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Vacuum Pumps Instrumentation Fittings and Valves LEYBOLD VACUUM
Right-Angle and Straight-Through Valves with Electropneumatic ActuatorDN 10 KF – DN 40 KF
If equipment is returned to Leybold, indicate whether theequipment free of substances damaging to health orwhether it is contaminated.
If it is contaminated also indicate the nature of thehazard. Leybold must return any equipment without a“Declaration of Contamination” to the sender’s address.
Indicates procedures that must be strictlyobserved to prevent hazards to persons.
Indicates procedures that must strictly beobserved to prevent damage to, ordestruction of the equipment.
Figures
The references to figures, e.g. (1/2) consist of the Fig.No. and the item No. in that order.
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Warning
Caution
1 Description1.1 Areas of Application and
General InformationThe DN 10 to DN 40 Leybold KF (small flange) valvesare blocking devices for tubes in vacuum systems.There are two types available: straight-through and right-angle valves.
The supply voltage is selected by choosing a suitablesolenoid pilot valve (see Section 1.4)
All valves are capable of opening and closing againstatmospheric pressure and vacuum, independently of thedirection of the flow. A difference is made betweennormally open and normally closed states of the valves.
A valve which is normally open closes whenapplying the operating voltage andcompressed air.
The operating mode is determined by suitable selectionof one of the pilot valves offered and no changes willhave to be made to the valve.The position of the valve is indicated by an indicator pinon the valve body. This pin is visible when the valve isopen.
The valves are equipped with KF flanges in accordancewith DIN 28 403.The valves may be installed in any orientation.
All valves with pneumatic actuator and electric pilot valveclose when the supply voltage or the compressed airfails.
Also valves which are normally open willclose when the compressed air fails.
When planning to expose the valves toradioactive radiation, please contact usfirst.
All inner parts of the valve which come intocontact with the medium flowing throughthe valve must be protected againstaggressive or corrosive gases andcondensate.
Also in the case of explosion-like pressurebursts, the max. permissible operatingpressure must not be exceeded. The entiresystem must be protected againstexplosions and detonations in aprofessional manner.
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Caution
Warning
Caution
1.1.1 Bellows-Sealed Valves
Elastic bellows are employed in the case of the bellows-sealed valves for sealing against the atmosphere.
Thus only the bellows come into contact with themedium.
Service life of these valves is at least 10,000,000switching cycles.
1.1.2 Elastomer-Sealed Valves
In the case of the elastomer-sealed valves an O-ringsealed and greased slide lock provides the seal againstthe atmosphere.
Service life of this slide lock is over 5,000,000 switchingcycles.
All valves have on their valve body a leak detection hole(7/5).
In the case of the elastomer-sealed valves the O-ringsare exchangeable (see Section 4).
1.1.3 Special Bellows-Sealed Valve
For safety reasons, a special valve has been developedfor increased differential pressures in connection withDOT1) brake fluid.
This valve is equipped with EPDM seals at the valve diskas well as on the housing and has a stronger spring.
EPDM is compatible with brake fluid.
Service life of these valves is at least 10,000,000switching cycles.
Cat. No. 287 91
1) DOT is the abbreviation for: “Department of Transportation”
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1.2 Supplied EquipmentThe KF valves are supplied with an integrated opticalposition indicator.
When supplied, the valves are in the closed state.
The connection flanges are protected by protection capsin order to prevent the flanges from being damaged.
A fully functional valve consists of the valve body withpneumatic actuator and a separate pilot valve includingsolenoid coil.
The available pilot valves and their different supplyvoltages are listed in the table on page 9.
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Right-angle valve, aluminium,bellows-sealed
DN 10 DN 16 DN 25 DN 40
Right-angle valve, stainlesssteel, bellows-sealed
Right-angle valve, aluminium,O-ring sealed
Straight-through valve,aluminium, bellows-sealed
1.3 Technical Data
DN 10 DN 16 DN 25 DN 40
DN 16 DN 25 DN 40
DN 16 DN 25 DN 40
Power consumption WValid for
Supply voltage V various voltage are possible, see table on page 9
DC: 4.5 W / AC: hold 6 VA / actuate 7.5 VANormal voltages and explosion hazard protection
3-part clamping rings + Al/NBR centering rings orstainless steel with FPM O-ring, but with outside ring.
