VAT 192 Series Assembly instructions

Installation, Operating &
Maintenance Instructions
600246EA
Edition
2018
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08
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22
Large HV / UHV gate valve
with double acting pneumatic actuator
Series 191 / 192
DN 900 – 1250 mm (I. D. 36" – 50")
This manual is valid for the following product ordering numbers:
19159- . E14 / 24 / 34 / 44
19160- . E14 / 24 / 34 / 44
19162- . E14 / 24 / 34 / 44
19259- . E14 / 24 / 34 / 44
19260- . E14 / 24 / 34 / 44
19262- . E14 / 24 / 34 / 44
Sample picture
1Sealingsurface

Series 191 /
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Imprint
Manufacturer
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Website:
Phone:
Fax:
Email:
www.vatvalve.com
[phone]
[phone]
[email protected]
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 2018
No part of these Instructions may be reproduced in any way (photo-
copies, 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.

Series 191 / 192
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Contents
1 Description of product........................................................................4
1.1 Identification of product.......................................................................................4
1.2 Use of product.....................................................................................................4
1.3 Related documents.............................................................................................4
1.4 Important information..........................................................................................4
1.5 Technical data.....................................................................................................4
2 Safety ...................................................................................................5
2.1 Compulsory reading material..............................................................................5
2.2 Danger levels......................................................................................................5
2.3 Personnel qualifications......................................................................................6
2.4 Safety labels........................................................................................................6
3 Design and Function...........................................................................7
3.1 Design.................................................................................................................7
3.2 Function ..............................................................................................................7
4 Installation...........................................................................................8
4.1 Unpacking ...........................................................................................................8
4.1.1 Unpacking of the valve ...........................................................................8
4.2 Installation into the system..................................................................................9
4.2.1 Admissible forces and bending moments.............................................11
4.3 Compressed air connection ..............................................................................12
4.4 Electrical connection.........................................................................................12
5 Operation...........................................................................................13
5.1 Normal operation...............................................................................................13
5.2 Operation under increased temperature...........................................................13
5.3 Behavior in case of compressed air pressure drop ..........................................13
5.4 Behavior in case of power failure......................................................................13
5.4.1 Manual emergency operation...............................................................13
5.5 Trouble shooting ...............................................................................................15
6 Maintenance ......................................................................................16
6.1 Maintenance intervals.......................................................................................16
6.2 Required tools...................................................................................................16
6.3 Replacement of valve gate / mechanism unit...................................................17
7 Repairs...............................................................................................19
8 Dismounting and Storage.................................................................20
8.1 Dismounting ......................................................................................................21
8.2 Storage..............................................................................................................21
9 Packaging and Transport.................................................................22
9.1 Packaging .........................................................................................................23
9.2 Transport...........................................................................................................23
10 Disposal.............................................................................................24
11 Spare parts ........................................................................................25

DESCRIPTION OF PRODUCT Series 191 /
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1 Description of product
1.1 Identification of product
The fabrication number and order number are fixed on the product directly or by means of
an identification plate.
made in Switzerland
Fabrication No.:
19 . . .- . . . .- . . . ./ . . . .
A - . . . . . .


Fabrication number
Order number
1.2 Use of product
Use product for clean and dry vacuum applications only. Other applications are only allowed
with the written permission of VAT.
1.3 Related documents
•Product data sheet
•Dimensional drawing
1.4 Important information
This symbol points to a very important statement that requires particular
attention.
Example
:
VAT disclaims any liability for damages resulting from inappropriate packaging.
1.5 Technical data
See product data sheet and dimensional drawing.

Series 191 / 192 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.
These Installation, Operating & Maintenance Instructions are an integral part
of a comprehensive documentation belonging to a complete technical
system. They 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 Series 191 /
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2.3 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.
2.4 Safety labels
Label Part No. Location on valve
T-9001-156 Protective cover
Table 2-1

Series 191 / 192 DESIGN AND FUNCTION
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3 Design and Function
3.1 Design
1 Sealing surface
2 Body lower part
3 Body upper part
4 Actuator
Figure 3-1
3.2 Function
The valve features the VATLOCK sealing technology. This means, the valve is mechani-
cally locked in the closed position. In the open position, the mechanism is not locked. Leaf
springs hold gate and counter plate against the carriage with the ball retainers. The ball
pairs are in the detents. For closing, the mechanism is moved forward into the closing
position. The locking starts after the leaf spring stop touches the body. The ball retainers
move the ball pairs out of the detents. Gate and counter plate are spread apart. The gate
seal is pressed against the sealing surface without scuffing. The arrangement of the ball
pairs ensures an increase of the sealing force with vacuum on either side of the gate.
During opening the movements proceed in the reverse order; see «Figure 3-2».
1 Valve gate
2 Counter plate
3 Leaf springs
4 Ball pairs
5 Ball detents
6 Gate seal
7 Spring stop
Figure 3-2
1
3
2
4
7
5
2
1
3
6
4

