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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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QM-S

UHV gate valve

with 3 position pneumatic actuator

This manual is valid for the valve ordering numbers:

10836- . E28/48
10840- . E28/48
10844- . E28/48
10846- . E28/48

The respective product identification is given on each valve in the following or in a

similar way:

made in Switzerland 96
Fabrication No.: patented
F10 – . . . . . / . .
108 . . – . . . . – . . . .

Explanation of symbols:

Read declaration carefully before you start any other Keep body parts and objects away from the valve
action! opening!

Attention! Hot surfaces; do not touch!

Product is in conformity with EC guidelines, Loaded springs and/or air cushions are potential
if applicable! hazards!

Disconnect electrical power and compressed air

Wear gloves!
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!

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Imprint:

Manufacturer VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Website Phone Fax Email

www.vatvalve.com +41 81 771 61 61 +41 81 771 48 30 [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 2008

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.

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

ep
Series 10.8, DN 63 - 200 (2½" - 8")

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QM-S

Intended use of product

Use product for vacuum applications under the conditions indicated in the chapter «Technical data» only! Other
applications are only allowed with the written permission of VAT.

Technical data
Pressure range 1 x 10-10 mbar to 1.6 bar (abs)
Differential pressure on the gate ≤ 1.6 bar in either direction
Differential pressure at opening ≤ 30 mbar
Admissible temperature: Valve ≤ 250°C open, 200°C closed
Pneumatic actuator ≤ 200°C
Position indicator ≤ 80°C
Solenoid ≤ 50°C
Position indicator: contact rating 5 A / 250 V AC, 3 A / 50 V DC
Solenoid see tag on solenoid

Installation into the vacuum system

The valve seat side is indicated by the symbol "∇" on the connection flange.

Admissible forces
Forces from evacuating the system, from the weight of other components, and from baking can lead to deformation of the
valve body and to malfunction of the valve. The stress has to be relieved by suitable means, e.g. bellows sections. The
following forces are admissible:

DN (nom. I.D.) Axial tensile or Bending moment «M»

compressive force «FA»
mm inch N lbf Nm lbf • ft
63 2½ 2000 448 80 59
100 4 2500 560 100 74
160 6 3000 672 150 110
200 8 3000 672 150 110
FA M
If a combination of both forces («FA» and «M») occurs, the values mentioned
above are invalid. Please contact VAT for more information.

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Compressed air connection

Connect compressed air only if
- valve has been installed into the vacuum system
- moving parts cannot be touched
With solenoid: Connect compressed air to IN (internal thread R 1/8“, 1/8“ NPT for USA)
1
Without solenoid: Connect compressed air to OPEN and CLOSE (internal thread /8")
Compressed air pressure (min. - max. overpressure): 4 - 7 bar / 55 - 100 psig
Use only clean, dry or slightly oiled air!

Electrical connection
Do not touch electrical parts under voltage!

Connect electrical power only if

- valve has been installed into the vacuum system
- moving parts cannot be touched
Verify that mains voltage matches voltage stated on the solenoid! Sockets for position indicator and
solenoid are supplied with the valve.
Wire solenoid and position indicator according to the following diagrams:

Standard solenoids Position indicator for three positions

Main cylinder MV1 and auxiliary cylinder
MV2 for third position
(see drawing on page 5)
1
MV 1 Lo
power 2 1 2
6 Lg
6 1
5 2
5
1 4
MV 4 3
Lz
2 2 3
1
2

MV = coils of solenoid Lo = position indicator «open»

Lg = position indicator «closed»
Lz = position indicator for the intermediate position
Solenoid MV1 MV2
Valve position:
open 1 1
Intermediate position 1 0
closed 0 1
1 = coil of solenoid supplied with current
0 = coil of solenoid not supplied with current

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Operation

Normal operation
Valve is opened and closed by means of compressed air.

Admissible temperature
See «Technical data»!

