VAT 590 Series Assembly instructions

Installation, Operating &
Maintenance Instructions
820655EA Edition 2015-12-02
Variable leak valve DN 16 (5/8")
with integrated controller
with RS232 interface
Series 590
DN 16 mm (I.D. 5/8")
This manual is valid for the following product ordering number:
59024-.EGG-….
configured with firmware 600P.1G.21.00
Sample picture

Series
590
2/77 Edition 2015-12-02 820655EA
Imprint
Manufactur
er
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
2016
No part of these Instructions may be reproduced in any way (photocopies,
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 590
820655EA Edition 2015-12-02 3/
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Contents
1 Description of product........................................................................5
1.1 Identification of product ...................................................................................................5
1.2 Use of product.................................................................................................................5
1.3 Used abbreviations..........................................................................................................5
1.4 Related documents..........................................................................................................5
1.5 Important information.......................................................................................................5
1.6 Technical data.................................................................................................................6
1.6.1 Control and actuating unit..................................................................................6
1.6.2 Valve unit...........................................................................................................7
2 Safety ...................................................................................................8
2.1 Compulsory reading material...........................................................................................8
2.2 Danger levels ..................................................................................................................8
2.3 Personnel qualifications...................................................................................................9
3 Design and Function.........................................................................10
3.1 Design...........................................................................................................................10
3.2 Function.........................................................................................................................10
4 Installation.........................................................................................11
4.1 Unpacking .....................................................................................................................11
4.2 Installation into the system............................................................................................12
4.2.1 Installation space condition..............................................................................13
4.2.2 Connection overview........................................................................................14
4.2.3 Installation procedure.......................................................................................15
4.2.4 Admissible forces.............................................................................................15
4.2.4.1 Admissible forces at controller........................................................15
4.3 Electrical connection......................................................................................................16
4.3.1 Ground connection ..........................................................................................17
4.3.2 Sensor supply concepts...................................................................................18
4.3.3 Power and sensor connection (+24 VDC sensors)..........................................19
4.3.3.1 Sensor power wiring via controller..................................................19
4.3.3.2 Sensor power wiring external.........................................................20
4.3.4 Power and sensor connection (±15 VDC sensors) without opt. SPS module..21
4.3.4.1 Sensor power wiring via controller..................................................21
4.3.4.1 Sensor power wiring external.........................................................22
4.3.5 Service port connection ...................................................................................23
4.4 RS232 interface.............................................................................................................23
4.4.1 Settings............................................................................................................23
4.4.2 RS232 Schematics ..........................................................................................23
4.4.2.1 Configuration with switches for digital inputs..................................24
4.4.2.2 Configuration with voltage source for digital inputs ........................25
4.4.2.3 Digital inputs...................................................................................26
4.5 Initial operation..............................................................................................................27
4.5.1 Setup procedure ..............................................................................................27
4.5.2 RS232 Interface configuration .........................................................................27
4.5.3 LOGIC I/O configuration ..................................................................................29
4.5.4 Valve configuration..........................................................................................30
4.5.5 Sensor configuration........................................................................................30
4.5.6 ZERO...............................................................................................................31
4.5.7 Fixed PI upstream configuration......................................................................32
4.5.7.1 Position Limit open adjustment.......................................................33
4.6 Tuning of control performance.......................................................................................33
4.6.1 Tuning of control performance with fixed PI pressure controller......................34
4.6.1.1 Optimizing P gain and I gain...........................................................34

Series
590
4/77 Edition 2015-12-02 820655EA
4.7 RS232 interface commands ..........................................................................................37
4.7.1 RS232 command syntax..................................................................................37
4.7.2 Control commands...........................................................................................37
4.7.3 Inquiry commands............................................................................................38
4.7.4 Position Limit open (setup command)..............................................................42
4.7.5 Setup commands.............................................................................................43
4.7.5.1 Overview pressure controller..........................................................50
4.7.6 Pressure control algorithem.............................................................................51
4.7.6.1 Adaptive control algorithm (downstream) .......................................51
4.7.6.2 Fixed 1 control algorithm (default fixed PI upstream)......................53
4.7.6.3 Fixed 2 control algorithm ................................................................54
4.7.6.4 Soft pump control algorithm............................................................55
4.7.7 Error messages................................................................................................56
5 Operation........................................................................................... 57
5.1 Normal operation...........................................................................................................57
5.1.1 Local operation.................................................................................................57
5.1.2 Remote operation.............................................................................................58
5.2 Close valve....................................................................................................................58
5.3 Open valve.....................................................................................................................58
5.4 Position control..............................................................................................................59
5.5 Pressure control.............................................................................................................59
5.6 Display information........................................................................................................60
5.6.1 Power up..........................................................................................................60
5.6.2 Operation .........................................................................................................61
5.6.3 Errors...............................................................................................................61
5.6.4 Safety mode.....................................................................................................61
5.7 Operation under increased temperature........................................................................62
5.7.1 Bake-out...........................................................................................................62
5.8 Behavior during power up..............................................................................................63
5.9 Behavior during power failure........................................................................................63
5.10 Trouble shooting............................................................................................................64
6 Maintenance...................................................................................... 66
7 Repairs .............................................................................................. 67
7.1 Replacement of diaphragm............................................................................................68
8 Dismounting and Storage................................................................ 70
8.1 Dismounting...................................................................................................................70
8.2 Storage..........................................................................................................................71
9 Packaging and Transport................................................................. 72
9.1 Packaging......................................................................................................................72
9.2 Transport .......................................................................................................................73
10 Disposal............................................................................................. 74
11 Spare parts........................................................................................ 75
12 Appendix ........................................................................................... 76

