VAT 25740-QE99-0001 User manual

Translation of
Installation- Operating-
and Mounting Instruction
Quick Shut-off Valve
25740-QE99-0001
DN 100 mm / I.D. 4"
1079948EA

PUBLICATION DETAILS
1079948EA 2
Publication details
Manufacturer
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Website: www.vatvalve.com
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
© VAT Vakuumventile AG 2020
No part of these instructions may be reproduced in any way (photocopies, microfilms or any other
method of reproduction) nor may it be duplicated or distributed using electronic systems without
written permission from VAT.
Infringements shall be liable for 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 an unlimited number of user licenses. The
VAT firmware may only be used for the permitted purposes. The creation of copies of the VAT
firmware is allowed. It is however strictly forbidden to give copies of the VAT firmware to other
people.
The use of trade names, brand names and trademarks in these instructions does not entitle third
parties to consider these names to be unprotected. This is in line with legislation relating to brands,
names and trademarks.
© 2020 All contents, in particular texts, photographs and graphics, are protected by copyright. VAT
Vakuumventile AG reserves all rights, including reproduction, publication and translation.

LIST OF CONTENTS
1079948EA iii
List of contents
1 General information .....................................................................................................................................
5
1.1 Scope of delivery....................................................................................................................................
5
1.2 Other applicable documents ..................................................................................................................
5
1.3 Typographical conventions.....................................................................................................................
5
1.3.1 Important information..................................................................................................................
5
1.3.2 Danger levels..............................................................................................................................
5
1.4 Forwarding .............................................................................................................................................
6
2 Safety.............................................................................................................................................................
7
2.1 Standards and directives........................................................................................................................
7
2.2 Intended use and purpose......................................................................................................................
7
2.3 Predictable misuse and improper use....................................................................................................
7
2.4 Operator’s obligations ............................................................................................................................
7
2.5 Staff obligations......................................................................................................................................
8
2.6 Personal protective equipment...............................................................................................................
8
2.7
Valve damage
........................................................................................................................................
8
2.7.1
Valve
contamination....................................................................................................................
8
2.8 Product handling ....................................................................................................................................
9
2.8.1 Unsuitable packaging..................................................................................................................
9
3 Technical data...............................................................................................................................................
10
3.1
Valve
.......................................................................................................................................................
10
4
Design and function
................................
................................
................................
................................
.....
11
4.1 Type label...............................................................................................................................................
11
4.2
Valve structure
.......................................................................................................................................
11
4.3 Function of the quick shut-off valve........................................................................................................
12
5 Start valve operation....................................................................................................................................
13
5.1 Unpacking ..............................................................................................................................................
13
5.2
Valve installation
....................................................................................................................................
13
5.3 Installation position.................................................................................................................................
13
5.4 Installation in the pump line....................................................................................................................
14
6 Troubleshooting ...........................................................................................................................................
15
6.1 Shut-off valve without drive unit.............................................................................................................
15
7 Maintenance..................................................................................................................................................
16
7.1 Maintenance schedule ...........................................................................................................................
17
7.2 Change seal ...........................................................................................................................................
19
7.3 Cleaning seals........................................................................................................................................
20
8
Consumable and spare parts
................................
................................
................................
......................
21
8.1 Overview of spare parts .........................................................................................................................
21
8.2 Overview of auxiliary devices.................................................................................................................
21

LIST OF CONTENTS
1079948EA iv
9 Repair & Service...........................................................................................................................................
23
9.1 Fixed Price Refurbishment.....................................................................................................................
23
10 Dismantling and storage..............................................................................................................................
24
10.1
Store valve .............................................................................................................................................
24
11 Transport packaging and shipping ............................................................................................................
25
11.1
Pack and transport the valve..................................................................................................................
25
11.2
Sending returns......................................................................................................................................
25
12 Disposal.........................................................................................................................................................
26
12.1
Disposal..................................................................................................................................................
26
12.2
Hazardous materials ..............................................................................................................................
26
12.3
Returning the product.............................................................................................................................
26

