VAT 121 series Installation, Operating, & Maintenance Instructions

Installation, Operating &
Maintenance Instructions

600968EA

Edition

2015

-11-16

Vacuum gate valve

with double acting pneumatic actuator
Series 121

DN 63 – 320 mm (I. D. 2½" – 12")

This manual is valid for the following product ordering numbers:

121 .. - .... - ....

Sample picture

Series

121

2/27 Edition

2015

-11-16

600968EA

Imprint

Manufacturer VAT Vakuumventile AG, CH-9469 Haag, Switzerland

Website:
Phone:
Fax:
Email:

www.vatvalve.com
[phone]
[phone]
[e-mail]

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 2015
No part of these instructions may be reproduced in any way (photo-

copies, microfilms or any other reproduction processes) nor may it be
manipulated with electronic systems, duplicated or distributed without
written permission from VAT. Offenders are liable to pay damages.

The original VAT firmware and updated state of the art versions of the

VAT firmware are intended for use with VAT products. The VAT firmware
contains a limited, time unlimited user license. The VAT firmware may not
be used for purposes other than those intended nor is it permitted to
make copies of the VAT firmware. In particular, it is strictly forbidden to
give copies of the VAT firmware to other people.

The use of trade names, brand names, trademarks, etc. in these

Instructions does not entitle third parties to consider these names to be
unprotected and to use them freely. This is in accordance with the
meaning of the laws and acts covering brand names and trademarks.

Series 121 DESCRIPTION OF PRODUCT

600968EA

Edition

2015

-11-16 3/

27

Contents

1 Description of product ........................................................................ 4

1.1 Identification of product ....................................................................................... 4

1.2 Use of product ..................................................................................................... 4

1.3 Related documents ............................................................................................. 4

1.4 Important information .......................................................................................... 4

1.5 Technical data ..................................................................................................... 4

2 Safety ................................................................................................... 5

2.1 Compulsory reading material .............................................................................. 5

2.2 Danger levels ...................................................................................................... 5

2.3 Personnel qualifications ...................................................................................... 6

2.4 Safety labels ........................................................................................................ 6

3 Design and Function ........................................................................... 7

3.1 Design ................................................................................................................. 7

3.2 Function .............................................................................................................. 7

4 Installation ........................................................................................... 8

4.1 Unpacking ........................................................................................................... 8

4.2 Installation into the system .................................................................................. 8

4.2.1 Admissible forces and bending moments ............................................. 10

4.3 Compressed air connection .............................................................................. 11

4.4 Electrical connection ......................................................................................... 11

5 Operation ........................................................................................... 12

5.1 Normal operation ............................................................................................... 12

5.2 Operation under increased temperature ........................................................... 12

5.3 Behavior in case of compressed air pressure drop .......................................... 12

5.4 Behavior in case of power failure ...................................................................... 12

5.4.1 Manual emergency operation ............................................................... 13

5.5 Trouble shooting ............................................................................................... 14

6 Maintenance ...................................................................................... 15

6.1 Maintenance intervals ....................................................................................... 15

6.2 Tightening torque specifications ....................................................................... 16

6.3 Required tools ................................................................................................... 16

6.4 Replacement of gate seal and bonnet seal ...................................................... 16

7 Repairs ............................................................................................... 20

8 Dismounting and Storage ................................................................. 21

8.1 Dismounting ...................................................................................................... 22

8.2 Storage .............................................................................................................. 22

9 Packaging and Transport ................................................................. 23

9.1 Packaging ......................................................................................................... 24

9.2 Transport ........................................................................................................... 24

10 Disposal ............................................................................................. 25

11 Spare parts ........................................................................................ 26

DESCRIPTION OF PRODUCT Series

121

4/27 Edition

2015

-11-16

600968EA

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.:

121 . . - . . . . - . . . . / . . . .

A - . . . . . .




Fabrication number
Order number

1.2 Use of product

Use product for clean and dry vacuum applications only. Other applications are only allowed
with the written permission of VAT.

1.3 Related documents

• Product data sheet

• Dimensional drawing

1.4 Important information

This symbol points to a very important statement that requires particular
attention.

Example

:

VAT disclaims any liability for damages resulting from inappropriate packaging.

1.5 Technical data

See product data sheet and dimensional drawing.

Series 121 SAFETY

600968EA

Edition

2015

-11-16 5/

27

2 Safety

2.1 Compulsory reading material

Read this chapter prior to performing any work with or on the product. It contains important
information that is significant for your own personal safety. This chapter must have been
read and understood by all persons who perform any kind of work with or on the product
during any stage of its serviceable life.

