move the gate valve in the open position
Disconnect the compressed air and electrical power from the gate
valve during maintenance!
Open the bonnet cover flange with a 5mm allen key.
Remove the valve insert from the valve body
Do not touch the sealing surfaces with the gate
Check the sealing surfaces for scratches and dirt inside of the body
(easy visible through the wedge design).
If necessary clean the sealing surfaces inside the valve body with an
tissue and alcohol

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
10/15
5.2 Exchange of gate o-ring and gliders
1) Vent vacuum chamber on either side of the valve.
2) Open the valve by means of compressed air.
3) Switch off compressed air and power supply.
4) Disconnect compressed air and power supply lines from the valve.
5) Remove valve insert as described in section 5.1 .
6) Clean the gate o-ring with a tissue first and proceed with the visual
inspection of the gate o-ring.
If the o-ring has scratches or if it is damaged proceed with the exchange of
the o-ring. To get the o-ring out of the groove use a compressed air pistol
right at the venting point of the groove like in the right picture. The o-ring
will move out of the groove without any damage of the o-ring groove.
Remove the o-ring from the groove and
clean the groove with alcohol.
Remove the gate gliders from the valve gate with a little tool e.g.
screwdriver.
VAT recommends that whenever the gate o-ring is changed to also change
the gliders on both sides of the gate..

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
11/15
5.3 Exchange of bellows feedthrough unit
Open the valve gate fixation
screw with a 5mm allen key
holding back the gate. Do not
twist the bellows feed through
unit.
Remove the valve gate from
the valve insert assembly. Pull
down the bellows feed
through unit from the actuator
shaft and exchange this part
with a new one.
Before mounting the new bellows feedthrough be aware about the flat
encoding sections on the actuator shaft. This flat encoding section
should orientate the valve gate later on.
Move the new bellows
feedthrough unit on the
actuator shaft until you can
see the flat encoding sections
for the valve gate, followed by
the assemble of the o-ring
onto the bellows feedthrough.
Place the gate on the top of
the shaft and turn it so that
the encoding flats on the
actuator shaft are in line with
the corresponding grooves of
the valve gate.

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
12/15
Reinstall the fixation screw
with an new O-ring and
thighten it with a 5mm torque
allen wrench.
Thighten the gate fixation
screw with the torque wrench
to the specified torque of
8Nm.
Change gate seal on the
bonnet.
Slide the gate valve insert
back into the valve body
housing. Make sure that the
gate O-ring shows towards
the seat side marking
shown on the side surface of
the body flange. Tighten the
bonnet flange screws with the
5mm allen key.

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
13/15
6 Drawing
Item
Description
Item
Description
1
Gate (SS)
9
Gate Allen screw
2
Glider
10
Solenoid valve
3
Gate o-ring
11
Valve body
4
Bellows feedthrough o-ring
12
Bonnet flange
5
Bonnet flange o-ring
13
Position indicator
6
Gate Screw o-ring
14
Bonnet Allen screw
7
Bellows feedthrough
15
Allen Screw
8
Pneumatic actuator
16
Washer

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
14/15
7 Spare parts
Please specify the fabrication number of the valve (see yellow label on valve) when ordering spare parts. This is
to ensure that the appropriate spare parts are supplied.
Part no.
Description
Position
Req.qty
Remarks
94800-R1
Solenoid Valve for DN50, 63, 80, 100 and
160
10
1
Please inform the voltage
368383
Bellows Feedthrough DN50
7
1
255572
Bellows Feedthrough DN63
7
1
253807
Bellows Feedthrough DN80 and 100
7
1
255727
Bellows Feedthrough DN160
7
1
356199
Seal Kit Vacuum DN50
2.3.4.5.6
1
Number may change if
suppled with other sealing
material than Viton. Please
double check with VAT
256696
Seal Kit Vacuum DN63
2,3,4,5,6
1
256021
Seal Kit Vacuum DN80 and 100
2,3,4,5,6
1
256031
Seal Kit Vacuum DN160
2,3,4,5,6
1
356865
Gate DN50
1
1
262443
Gate DN63
1
1
262444
Gate DN80 and 100
1
1
262445
Gate DN160
1
1

Installation, Operating & Maintenance Instructions
Series 09.1,DN 50, 63, 80, 100, 160 (I.D. 2”- 6”)
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
261261EB
2012-11-20
15/15
8 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 warranty period stated in VAT's «Terms of Sale» 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.