GENERAL INFORMATION
1079948EA 5
General information
This document contains the original Assembly and Operating Instructions (AOI).
Scope of delivery
The scope of delivery corresponds to your order with VAT Vakuumventile AG. When you receive
your order, check it against your order list. If you find discrepancies between what was ordered and
delivered, contact VAT Vakuumventile AG. Publication details [ 2]
The scope of delivery of your order always includes the ordered product, the assembly and
operating instructions and the safety data sheet.
Other applicable documents
The following documents belong to the product and must be observed:
– Product data sheet
– Product drawings
Typographical conventions
Important information
This icon indicates important and useful information.
Danger levels
To avoid injury and equipment damage, you must observe the warning and safety information in
the instructions. The warnings describe the following danger levels:
DANGER
Situations which, if not avoided, will lead directly to death or serious injury.
WARNING
Situations which, if not avoided, could lead to death or serious injury.
CAUTION
Situations which, if not avoided, could lead to moderately serious or slight injury.
NOTICE
Situations which, if not avoided, could lead to equipment damage.
1
1.1
1.2
1.3
1.3.1
1.3.2

GENERAL INFORMATION
1079948EA 6
Forwarding
This document is part of the product and if the product is forwarded, the document must also be
forwarded to the product recipient.
If the product becomes part of a machine as a result of installation on or combination with other
parts, or by another method, this document must also be forwarded when the machine is sold. The
only circumstance in which forwarding is not required is if all relevant parts of this document are
included in the documentation accompanying the new machine. In the two latter cases, the
machine manufacturer, not the manufacturer of this product, is legally responsible for the safety
and for the content and scope of the instructions accompanying the machine.
1.4

SAFETY
1079948EA 7
Safety
Standards and directives
This product meets the requirements of the following standards and directives.
– Commissioning or proper operation of a machine containing the product is forbidden until it can
be demonstrated that the machine meets the requirements of EC Directive 2006/42/EC:
Machinery Directive; note EN 60204−1.
– The product meets the requirements of Directive 2011/65/EU RoHS 3: Restriction of
Hazardous Substances.
Intended use and purpose
This quick shut-off valve is a plate-sealed shut-off valve that reacts to pressure differences in the
vacuum system. It is meant to prevent contamination of the process chamber by media backflow.
The valve's home position, the Open position, is maintained through gravitational pull. The valve is
shifted into the Close position by increasing pressure on the pump side and the resulting media
backflow.
– The product is intended solely as a component for further use in a commercial context.
– The product may only be operated under the technical conditions described in this
documentation.
– The product may only be operated under the environmental conditions described in this
documentation. Technical data [ 10]
– Examine the product prior to use and never operate if visibly damaged.
– Never technically modify the product.
– Never operate the product if it has not been completely installed.
– Only connect and disconnect plug-in connections when not under voltage.
– Only connect and disconnect compressed air connections in an unpressurized state.
Predictable misuse and improper use
Any use of the product that does not comply with the intended use, be this intentional or negligent,
is forbidden by the manufacturer.
Operator’s obligations
The operator of the plant is responsible for observing the safety regulations. Unqualified staff
working on the product or located in danger zones can cause risks that could lead to serious injury.
– Have all activities carried out by qualified staff.
– Qualified staff are those people authorized to operate devices, systems and electrical
circuits in accordance with safety standards.
– Keep unqualified staff away from danger zones.
– Make sure that everybody who works on or with the product has read and understood the
document.
– Make sure that safety information is observed.
– File this document together with the documentation of the entire plant and ensure that it can be
accessed at all times.
– This document is part of the product and must be forwarded together with the product.
– Note the relevant accident protection regulations and the recognized local safety rules.
– Provide the necessary personal protective equipment.
– Provide possibilities for ESD measures.
2
2.1
2.2
2.3
2.4