NOTICE

Lack of knowledge

Failing to read this manual may result in property damage.
Firstly, read manual.

These Installation, Operating & Maintenance Instructions are an integral part
of a comprehensive documentation belonging to a complete technical
system. They must be stored together with the other documentation and
accessible for anybody who is authorized to work with the system at any
time.

2.2 Danger levels

DANGER

High risk

Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.

WARNING

Medium risk

Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION

Low risk

Indicates a hazardous situation which, if not avoided, may result in minor or
moderate injury.

NOTICE

Command

Indicates a hazardous situation which, if not avoided, may result in property
damage.

SAFETY Series

121

6/27 Edition

2015

-11-16

600968EA

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-9001-155 (DN 63 – 100) Protective cover

T-9001-156 (DN 160 – 320) Protective cover

N-6289-351 On the actuator

Table 2-1

Series 121 DESIGN AND FUNCTION

600968EA

Edition

2015

-11-16 7/

27

3 Design and Function

3.1 Design

1 Sealing surface
2 Valve body
3 Actuator
4 Position indicator
5 Solenoid valve

Figure 3-1

3.2 Function

The valve features the VATLOCK sealing technology. This means, the valve is mechani­cally locked in the closed position. In the open position, the mechanism is not locked. Leaf
springs hold gate and counter plate against the carriage with the ball retainers. The ball
pairs are in the detents. For closing, the mechanism is moved forward into the closing
position. The locking starts after the leaf spring stop touches the body. The ball retainers
move the ball pairs out of the detents. Gate and counter plate are spread apart. The gate
seal is pressed against the sealing surface without scuffing. The arrangement of the ball
pairs ensures an increase of the sealing force with vacuum on either side of the gate.
During opening the movements proceed in the reverse order; see «Figure 3-2».

1 Valve gate
2 Counter-plate
3 Leaf springs
4 Spring stop
5 Ball pairs
6 Ball detents
7 Gate seal

Valve seat side

Figure 3-2

INSTALLATION Series

121

8/27 Edition

2015

-11-16

600968EA

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.

WARNING

Heavy weight

Physical overstraining.
Use a crane to lift the product.

4.1 Unpacking

•

Make sure that the supplied products are in accordance with your order.

• Inspect the quality of the supplied products visually. If it does not meet
your requirements, please contact VAT immediately.

• Store the original packaging material. It may be useful if products must be
returned to VAT.

The valve can be lifted only at the eyebolt threads;
see dimensional drawing.

4.2 Installation into the system

WARNING

Movable parts

Human body parts may get jammed and severely injured.
Do not connect or supply electrical power and compressed air before the

product is completely mounted in the system.

NOTICE

Contamination

Product may get contaminated.
Always wear cleanroom gloves when handling the product.

Series 121 INSTALLATION

600968EA

Edition

2015

-11-16 9/

27

NOTICE

Inappropriate tools

Sealing surfaces may get damaged.
Do not use sharp-edged tools.

NOTICE

Wrong tightening torque

Valve body and screws may get damaged.
Use tightening torque according the size of the screws.

NOTICE

Too long screws

Valve body may get deformed and / or malfunctions may occur.
Use only screws recommended by VAT.

1. Remove protective covers from body flanges.

2. Clean sealing surfaces and seals of both flanges;
see (1) and (2) according to «Figure 4-1».

The valve seat side is marked with the symbol «∇» on flange «A».

3. Lift the valve to the mounting position. For the size DN 320 (12150- . .14 / 24 / 34 / 44)
use only the eyebolts threads; see dimensional drawing.

4. Mount the four screws (3) according to «Figure 4-1», evenly in crosswise order until the
seal touches the sealing surface.

5. Tighten all screws with the torques appropriate for their property classes.

1 Flange A
2 Flange B
3 Screws

Figure 4-1

INSTALLATION Series

121

10/27 Edition

2015

-11-16

600968EA

4.2.1 Admissible forces and bending moments

Forces from evacuating the system, from the weight of other components or
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 or bending moments are admissible:

DN (nom. I. D.)

Axial tensile or com-

pressive force «FA»

Bending moment

«M»

mm inch N lbf Nm lbf · ft

63 2½ 980 220 39 29
80 3 1025 230 43 32
100 4 1080 242 49 36
160 6 3000 674 150 110
200 8 3000 674 150 110
250 10 3500 787 200 148
320 12 4000 900 300 220

If a combination of both forces («FA» and «M») occurs, the values

mentioned above are invalid. Please contact VAT for more
information.