INSTALLATION Series 191 /
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4 Installation
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
WARNING
Heavy weight
Physical overstraining.
Use a crane to lift the product.
4.1 Unpacking
•
Make sure that the supplied products are in accordance with your order.
•Inspect the quality of the supplied products visually. If it does not meet
your requirements, please contact VAT immediately.
•Store the original packaging material. It may be useful if products must be
returned to VAT.
The valve can be lifted only at the five eyebolt threats;
see «Figure 4-1» below.
4.1.1 Unpacking of the valve
a) Open wooden case
b) Remove wooden bars inside
c) On the valve you will find M30 eye bolts. Lift the valve out of the wooden box by attaching the lifting
strips onto these M30 eye-bolts.

Series 191 / 192 INSTALLATION
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1 Load rings for
valve lifting
Figure 4-1
d) Make sure that the valve is in the closed position and locked
e) Lift the valve out of the wooden case.
Important: Air cylinder is under pressure for transport protection. First, air has to be released from the
cylinder by opening the air valve fitting Pos.73. See the picture bellow.
4.2 Installation into the system
WARNING
Movable parts
Human body parts may get jammed and severely injured.
Do not connect or supply electrical power and compressed air before the
product is completely mounted in the system.

INSTALLATION Series 191 /
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NOTICE
Contamination
Product may get contaminated.
Always wear cleanroom gloves when handling the product.
NOTICE
Inappropriate tools
Sealing surfaces may get damaged.
Do not use sharp-edged tools.
NOTICE
Wrong tightening torque
Valve body and screws may get damaged.
Use tightening torque according the size of the screws.
NOTICE
Too long screws
Valve body may get deformed and / or malfunctions may occur.
Use only screws recommended by VAT.
1. Remove protective covers from body flanges.
2. Clean sealing surfaces and seals of both flanges;
see (1) and (2) according to «Figure 4-2» on page 11.
The valve seat side is marked with the symbol «∇» on flange «A».
3. Lift the valve to the mounting position, use only the Load rings; see «Figure 4-1» on
page 9.
4. Mount the four screws (3) according to «Figure 4-2» on page 11, evenly in crosswise
order until the seal touches the sealing surface.
5. Tighten all screws with the torques appropriate for their property classes.

Series 191 / 192 INSTALLATION
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1 Flange A
2 Flange B
3 Screws
Figure 4-2
4.2.1 Admissible forces and bending moments
Forces from evacuating the system, from the weight of other components or
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; see «Table 4-1»
below.
The following forces or bending moments are admissible:
DN (nom. I.D.) Axial tensile or com-
pressive force «FA» Bending moment «M»
mm inch N lbf Nm lbf ·ft
900 36 9800 2200 1274 940
1000 40 9800 2200 1372 1015
1250 50 9800 2200 1470 1090
If a combination of both forces («FA» and «M») occurs, the values
mentioned above are invalid. Please contact VAT for more
information.
Table 4-1
1
2
3
F
A M

INSTALLATION Series 191 /
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4.3 Compressed air connection
WARNING
Valve in open position
Risk of injury when compressed air is connected to the valve.
Connect compressed air only when:
– valve is installed in the vacuum system
– moving parts cannot be touched
Use clean, dry or slightly oiled air only.
Admissible air pressure range, see product data sheet.
1. Connect compressed air according to the product data sheet and dimensional drawing.
4.4 Electrical connection
DANGER
Electric shock
Parts being under voltage will result in serious injury or death.
Do not touch parts being under voltage.
NOTICE
Wrong voltage
Electrical components may get damaged.
Supply electrical components with the correct voltage.
1. Connect solenoid valve according to the product data sheet and dimensional drawing.
2. Connect position indicator according to the product data sheet and dimensional
drawing.

Series 191 / 192 OPERATION
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5 Operation
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
WARNING
Movable parts
Human body parts may get jammed and severely injured.
Do not operate before product is installed completely into the vacuum system.
5.1 Normal operation
Valve is opened and closed pneumatically.
5.2 Operation under increased temperature
Maximum allowed temperature, see product data sheet.
5.3 Behavior in case of compressed air pressure drop
See product data sheet.
5.4 Behavior in case of power failure
See product data sheet.
5.4.1 Manual emergency operation
WARNING
Movable parts
Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.