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1.5 Notes ConcerningOperation
The sealing surfaces must be treated with care. It isrecommended to handle the valve with the protectioncaps in place.
The valve must be installed whiledisconnected from the power supply(mains).
During operation you must ensure that nopart of the body can enter into the valve, inparticular when operating the valve at theend of a (open) line.
Remove the protection caps before installing the valve.
The sealing surfaces and the sealing rings must becleaned with a solvent (acetone / alcohol).
Never use any aggressive cleaning agents.
Pneumatically actuated valves may be operated directlyvia the central compressed air supply (note max.operating pressure) or via the pilot valves.
Before installing the compressed air connection or thepilot valve, you must remove the sealing stopper (on theside of the valve housing).
Install the pilot valves as described in Section 2.2.
Provide the electrical connection as described in Section2.5.
1.6 Operating Temperatures/Bake Out Temperatures
The max. ambient temperature for the complete valve(valve with the pilot valve including solenoid coil) is
50 °C.
The valve with the pilot valve (without solenoid coil) may
be heated to 80 °C max.
The valve body without pilot valve and without solenoid
coil may be heated to 120 °C max.
The flange area of the valve may be heated to 150 °Cmax. provided adequate cooling is ensured for the pilotvalve, the solenoid coil and the valve body so that thepermissible temperature limits are not exceeded.
Warning
Caution
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2.2 Fitting the Pilot ValveCheck that the pilot valve is complete (Fig. 2, items 2 to 18)
The outlet for the compressed air fromthe pilot is marked by an “A” on thehousing; the inlet for the compressed airis marked by a “P”.
The reducer (2/3) is screwed into the valve together withthe gasket (2/2) and tightened to 2 Nm max.
Screw the pilot valve (2/4) with the gasket (2/2a) on tothe reducer (connection “A”) and tighten it slightly (1 Nmapprox.)
If possible, the pilot valve should be fitted parallel to theKF valve.
2 Start Up2.1 Compressed Air SupplyThe range of operating pressures for the compressed airspans from 4 to 8 bar.
The tubing for the compressed air must berated for at least 10 bar, and the tubingmust be connected in a professionalmanner.
You must ensure that the max. permissibleoperating pressure can not be exceeded.
The compressed air may be oiled or dry; if required, thecompressed air should be filtered.
The type of compressed air used, should bemaintained from thereon.
Warning
Caution
Caution
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2.3 Compressed AirConnection
The L-type screw joint (2/6) is screwed in at connection“P” on the pilot valve using hollow screw (2/7) and thetwo gaskets (2/5); tighten only slightly.
The compressed air connection has been designed toaccept a compressed air hose having an outsidediameter of 6 mm and an inside diameter of 4 mm.
In order to attach the compressed air hose, the union nut(2/8) is removed from the L-type screw joint and it ispushed over the compressed air hose.
Next, the end of the hose is pushed on to the hosenozzle and secured in place by the union nut.
The union nut is only tightened manually.
Compressed air hoses may be pressurisedat times and must be protected against anymechanical damage.
If required, soap solution may be used to check leak-tightness.
Warning
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3
2a
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Fig. 2 Installation of the pilot valve and the compressed air connection
Key to Fig. 21 Right-angle valve2 1/8” gasket2a 5 mm gasket3 Reducer 1/8” / M5 (size 13)4 Pilot valve5 5 mm gasket (2x)6 L-type screw joint7 Hollow screw (size 8)8 Union nut for securing the compressed air hose9 Solenoid coil10 Seal11 Plug insert for solenoid coil12 Plug housing13 Securing screw14 Clamping screw for strain relief15 Disk16 Rubber ring17 Knurled screw18 Corrugated washer
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2.4 Supply VoltageThe supply voltage for the solenoid coil has beenimprinted on the housing of the solenoid coil (2/9).
