VAT 48 Series Assembly instructions

Installation, Operating &
Maintenance Instructions
288914ED
Edition 2013-05-24
All-metal gate valve
with compact or extended pneumatic actuator
Series 48
DN 16–320 mm (I.D. ⅝"–12")
This manual is valid for the following product ordering numbers:
With compact actuator
With extended actuator
48146- . E7 . - ....
48148- . E7 . - ....
48150- . E7 . - ....
48236- . E7 . - ....
48240- . E7 . - ....
48244- . E7 . - ....
48124- . E .. - ....
48132- . E .. - ....
48146- . E .. - ....
48148- . E .. - ....
48150- . E .. - ....
48236- . E .. - ....
48240- . E .. - ....
48244- . E .. - ....
Sample pictures
-1

Series 48
2/27
Edition 2013-05-24
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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 2013
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 48
288914ED
Edition 2013-05-24
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Contents
1Description 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
2Safety ...................................................................................................5
2.1 Compulsory reading material..............................................................................5
2.2 Danger levels......................................................................................................5
2.3 Personnel qualifications......................................................................................6
2.4 Safety labels........................................................................................................6
3Design and Function...........................................................................7
3.1 Design.................................................................................................................7
3.2 Function ..............................................................................................................8
4Installation...........................................................................................9
4.1 Unpacking...........................................................................................................9
4.2 Installation into the system................................................................................10
4.2.1 Preparation for installation.....................................................................11
4.2.2 Mounting to the system .........................................................................12
4.3 Compressed air connection..............................................................................13
4.4 Electrical connection.........................................................................................14
5Operation...........................................................................................15
5.1 Normal operation...............................................................................................15
5.2 Operation under increased temperature...........................................................16
5.3 Bake-out............................................................................................................17
5.4 Behavior in case of air pressure drop...............................................................17
5.5 Behavior in case of power failure......................................................................17
5.5.1 Manual emergency operation................................................................17
5.6 Trouble shooting ...............................................................................................19
6Maintenance ......................................................................................20
6.1 Maintenance intervals.......................................................................................20
7Repairs...............................................................................................21
8Dismounting and Storage.................................................................22
8.1 Dismounting......................................................................................................23
8.2 Storage..............................................................................................................23
9Packaging and Transport.................................................................24
9.1 Packaging .........................................................................................................25
9.2 Transport...........................................................................................................25
10 Disposal.............................................................................................26
11 Spare parts ........................................................................................27

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.:
48..-....-..../....
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.
Weights of standard valves:
DN 16: 4 kg
DN 40: 7.5 kg
DN 63: 16 kg
DN 100: 27 kg
DN 160: 45 kg
DN 200: 87 kg
DN 250: 157 kg
DN 320: 233 kg
Weight of special valves, see product data sheet.

Series 48
SAFETY
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Edition 2013-05-24
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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
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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.
Label size
(mm)
Location on valve
DN 16–100: T-9001-155
DN 160–320: T-9001-156
20 × 20
80 × 80
On protective
covers of flanges

Series 48
DESIGN AND FUNCTION
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Edition 2013-05-24
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3 Design and Function
3.1 Design
With compact actuator:
type 48 ... - . E7 . - ....
With extended actuator:
type 48 ... - . E .. - ....
Figure 3-1
1 Actuator
2 Valve body
3 Connecting flange
4 Sealing surface
5 Distance piece
1
2
4
3
435452
1
2
4
5
3
435452

DESIGN AND FUNCTION
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3.2 Function
Valve is closed and opened pneumatically.
Closing: The valve mechanism moves towards the valve opening until it touches the
mechanical stop (4). Due to continued pressure, valve gate (1) and counter plate (2) spread
apart and effect leaktight closing.
Opening: Valve gate (1) and counter plate (2) are retracted and valve mechanism moves
back into the valve body.
OPEN
CLOSED
Figure 3-2
1 Valve gate
2 Counter plate
3 Guide plate
4 Spring stop
5 Leaf spring
6 Support
7 VATRING
Valve seat side

Series 48
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.
Open the plastic bag protecting the valve only at the points where you need
access to the eyebolts (1) for fastening the crane hooks; see «Figure 4-1» on
page 10. Keep valve in the plastic bag until it is being installed into the
system.
NOTICE
Wrong lifting
Valve may crash and get damaged.
Use only the eyebolts shown in the dimensional drawing and in «Figure 4-1»
on page 10 to lift the valve. Using any other components (e. g. position
indicators, solenoids) to lift the valve is strictly forbidden.
NOTICE
Sensitive product
Valve parts may get damaged.
–When lifting the valve, pay attention that the valve does not touch any solid
objects.
–Lift valve carefully and put it down on a clean surface or mount it to a clean
system.