Table 4-1

Series 121 INSTALLATION

600968EA

Edition

2015

-11-16 11/

27

4.3 Compressed air connection

WARNING

Valve in open position

Risk of injury when compressed air is connected to the valve.
Connect compressed air only when:

– valve is installed in the vacuum system
– moving parts cannot be touched

Use clean, dry or slightly oiled air only.

Admissible air pressure range, see product data sheet.

1. Connect compressed air according to the product data sheet and dimensional drawing.

4.4 Electrical connection

DANGER

Electric shock

Parts being under voltage will result in serious injury or death.
Do not touch parts being under voltage.

NOTICE

Wrong voltage

Electrical components may get damaged.
Supply electrical components with the correct voltage.

1. Connect solenoid valve according to the product data sheet and dimensional drawing.

2. Connect position indicator according to the product data sheet and dimensional
drawing.

3. Connect heater (option) according to the product data sheet and dimensional drawing.

OPERATION Series

121

12/27 Edition

2015

-11-16

600968EA

5 Operation

WARNING

Unqualified personnel

Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.

WARNING

Movable parts

Human body parts may get jammed and severely injured.

Do not operate before product is installed completely into the vacuum system.

WARNING

Hot surfaces

Risk of burning when touching hot surfaces.
Do not touch hot surfaces.

5.1 Normal operation

Valve is opened and closed pneumatically.

5.2 Operation under increased temperature

Maximum allowed temperature, see product data sheet.

5.3 Behavior in case of compressed air pressure drop

See product data sheet.

5.4 Behavior in case of power failure

See product data sheet.

Series 121 OPERATION

600968EA

Edition

2015

-11-16 13/

27

5.4.1 Manual emergency operation

WARNING

Movable parts

Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.

Only valid for the ordering number 121..-..

3

4/44

(with solenoid valve)

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

Standard solenoid valve

Press push-button (1): valve opens
Release push-button (1): valve closes

Solenoid valve with lockable emergency operation (option)

Push and rotate in lockable: valve opens
Push and rotate unlockable: valve closes

OPERATION Series

121

14/27 Edition

2015

-11-16

600968EA

Solenoid valve for impulse actuation (option)

Press push-button (1): valve opens
Press push -button (2): valve closes

5.5 Trouble shooting

Failure Check Action See

Valve does not

close / open

Air pressure Connect

compressed air

«4.3 Compressed air
connection»

Operating

pressure

Adjust operating
pressure

Product data sheet

Voltage at

solenoid valve

Connect voltage «4.4 Electrical connection»

Leak at gate Gate seal all

right?

Replace valve
gate

«6.4 Replacement of gate
seal and bonnet seal»

Gate damaged or

contaminated?

Replace valve
gate

«6.4 Replacement of gate
seal and bonnet seal»

Operating

pressure

Adjust operating
pressure

Product data sheet

Leak at body Bonnet seal and

sealing surface all
right?

Clean sealing
surface, if
necessary,
replace bonnet
seal

«6.4 Replacement of gate
seal and bonnet seal»

Table 5-1
If you need any further information, please contact one of our service centers. You will find

the addresses on our website www.vatvalve.com.

Series 121 MAINTENANCE

600968EA

Edition

2015

-11-16 15/

27

6 Maintenance

WARNING

Unqualified personnel

Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.

WARNING

Heavy weight

Physical overstraining.
Use a crane to lift the valve insert.

WARNING

Hazardous components

Human body parts may get jammed and severely injured.
Before starting maintenance:

– disconnect compressed air supply
– disconnect electrical power supply

WARNING

Movable parts

Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.

WARNING

Hot surfaces

Risk of burning when touching hot surfaces.
Touch hot surfaces only if the valve has cooled down.

6.1 Maintenance intervals

Under clean operating conditions the valve does not require any maintenance during the
specified cycles; see product data sheet. After these cycles, VAT recommends replacing
the mechanism unit; see chapter «6.4 Replacement of gate seal and bonnet seal».

For more information or a general overhaul please contact one of our service centers. You
will find the addresses on our website www.vatvalve.com.

MAINTENANCE Series

121

16/27 Edition

2015

-11-16

600968EA

6.2 Tightening torque specifications

Item-No. Description

Tightening torque [Nm]

DN 160–200 DN 250–320

2

Bonnet screw

14 20

Item-No. Description

Tightening torque [Nm]

DN 63–100

2

Bonnet screw

3.5

Table 6-1

6.3 Required tools

• Torque wrench according «Table 6-1»

• Cleanroom wiper soaked with alcohol (2% methyl ethyl ketone)

• O-Ring removal tool; see «Table 11-1» on page 27

Figure 6-1

6.4 Replacement of gate seal and bonnet seal

WARNING

Loaded spring steel sheet

Human body parts may get jammed and severely injured.
Do not put human body parts between valve gate and spring steel sheet.