Check whether the available supply voltageis suitable. It must be equal to the voltageimprinted on the solenoid coil.
2.4.1 Exchanging the solenoid coil
If required, the solenoid coil may be exchanged. For thisloosen knurled nut (2/17) and remove the solenoid coiltogether with the corrugated washer (2/18).
Push the new coil over the pole tube, fit the corrugatedwasher and manually tighten the knurled nut.
Torque for the knurled nut should bebetween 100 and 150 Ncm, whereby thesolenoid coil should still be able to turn.The pole tube must be undamaged.
For the range of available solenoid coils for the varioussupply voltages, please refer to the table on page 9.
2.5 Electrical ConnectionDuring all electrical work ensure that thepower supply lines have reliably beenswitched off. The electrical connectionsmay only be made by an electrician asdefined by VDE 0105 in accordance withthe VDE 0100 guidelines.
A three core mains cable is recommendedfor the power supply connection: 3 x 1mm2.
Unscrew screw (3/4) from the connection plug and pullthe plug off.
Use a narrow screwdriver to force the plug insert (3/6)out through the hole.
The terminals have been assigned as follows:
“1” and “2” = phase, the third connection is provided forthe ground connection and is marked by the ground
symbol .
Push the clamping screw (3/1) as well as the disk and
Caution
Caution
Warning
Caution
the rubber ring (3/2 and 3/3) over the cable.
Pull the cable through the housing of the plug (3/5) andattach it to plug insert (3/6) (see Fig. 4).
Press the plug insert into the housing until it engages.
Provide the strain relief for the cable by tighteningclamping screw (3/1).
Connect the complete connection plug with seal (3/7)and secure it in place with fixing screw (3/4).
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Fig. 3 Connection plug for electropneumatic KF valves
Key to Fig. 31 Clamping screw at the cable feedthrough2 Disk3 Rubber ring4 Fixing screw5 Plug housing6 Plug insert7 Seal
2.6 Opening and Closing theValve Manually
A slotted screw made of brass is located on the pilotvalve under the solenoid coil.
With the aid of a screwdriver this screw can be used toopen and close the valve manually (see Fig. 8 and 9).
However, the supply of compressed air must beavailable to the valve.
There are two positions:
Position 0 = normal position(Fig. 5) (for operation via the solenoid)
In this position the valve is closed.
Position 1 = valve is open.(Fig. 5)
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Fig. 4 Pin assignments on the plug
1 2 3
Key to Fig. 41 Phase2 Phase
3 Ground
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Fig. 5 Functional diagram of the pilot valve for the “0” position
Fig. 6 Functional diagram for the pilot valve in the “1” position
A
A
P R
P R
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The valve position sensor is of the mechanical type andindicates, by means of a microswitch, the position of thevalve (open/closed) to a central control system.
The terminals are floating.
The optionally available valve position sensor can beordered from Leybold by quoting Cat. No. 287 80.
Separate Operating Instructions GA 06.295 are availablefor this valve position sensor.
When wanting to use non-contact proximity switchesplease contact us first.
3 Valve Position Sensor
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Fig. 7 Right-angle valve with valve position sensor
Key to Fig. 71 Right-angle valve2 Valve position sensor3 Optical valve position indicator4 Electrical connection5 Leak detection hole
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4 MaintenanceAll bellows-sealed and elastomer-sealed valves will notrequire any maintenance within the range of the numberof switching cycles specified.
If none-the-less cleaning of the valves is required, or ifthe gaskets must be exchanged, then the pneumaticassembly must be disassembled.
Before starting with any disassembly workon the valve, disconnect all electricalconnections leading to the valve first. The compressed air connection must bedisconnected.
All sealing surfaces, the bellows and thepiston rod (10/5) must be protected againstdamage.Only use commercially cleaning agents(acetone/alcohol).Only suitably trained personnel mayexchange the gaskets including those in thecompressed air cylinder.
The screws (10/1) for loosening the(pneumatic) valve actuator are tensionedby the closure spring.
The lid on the valve should be opened whilemaintaining a parallel orientation andwithout edging in order to prevent damage.
