VAT 244 Series Assembly instructions

Installation, Operating &
Maintenance Instructions
288231
ED
Edition
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Vacuum angle valve
with double acting pneumatic actuator
Series 244
DN 200 – 1000 mm (I. D. 8” – 40”)
This manual is valid for the following product ordering numbers:
244 .. - …. - ….
Sample picture

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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 2015
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 244
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Contents
1 Description of product........................................................................5
1.1 Identification of product.......................................................................................5
1.2 Use of product.....................................................................................................5
1.3 Related documents.............................................................................................5
1.4 Important information..........................................................................................5
1.5 Technical data.....................................................................................................5
2 Safety ...................................................................................................6
2.1 Compulsory reading material..............................................................................6
2.2 Danger levels......................................................................................................6
2.3 Personnel qualifications......................................................................................7
2.4 Safety labels........................................................................................................7
3 Design and Function...........................................................................8
3.1 Design.................................................................................................................8
3.2 Function ..............................................................................................................8
4 Installation...........................................................................................9
4.1 Unpacking ...........................................................................................................9
4.2 Installation into the system................................................................................11
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
5.5 Trouble shooting ...............................................................................................13
6 Maintenance ......................................................................................14
6.1 Maintenance intervals.......................................................................................15
6.2 Required tools...................................................................................................15
6.3 Replacement of vacuum seals..........................................................................15
6.3.1 Dismount actuator / plate assembly......................................................15
6.3.2 Replacement of plate seal ....................................................................16
6.3.3 Mount actuator / plate assembly...........................................................16
6.4 Replacement of shaft feedthrough seal and pneumatic seals..........................16
7 Repairs...............................................................................................18
8 Dismounting and Storage.................................................................19
8.1 Dismounting ......................................................................................................20
8.2 Storage..............................................................................................................20
9 Packaging and Transport.................................................................21
9.1 Packaging .........................................................................................................22
9.2 Transport...........................................................................................................22

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10 Disposal............................................................................................. 23
11 Spare parts........................................................................................ 24

Series 244 DESCRIPTION OF PRODUCT
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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.:
244 . .- . . . .- . . . ./ . . . .
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.

SAFETY Series 2
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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.

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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-9001-155 On protective foil covering
the valve opening
Table 2-1

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3 Design and Function
3.1 Design
1 Plate seal
2 Shaft feedthrough
3 Bonnet seal
Valve seat side
Figure 3-1
100%Zuhn
3.2 Function
Valve opens and closes pneumatically.

Series 244 INSTALLATION
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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 protective covers may only be removed immediately before the valve is
mounted into the system. Unprotected sealing surfaces must be treated with
care and keep clean.
The valve can be lifted only at the eyebolts;
see dimensional drawing.

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NOTICE
Sensitive product
Product will get damaged if not handled carefully.
Handle product with care: Do not touch solid objects when lifting the product.
1. Lift valve carefully with lifting ropes at the two eyebolts (1); see «Figure 4-1».
Weight of product, see product data sheet.
Put it down on a clean surface or mount it to a clean system.
1 Eyebolts
2 Lifting ropes
Figure 4-1
2
1
1

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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.
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.
4.2.1 Admissible forces and bending moments
DN (nom. I.D.) Axial tensile or com-
pressive force «F
A
» Bending moment «M»
mm inch N lbf Nm lbf ·ft
200 8 500 112 64 47
250 10 700 157 85 62
320 12.5 1000 225 250 180
400 16 2000 450 580 427
500 20 2000 450 680 501
630 25 2500 562 1050 774
800 31.5 3000 674 1500 1106
1000 40 3000 674 1800 1327
A combination of both forces «F
A
» and «M» is prohibited. Please contact VAT for more
information.
Table 4-1