SAFETY
1079948EA 8
Staff obligations
To avoid equipment damage and injury when handling the product, staff are obliged to:
► Read the operating instructions and in particular follow the safety information.
► Note the relevant accident protection regulations and the other generally recognized safety
rules.
► Wear the necessary personal protective equipment.
Personal protective equipment
Personal protective equipment is not included in the scope of delivery.
To ensure the product is not contaminated or damaged, VAT recommends that the operator
provides at least the following personal protective equipment for work with and on the product. If
further protective clothing is required as a result of a special use of the product, the operator is
responsible for making this known.
Wear antistatic shoes
Wear protective clothing
Use gloves
Use a hairnet
Table 1: Personal protective equipment
Valve damage
Valve contamination
To ensure correct operation of the valve, we recommend implementing appropriate measures in
the vacuum system as needed to avoid process sediment as much as possible.
Personal protective equipment is not included in the scope of delivery.
► When working on and with the valve, wear clean-room gloves.
2.5
2.6
2.7
2.7.1

SAFETY
1079948EA 9
Product handling
Unsuitable packaging
Unsuitable packaging material can cause product contamination.
► Keep the original packaging material.
► Use the original packaging material during transport and storage.
► Handle the product with care.
2.8
2.8.1

TECHNICAL DATA
1079948EA 10
Technical data
Valve
Flange type ISO-K
Nominal diameter (DN) 100
Valve body leak rate [20 °C] < 1 x 10E-9 mbar ls-1
Valve seat leak rate [20 °C] < 1 x 10E-6 mbar ls-1
Pressure range (abs.) Vacuum to 1.2 bar (abs)
Differential pressure on the plate in closing
direction ≤1 bar
Conductance (laminar flow) 70 ls-1
Plate movement closing time, [ms] ≤10 ms
Triggering pressure (ΔP on plate) ≥5 mbar
Operating temperature of housing ≤200 °C
Heating and cooling rate ≤50 °C h-1
Weight 3.7 kg / 8.16 lbs
Cycles until maintenance interval recommended after each backflow event with
regular maintenance cycles
Materials
Valve housing AISI 304 (1.4301)
Plate AISI 304 (1.4301)
Housing seal FKM
Seat seal FKM
Assembly position
Assembly position Fore line installation vertical only plate facing
chamber
3
3.1

DESIGN AND FUNCTION
1079948EA 11
Design and function
Type label
The article and serial number and the order number are indicated on the product or on a type label.
Illustration 1: Type label
1 Article and serial number
2 Order number
Valve structure
1 Transport fixation device 5 Body seal
2 Screws (8x) 6 Plate
3 Flange 7 Body
4 Seat seal
1
2
4
4.1
4.2

DESIGN AND FUNCTION
1079948EA 12
Function of the quick shut-off valve
The quick shut-off valve is a passively acting non-return valve without a drive unit. The moving part
of the valve is the valve plate. It blocks backstreaming of the pump volume in case of pressure
deviations caused by leaks or a drop in pump capacity.
WARNING
Danger of burns from hot valve surface!
Serious burns on the skin.
► Let the system cool down before you perform work on it.
Open Close
4.3

START VALVE OPERATION
1079948EA 13
Start valve operation
Unpacking
If the product or packaging shows damage, then photograph the damage and the type plate
and report the damage to the VAT Service Center.
Use a blunt object to open the protective sleeves.
1. Check whether the packaging is damaged. If it is, report this to VAT.
2. Make sure that the protective sleeves are not damaged.
3. Remove the packaging material.
4. Check whether the delivered product and its components match the purchase order.
5. Check whether the product is damaged. If it is, report this to VAT.
6. Lift the product out of the packaging.
Valve installation
The valve is unpacked.
Sealing surfaces on the connection flange are not scratched.
Illustration 2: Sectional view of valve transport fixation device
1. Dismount the transport fixation device [1].
2. Remove the protective cap [2].
The transport fixation device is removed.
The valve can now be installed in your system.
Installation position
It must be ensured that the quick shut-off valve is installed vertically with the plate seat side facing
upward and in the direction of the process chamber.
5
5.1
5.2
5.3

START VALVE OPERATION
1079948EA 14
Installation in the pump line
The valve can now be installed in the pump line as illustrated in the diagram below.
Use appropriate centering rings [1] and clamping claw grips [2] during installation.
5.4