NOTICE

Contamination

Product may get contaminated.
Always wear cleanroom gloves when handling the product.

Series 121 MAINTENANCE

600968EA

Edition

2015

-11-16 17/

27

NOTICE

Inappropriate tools

Sealing surfaces may get damaged.
Do not use sharp-edged tools.

The numbers in brackets ( ) refer to «Figure 6-4» on page 19.

1. Vent chambers on either side to atmospheric pressure.

2. Open valve.

3. Disconnect compressed air supply.

4. Disconnect electrical power supply.

5. Loosen both screws (2).

6. Swing the both screws (2) out (only for DN 160 or higher).

Make sure to maintain upper valve body (5) in its position while losing and
swinging out the screws!

7. Lift upper valve body (5) carefully from lower part of body (1) without touching the body
wall and put it on a clean place (seat side symbol «∇» on top).

Do not touch the actuator with the lifting ropes, if you lift the upper valve
body!

8. Apply compressed air (air pressure approx. 1 bar) and move mechanism slowly out of
upper part of body (5).

Provide sufficient free space in order to prevent the mechanism from

touching any objects.

9. Disconnect compressed air.

10. Remove gate seal (1) from groove; see «Figure 6-2»; use O-ring removal tool.

1 Gate seal
2 Valve gate

Figure 6-2

MAINTENANCE Series

121

18/27 Edition

2015

-11-16

600968EA

11. Check and clean sealing surface of valve seat; use cleanroom wiper.

12. Install new gate seal (1); see «Figure 6-2».
Press O-ring uniformly in crosswise order (diagonal) into groove.

13. Remove bonnet seal (3) from groove; use O-ring removal tool.

14. Check and clean sealing surface of bonnet seat; use cleanroom wiper.

15. Install new bonnet seal (5).

• Press O-ring into groove on one short side.

• Distribute seal uniformly over long sides to opposite short side and press it

fully into groove.

Make sure to have gate (2); see «Figure 6-2»; on seat side «∇»;
see «Figure 6-4» on page 19.

Align mechanism with opening of upper part of body.

16. Apply compressed air (air pressure approx. 1 bar) and move mechanism slowly into

upper valve body (5).

Provide sufficient free space in order to prevent the mechanism from
touching any objects.

17. Disconnect compressed air from valve.

18. Lift upper valve body (5) carefully back into the lower valve body (1) without touching

the body wall.

The tips of the triangles «∇» of both body parts must face each other;
see «Figure 6-3 » on page 19 and «Figure 6-4» on page 19.

Series 121 MAINTENANCE

600968EA

Edition

2015

-11-16 19/

27

DN 63–100

DN 160
or higher

Figure 6-3

19. For DN 160 or higher: Swing back both screws (2); see «Figure 6-4».

20. Tighten the screws (2) with the appropriate torque specified in chapter
«6.2 Tightening torque specifications».

21. Connect electrical power supply.

22. Connect compressed air supply.

23. Close the valve.

1 Lower valve body
2 Screws
3 Bonnet seal
4 Gate
5 Upper valve body

Valve seat side

Figure 6-4

Valve is ready for use.

REPAIRS Series

121

20/27 Edition

2015

-11-16

600968EA

7 Repairs

Repairs may only be carried out by the VAT service staff. In exceptional cases, the
customer is allowed to carry out the repairs, but only with the prior consent of VAT.

Please contact one of our service centers. You will find the addresses on our website
www.vatvalve.com.

Series 121 DISMOUNTING AND STORAGE

600968EA

Edition

2015

-11-16 21/

27

8 Dismounting and Storage

WARNING

Unqualified personnel

Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.

WARNING

Heavy weight

Physical overstraining.
Use a crane to lift the product.

WARNING

Hazardous components

Human body parts may get jammed and severely injured.
Before dismounting the product

– disconnect compressed air supply
– disconnect electrical power supply

WARNING

Movable parts

Human body parts may get jammed and severely injured.
Keep human body parts away from movable parts.

WARNING

Hot surfaces

Risk of burning when touching hot surfaces.
Touch hot surfaces only if the valve has cooled down.

NOTICE

Contamination

Product may get contaminated.
Always wear cleanroom gloves when handling the product.

DISMOUNTING AND STORAGE Series

121

22/27 Edition

2015

-11-16

600968EA

8.1 Dismounting

NOTICE

Valve in open position

Valve mechanism may get damaged if valve is in open position.
Close valve before dismounting the valve from the system.