Unscrew the screws on the top of the valve, remove thelid (10/2) of the valve and also remove the securing ring(10/3).
In order to exchange the gaskets at the valve piston orthe piston rod, the lid of the valve must be attached tothe valve housing again; for this the top screws arescrewed in a few turns.
Now the valve piston (10/4) is carefully lifted to a positionunder the lid by carefully applying some compressed air.
The lid of the valve is disassembled and the piston (10/4)can be pulled off from the piston rod (10/5).
When exchanging gaskets, also those atthe valve disk (10/6), the bottom of thegroove and the flanks of the groove mustnot be damaged.The gaskets must be fitted in such a waythat they are not twisted.After having exchanged the gaskets, theinside volume of the valve should becleaned.
Warning
Caution
Caution
Warning
Caution
4.1 Leybold ServiceIf equipment is returned to Leybold, indicate whether theequipment free of substances damaging to health orwhether it is contaminated.
If it is contaminated also indicate the nature of thehazard. For this you must use a form which has beenprepared by us which we will provide upon request.
A copy of this form is reproduced at the end of theseOperating Instructions: “Declaration of Contamination ofVacuum Instruments and Components”.
Please attach this form to the equipment or enclose itwith the equipment.
This declaration of contamination is required to meetGerman Law and to protect our personnel.
Leybold must return any equipment without a“Declaration of Contamination” to the sender’s address.
The valves must be packaged in such away, that they will not be damaged duringshipping and so that any contaminants arenot released from the package.
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The new gaskets must be greased with special grease(Ref. No. 070 27 009).
Now the piston may be attached to the piston rod againand carefully pressed into the cylinder recess.
Finally the components are fitted in the reverse order asduring the disassembly process.
Warning
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5 Figures and Tables• Since the internal design of the valves isalmost the same for all types, only Fig. 10has been included to assist disassemblyand assembly
• The O-ring sealed stainless steel right-angle valve is not shown in a sectionaldiagram. The inner part corresponds to what isshown in Fig. 10; the dimensions andhousing correspond to those provided inFig. 9.
Notes
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Right-angle valve,aluminium, bellows-sealed
DN 10 DN 16 DN 25 DN 40
10 14 23 38
103 113 142 178
30 40 50 65
12.2 17.2 26.2 41.2
36 36 60 80
G 1/8 “
39.5 39.5 47.5 62
11 21 24 25
30 30 40 55
30 30 40 55
12 22 20.5 25.5
10
110 120 141 162.5
51
20 20 30 45.5
32
4 4 6.25 10
DN mm
h mm
a mm
c mm
d mm
e -
f mm
g mm
k mm
l mm
m mm
n mm
h1, approx. mm
o mm
p mm
b mm
Stroke mm
Fig. 8 Sectional drawing for the aluminium right-angle valve, bellows-sealed with attached pilot valve
n
ob
f
h1
g
DN
a
m
c
a
h
k
l
d
p
c
e x
x = Slotted screw for manual valve operation
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Right-angle valve,stainless steel,bellows-sealed
DN 10 DN 16 DN 25 DN 40
10 14 23 38
103 113 142 178
30 40 50 65
12.2 17.2 26.2 41.2
36 36 60 80
G 1/8 “
39.5 39.5 47.5 62
15 25 29 36.5
16 20 30 45
16 20 30 45
110 120 141 162.5
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32
4 4 6.25 10
DN mm
h mm
a mm
c mm
d mm
e -
f mm
g mm
k mm
l mm
mh1, approx. mm
o mm
b mm
Stroke mm
Fig. 9 Sectional drawing for the stainless steel angle valve, bellows-sealed with attached pilot valve
o
h
m
l
k
DNc
a
h1
b
f
d
ga
c
e
Closurespring
x
x = Slotted screw for manual valve operation
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Fig. 10 Sectional drawing for the aluminium right-angle valve, O-ring sealed (dimensions are the same as for Fig. 8)
Key to Fig. 101 Top screws2 Lid of the valve3 Securing ring4 Piston5 Piston rod6 Valve disk7 Closure spring