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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 244 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 opens and closes pneumatically.
5.2 Operation under increased temperature
Maximum allowed temperature; see product data sheet.
5.3 Behavior in case of compressed air pressure drop
Depends on customer installation.
5.4 Behavior in case of power failure
Depends on customer installation.
5.5 Trouble shooting
Failure Check Action See
Valve does not
close / open Air pressure Connect compressed air Product data sheet
Voltage at
solenoid
valve Connect correct voltage Product data sheet and
specification on solenoid
valve
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 2
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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
Radioactive or toxic components
Health hazard.
Do not touch contaminated or toxic parts.
WARNING
Hazardous components
Human body parts may get jammed and severely injured.
Before starting maintenance:
– disconnect compressed air supply
– disconnect electrical power supply
WARNING
Heavy weight
Physical overstraining.
Use a crane to lift the product.
NOTICE
Contamination
Product may get contaminated.
Always wear cleanroom gloves when handling the product.
NOTICE
Inappropriate tools
Sealing surfaces and valve plate may get damaged.
Do not use sharp-edged tools.

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6.1 Maintenance intervals
Under clean operating conditions the valve does not require any maintenance during the
specified cycles.
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.
Contamination from the process may require more frequent maintenance.
6.2 Required tools
•Allen wrench depending on valve size
•Torque wrench according «Table 6-1» on page 16
•Cleanroom wiper soaked with alcohol (2% methyl ethyl ketone)
•O-Ring removal tool; see «Table 11-1» on page 25
Figure 6-1
6.3 Replacement of vacuum seals
6.3.1 Dismount actuator / plate assembly
The follow item numbers in brackets refer to «Figure 6-2» on page 17.
1. Remove the screws (60) uniformly and crosswise.
2. Lift pneumatic actuator (26) carefully from body by using a crane;
see chapter «4.1 Unpacking», «Figure 4-1».
3. Remove bonnet seal (62) from groove; use O-ring removal tool.

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6.3.2 Replacement of plate seal
1. Dismount actuator / plate assembly; see chapter «6.3.1 Dismount actuator / plate
assembly».
2. Remove the plate seal (61) with an O-ring removal tool.
3. Check sealing surface and clean it with alcohol (ethanol 2% methyl ethyl ketone).
4. Put new plate seal (61) on plate groove and press it crosswise into groove at 4 points.
5. Press plate seal uniformly into groove.
6. Mount actuator / plate assembly as follow chapter.
6.3.3 Mount actuator / plate assembly
1. Check and clean sealing surfaces of bonnet flange and valve seat.
2. Put bonnet seal (62) into groove.
3. Carefully insert actuator / plate assembly by using a crane.
Do not cant.
4. Fasten screws (60) uniformly and crosswise in 2 to 3 rounds with specified torques
according table below.
DN200 DN250 DN320 DN400 DN500 DN630 DN800 DN1000
20 Nm 20 Nm 40 Nm 50 Nm 50 Nm 60 Nm 60 Nm 60 Nm
Table 6-1 Admissible torques
6.4 Replacement of shaft feedthrough seal and pneumatic seals
Please contact VAT. You will find the addresses on our website www.vatvalve.com.

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26 Pneumatic actuator
60 Pneumatic actuator screws
61 Plate seal (O-ring)
62 Bonnet seal (O-ring)
Figure 6-2

REPAIRS Series 2
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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.

Series 244 DISMOUNTING AND STORAGE
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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
Radioactive or toxic components
Health hazard.
Do not touch contaminated or toxic parts.
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.

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8.1 Dismounting
NOTICE
Valve in open position
Valve body and plate may get damaged if valve is in open position.
Close the valve before dismounting the valve from the system.
1. Disconnect compressed air supply.
2. Disconnect electrical power supply.
3. Dismount valve from system.
8.2 Storage
NOTICE
Wrong storage
Inappropriate temperatures and humidity may cause damage to the product.
Valve must be stored at:
– relative humidity between 10% and 70%
– temperature between +10 °C and +50 °C
– non-condensing environment
NOTICE
Inappropriate packaging
Product may get damaged if inappropriate packaging material is used.
Always use the original packaging material and handle product with care.
1. Clean / decontaminate valve.
2. Cover all valve openings with a protective foil.
3. Pack valve appropriately, by using the original packaging material.