VAT 615 Series Assembly instructions

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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Butterfly control & isolation valve
with extended control range
with DeviceNet interface
sample picture
This manual is valid for the valve ordering number(s):
61532-KEAQ-0001
configured with firmware 615P.1F.08 and 502689 (DeviceNet®)
The fabrication number is indicated on each product as per the label
below (or similar):
made in Switzerland
Fabrication No.:
615 .. –....–.... / ....
A–.. . ...
Fabrication number
Explanation of symbols:
Read declaration carefully before you start any other
action!
Keep body parts and objects away from the valve
opening!
Attention!
Hot surfaces; do not touch!
Loaded springs and/or air cushions are potential
hazards!
Wear gloves!
Disconnect electrical power and compressed air lines.
Do not touch parts under voltage!
Read these «Installation, Operating & Maintenance Instructions» and the enclosed «General
Safety Instructions» carefully before you start any other action!

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
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2013-07-25
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Imprint
Manufacturer
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Website
www.vatvalve.com
Phone
[phone]
Fax
[phone]
Email
[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 2012
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.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
Tel [phone] Fax [phone] [email protected] www.vatvalve.com
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2013-07-25
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Contents:
1Use of product........................................................................................................................................................... 5
1.1 Technical data.................................................................................................................................................. 6
2Installation................................................................................................................................................................. 7
2.1 Unpacking........................................................................................................................................................ 8
2.2 Installation into the system............................................................................................................................... 8
2.3 Tightening torque............................................................................................................................................. 9
2.3.1 Mounting of ISO-KF flanges ................................................................................................................ 9
2.4 Admissible forces........................................................................................................................................... 10
2.4.1 Admissible forces at controller........................................................................................................... 11
2.5 Requirements to sensor connection............................................................................................................... 12
2.6 Electrical connection...................................................................................................................................... 13
2.6.1 Ground connection ............................................................................................................................ 13
2.6.2 Sensor supply concepts..................................................................................................................... 14
2.6.3 Power and sensor connection ( 15 VDC sensors) with optional SPS module................................... 15
2.6.4 DeviceNet connection..................................................................................................................... 16
2.6.5 LOGIC I/O.......................................................................................................................................... 17
2.6.6 Digital input........................................................................................................................................ 18
2.6.7 Digital output...................................................................................................................................... 18
2.6.8 Service port connection..................................................................................................................... 18
3Operation................................................................................................................................................................ 19
3.1 Introduction.................................................................................................................................................... 19
3.1.1 Local operation.................................................................................................................................. 20
3.1.2 Remote operation.............................................................................................................................. 20
3.1.3 Safety mode....................................................................................................................................... 21
3.1.4 Service indication............................................................................................................................... 21
3.2 Operation under increased temperature ........................................................................................................ 21
3.3 Behavior during power up .............................................................................................................................. 21
3.4 Behavior in case of power failure................................................................................................................... 22
3.5 Display information......................................................................................................................................... 23
3.5.1 Display controller............................................................................................................................... 23
3.6 Setup procedure............................................................................................................................................. 24
3.6.1 DeviceNet®configuration................................................................................................................... 25
3.6.2 DeviceNet® LEDs.............................................................................................................................. 27
3.6.3 LOGIC I/O configuration.................................................................................................................... 29
3.6.4 Valve configuration............................................................................................................................ 30
3.6.5 Sensor configuration.......................................................................................................................... 30
3.6.6 ZERO................................................................................................................................................. 31
3.6.7 Pressure control configuration........................................................................................................... 32
3.7 Close valve .................................................................................................................................................... 38
3.8 Open valve..................................................................................................................................................... 38
3.9 Position control............................................................................................................................................... 39
3.10 Pressure control............................................................................................................................................. 39
3.10.1 Pressure control operation with 2 sensors......................................................................................... 40
3.11 Tuning of pressure control performance ........................................................................................................ 40
3.11.1 Tuning of pressure control with adaptive algorithm............................................................................ 41
3.11.2 Tuning of pressure control performance with Fixed algorithm ........................................................... 46
3.11.3 Tuning of control performance with soft pump algorithm ................................................................... 50
4DeviceNet interface............................................................................................................................................... 53
4.1 Introduction.................................................................................................................................................... 53
4.2 Factory default assemblies............................................................................................................................. 54
4.3 Messaging Format ......................................................................................................................................... 54
4.3.1 Explicit Messaging Connections........................................................................................................ 54
4.3.2 I/O Poll Messaging Connections........................................................................................................ 55
4.4 Object............................................................................................................................................................. 56
4.4.1 Object Model for the Process Control Valve Device.......................................................................... 56