Compressed air failure

Valve closed:
valve remains closed

Valve open:
Valve position is undefined, depending on mounting

Valve intermediate position:

Valve position is undefined, depending on mounting position

At compressed air return, the valve gate moves to the present position.

Power failure
Standard solenoid: valve closes

Emergency operation at power failure

In case of a power failure, the valve can be actuated manually if compressed air is available.

Standard solenoid
Press both push-buttons MV1 + MV2: valve opens
Release both push-buttons MV1 + MV2: valve closes
Press only push-button MV1:
Valve gate moves to the intermediate position

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Conversion from double acting to 3-position pneumatic actuator

(see drawing below)

1. Vent chambers and open valve

2. Disconnect compressed air and electrical supply from valve
3. Remove position indicator (1)
4. Remove screws (23) and cylinder cover (22)
(old cylinder cover and old position indicator are no longer used)
5. Remove nut (24, transport safety device) and screws (28) from 3-position pneumatic actuator and withdraw shaft
extension (29) carefully
Attention: Do not disassemble unit!
6. Screw shaft extension (29) into shaft (31) by turning at the square section (30), and tighten it
7. Put complete unit on cylinder (20) and tighten screws (28)
8. Schrew on new position indicator for 3-position pneumatic actuator (old cylinder cover and old position indicator are
no longer used)
9. Insert position indicator actuator (21) and position indicator strip (26) into groove and screw on cover plate (25)
Attention: Leaf spring (27) must be inserted!
10. Connect compressed air and electrical power supply
11. Set desired intermediate position be means of the setscrew (8)

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Conversion of a manual actuator to a 3-position pneumatic actuator

(see following drawing)

1. Disassembly of manual actuator

1.1 Vent chambers and open valve

1.2 Loosen screw (35) through access hole (37)
1.3 Remove screws (33)
1.4 Withdraw manual actuator (36) carefully

2. Assembly of actuator unit «A»:

2.1 Valve is in open position

2.2 Remove nuts (34)
2.3 Remove cylinder cover (22) and screws (23), but do not remove O-ring from cover
Attention! Do not disassemble remaining unit
2.4 Remove guiding shafts (31) from unit «A» and insert them into the bellows end piece (38) of the valve by turning at
the squared sections (39)
2.5 Put actuator unit (A) in place
2.6 Tighten screw of piston (32) until resistance is noticeable
2.7 Put cylinder cover (22) in place and fix it by means of screws (23)
2.8 Close valve by means of compressed air (approx. 3 bar)
2.9 Disconnect compressed air supply and vent cylinder interior completely
2.10 Remove cylinder cover (22)
2.11 Tighten screw of piston (32) until valve unlocks (audible)
2.12 Loosen screw of piston (32) by ½ turn
2.13 Put cylinder cover (22) in place and fix it by means of screws (23)
2.14 Close valve by means of compressed air (approx. 3 bar) (Lever audible over dead center)
2.15 Measure opening pressure (should be between 1.0 and 1.3 bar in order to keep the valve ub locked position in the
event of compressed air failure)
2.16 If the opening pressure is below 1.0 bar: Loosen screw of piston (32) by 1/8 turn
2.17 If the opening pressure exceeds 1.3 bar: Tighten screw of piston (32) by 1/8 turn
2.18 Attention! Before disassembling the cylinder cover always disconnect compressed air supply and vent cylinder
interior completely

3. Assembly of 3-position pneumatic actuator «B»:

3.1 Remove cylinder cover (22) (is no longer necessary)

3.2 Remove nuts (24, transport safety screws) and screws (28) from 3-position pneumatic actuator and withdraw shaft
extension (29)
Attention! Do not disassemble unit
3.3 Insert shaft extensions (29) into shafts (31) by turning at the squared sections (30) and tighten them
3.4 Put complete unit (B) on cylinder (20) and tighten screws (28). Make sure that the O-ring (40) has been installed.
3.5 Connect compressed air and power
3.6 Adjust desired intermediate position by means of screw (8)

