DIA-FLO & PURE-FLO Diaphragm Valves Instruction Manual With
Contents
1. a MAP MRRENS E BEEUNENUNEKEENRENIUSEESXII 200 2201 240 260 275 225 160 F 120 140 180 TEMPERATURE WEIR MES 107 121 EE FERT ASSES CSS te SS AHON MS e HEEE ee P ee NEN RUN aH oe PP aS SEE GO IE ER 50 80 100 10 10 10 1090 200 22 340 350 225 325 TEMPERATURE F KPA G KPA G Holland APPLIED TECHNOLOGIES Indianapolis e Chicago e San Juan www hollandapt com 800 800 8464 Industrial Group For more information write to Engineered Valves Headquarters 33 Centerville Road Box 6164 Lancaster PA 17603 2064 USA or call 800 366 1111 717 509 2200 Fax 717 509 2336 Website www engvalves com E mail engvalves_custserv fluids ittind com 2001 ITT Industries REGIONAL OFFICES ATLANTIC USA Phone 800 231 0328 Phone 717 509 2200 Fax 800 231 0330 Fax 717 509 2336 CENTRAL USA Phone 800 366 4770 Phone 717 509 2200 Fax 800 231 0330 Fax 717 509 2336 PACIFIC USA 725 E Cochran Street Unit E Valley CA 93065 Phone 800 926 8884 Phone 805 520 7200 Fax 805 520 7205 SOUTH AMERICA Av 11 de Septiembre 1363 Of 1403 Providencia Santiago Chile Phone 56 2 264 9491 9637 Fax 56 2 22. MOORE POSITIONER PCSITIDNER SUPPLY GAUGE INSTRUMENT AIR GAUGE REGULATOR TYPICAL SCHEMATIC FIGURE 13 DiaFlo Diaphragm Valves Weir Valve Pressure Temperature Recommendations 1 To find the maximum recommended operating temperature enter the graph on the maximum operating temperature line 2 The intersection of temperature line with respective valve size curve determines the maximum recommended operating pressure read at left of the graph 3 Maximum recommended operating temperature may be determined by knowing the maximum operating pressure and reversing the above procedure 4 Operating pressure and temperature combinations above respective valve size curves should be avoided for maximum diaphragm flex life 5 Maximum temperature limitations of various diaphragm materials are also indicated by arrows under diaphragm material Note Maximum pressure rating for Dualrange Control Valves is 100 psi PAS bonnet required above 200 F 93 C 2 a 222 RSS A SUPREY BACKING CUSHION V R 2 DIAPHRAGM Su FIGURE 14 PLASTIC DIAPHRAGM DETAIL LINE PRESSURE CPSIG LINE PRESSURE PSIG TEMPERATURE C 49 60 71 83 93 150 1034 CAN TR rae T T ae eS eS eee eae th SERN cee HA O EENG CET HACE e
3. SPRING 7 COLUMN 48 Qi i LLL N CAP SCREW ME SPINDLE CONN 1 SPRING SEAT 2 LIPPER AS 1 9 Nx ACTUATOR PLATE Se HEX NUT 727 24 O RING B O RING A A U RING A O RING B SENNET SPINDLE BONNET BOLTS amp NUTS HEX NUT A iw YH COMPRESSOR Woy 3 7 VALVE DIAPHRAGM l FIGURE 4 D Z FIGURE 4 E 3250 3275 32101 32250 TOP COVER SPINDLE NUT 9 DIAPHRAGM PLATE le ACTUATOR DIAPHRAGM 8 ZA ACTUATOR BOLTS amp NUTS SPRING A SPINDLE a O RING A 2 LUBE FITTING 2 COMPRESSOR 90 VALVE BONNET BOLTS amp NUTS A VALVE BUDY 5 FIGURE 4 F FIGURE 4 G 3112 3125 COLUMN NUTS SPRING COVER GASKET JAM NUT SPRING SEAT ADJ BUSHING COLUMN Arce SPINDLE COUPLING rae 7 SPRING SEAT HS Ha GASKET x IMO Ss IWS CH N 1 N WIS S S LS S O RING 222220 NN Y FIGURE 4 H 3150 INDICATUR HDUSING U RING 110 INDICATUR TUBE INDICATUR RUD O RING 113 O RING 010 O RING 115 SPACER O RING 110 RETAINING RING FIGURE 5 A FIGURE 5 B 3312 25 250 POSITION INDICATOR POSITION INDICATOR JAM NUT RED SPRING Hp HANOWHEEL pz SET SCREW 22 ADJ BUSHING THRUST WASHER 7 ANNO SPR