1. Close valve.

2. Carry out the steps according to chapter «4 Installation» in reverse order.
Pay attention to the safety instructions!

8.2 Storage

NOTICE

Wrong storage

Inappropriate temperatures and humidity may cause damage to the product.
Valve must be stored at:

– relative humidity between 10% and 70%
– temperature between +10 °C and +50 °C
– non-condensing environment

NOTICE

Inappropriate packaging

Product may get damaged if inappropriate packaging material is used.
Always use the original packaging material and handle product with care.

1. Clean / decontaminate valve.

2. Cover all valve openings with a protective foil.

3. Pack valve appropriately, by using the original packaging material.

Series 121 PACKAGING AND TRANSPORT

600968EA

Edition

2015

-11-16 23/

27

9 Packaging and Transport

WARNING

Unqualified personnel

Inappropriate handling may cause serious injury or property damage.
Only qualified personnel are allowed to carry out the described work.

WARNING

Heavy weight

Physical overstraining.
Use a crane to lift the product.

WARNING

Harmful substances

Risk of injury in case of contact with harmful substances.
Remove harmful substances (e. g. toxic, caustic or microbiological ones) from

valve before you return the valve to VAT.

NOTICE

Inappropriate packaging

Product may get damaged if inappropriate packaging material is used.
Always use the original packaging material and handle product with care.

•

When returning products to VAT, please fill out the VAT form «Declaration

of Chemical Contamination» and send it to VAT in advance. The form can
be downloaded from our website www.vatvalve.com.

• If products are radioactively contaminated, the VAT form «Contamination
and Radiation Report» must be filled out. Please contact VAT in advance.

• If products are sent to VAT in contaminated condition, VAT will carry out
the decontamination procedure at the customer's expense.

PACKAGING AND TRANSPORT Series

121

24/27 Edition

2015

-11-16

600968EA

9.1 Packaging

NOTICE

Valve in open position

Valve mechanism may get damaged if valve is in open position.
Make sure that the valve is closed.

1. Cover all valve openings with a protective foil.

2. Pack valve appropriately, by using the original packaging material.

VAT disclaims any liability for damages resulting from inappropriate
packaging.

9.2 Transport

NOTICE

Inappropriate packaging

Product may get damaged if inappropriate packaging material is used.
Always use the original packaging material and handle product with care.

VAT disclaims any liability for damages resulting from inappropriate
packaging.

Series 121 DISPOSAL

600968EA

Edition

2015

-11-16 25/

27

10 Disposal

WARNING

Harmful substances

Environmental pollution.
Discard products and parts according to the local regulations.

SPARE PARTS Series

121

26/27 Edition

2015

-11-16

600968EA

11 Spare parts

NOTICE

Non-original spare parts

Non-original spare parts may cause damage to the product.
Use original spare parts from VAT only.

• Please specify the fabrication number of the product when you place an
order for spare parts; see chapter «1.1 Identification of product». This is to
ensure that the appropriate spare parts are supplied.

• VAT makes a difference between spare parts that may be replaced by the
customer and those that need to be replaced by the VAT service staff.

• «Table 11-1» only contains spare parts that may be replaced by the
customer. If you need any other spare parts, please contact one of our
service centers. You will find the addresses on our website
www.vatvalve.com.

Description Part No.

Quantity
per valve

Maintenance procedure
see chapter

DN 63–100

Replacement kit on request 1

«6.4 Replacement of gate seal and
bonnet seal»

Gate O-ring

on request

1

«6.4 Replacement of gate seal and
bonnet seal»

Bonnet flange O-ring

on request

1

«6.4 Replacement of gate seal and
bonnet seal»

O-ring removal tool 234859 1

«6.4 Replacement of gate seal and
bonnet seal»

VAT vacuum grease on request

1

«6.4 Replacement of gate seal and
bonnet seal»

Series 121 SPARE PARTS

600968EA

Edition

2015

-11-16 27/

27

Description Part No.

Quantity
per valve

Maintenance procedure
see chapter

DN 160
or higher

Replacement kit on request 1

«6.4 Replacement of gate seal and
bonnet seal»

Gate O-ring

on request

2

«6.4 Replacement of gate seal and
bonnet seal»

Bonnet flange O-ring on request 1

«6.4 Replacement of gate seal and
bonnet seal»

O-ring removal tool 234859 1

«6.4 Replacement of gate seal and
bonnet seal»

VAT vacuum grease on request 1

«6.4 Replacement of gate seal and
bonnet seal»

Table 11-1