VAT 590 Series Assembly instructions

Installation, Operating &
Maintenance Instructions
299498EA
Edition 2013-07-03
Variable leak valve
with manual actuator
Series 590
DN 16 mm (I. D. ⅝")
This manual is valid for the following product ordering numbers:
59024- . E01 - ....
Sample picture

Series 590
2/23
Edition 2013-07-03
299498EA
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 590
299498EA
Edition 2013-07-03
3/23
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
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....................................................................10
4.2.2 Mounting to the system ........................................................................12
5Operation...........................................................................................13
5.1 Normal operation...............................................................................................13
5.2 Operation under increased temperature...........................................................14
5.3 Bake-out............................................................................................................14
5.4 Trouble shooting ...............................................................................................14
6Maintenance ......................................................................................15
6.1 Maintenance intervals.......................................................................................15
7Repairs...............................................................................................16
7.1 Replacement of diaphragm...............................................................................17
8Dismounting and Storage.................................................................19
8.1 Dismounting......................................................................................................19
8.2 Storage..............................................................................................................19
9Packaging and Transport.................................................................20
9.1 Packaging .........................................................................................................21
9.2 Transport...........................................................................................................21
10 Disposal.............................................................................................22
11 Spare parts ........................................................................................23

DESCRIPTION OF PRODUCT
Series 590
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Edition 2013-07-03
299498EA
1 Description of product
1.1 Identification of product
The fabrication number is lasered directly on the product.
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. Suitable for XHV applications.
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.
Weights of standard valve:
DN 16: 0.95 kg
Weight of special valves, see product data sheet.

Series 590
SAFETY
299498EA
Edition 2013-07-03
5/23
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 590
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299498EA
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.

Series 590
DESIGN AND FUNCTION
299498EA
Edition 2013-07-03
7/23
3 Design and Function
3.1 Design
With handwheel:
Type 590 … - . E01 - ….
1 Handwheel
2 Valve body
3 Connecting flange
4 Sealing surface
5 Position indication
side scale and
scale ring
Figure 3-1

DESIGN AND FUNCTION
Series 590
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299498EA
3.2 Function
Valve is closed and opened manually.
Figure 3-2
1 Diaphragm
2 Pressure spring
3 Spindle
4 Handwheel
5 Scale
6 Rotary flange / seat port
7 Rotary flange / side port
Valve seat side
Further function definitions see chapter «5.1 Normal operation».

Series 590
INSTALLATION
299498EA
Edition 2013-07-03
9/23
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
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.
Do not open the plastic bag before mounting into the system.
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.
Weight of standard valves; see chapter «1.5 Technical data».

INSTALLATION
Series 590
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Edition 2013-07-03
299498EA
4.2 Installation into 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.
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.

Series 590
INSTALLATION
299498EA
Edition 2013-07-03
11/23
1. Remove plastic bag.
2. Remove protective covers (1); see «Figure 4-1».
1 Protective covers
Figure 4-1
Store protective covers. They may be useful when valve needs to be
repacked.
3. Clean sealing surfaces; see «Figure 3-1» on page 7, with cleanroom wiper soaked with
pure alcohol (Isopropanol).
4. Clean sealing surface with clean, oil free compressed air.

INSTALLATION
Series 590
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Edition 2013-07-03
299498EA
4.2.2 Mounting to the system
1. Mount valve to your system by using appropriate flange screws.
2. Mount screws evenly in crosswise order until the seal touches the sealing surface.
3. Tighten all screws with the torques appropriate for the property classes of the screws.
1 Flange A (valve seat side)
2 Flange B
3 Screw holes
Figure 4-2

Series 590
OPERATION
299498EA
Edition 2013-07-03
13/23
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.
5.1 Normal operation
Valve is closed and opened manually.
Closing: turn handwheel clockwise to the zero on the scale. The valve is completely closed
when the stop is reached. A stopper is implemented in the leak valve to prevent over
tightening of the seat in the closed position. Do not turn the handwheel beyond the zero on
the scale.
Opening: turn handwheel counter clockwise to it` s stop. After 22 turns the valve is
completely open when the mechanical stop is reached.
Leak rate adjustment:
–Leak rate adjustment is starting after a few turns of the handwheel in opening direction
(depending on gas type, life cycles,…) Adjusting the gas flow can be done very
accurately by turning the handwheel until the required leak rate is reached. Depending
on the application, base pressure and different gas types, the adjustment range and
accuracy can vary.
–Inserting a gas flow, by opening the valve, into a system results in a pressure rise. By
closing the valve it can be found that the leak rate is higher at the same scale index of
compared being opened. This is mainly given due to the additional time needed to
pump the system.
For technical details, see product data sheet.