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Adjustment of the intermediate position

a) with solenoids: b) without solenoids:

- MV1: coils of solenoids supplied with electrical power - Cylinder «A»: compressed air to «OPEN»
- MV2: coils of solenoids not supplied with electrical power - Cylinder «B»: compressed air to «MID»
- Adjust the desired intermediate position - Adjust the desired intermediate position
by means of the adjustment screw (8) by means of the adjustment screw (8)

Attention: If the compressed air pressure applied for adjusting the intermediate position differs from that specified in the
chapter «Compressed air pressure» (page 2) it may happen that the carrier nut inside the actuator
disengages from the adjustment screw (8). The same problem can occur when the adjustment screw (8) is
still being turned in counter-clockwise direction after the mechanism has reached the closed position.

In order to recapture the carrier nut, please follow the instructions below:
1. Supply the inlet «OPEN» with 1 bar / 15 psig of compressed air
2. Turn the adjustment screw (8) in clockwise direction until the carrier nut is completely recaptured
(We recommend to carry out 20 full turns!)
3. Adjust the intermediate position according to above instructions [ a) or b) ]

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

ep
Series 10.8, DN 63 - 200 (2½" - 8")

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QM-S

Preventive maintenance

Under clean operating conditions, the valve does not require any maintenance during the specified cycle life.

Maintenance

Replacement of actuator/mechanism assembly

The figures in brackets refer to the drawing on page 11

- Vent chambers and open valve

- Disconnect compressed air and electrical power from valve
- Remove bonnet screws (61) in crosswise order
- Withdraw actuator/mechanism assembly carefully from body
- Check and clean sealing surfaces of bonnet and valve seat
- Put new bonnet seal (60) on body or bonnet (depending on mounting position). If the actuator is directed downwards,
proceed according to the following drawing:
- Reassemble in reverse direction
Note! Tighten screws in crosswise order!
Torque: DN 63 - 160 20 Nm / 15 lbf . ft
DN 200 40 Nm / 30 lbf . ft

Body

Adhesive tape

Bonnet seal

Bonnet

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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QM-S

Replacement of gate
- Remove actuator/mechanism assembly as described in the section «Replacement of actuator/mechanism assembly»
- Put mechanism into horizontal position to prevent the locking balls from falling out
- Lift plate manually at «H» and insert tool (W1) [e.g. a screw driver] between spring (21/6) and ball guidance (21/3)
- Remove gate (21/4) in direction of the arrow
- Insert new gate in reverse direction
- Remove tool (W1)
- Check whether gate is inserted properly. The markings ∆ and ∇ (W2) on ball guidance and gate must face each other.

W1 21/6 21/4 W1

Y
X X

X
"H" W2 21/3 W1 21/6

DN mm 63 100 160 200

inch 2½ 4 6 8
X mm 4.0 4.0 8.0 5.0
inch 0.16 0.16 0.31 0.20
Y mm 0.0 0.0 7.0 10.0
inch 0.0 0.0 0.27 0.40

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Spare parts

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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The item numbers refer to the drawing on page 11

Item Description DN Part No. Air connection kit (standard without solenoid)
Seal kit, 63 82484-R1 Item Description DN Qty. Part No.
Consisting of: 100 82485-R1 44 Pneumatic 63-200 1 94827-R1
connection kit
- Gate /21/4) 160 82486-R1
- Bonnet seal (60) 200 82487-R1
21/4 Gate 63 84065-R1
100 80506-R1
160 80510-R1
200 79324-R1
21/30 1 Set of 8 pcs 63 331584
locking balls 12 pcs 100 331587
16 pcs 160 331589
16 pcs 200 329723
60 Bonnet seal 63 63215-01
100 63216-01
160 93160-01
200 63217-01

Solenoid kit: (standard) Solenoid kit: impulse actuation (option)

Item Description Qty. Part No. Item Description Qty. Part No.
Solenoid kit 1 94800-R1 Solenoid kit 1 94801-R1
43/1 Solenoid 1 N-7557-018 *) 43/1 Solenoid 1 N-7557-021 *)
43/10 Plug 1 N-8501-400 43/10 Plug 2 N-8501-400

..... *) Specify voltage!