Series 590 DESCRIPTION OF PRODUCT
820655EA Edition 2015-12-02 5/
77
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.
590 . .- . . . .- . . . ./ . . . .
made in Switzerland
 Fabrication 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 Used abbreviations
Abbreviation Description
CPA Control Performance Analyzer
1.4 Related documents
• Product data sheet
• Dimensional drawing
1.5 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.

DESCRIPTION OF PRODUCT Series
590
6/77 Edition 2015-12-02 820655EA
1.6 Technical data
1.6.1 Control and actuating unit
Description
Input voltage
1)
+24 VDC (±10%) @ 0.5 V pk-pk max. [connector: POWER]
Power consumption 38 W [connector: POWER]
Sensor power supply output
2)
+24 VDC / 1500 mA max. [connector: SENSOR]
Sensor input
Signal input voltage / Input resistance
ADC resolution
Sampling time
0-10 VDC / Ri>100 kΩ
0.23 mV
10 ms
[connector: SENSOR]
Ambient temperature 0 °C to +50 °C max. (<35 °C recommended)
Pressure control accuracy 5 mV or 0.1% of setpoint, whichever is greater
Position resolution / position control capability 100’000 (full stroke)
Typical closing / opening time 3.5 s
1)
Internal overcurrent protection by a PTC device.
2)
Refer to chapter «Sensor supply concepts» for details.

Series 590 DESCRIPTION OF PRODUCT
820655EA Edition 2015-12-02 7/
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1.6.2 Valve unit
Please refer to Product data sheet.

SAFETY Series
590
8/77 Edition 2015-12-02 820655EA
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.

Series 590 SAFETY
820655EA Edition 2015-12-02 9/
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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.

DESIGN AND FUNCTION Series
590
10/77 Edition 2015-12-02 820655EA
3 Design and Function
3.1 Design
mechanical position indicator
3.2 Function
The valve plate acts as a throttling element and varies the conductance of the valve opening.
Actuation is performed with a stepper motor and controller. The stepper motor/controller version
ensures accurate pressure control due to exact gate positioning.
open
closed

Series 590 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.
4.1 Unpacking
NOTICE
Physical overstraining at controller
Inappropriate handling with the valve may cause in damage of controller.
Do not place the valve on the controller panel.
NOTICE
Damage of valve and flanges
Inappropriate handling with the valve may cause in damage of controller.
Pay attention that valve and flanges don’t get damaged when the valve is lifting out of
the box and handled afterwards.
NOTICE
Contamination
Plate and other parts of the valve must be protected from contamination.
Always wear clean room gloves when handling the valve.
• 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.
1. Open the transport case and remove inside packing material as far as necessary.
2. Lift the valve carefully and place it on a clean place.
Do not remove protective foils from valve opening

INSTALLATION Series
590
12/77 Edition 2015-12-02 820655EA
4.2 Installation into the system
NOTICE
Sealing surfaces
Sealing surfaces of valve and vacuum system could be damage in case of incorrect
handling.
Only qualified personal are allowed to install the valve into the vacuum system.
NOTICE
Wrong connection
Wrong connection may result in damage of controller or power supply.
Connect all cables exactly as shown in the following descriptions and schematics.
NOTICE
Burned connector pins (spark)
Connector pins or electronic parts could damage, if plugged and unplugged under
power.
Do not plug or unplug connectors under power.
NOTICE
Contamination
Plate and other parts of the valve must be protected from contamination.
Always wear clean room gloves when handling the valve.
Mount valve to a clean system only.