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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4.4.2 Object Definition ................................................................................................................................ 57
4.5 Identity Object (Class ID 1)............................................................................................................................ 58
4.6 Assembly objects (Class ID 4) ....................................................................................................................... 58
4.6.1 Assembly describtion......................................................................................................................... 59
4.7 Connection Object (Class ID 5)...................................................................................................................... 62
4.8 Discrete Input Object (Class ID 8).................................................................................................................. 63
4.9 Selection Object (Class ID 46)....................................................................................................................... 63
4.10 S-Device Supervisor Object (Class ID 48) ..................................................................................................... 64
4.11 S-Analog Sensor Object (Class ID 49)........................................................................................................... 67
4.12 S-Singel Stage Controller Object (Class ID 51).............................................................................................. 70
4.13 Pressure Controller Object (Class ID 100)..................................................................................................... 73
4.14 Definition of terms.......................................................................................................................................... 74
5Trouble shooting ..................................................................................................................................................... 75
6Maintenance & repairs............................................................................................................................................ 78
6.1 Maintenance procedures................................................................................................................................ 79
6.1.1 Replacement of plate o-ring............................................................................................................... 80
6.1.2 Replacement of shaft feedtrough seals and plate o-ring.................................................................... 83
6.2 Option board .................................................................................................................................................. 92
6.2.1 Durability of power fail battery............................................................................................................ 92
6.2.2 Retrofit / replacement procedure ....................................................................................................... 93
7Drawing................................................................................................................................................................... 97
8Spare parts ............................................................................................................................................................. 98
8.1 Valve unit....................................................................................................................................................... 98
8.2 Seal kit........................................................................................................................................................... 98
8.3 Control and actuating unit.............................................................................................................................. 99
8.4 Accessories.................................................................................................................................................. 100
8.4.1 Centering ring with Viton o-ring........................................................................................................ 100
9Warranty ............................................................................................................................................................... 101

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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1 Use of product
This product is a Butterfly control valve with isolation functionality for downstream pressure control in vacuum systems.
Use product for clean and dry indoor vacuum applications under the conditions indicated in chapter «Technical data» only!
Other applications are only allowed with the written permission of VAT.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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1.1 Technical data
Control and actuating unit
Input voltage 1)
+24 VDC (±10%) @ 0.5 V pk-pk max.
[connector: POWER]
Power consumption
74 W
[connector: POWER]
Power input (DeviceNet®)
3 W max. (from DeviceNet®)
[DeviceNet® connector]
LOGIC I/O (configurable)
1 digital input
[connector: LOGIC I/O]
1 digital output
Sensor power supply output 2)
±15 VDC (±5%) / 1000 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]
PFO3) 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
>28000 (full stroke)
Closing time throttling only
0.5 s (full stroke)
Opening time throttling only
0.5 s (full stroke)
Closing time throttling & isolation
0.6 s (full stroke)
Opening time throttling & isolation
0.6 s (full stroke)
1) Internal overcurrent protection by a PTC device.
2) Refer to chapter «Sensor supply concepts» for details.
3) PFO = Power Failure Option. Refer to «Behavior in case of power failure» for details.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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Valve unit
Pressure range at 20 C
1 x 10E-8 mbar to 1.2 bar (abs)
Leak rate to outside at 20 C
1 x 10E-8 mbar l/s
Leak rate valve seat at 20 C
1 x 10E-7 mbar l/s
Cycles until first service:
- Isolation cycles (open - closed - open)
250’000 (with FKM e.g. Viton®) seals, under clean and unheated conditions)
- Throttling cycles (open - max. throttle - open)
2’000’000 (with FKM e.g. Viton®) seals, under clean and unheated conditions)
Admissible operating temperature
10°C to +120°C
Mounting position
Valve seat must face chamber side. Control unit for ISO-KF version needs
support, when mounted on horizontal piping and control unit does not hang.
Wetted Materials
- Body
Stainless steel 316L (1.4404 or 1.4435)
- Plate
Stainless steel 316L (1.4404 or 1.4435)
- Shaft
Stainless steel 316L (1.4404 or 1.4435)
- Plate screws
Stainless steel 316L (A4)
- Plate seal
Kalrez 9100
- Rotary feedthrough seals atmosphere side
Viton
- Rotary feedthrough seals vacuum side
Viton
- Slide bearing for shaft
iglidur® X
Other parts
Stainless steel 316L (1.4404 or 1.4435), 1.4122, 301 (1.4310),
304 (1.4303), 1.4571, 304 (A2)
Max. differential pressure on plate during isolation
1000 mbar
Max. differential pressure on plate
during opening and throttling
1000 mbar
Min. controllable conductance [N2molecular flow]
0.1 l/s
Conductance in open position [N2molecular flow]
120 l/s
Weight about
3.6 kg
Dimensions
Refer to dimensional drawing of specific valve ordering number
(available on request)
2 Installation