INSTALLATION
Series 48
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Use a crane for lifting valve DN100 and higher out of the transport box; see «Figure 4-1».
Weight of standard valves; see chapter «1.5 Technical data».
1 Eyebolts
2 Lifting ropes
A Valve movement
direction
B Support required
to stabilize the
valve
Figure 4-1
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
Force effect from other components of the system
Valve body may get deformed and/or malfunctions may occur.
–Do not use valve to support other components.
–Make sure that forces from other components do not impair the valve;
use bellows sections, for instance.
1
2
A
B

Series 48
INSTALLATION
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Edition 2013-05-24
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4.2.1 Preparation for installation
WARNING
Danger of injury in case of insufficient skills
Inappropriate handling may cause serious injury or property damage.
Make sure that the valve does not topple or fall down while removing the
protective covers from the flanges.
NOTICE
Sensitive product
Valve parts may get damaged.
When removing the protective covers from the flanges, be careful to avoid
damage to the valve.
1. Remove plastic bag.
2. Remove screws (2) and protective covers (3); see «Figure 4-2».
3. Remove O-rings (4).
1 Eyebolts to fasten
the crane hooks
2 Screws (quantity
depends on valve
size)
3 Protective covers
4 O-rings
Figure 4-2
Store screws, protective covers and O-rings. They may be useful when valve
needs to be repacked.
2
3
43
1

INSTALLATION
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4. Clean sealing surfaces; see «Figure 3-1» on page 7, with a cleanroom wiper soaked
with pure alcohol (Isopropanol).
5. Clean surface with clean, oil free compressed air.
4.2.2 Mounting to the system
The valve seat side is marked with the symbol «» on flange «A»;
see «Figure 4-3».
1. Mount valve to your system by using appropriate flange screws
(different quantity of screws required –depending on valve size).
2. Initially, mount four screws evenly in crosswise order until the seal touches the sealing
surface.
3. Afterwards, mount all screws evenly in crosswise order.
4. Tighten all screws with the torques appropriate for the property classes of the screws.
1 Flange B
2 Flange A
3 Marking for valve seat side
(symbol «»)
4 Screw holes
Figure 4-3
1
4
2
3
435452

Series 48
INSTALLATION
288914ED
Edition 2013-05-24
13/27
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
NOTICE
Wrong sequence of connections
Valve mechanism may get damaged when electrical power is being
connected before compressed air is connected.
Always connect compressed air before connecting electrical power.
Use clean, dry or slightly oiled air only.
Admissible air pressure range, see product data sheet.
1. Connect compressed air according the specification on the product data sheet and
specification on the pneumatic connectors.
Ordering numbers:
compact:
48 ... - . E72
48 ... - . E74
extended:
48 ... - . E24
48 ... - . E44
with position indicator, without solenoid
with position indicator, with solenoid
with position indicator, without solenoid
with position indicator, with solenoid

INSTALLATION
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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 sequence of connections
Valve mechanism may get damaged when electrical power is being
connected before compressed air is connected.
Always connect compressed air before connecting electrical power.
NOTICE
Wrong voltage
Electrical components may get damaged.
Supply electrical components with the correct voltage.
1. Connect position indicator according to product data sheet.
2. Connect solenoid according to wiring diagram on product data sheet and specification
on solenoid coil.
Ordering numbers:
compact:
48 ... - . E72
48 ... - . E74
extended:
48 ... - . E24
48 ... - . E44
with position indicator, without solenoid
with position indicator, with solenoid
with position indicator, without solenoid
with position indicator, with solenoid

Series 48
OPERATION
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Edition 2013-05-24
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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 closed and opened pneumatically.
For technical details, see product data sheet.
Action
Solenoid
Procedure
To open
the valve
Without solenoid
48 ... - . E14- ....
48 ... - . E24- ....
48 ... - . E72- ....
At first, supply admissible compressed air to
connection CLOSE.
Afterwards, supply admissible compressed air to
connection OPEN and release air through
connection CLOSE.
Standard solenoid
48 ... - . E44- ....
48 ... - . E74- ....
Supply admissible compressed air to connection
OPEN/CLOSE (PORT 1).
Supply voltage (observe voltage specification on coil)
to connection SV.
Impulse solenoid
(option)
48 ... - . E44-xxxx
48 ... - . E74-xxxx
xxxx = option code
Supply admissible compressed air to connection
OPEN/CLOSE (PORT 1).
Supply a voltage impulse (observe voltage
specification on coil) to connection SV OPEN.
Impulse must last for at least 50 ms.
Table 5-1