Series 590 INSTALLATION
820655EA Edition 2015-12-02 13/
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4.2.1 Installation space condition
Install the valve with integrated controller with space for dismantling and air circulation
as shown in figure below.
75

INSTALLATION Series
590
14/77 Edition 2015-12-02 820655EA
4.2.2 Connection overview
System:
1 Valve
2 Process chamber
3 Gas inlet
4 Controller
5 Pressure sensor
6 Sensor cable
7 Cable to remote control unit (RS232)
8 Cable to power supply
9 Pump
Controller:
M
3
4
5
7 8
2
1
96

Series 590 INSTALLATION
820655EA Edition 2015-12-02 15/7
7
4.2.3 Installation procedure
1. Remove protection flanges only prior assembly into the vacuum system.
2. Install valve [1] into the vacuum system.
•The valve seat side is indicated by the symbol «∆» on dimensional drawing, see
also «Installation space condition».
•Do not admit higher forces to the valve than indicated under «Admissible forces».
•Make sure that enough space is kept free to do preventive maintenance work.
The required space is indicated on the dimensional drawing.
3. Install the sensor [5] according to the recommendations of the sensor manufacturer and directives
given under «Requirements to sensor connection».
4. Connect pressure sensor cable [6] to sensor and then to valve (connector: SENSOR). Refer to
chapter «Electrical connection» for correct wiring. 59024-.EGG-…. supports 1 sensor.
5. Connect valve to RS232 [7] (connector: INTERFACE). Refer to «RS232 schematics» for correct
wiring.
6. Connect power supply [8] to valve (connector: POWER). Refer to chapter «Electrical connection»
for correct wiring.
To provide power to the valve motor pins 4 and 8 must be bridged, otherwise motor
interlock is active and thevalve enters the safety mode and is not operative. Refer
also to «Safety mode».
7. Perform «Setup procedure» to prepare valve for operation.
Without performing the setup procedure the valve will not be able to do pressure
control.
4.2.4 Admissible forces
NOTICE
Force at valve body and flange
Forces from the weight of other components can lead to deformation of the valve body
and flanges.
Do not apply any force at valve body or flanges.
4.2.4.1 Admissible forces at controller
NOTICE
Force at controller
Forces from the weight of other components can lead to deformation the controller.
Do not apply any force at controller.

INSTALLATION Series
590
16/77 Edition 2015-12-02 820655EA
4.3 Electrical connection
NOTICE
Wrong connection
Wrong connection may result in damage of controller or power supply.
Connect all cables exactly as shown in the following descriptions and schematics.
NOTICE
Burned connector pins (spark)
Connector pins or electronic parts could damage, if plugged and unplugged under
power.
Do not plug or unplug connectors under power.

Series 590 INSTALLATION
820655EA Edition 2015-12-02 17/
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4.3.1 Ground connection
Recommendation for ground strap between controller and system (chassis)
Material L (Length max.) B1 (min.) B2 (min.) d1 (
∅
) d2 (
∅
)
copper
tinned 200 mm 25 mm 25 mm 4.5 mm customized
• Connection plates of ground strap must be total plane for a good electrical contact!
• The connection point at chassis (FE) must be blank metal (not coated). It is also
possible to connect the ground strap at system chamber if it is well connected to PE.
• Avoid low chassis cross section to the system PE connection. (min. same cross
section as ground strap)
Valve controller
System
Ground connection
Chassis (FE)
(Functional Earth)
B1
B2
d1 d2
L
Ground strap PE
Recommended torque: 1,3…1,7Nm

INSTALLATION Series
590
18/77 Edition 2015-12-02 820655EA
4.3.2 Sensor supply concepts
This valve offers 2 alternative concepts to supply the sensor(s) with power. This depends on the
sensor type and valve version that is used.
Concepts:
• External +24 VDC supplied to POWER connector is feedthrough to SENSOR connector to supply
24 VDC sensors. Refer to chapter «Power and sensor connection (+24 VDC sensors)» for
schematic and correct wiring.
• External ±15 VDC supplied to POWER connector is feedthrough to SENSOR connector to supply
±15 VDC sensors. Refer to chapter «Power and sensor connection (±15 VDC sensors) without
optional SPS module» for schematic and correct wiring.

Series 590 INSTALLATION
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4.3.3 Power and sensor connection (+24 VDC sensors)
4.3.3.1 Sensor power wiring via controller
• Use shielded sensor cable(s). Keep cable as short as possible, but locate it away
from noise sources.
• Connect Power supply (+24 / GND) at DB–9 male power connector and
Sensors (+24V / 0V / + / -) at DB–15 female sensor connector exactly as shown in
the drawing above!
• Connector: Use only screws with 4–40 UNC thread for fastening the connectors!
Pins 4 and 8 must be
bridged for operation.
An optional switch
would allow for motor
interlock to prevent
valve from moving.

INSTALLATION Series
590
20/77 Edition 2015-12-02 820655EA
4.3.3.2 Sensor power wiring external
• Use shielded sensor cable(s). Keep cable as short as possible, but locate it away
from noise sources.
• Connect Power supply (+24 / GND) at DB–9 male power connector and
Sensors (0V / + / -) at DB–15 female sensor connector exactly as shown in the
drawing above!
• Connector: Use only screws with 4–40 UNC thread for fastening the connectors!
Pins 4 and 8 must be
bridged for operation.
An optional switch
would allow for motor
interlock to prevent
valve from moving.