OPERATION Series 191 /
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Standard solenoid valve
To close the valve: Turn the slotted screw (1) counter-clockwise to its stop.
To open the valve: Turn the slotted screw (1) clockwise to its stop.
1 Slotted screw
Figure 5-1
For remote operation make sure that the slotted screw is turned counter-
clockwise
to its stop.
Impulse solenoid valve
To close the valve: Turn the slotted screw (3) – coil CLOSE – clockwise to its stop.
As soon as valve is closed, turn screw back to its original position.
To open the valve: Turn the slotted screw (2) – coil OPEN – clockwise to its stop.
As soon as valve is ope
n, turn screw back to its original position.
1 Coil OPEN
2 Slotted screw of coil OPEN
3 Slotted screw of coil CLOSE
4 Coil CLOSE
Figure 5-2
For remote operation make sure that both slotted screws are turned counter-
clockwise to their stop (original position).
1 2
3 4

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5.5 Trouble shooting
Failure Check Action See
Valve does not
close / open Air pressure Connect compressed air «4.3 Compressed air connection»
Operating
pressure Adjust operating pressure Product data sheet
Voltage at
solenoid valve Connect voltage «4.4 Electrical connection»
Leak at gate Gate seal all
right? Replace valve gate «6.3 Replacement of valve gate / mechanism unit»
Gate damaged or
contaminated? Replace valve gate «6.3 Replacement of valve gate / mechanism unit»
Operating
pressure Adjust operating pressure Product data sheet
Leak at body Bonnet seal and
sealing surface all
right?
Clean sealing
surface, if
necessary,
replace bonnet
seal
«6.3 Replacement of valve
gate / mechanism unit»
Bellows all right? Contact VAT www.vatvalve.com
Table 5-1
If you need any further information, please contact one of our service centers. You will find
the addresses on our website www.vatvalve.com.

MAINTENANCE Series 191 /
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6 Maintenance
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
WARNING
Heavy weight
Physical overstraining.
Use a crane to lift the valve insert.
WARNING
Hazardous components
Human body parts may get jammed and severely injured.
Before starting maintenance:
– disconnect compressed air supply
– disconnect electrical power supply
WARNING
Movable parts
Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.
6.1 Maintenance intervals
Under clean operating conditions the valve does not require any maintenance during 10 000
cycles; see product data sheet. After these cycles, VAT recommends replacing the
mechanism unit; see chapter «6.3 Replacement of valve gate / mechanism unit».
For more information or a general overhaul please contact one of our service centers. You
will find the addresses on our website www.vatvalve.com.
6.2 Required tools
•Torque wrench
•Cleanroom wiper soaked with alcohol (2% methyl ethyl ketone)

Series 191 / 192 MAINTENANCE
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6.3 Replacement of valve gate / mechanism unit
WARNING
Loaded spring steel sheet
Human body parts may get jammed and severely injured.
Do not put human body parts between valve gate and spring steel sheet.
NOTICE
Contamination
Product may get contaminated.
Always wear cleanroom gloves when handling the product.
NOTICE
Inappropriate tools
Sealing surfaces may get damaged.
Do not use sharp-edged tools.
1. Vent chambers on either side to atmospheric pressure.
2. Open the valve.
3. Disconnect compressed air supply.
4. Disconnect electrical power supply.
5. Remove the screws (3) from the body cover (7) in crosswise order; see «Figure 6-1» on
page 18.
6. Lift actuator / mechanism unit carefully from body without touching the body wall.
Do not touch the actuator with the lifting ropes, if you lift the actuator +
mechanism out of the valve body!
7. If the mechanism unit is out of the valve body you have the opportunity to clean the
mechanism unit with alcohol.
8. If the plate seal at the mechanism unit and the bonnet seal (4) are not damaged you
should clean them with cleanroom wiper.
Do not clean the Sealing with alcohol, because alcohol may damage the
surface of the Sealing, by O-ring sealing, we recommend to treat it with a
small amount of vacuum grease.
9. Lift the actuator / mechanism unit back into the valve body.

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10. Tighten the screws (3) from the body cover (7) according the sealing technology with
the correct tightening torque.
11. Connect electrical power supply.
12. Connect compressed air supply.
13. Close the valve.
1 Lifting ropes
2 Load ring
3 Screws / Pins
4 Bonnet seal
5 Body lower part
6 Bearings
7 Body upper part
Figure 6-1
Valve is ready for use.
1
2
3
4
5
6
7

Series 191 / 192 REPAIRS
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7 Repairs
Repairs may only be carried out by the VAT service staff. In exceptional cases, the
customer is allowed to carry out the repairs, but only with the prior consent of VAT.
Please contact one of our service centers. You will find the addresses on our website
www.vatvalve.com.

DISMOUNTING AND STORAGE Series 191 /
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8 Dismounting and Storage
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
WARNING
Heavy weight
Physical overstraining.
Use a crane to lift the product.
WARNING
Hazardous components
Human body parts may get jammed and severely injured.
Before dismounting the product
– disconnect compressed air supply
– disconnect electrical power supply
WARNING
Movable parts
Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.
NOTICE
Contamination
Product may get contaminated.
Always wear cleanroom gloves when handling the product.