OPERATION
Series 590
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Edition 2013-07-03
299498EA
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 300 °C
–Make sure that the temperature differences over the whole body do not
exceed 30 °C.
5.3 Bake-out
Bake-out temperature see product data sheet.
5.4 Trouble shooting
Failure
Check
Action
See
Leak at gate
Condition of gate
seal
Please contact VAT
www.vatvalve.com
Condition of
valve gate
Please contact VAT
www.vatvalve.com
Leak at body
Condition of
bonnet seal and
sealing surface
Please 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.

Series 590
MAINTENANCE
299498EA
Edition 2013-07-03
15/23
6 Maintenance
6.1 Maintenance intervals
Under clean operating conditions the valve does not require any maintenance during
specified lifetime.
Impacts from the process may require more frequent maintenance.
When the valve has reached the specified lifetime; 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.

REPAIRS
Series 590
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299498EA
7 Repairs
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
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
Contamination
Product may get contaminated.
Always wear cleanroom gloves when handling the product.

Series 590
REPAIRS
299498EA
Edition 2013-07-03
17/23
7.1 Replacement of diaphragm
In case of a seat seal leak caused by environmental influences and no visible damage of
the sealing surface at the seat, the diaphragm seal can be replaced.
VAT offers a range of components; see «Table 11-1 » on page 23. The seal exchange can
be carried out by the user.
1 Valve body
36 Diaphragm
60 Disc spring
61 Bonnet screws
Figure 7-1

REPAIRS
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Required material: Diaphragm
Ordering information: See chapter «11 Spare parts» on page 23 and «Figure 7-1» on
page 17.
NOTICE
Inappropriate mounting position of valve
Maintenance may be troublesome and parts may drop down.
Ideally dismount valve from the system and put it on a clean workbench with
the actuator upwards.
Procedure:
The item numbers in brackets refer to; see «Figure 7-1» on page 17.
1. Open valve completely.
2. Loosen bonnet screws (61).
3. Remove valve body (1).
4. Remove disc spring (60).
5. Exchange diaphragm (36).
Check surfaces on its cleanliness and on damages.
Make sure that the sealing surface is free of scratches.
6. Insert disc spring (60) centered to the diaphragm (36).
Make sure that the disc spring (60) is assembled in the correct direction.
7. Clean valve body (1) with pure alcohol (Isopropanol), use a cleanroom wiper. Use oil
free compressed air to blow off surfaces.
8. Assemble valve body (1) with caution. Tighten all bonnet screws (61) slowly in
crosswise order with the following torque:
DN 16: 3 Nm
9. Open and close valve 5 times.
Valve is ready for use.

Series 590
DISMOUNTING AND STORAGE
299498EA
Edition 2013-07-03
19/23
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.
NOTICE
Contamination
Product may get contaminated.
Always wear cleanroom gloves when handling the product.
8.1 Dismounting
1. Dismount valve according chapter «4 Installation», however in reverse order.
Observe safety instruction of chapter «4 Installation».
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 cover.
3. Pack valve appropriately, by using the original packaging material.

PACKAGING AND TRANSPORT
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9 Packaging and Transport
WARNING
Unqualified personnel
Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.
WARNING
Harmful substances
Risk of injury in case of contact with harmful substances.
Remove harmful substances (e. g. toxic, caustic or microbiological ones) from
valve before you return the valve to VAT.
NOTICE
Inappropriate packaging
Product may get damaged if inappropriate packaging material is used.
Always use the original packaging material and handle product with care.
When returning products to VAT, please fill out the VAT form «Declaration
of Chemical Contamination» and send it to VAT in advance. The form can
be downloaded from our website www.vatvalve.com.
If products are radioactively contaminated, the VAT form «Contamination
and Radiation Report» must be filled out. Please contact VAT in advance.
If products are sent to VAT in contaminated condition, VAT will carry out
the decontamination procedure at the customer's expense.