OPERATION
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Action
Solenoid
Procedure
To close
the valve
Without solenoid
48 ... - . E14- ....
48 ... - . E24- ....
48 ... - . E72- ....
At first, supply admissible compressed air to
connection OPEN.
Afterwards, supply admissible compressed air to
connection CLOSE and release air through
connection OPEN.
Standard solenoid
48 ... - . E44- ....
48 ... - . E74- ....
Supply admissible compressed air to connection
OPEN/CLOSE (PORT 1).
Release voltage from connection SV.
Impulse solenoid
(option)
48 ... - . E44-xxxx
48 ... - . E74-xxxx
xxxx = option code
Supply admissible compressed air to connection
OPEN/CLOSE (PORT 1).
Supply a voltage impulse (observe voltage
specification on coil) to connection SV CLOSE.
Impulse must last for at least 50 ms.
Table 5-2
5.2 Operation under increased temperature
Maximum allowed temperature, see product data sheet.
NOTICE
Inconstant temperatures
Performance of the valve may deteriorate.
–Actuate valve only after the bake-out temperature has been stable for two
hours.
–If valve must be actuated during bake-out, make sure that the heating or
cooling rate does not exceed 10 °C per hour in the temperature range
from 100 °C to 200 °C (version with compact actuator).
from 100 °C to 300 °C (version with extended actuator).
–Make sure that the temperature differences over the whole body do not
exceed 30 °C.

Series 48
OPERATION
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Edition 2013-05-24
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5.3 Bake-out
Inside under vacuum pressure 10-5 mbar to prevent oxidation.
compact
extended
Valve:
≤200 °C in open and
closed position
≤300 °C in open and
closed position
Actuator:
standard:
≤ 200 °C for max.100 h *
≤ 200 °C for max.100 h *
option: 106 Gy (108 rad)
≤ 140 °C for max.100 h *
≤ 140 °C for max.100 h *
option: 108 Gy (1010 rad)
≤ 200 °C *
≤ 200 °C *
Position
indicator:
standard:
≤ 80 °C
≤ 80 °C
option: 200 °C
≤ 200 °C
≤ 200 °C
Solenoid:
≤80 °C
≤80 °C
Heating and cooling rate:
DN 16–40
DN 63–160
DN 200–320
–
≤ 50 °C / h
≤ 25 °C / h
≤ 80 °C / h
≤ 50 °C / h
≤ 25 °C / h
Table 5-3
*Applied high temperatures and radiation exposure are weakening the sealing materials of
the actuator. A combination of both will shorten the lifetime.
5.4 Behavior in case of air pressure drop
Valve closed:
Valve remains closed and leaktight.
Valve open:
Valve position is undefined.
Option –actuator mechanically locked in position open:
Valve remains open.
5.5 Behavior in case of power failure
Standard solenoid:
Valve closes.
Impulse solenoid (option):
Valve position does not change. A started movement will
continue to the end.
5.5.1 Manual emergency operation
WARNING
Movable parts
Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.

OPERATION
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The solenoids are provided with manual emergency operation (slotted screw). This screw
allows actuating the valve in case of a power failure. Compressed air must be supplied!
Standard solenoid
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
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 open, 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).

Series 48
OPERATION
288914ED
Edition 2013-05-24
19/27
5.6 Trouble shooting
Failure
Check
Action
See
Valve
mechanism does
not move
Air pressure
Connect
compressed air
«4.3 Compressed air
connection»
Electrical power
Connect electrical
power
«4.4 Electrical
connection»
Operating
pressure
Adjust operating
pressure
«4.3 Compressed air
connection»
Position of
slotted screw
Turn slotted screw to
the correct position
«5.5.1 Manual emergency
operation»
Leak at gate
Condition of gate
seal
Please contact VAT
www.vatvalve.com
Condition of
valve gate
Please contact VAT
www.vatvalve.com
Operating
pressure
Adjust operating
pressure
«4.3 Compressed air
connection»
Leak at body
Condition of
bonnet seal and
sealing surface
Please contact VAT
www.vatvalve.com
Condition of
bellows
Please contact VAT
www.vatvalve.com
Whistling sound
during opening
or closing
–
No action required
when valve is actu-
ated at atmosphere
–
–
No action required
when valve is actu-
ated in vacuum as
long as the sound is
not excessive
–
Table 5-4
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 48
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Edition 2013-05-24
288914ED
6 Maintenance
6.1 Maintenance intervals
Under clean operating conditions the valve does not require any maintenance during the
specified life cycle.
Impacts from the process may require more frequent maintenance.
When the valve has reached the specified life cycle; see product data
sheet, we recommend to have it serviced by VAT. Please contact your
nearest VAT service center to get recommendations and an offer. You will
find the addresses on our website www.vatvalve.com.