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.1 Unpacking
Valves DN63 / 2½" and larger must not be lifted solely by the actuator.
2.2 Installation into the system
Fingers and objects must be kept out of the valve opening and away from moving parts.
The valve plate may start to move just after power is supplied.
Do not connect or disconnect sensor cable when device is under power.
Connection overview Connectors at controller panel
Ground
connection

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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1. Install valve [1] into the vacuum system. Valve seat side must faced process chamber. The valve seat side is indicated
by the symbol " " on the valve flange.
Caution: Do not tighten the flange screws stronger than indicated under «Tightening torque».
Caution: Do not admit higher forces to the valve than indicated under «Admissible forces».
Note: Make sure that enough space is kept free to do preventive maintenance work. The required space is indicated
on the dimensional drawing.
Note: Control unit of valves with ISO-KF flanges (615 . . –K. . . ) needs support when mounted on horizontal piping
and control unit does not hang.
2. Install a ground connection cable at controller. Refer to «Electrical connection»
3. Install sensor(s) [2] according to the recommendations of the sensor manufacturer and directives given under
«Requirements to sensor connection».
4. Connect pressure sensor cable [3] to sensor(s) and then to valve (connector: SENSOR). Refer to chapter «Electrical
connection» for correct wiring.
Note: 61534-KEAQ-AQU2 supports 2 sensor(s).
5. Connect valve to remote control unit [4] (connector: INTERFACE). Refer to «DeviceNet connection» for correct wiring.
6. Connect power supply [5] to valve (connector: POWER). Refer to chapter «Electrical connection» for correct wiring.
Note: 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 «Safety mode».
7. This valve may optionally be equipped with a heating device. Connect VAT heating device according to manual of
respective heating device.
8. Perform «Setup procedure» to prepare valve for operation.
Note: Without performing the setup procedure the valve will not be able to do pressure control.
2.3 Tightening torque
2.3.1 Mounting of ISO-KF flanges
Tightening torques for ISO-KF flange connections depends on the type of seal which is used. Follow recommendations of
seal manufacturer.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.4 Admissible forces
Forces from the weight of other components can lead to deformation of the valve body and to malfunction of the valve. The
stress has to be relieved by suitable means. The following forces are admissible:
Valve size
Axial tensile or
compressive force «FA»
Bending moment «M»
M FA
mm
inch
N
lb.
Nm
lbf.
50
2
150
34
11
8

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.4.1 Admissible forces at controller
Attention!
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. In case higher force is
applied, the pedestal could be permanently damaged!
Admissible force «F»
Overview
F= Force
a = middle of aluminium part of controller (b / 2)
c = pedestal
400 N
a a
F
bc
a a
F
bc

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.5 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.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.6 Electrical connection
2.6.1 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
Note: Connection plates of ground strap must be total plane for a good electrical contact!
Note: 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.
Note: 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, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.6.2 Sensor supply concepts
This valve has a built in sensor power supply (SPS). It supplies 15 VDC.
Concept:
External + 24 VDC supplied to POWER connector is converted into 15 VDC by the valve internal SPS and
supplied to SENSOR connector to supply 15 VDC sensors. Refer to chapter «Power and sensor connection ( 15
VDC sensors) with optional SPS module» for schematic and correct wiring.
Valve versions:
615 . . - . . A. - . . . . / 615 . . - . . C. - . . . . SPS module included
Note: The SPS module can be retrofitted. Refer to chapter «Retrofit / replacement procedure» for instruction.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.6.3 Power and sensor connection ( 15 VDC sensors) with optional SPS module
[615 . . - . . A. - . . . . / 615 . . - . . C. - . . . . versions only]
Note:
Use shielded sensor cable(s). Keep cable as short as possible, but locate it away from noise sources.
Connect the 15 VDC sensors at DB–15 female sensor connector exactly as shown in the drawing above. Do not
connect other pins that may damage sensors, power supply or controller!
Connector: Use only screws with 4-40UNC 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.
Low range sensor may be connected to
sensor 1 or sensor 2 input.
Do configuration accordingly.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.6.4 DeviceNet connection
Connector type: Micro-style male (5 pin), connector is shown on panel refer to chapter «Installation into the system».
At valve controller
DeviceNet cable
PIN
Name
Wire color
Description
1
Drain
Bare
Shield
2
V+
Red
DeviceNet® power supply +
3
V-
Black
DeviceNet® power supply -
4
CAN_H
White
DeviceNet® signal
5
CAN_L
Blue
DeviceNet® signal
Note: The DeviceNet®interface is galvanic isolated from control unit.
Micro Connector Pinout
Female (sockets)
at DeviceNet cable
1
5
2
3
4
5
1
2
3
4
Male (pins) at
valve controller

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.6.5 LOGIC I/O
This interface allows for remote operation by means of a command set based on the DeviceNet protocol.
In addition there is a digital input and a digital output. Digital input may only be operated by a switch.
Active digital input has:
higher priority than DeviceNet commands
higher priority than Local commands
customer side
M8 male connector M8 female
connector
LOGIC I/O
Note: Do not connect other pins than indicated in the schematics above! Example for connector: Type «Binder M8 male,
4-pole, shielded (recommended)» (99-3363-00-04).

