VAT 61228-KAGG-0002 Assembly instructions

Installation, Operating &
Maintenance Instructions
601894EA
Edition 2013-04-12
Butterfly Pressure Control Valve
with RS232 interface
Series 612
DN 25 mm (I.D. 1")
This manual is valid for the following product ordering numbers:
61228-KAGG-0002
Configured with firmware: 612P.1E.00
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 2013
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.

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Contents
1Description 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
2Safety ...................................................................................................8
2.1 Compulsory reading material...........................................................................................8
2.2 Danger levels ..................................................................................................................8
2.3 Personnel qualifications...................................................................................................9
2.4 Safety labels....................................................................................................................9
3Design and Function.........................................................................10
3.1 Design...........................................................................................................................10
3.2 Function.........................................................................................................................10
3.2.1 Pressure control system overview and function..............................................11
3.2.2 Principle of a pressure control system ............................................................12
4Installation.........................................................................................13
4.1 Unpacking .....................................................................................................................13
4.2 Installation into the system............................................................................................14
4.2.1 Installation space condition.............................................................................15
4.2.2 Connection overview.......................................................................................15
4.2.3 Installation procedure......................................................................................16
4.3 Tightening torque ..........................................................................................................17
4.3.1 Mounting of ISO-KF flanges............................................................................17
4.4 Admissible forces ..........................................................................................................17
4.4.1 Admissible forces at controller........................................................................18
4.4.2 Requirements to sensor connection................................................................19
4.5 Electrical connection......................................................................................................19
4.5.1 Ground connection..........................................................................................20
4.5.2 Sensor supply concepts..................................................................................21
4.5.3 Power and sensor connection (+24 VDC sensors) .........................................22
4.5.4 Power and sensor connection ( 15 VDC sensors) without opt. SPS module .24
4.5.5 Service port connection...................................................................................26
4.5.6 RS232 Functions and Wiring ..........................................................................27
4.6 Initial operation..............................................................................................................30
4.6.1 Setup procedure RS232..................................................................................30
4.6.2 RS232 interface configuration.........................................................................30
4.6.3 Valve configuration .........................................................................................31
4.6.4 Sensor configuration.......................................................................................31
4.6.5 ZERO..............................................................................................................31
4.6.6 LEARN............................................................................................................32
4.6.7 Tuning of control performance........................................................................34
4.7 RS232 interface commands..........................................................................................38
4.7.1 Command syntax............................................................................................38
4.7.2 RS232 Control commands..............................................................................39
4.7.3 RS232 Inquiry commands...............................................................................40
4.7.4 RS232 Setup commands................................................................................45
4.7.5 Error messages...............................................................................................50

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5Operation........................................................................................... 51
5.1 Normal operation...........................................................................................................51
5.1.1 Local operation................................................................................................52
5.1.2 Remote operation............................................................................................53
5.2 Close valve....................................................................................................................54
5.3 Open valve.....................................................................................................................54
5.4 Position control..............................................................................................................54
5.5 Pressure control.............................................................................................................54
5.6 Display information........................................................................................................55
5.6.1 Power up.........................................................................................................55
5.6.2 Operation ........................................................................................................56
5.6.3 Fatal error........................................................................................................56
5.6.4 Safety mode....................................................................................................56
5.6.5 Service indication............................................................................................56
5.7 Operation during power up ............................................................................................57
5.8 Behavior in case of power failure...................................................................................57
5.9 Operation under increased temperature........................................................................57
6Trouble shooting .............................................................................. 58
7Maintenance...................................................................................... 61
7.1 Maintenance intervals....................................................................................................61
7.2 Maintenance procedures...............................................................................................62
7.2.1 Replacement of shaft feedthrough seals and valve cleaning ..........................63
7.2.2 Replacement of Option board .........................................................................67
8Repairs .............................................................................................. 72
9Dismounting and Storage................................................................ 73
9.1Dismounting...................................................................................................................73
9.2 Storage..........................................................................................................................74
10 Packaging and Transport................................................................. 75
10.1 Packaging......................................................................................................................75
10.2 Transport .......................................................................................................................76
11 Disposal............................................................................................. 77
12 Spare parts........................................................................................ 78
12.1 Drawing .........................................................................................................................79
12.1.1 Valve unit ........................................................................................................80
12.1.2 Seals and grease ............................................................................................80
12.1.3 Control and actuating unit ...............................................................................80
12.1.4 Accessories.....................................................................................................81
13 Appendix ........................................................................................... 82

Series 612
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.:
000..-....-..../....
A-......


Fabrication number
Order number
1.2 Use of product
This product is a Butterfly control valve for downstream pressure control in vacuum systems.
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
CV
Control View
PFO
Power Failure Option
SFS
Sensor Full Scale
SPS
Sensor Power Supply
ADC
Analog-to-digital converter
1.4 Related documents
Product Data Sheet
Dimensional Drawing
IOMI Heating device (if valve with heater)
1.5 Important information
This symbol points to a very important statement that requires particular attention.
Example:
Refer to chapter: «Technical data» for detailed information.

