VAT 642 Series Assembly instructions

Installation, Operating &
Maintenance Instructions
603696EA
Edition 2013-08-16
Control gate valve
with RS232 interface
Series 642
DN 100 mm (I.D. 4")
This manual is valid for the following product ordering numbers:
64240-PEAG-0001
Configured with firmware: 642P.2E.02

Series 642
2/82
Edition 2013-08-16
603696EA
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.

Series 642
603696EA
Edition 2013-08-16
3/82
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.......................................................................................16
4.2.3 Installation procedure......................................................................................17
4.3 Tightening torque ..........................................................................................................18
4.3.1 Mounting with centering rings .........................................................................18
4.3.2 Mounting with O-ring in grooves .....................................................................18
4.4 Admissible forces ..........................................................................................................19
4.4.1 Requirements to sensor connection................................................................20
4.5 Electrical connection......................................................................................................20
4.5.1 Ground connection..........................................................................................21
4.5.2 Sensor supply concepts..................................................................................22
4.5.3 Power and sensor connection ( 15 VDC sensors) with opt. SPS module ......23
4.5.4 Service port connection...................................................................................24
4.5.5 RS232 Functions and Wiring ..........................................................................25
4.6 Initial operation..............................................................................................................28
4.6.1 RS232 interface configuration.........................................................................28
4.6.2 Valve configuration..........................................................................................29
4.6.3 Sensor configuration.......................................................................................29
4.6.4 ZERO..............................................................................................................29
4.6.5 LEARN............................................................................................................30
4.6.6 Tuning of control performance ........................................................................32
4.7 RS232 interface commands..........................................................................................36
4.7.1 RS232 Command syntax................................................................................36
4.7.2 Control commands..........................................................................................37
4.7.3 Inquiry commands...........................................................................................38
4.7.4 Setup commands............................................................................................43
4.7.5 Error messages...............................................................................................48
5Operation...........................................................................................49
5.1 Normal operation...........................................................................................................49

Series 642
4/82
Edition 2013-08-16
603696EA
5.1.1 Local operation................................................................................................50
5.1.2 Remote operation............................................................................................51
5.2 Close valve....................................................................................................................52
5.3 Open valve ....................................................................................................................52
5.4 Position control..............................................................................................................52
5.5 Pressure control.............................................................................................................52
5.6 Display information........................................................................................................53
5.6.1 Power up.........................................................................................................53
5.6.2 Operation ........................................................................................................54
5.6.3 Errors ..............................................................................................................54
5.6.4 Safety mode....................................................................................................54
5.6.5 Service indication............................................................................................54
5.7 Operation during power up............................................................................................55
5.8 Behavior in case of power failure...................................................................................55
5.9 Operation under increased temperature........................................................................55
6Trouble shooting .............................................................................. 56
7Maintenance...................................................................................... 59
7.1 Maintenance intervals....................................................................................................59
7.2 Maintenance procedures...............................................................................................60
7.2.1 Replacement of gate seals and valve cleaning ...............................................61
7.2.2 Replacement of Option board .........................................................................66
7.2.3 Retrofit / replacement procedure.....................................................................68
8Repairs .............................................................................................. 71
9Dismounting and Storage................................................................ 72
9.1Dismounting...................................................................................................................72
9.2 Storage..........................................................................................................................73
10 Packaging and Transport................................................................. 74
10.1 Packaging......................................................................................................................74
10.2 Transport.......................................................................................................................75
11 Disposal............................................................................................. 76
12 Spare parts........................................................................................ 77
12.1 Drawing .........................................................................................................................78
12.1.1 Valve unit with seals and grease.....................................................................79
12.1.2 Control and actuating unit ...............................................................................80
12.1.3 Accessories.....................................................................................................80
13 Appendix........................................................................................... 81

Series 642
DESCRIPTION OF PRODUCT
603696EA
Edition 2013-08-16
5/82
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 control gate valve with isolation functionality. It is intended to use for downstream
pressure control applications.
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
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
Series 642
6/82
Edition 2013-08-16
603696EA
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
86 W
[connector: POWER]
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]
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]
PFO4) battery pack (optional)
Charging time
Durability
2 minutes max.
up to 10 years @ 25°C ambient
refer to «Durability of power fail battery» for details
Compressed air supply
4 - 7 bar / 55 - 100 psi (above ATM)
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
9155 (full stroke)
Closing time throttling only
3 s typ.
Opening time throttling only
3 s typ.
Closing time throttling & isolation
6 s typ.
Opening time throttling & isolation
6 s typ.
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 «Behavior in case of power failure» for details.

Series 642
DESCRIPTION OF PRODUCT
603696EA
Edition 2013-08-16
7/82
1.6.2 Valve unit
Valve unit
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
Leak rate valve seat at 20 C
1 x 10E-9 mbar l/s
Cycles until first service
- Throttling cycles (open - max. throttle - open)
- Isolation cycles (open - closed - open)
1’000’000 (unheated and under clean conditions)
200’000 (unheated and under clean conditions)
Admissible operating temperature
+10°C to +150°C
Mounting position
any (valve seat on chamber side is recommended)
(valve seat to face chamber is recommended)
Process side materials
body
Stainless steel 316L (1.4404 or 1.4435)
plate
Stainless steel 316L (1.4404 or 1.4435)
other parts
Aluminum: A356 (3.2371)
Stainless steel: 301 (1.4310), 303 (1.4305), 304 (1.4301
or 1.4303), 316L (1.4435 or 1.4404), A2 (304)
Seals
plate
FKM (e.g. Viton®)
rotary feedthrough
FKM (e.g. Viton®)
bonnet (vulcanized)
FKM (e.g. Viton®)
Max. differential pressure on plate during isolation
2000 mbar in either direction
Max. differential pressure on plate
during opening and throttling
30 mbar
Min. controllable conductance
(N2molecular flow)
1 l/s
Max. controllable conductance
(N2molecular flow)
1700 l/s
Dimensions
Refer to dimensional drawing of specific valve ordering
number
(available on request)