(e.g. N-7557-018-220V 50Hz)

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

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Series 10.8, DN 63 - 200 (2½" - 8")

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Position indicator kit: 3 positions

42/6

42/1

CLOSED OPEN

42/2

42/3+4

Item Description Qty. Part No.

Position indicator DN 63 1 81085-R1
kit DN 100 1 81085-R1
DN 160 1 81085-R1
DN 200 1 81085-R1
42/1 Position indicator 1 73656-R1
42/2 Slider 1 73638-R1
42/3 Strip 1 70987-01
42/4 Driving pin 2 70988-01
42/6 Plug 1 N-8504-002

Trouble shooting

Valve does not close/open: Power available?

Compressed air available?
Solenoid defective?
Check voltage!
Check air pressure!

Leak at gate: Clean valve seat and gate!

Replace gate, if damaged!
Correct air pressure?

Leak at body: Flanges leaktight?

Replace bonnet seal!

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14
 d Q M- S y s
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Installation, Operating, and Maintenance Instructions

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ISO 9001
EN 29001

ep
Series 10.8, DN 63 - 200 (2½" - 8")

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Repairs

Contact VAT for repairs or maintenance. The fabrication No. (F10- . . . . . / . . ) marked on the valve body has always to be
specified. It has to be individually decided whether the work can be performed by the customer or has to be carried out by
VAT.

All supplies (e. g. compressed air, electrical power) have to be disconnected for removal/installation of the valve from/into
the system.

Even with disconnected supply, loaded springs and/or air cushions in cylinders can be potential hazards.

Keep fingers and objects away from the valve opening!

Products returned to VAT for repair have to be free of harmful substances such as e.g. toxical, caustic or microbiological
ones. For radioactively contaminated products the customer has to fill in the VAT form «Contamination and Radiation
Report» and to send it with the product. The form is available at VAT. The maximum permissible values indicated in the
form must not be exceeded.

Warranty

Each product sold by VAT Vakuumventile AG (VAT) is warranted to be free from the manufacturing defects that adversely
affect the normal functioning thereof during the one-year period immediately following delivery thereof by VAT, provided
that the same is properly operated under conditions of normal use and that regular, periodic maintenance and service is
performed or replacements made, in accordance with the instructions provided by VAT. The foregoing warranty shall not
apply to any product or component that has been repaired or altered by anyone other than an authorized VAT
representative or that has been subject to improper installation or abuse, misuse, negligence or accident. VAT shall not be
liable for any damage, loss, or expense, whether consequential, special, incidental, direct or otherwise, caused by, arising
out of or connected with the manufacture, delivery (including any delay in or failure to deliver), packaging, storage or use
of any product sold or delivered by VAT shall fail to conform to the foregoing warranty or to the description thereof
contained herein, the purchaser thereof, as its exclusive remedy, shall upon prompt notice to VAT of any such defect or
failure and upon the return of the product, part or component in question to VAT at its factory, with transportation charges
prepaid, and upon VAT's inspection confirming the existence of any defect inconsistent with said warranty or any such
failure, be entitled to have such defect or failure cured at VAT's factory and at no charge therefor, by replacement or repair
of said product, as VAT may elect. VAT MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND, EXPRESS OR
IMPLIED, (INCLUDING NO WARRANTY OR MERCHANTABILITY), EXCEPT FOR THE FOREGOING WARRANTY AND
THE WARRANTY THAT EACH PRODUCT SHALL CONFORM TO THE DESCRIPTION THEREOF CONTAINED
HEREIN, and no warranty shall be implied by law.

Furthermore, the «Terms of sale» at the back of the price list are applicable.

VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Tel +41 81 771 61 61 Fax +41 81 771 48 30 [email protected] www.vatvalve.com
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2003-04-14