DESCRIPTION OF PRODUCT
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1.6 Technical data
1.6.1 Control and actuating unit
Describtion
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 (linear to
pressure)
0.23 mV
10 ms
[connector: SENSOR]
Digital inputs 3)
±24 VDC max.
[connector: INTERFACE]
Digital outputs 3)
Input voltage
Input current
Breaking capacity
70 VDC or 70 V peak max.
0.5 ADC or 0.5 A peak max.
10 W max.
[connector: INTERFACE]
Analog outputs 3) (optional)
0-10 VDC / 1 mA max.
[connector: INTERFACE]
PFO 4) battery pack
Charging time
Durability
2 minutes max.
up to 10 years @ 25°C ambient
refer to «Durability of power fail battery» for details
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
20000 (full stroke)
Closing time throttling only
0.3 s typ. (full stroke)
Opening time throttling only
0.3 s typ. (full stroke)
Utilizable valve torque
2.5 Nm
1) Internal overcurrent protection by a PTC device.
2) Refer to chapter «Sensor supply concepts» for details.
3) Refer to chapter «Schematics» for details.
4) PFO = Power Failure Option. Refer to chapter «Behavior in case of power failure» for details

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DESCRIPTION OF PRODUCT
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1.6.2 Valve unit
Data
Pressure range at 20 C
1 × 10E-8 mbar to 1.2 bar (abs)
Leak rate to outside at 20 C
1 × 10E-9 mbar l/s
Cycles until first service
2’000’000 (unheated and under clean conditions)
Admissible operating temperature
+10°C to +150°C
Mounting position
Any.
Control unit for ISO-KF version needs support when mounted on
horizontal piping and control unit does not hang.
Wetted materials
- Body
Aluminium AA6082 (3.2315)
- Plate
Aluminium AA6082 (3.2315)
- Shaft
Stainless steel 316L (1.4404 or 1.4435 )
- Plate screws
- Rotary feedthrough seals atmosphere side
Stainless steel 316L (A4)
FKM (e.g. Viton®)
- Rotary feedthrough seals vacuum side
FKM (e.g. Viton®)
- Slide bearing for shaft
iglidur®X
Max. differential pressure on plate
1000 mbar
Min. controllable conductance (Cmin)
[N2molecular flow]
0.15 l/s
Conductance in open position [N2molecular
flow]
22 l/s
Dimensions
Refer to dimensional drawing of specific valve ordering number
(available on request)

SAFETY
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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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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.
Location on valve
T-9001-156
On protective foil covering of
valve opening

DESIGN AND FUNCTION
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3 Design and Function
3.1 Design
1
Integrated controller
4
Double seal
2
Coupling
5
Plate
3
Bearing
6
Valve body
3.2 Function
The valve plate (5) acts as a throttling element and varies the conductance of the valve opening.
The integrated controller (1) calculates the required plate position to achieve the setpoint pressure.
See also principle drawing on chapter: «Connection Overview».
Actuation is performed by a stepper motor. An encoder monitors the position. This principle ensures
very fast and accurate process pressure control even in demanding contaminating processes.
Double seal of
rotary feedthrough
1
2
4
5
6
3

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DESIGN AND FUNCTION
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3.2.1 Pressure control system overview and function
Vacuum pressures are always absolute pressures unless explicitly specified as pressure differences.
M
3
4
5
7
8
2
1
9
Q
pV
Seff
6
Example: Downstream control
1 Valve
2 Process chamber
3 Gas inlet
4 Pressure sensor(s)
5 Sensor cable
6 Controller and actuator
7 Cable to remote control unit
8 Cable to power supply
9 HV Pump
Seff Q / p
Seff effective pump speed (ls-1)
Q Gas flow (mbar)
p Pressure (mbar)
or units used in USA
Seff = 12.7 •Q / p
Seff effective pump speed (ls-1)
Q Gas flow (sccm)
p Pressure (mTorr)

DESIGN AND FUNCTION
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3.2.1.1 Way of operation
The controller compares the actual pressure in the process chamber given by the pressure sensor
with the preset pressure. The controller uses the difference between actual and set pressure to
calculate the correct position of the control valve. The controller drives the control valve into the
correct position and the actual pressure again equals the set pressure.
This control operation is performed continuously. Pressure changes in the process chamber due to
leaks, desorption, and gas flow, reaction products, variations in pumping speed etc. are always
corrected at once.
3.2.1.2 Pressure control
In a vacuum system which is pumped and into which gas is admitted at the same time, the pressure
can be controlled in two ways:
1. Downstream control (standard):
The pressure is controlled by changing the conductance of a control valve between pump and
process chamber. This changes the effective pumping speed at the process chamber. Pressure
and gas flow can be independently controlled over a wide range.
2. Upstream control:
The pressure is controlled by changing the gas flow into the process chamber, while the pumping
speed remains constant.
3.2.1.3 Adaptive controller (standard)
A controller adapting itself to changes in pressure, gas flow and pumping speed without any manual
adjustments. This allows for a completely automatic operation of the system.
3.2.2 Principle of a pressure control system
1. Host computer sends
pressure set point
2. Controller reads actual
pressure from sensor
3. Optimizing module sends
new PID parameters
4. Actuator sets new valve
position
Host computer
(Example)
1.
4.
3.
2.