SAFETY
Series 642
8/82
Edition 2013-08-16
603696EA
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 642
SAFETY
603696EA
Edition 2013-08-16
9/82
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
Series 642
10/82
Edition 2013-08-16
603696EA
3 Design and Function
3.1 Design
14 3 9 2 5 7 6 8 11 10
1
Valve gate
7
Gate seal
2
Ball guidance
8
Actuator shaft
3
Leaf spring
9
Counter plate
4
Ball pairs
10
Bonnet seal
5
Detents
11
Rotary feed through seals
6
Crank bolt
3.2 Function
The valve gate (1) 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. For leak tight closing the VATLOCK principle is
applied. For details refer to VAT catalog.

Series 642
DESIGN AND FUNCTION
603696EA
Edition 2013-08-16
11/82
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
Series 642
12/82
Edition 2013-08-16
603696EA
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.

Series 642
INSTALLATION
603696EA
Edition 2013-08-16
13/82
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.
CAUTION
Valve is a heavy component
Physical overstraining.
Use a crane to lift valves DN 200 (8”) and larger.
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. Attach lifting device for valves DN 200 (8”) and larger. For attachment refer to dimensional drawing of
valve.
3. Lift the valve carefully and place it on a clean place.
Do not remove protective foils from valve opening

INSTALLATION
Series 642
14/82
Edition 2013-08-16
603696EA
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.

Series 642
INSTALLATION
603696EA
Edition 2013-08-16
15/82
4.2.1 Installation space condition
Install the valve with integrated controller with space for dismantling and air circulation
as shown in figure below.
100
220

INSTALLATION
Series 642
16/82
Edition 2013-08-16
603696EA
4.2.2 Connection overview
System:
M
3
4
5
6
7
2
198
10
11
1 Valve
2 Process chamber
3 Gas inlet
4 Pressure sensor(s)
5 Sensor cable(s)
6 Cable to RS232 remote control unit
7 Cable to power supply
8 Controller
9 Connection cable controller / actuator
10 Actuator
11 Pump
Actuator
Controller

Series 642
INSTALLATION
603696EA
Edition 2013-08-16
17/82
4.2.3 Installation procedure
1. Install valve [1] into the vacuum system.
Do not tighten the flange screws stronger than indicated under «Tightening
torque».
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.
2. Install the ground connection cable at controller. Refer to «Electrical connection»
3. Install connection cable between actuator (connector) and controller (connector: VALVE)
4. Install sensor(s) [4] according to the recommendations of the sensor manufacturer and directives
given under «Requirements to sensor connection».
5. Connect pressure sensor cable [5] to sensor(s) and then to valve (connector: SENSOR). Refer to
chapter «Electrical connection» for correct wiring.
Input for second sensor is available on 642 . . - . . . H - . . . . version only.
6. Connect valve to RS232 Interface [6] (RS232 connector). Refer to «DeviceNet schematics» for
correct wiring.
7. Connect power supply [7] 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».
8. This valve may optionally be equipped with a heating device. Connect VAT heating device according
to manual of respective heating device.
9. Perform «Setup procedure» to prepare valve for operation.
Without performing the setup procedure the valve will not be able to do pressure
control.

INSTALLATION
Series 642
18/82
Edition 2013-08-16
603696EA
4.3 Tightening torque
4.3.1 Mounting with centering rings
ISO-F
ISO-F
max. tightening torque
(Nm)
max. tightening torque
(lbs . ft)
8-10
6-8
hole depth (mm)
hole depth (inch)
12
0.47
4.3.2 Mounting with O-ring in grooves
ISO-F
JIS
ASA-LP
ISO-F
JIS
ASA-LP
max. tightening torque
(Nm)
max. tightening torque
(lbs . ft)
20-23
35-40
35-40
15-17
26-30
26-30
hole depth (mm)
hole depth (inch)
12
0.47
The torque values below are dependent on many factors, such as materials involved,
surface quality, surface treatment, and lubrication.
The torques below are valid if immersion depth of the mounting screws is at least
once the thread diameter (min. 1d), and the friction coefficient of the screw-flange
connection ( total = ( screw thread-helicoil + under screw head)/2) is bigger than 0.12. Lower
friction coefficients may damage the valve, as the resulting preload force gets too
high. Therefore for other friction coefficients the torque needs to be adapted. Please
review design guidelines for Helicoil-Screw connections and make sure that screws in
use are capable to withstand applied torques, are appropriate for the application and
are not too long. Too long screws may damage the valve, the immersion depth should
not exceed (hole depth –1 mm).
Tighten mounting screws of the flanges uniformly in crosswise order. Observe the
maximum torque levels in the following tables.
Refer to «Spare parts / Accessories» for centering rings ordering numbers.

Series 642
INSTALLATION
603696EA
Edition 2013-08-16
19/82
4.4 Admissible forces
NOTICE
Force at flange and valve body
Forces from evacuating the system, from the weight of other components, and from
baking can lead to deformation and malfunctioning 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»
FA
N
lb.
Nm
lbf.
1000
220
40
30
For a combination of both forces (FAand M) the values are invalid.
Verify that the depth of the mounting screws is min. 1 × thread diameter.
Please contact VAT for more information.

INSTALLATION
Series 642
20/82
Edition 2013-08-16
603696EA
4.4.1 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