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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2.6.6 Digital input
Pin
Signal type
Description
3
Digital
input
This function will close / open the valve.
Valve will be in interlock mode as long as function is activated.
After deactivation of function it will remain effective until converse DeviceNet control command
have been received
The function is activated when optocoupler is ‘on’ in non inverted configuration.
The function is activated when optocoupler is ‘off’ in inverted configuration.
Configuration can be adjusted in local operation via service port with CV, CPA or Hyper
terminal. Refer to chapter: «LOGIC I/O configuration».
1
Digital ground
Ground for digital input. Connect switch to ground.
See also chapter: «2.6.5 LOGIC I/O».
Note: The digital input is digitally filtered. Filter delay is 50ms. This means that digital signal must be applied for at least
50ms to be effective. Refer to chapter: «2.6.5 LOGIC I/O» for details about input circuit.
2.6.7 Digital output
Pin
Signal type
Description
2
Digital
output
This function will indicate that the valve is closed or open. If the function “ON” is configured the
output is continous on.
4
Digital common
Common for all digital output. Connect + or –terminal of source with common.
See also chapter: «2.6.5 LOGIC I/O».
2.6.8 Service port connection
The service port (connector: SERVICE) allows to connect the valve to a RS232 port of a computer.
This requires a service cable and software from VAT. You can either use our freeware 'Control View', which can be
downloaded from www.vatvalve.com or purchase our 'Control Performance Analyzer'.
Alternatively the VAT Service Box 2 can be connected to the service port for setup and local operation.
The service port is not galvanic isolated. Therefore we recommend using this only for setup, testing and maintenance and
not for permanent control.
Refer also to «Local Operation» for details and to «Spare parts / Accessories» for ordering numbers of service cable,
software and Service Box 2.
Connector: Use only screws with 4-40UNC thread for fastening the service port connector!

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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3 Operation
Valve opening
Fingers and objects must be kept out of the valve opening and away from moving
parts. Risk of injury.
Do not connect the controller to power before the valve isn’t installed complete into the
system.
3.1 Introduction
This valve is designed for downstream pressure control in vacuum chambers. It can be employed in a pressure control
mode or a position control mode.
In both cases local or remote operation is possible.

Installation, Operating & Maintenance Instructions
Series 615 DN 40 (I.D. 1½”), DeviceNet
VAT Vakuumventile AG, CH-9469 Haag, Switzerland
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3.1.1 Local operation
Local operation means that the valve is operated via the service port using a computer or the Service Box 2. When using a
computer, a service cable and a software from VAT are required. You can either download our freeware 'Control View' from
www.vatvalve.com or purchase our 'Control Performance Analyzer'.
These software are beneficial especially for setup, testing and maintenance.
How to start: Connect service cable, start software and push button ‘LOCAL’ to enable for operation. Then enter menu
Setup/Sensor and do sensor configuration according to your application to make sure that you get the correct pressure
displayed.
‘Control view’ supports:
- parameter setup
- manual control
- numeric monitoring
- basic diagnostic
'Control Performance Analyzer'
supports:
- parameter setup
- manual control
- sequence control
- numeric and graphical
monitoring
- data recording
- data analysis
- advanced diagnostic
When communication to service port is interrupted the valve will change to remote operation.
So when service cable will be disconnected or software will be shut down, the valve returns
automatically to remote operation.
This may result in an immediate movement of the valve depending on remote control.
Refer to «Spare parts / Accessories» for ordering numbers of service cable, software and Service Box 2.
3.1.2 Remote operation
This product is equipped with a DeviceNet interface to allow for remote operation. See section «DeviceNet Interface» for
details. ‘Control View’ software, 'Control Performance Analyzer' software or 'Service Box 2' may be used for monitoring
during remote control.
Note: In case ‘Control View’ or ‘Control Performance Analyzer’ software is connected to valve make sure ‘REMOTE’ button
is pushed to enable for remote operation. In case Service Box 2 is connected to valve make sure the LED on button
‘LOCAL’ is OFF for remote operation.