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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.
NOTICE
Physical overstraining at pedestal
Inappropriate handling with the valve may cause in damage of pedestal.
Lift valve at valve body out of transport case.
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
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4.2 Installation into the system
WARNING
Valve opening
Risk of serious injury.
Human body parts must be kept out of the valve opening and away from moving parts.
Do not connect the controller to power before the valve is installed complete 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
Gate 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.

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INSTALLATION
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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.
70 mm
4.2.2 Connection overview
System:
M
3
4
5
7
8
2
1
9
6
1 Valve
2 Process chamber
3 Gas inlet
4 Pressure sensor(s)
5 Sensor cable(s)
6 Controller and actuator
7 Cable to remote control unit
8 Cable to power supply
9 Pump

INSTALLATION
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Controller:
Ground connection
4.2.3 Installation procedure
All numbers in brackets refer to chapter: «Connection overview».
1. Remove protective covers from body flanges.
2. Install [1] valve into the vacuum system. Valve seat side must face process chamber.
The valve seat side is indicated by the symbol « » on the valve flange.
Do not tighten the flange screws stronger than indicated under chapter «Tightening
torque».
Do not admit higher forces to the valve than indicated under chapter «Admissible
forces».
Make sure that enough space is kept free to do preventive maintenance work. The
required space is indicated on the dimensional drawing.
Control unit of valves with ISO-KF (612 . . –K. . .) needs support when mounted
on horizontal piping and control unit does not hang.
3. Install the ground connection cable at controller. Refer to chapter «Electrical connection».
4. Install sensor(s) [4] according to the recommendations of the sensor manufacturer and directives
given under chapter «Requirements to sensor connection».
5. Connect sensor cable [5] to sensor(s) and then to valve (connector: SENSOR). Refer to chapter
«Electrical connection» for correct wiring.
61228-KAGG-0002 supports 1 sensor(s).
6. Connect valve with cable [7] to remote control unit (connector: INTERFACE). Refer to chapter
«RS232 connection» for correct wiring.
7. Connect power supply cable [8] to valve (connector: POWER). Refer to chapter «Electrical
connection» for correct wiring.

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To provide power to the valve motor pins 4 and 8 must be bridged, otherwise motor
interlock is active and the valve enters the safety mode and is not operative. Refer
also to chapter «Safety mode».
8. This valve may optionally be equipped with a heating device. Connect VAT heating device according
to manual of respective heating device.
9. Perform chapter «Setup procedure» to prepare valve for operation.
Without performing the setup procedure the valve will not be able to do pressure
Control.
4.3 Tightening torque
4.3.1 Mounting of ISO-KF flanges
Tightening torques for ISO-KF flange connections depend on the type of seal which is used. Follow
recommendations of seal manufacturer.
4.4 Admissible forces
NOTICE
Force at valve body
Forces from the weight of other components can lead to deformation of the valve body
and to malfunction of the valve.
Do not higher force the valve body as specified.
The following forces are admissible.
Axial tensile or
compressive force «FA»
Bending moment «M»
M FA
N
lb.
Nm
Lbf.
70
16
3
3.2

INSTALLATION
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4.4.1 Admissible forces at controller
NOTICE
Force at pedestal
In case higher force is applied, the pedestal could be permanently damaged.
–Do not pushing, shocking load, or stressing the valve controller
–Do not deposit anything at valve controller
The admissible force at valve controller in regards to the pedestal is shown in table
below
Admissible force
«F»
Overview
F= Force
a = middle of aluminium part of controller (b / 2)
400 N
a a
F
bc
a a
F
bc

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INSTALLATION
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4.4.2 Requirements to sensor connection
To achieve fast and accurate pressure control a fast sensor response is required. Sensor response time:
< 50ms. The sensor is normally connected to the chamber by a pipe. To maintain that the response time
is not degraded by this connection it needs to meet the following requirements:
Inner diameter of connection pipe: > = 10 mm
Length of connection pipe: < = 300 mm
These conductance guidelines must include all valves and limiting orifices that may also be present. Make
also sure that there is no obstruction in front of sensor connection port inside the chamber. The sensor
should also be mounted free of mechanical shock and vibration. Dynamic stray magnetic fields may
introduce noise to sensor output and should be avoided or shielded.
4.5 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.
Isolation Valve
(optional)
Process
Chamber
L1 + L2 < = 300 mm
L1
min. 10 mm
min.
10 mm
Pressure Sensor
L2

INSTALLATION
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4.5.1 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