TROUBLESHOOTING
1079948EA 15
Troubleshooting
Shut-off valve without drive unit
Disruption factors usually occur due to incorrect commissioning and operation.
Error Error source Troubleshooting
Valve does not close Installation Pay attention to the mounting
position
Valve does not seal Seat seal is contaminated Pay attention to maintenance
interval
Cleaning seals [ 20]
Valve plate is contaminated Pay attention to maintenance
interval
Clean/replace valve plate
Table 2: Error table
6
6.1

MAINTENANCE
1079948EA 16
Maintenance
The maintenance intervals should be observed to ensure that the product works reliably throughout
its lifetime. The type of application may make it necessary to shorten the maintenance intervals. In
this case, the maintenance schedule must be adjusted accordingly.
In addition to the maintenance interval, the VAT Service Center also offers other services.
If you require further information about the maintenance intervals or services, please contact VAT.
7

MAINTENANCE
1079948EA 17
Maintenance schedule
For any deviating maintenance work or additional maintenance work that may be necessary, contact VAT. The VAT customer service will need the
product serial number for this. Type label [ 11].
The frequency of the maintenance intervals depends on the process conditions.
Required inspections and preventative maintenance for the service programs.
Maintenance interval Maintenance section Responsibility Maintenance
work Maintenance description
Regular inspections:
- At least every 12 months
(strong correlations to
processes)
or
- together according to pump
maintenance schedule
Recommended inspections:
- after every pump back-flow
incident.
Kunde oder VAT via FPR Optical check for
contamination.
- perform cleaning
if necessary.
Change seal [ 19]
Kunde oder VAT via FPR Optical check on
disassembled
valve
- if disassembled,
carry out cleaning
of the body parts
7.1

MAINTENANCE
1079948EA 18
Maintenance interval Maintenance section Responsibility Maintenance
work Maintenance description
Kunde oder VAT via FPR . Change valve
plate.
- if disassembled,
carry out cleaning
of the parts
Kunde oder VAT via FPR Change seat seal.
- if disassembled,
carry out
replacement
Kunde oder VAT via FPR Change body seal.
- if disassembled,
carry out
replacement

MAINTENANCE
1079948EA 19
Change seal
NOTICE
Incorrect handling of the sealing surfaces!
Improper handling may lead to damage to the sealing surfaces.
► Get qualified staff to install the product in the vacuum system.
NOTICE
Non-original spare parts and wear-sensitive parts!
If you use non-original spare parts and wear-sensitive parts, you may damage the
product.
► Only use original spare parts and wear-sensitive parts from VAT.
Illustration 3: Exploded view of quick shut-off valve
1 Transport fixation 2 Screws
3 Flange 4 Seat seal
5 Body seal 6 Valve plate
7 Body
Interface to vacuum system is disconnected.
1. Remove the screws [2]
2. Remove the flange [3].
3. Remove the valve disc [6].
7.2

MAINTENANCE
1079948EA 20
4. Clean the valve plate.
NOTICE
Damage to the plate due to abrasive cleaning methods!
Leakage at the plate.
► Use dust- and lint-free cleaning cloths.
► Use an ultrasonic bath.
5. Check the valve plate for damages.
6. Replace the valve plate if it is damaged.
7. Pull the sealing O-ring [5] oft he flange [3], out of the groove.
8. To dismantle the O-ring, use the recommended tool VAT–O-ring [ 21] assembly tool.
9. Clean the O-ring [5]. Replace the O-ring [5] if obvious damage is evident.
10. Reinstall the O-ring [5] into the groove oft he flange [3].
11. Pull the seat seal [pos. 4] out of the groove of the body [7].
12. Clean the O-ring [4]. Replace the O-ring [4] if obvious damage is evident.
13. Reinstall the O-ring [4] of the valve seat into the groove of the body [7].
14. Reinstall the valve plate [6].
15. Mount the flange [3] and the body [7] together.
16. Mount the flange [3] with the screws [2].
17. Tighten the screws [2] with torque 3.4Nm / 2.5ft lb.
18. Reinstall the valve in your system.
The gasket set has been replaced.
Cleaning seals
1. Clean the sealing surfaces using a lint-free and dust-free cloth and a little isopropanol.
2. Clean the O-ring using a lint-free and dust-free cloth.
7.3