4. 30 psi and others are optional 4 9 2 2 Supply pressure 3 psi above re quired actuator pressure to a max imum of 85 psi A filtered air supply is recommended A WARNING Pressure in excess of 85 psi to any connection may cause dam age Failure to follow these in structions could result in prop erty damage and or moderate personal injury 4 9 3 Description The positioner is designed to operate a valve actuator to maintain the valve in a position determined by the control instrument The above positioners are direct acting with an increase in instrument pressure the valve actuator pressure positioner output will in crease On a bottom loading positioner 73 NB and GC33 output is connected to the actuator lower chamber via an external tube Therefore the valve will open as instrument pressure increases On a top loading positioner the output is applied directly to the actuator directly through the actuator housing no external tubing The valve will close as instrument pressure is increased 4 9 4 Installation The only task is to connect the supply and instrument air All connections are 1 4 NPT See Figure 13 Use 1 4 O D tubing for the instrument connection either 1 4 or 3 8 O D tubing for the supply connection Blow out all piping before connections are made to prevent the possibility of dirt or chips en tering the positioner Use pipe sealant spar ingly and then only on the male threads A
5. 3312 A 112 B A 114 114 116 116 214 3325 14 1 33250 214 TWO REQUIRED 238 Two required if sealed bonnet is used DIRECT ACTING ACTUATORS ACTUATOR VALVE SIZES 2 12 31101 214 TWO REQUIRED 238 Used with sealed bonnet only Two required if sealed bonnet is used DIRECT ACTING ACTUATORS ACTUATOR VALVE SIZES SIZE Two required if sealed bonnet is used 10 FIGURE 1 PROPER BOLTING RECOMMENDED INSTALLATION GLASS LINED BODIES SEQUENCE TORQUE pto Valves Ib Ft F 00 50 01 50 20 30 It is extremely important that all glass lined valves be d BS 02 00 02 50 30 60 installed with proper end flange gaskets and that VS AN 03 00 04 00 40 70 proper torque be applied to the bolts in correct se Nec MA 06 00 55 110 quence The use of PTFE plastic envelope gaskets 08 00 60 110 with soft insert materials is recommended See VALVE END FLANGE proper bolt torque and sequence at right FIGURE 2 FIGURE 3 Vv EN EEAO ACTUATOR DIAPHRAGM IDENTIFICATION ELASTOMER 1 PIECE MADE OF RUBBER WITH MOLDED IN STUD SEE TABS SIZE DESIGNATION SAME AS VALVE SIZE GRADE DESIGNATION IS ONE OR TWO LETTERS EX M OR SS PUNCHED HOLE FOR GRADE TM R2 TM PTFE THESE DIAPHRAGMS ARE TWO PIECE WHITE PLASTIC WITH BLACK ELASTOMER BACKING 2 For 00 75 with flanged ends use 01 00 diaphragm except for solid plastic For 01 25 solid plastic uses 01 50 dia
6. 4 6 1 Operation of Adjustable Opening Stop 4 6 1 1 Use bleed type regulator and air Supply to move valve to the de sired position Loosen jam nut 4 6 1 2 Rotate adjusting screw or hand wheel clockwise until contact with the valve spindle is felt Tighten jam nut Opening stop is now set A WARNING If upper chamber is pressurized during this adjustment leakage will occur past the adjusting spindle Note that the adjusting screw cannot be completely re moved Means are provided on the inboard side of the adjusting screw to prevent removal Failure to follow these instruc tions could result in property damage and or moderate per sonal injury 4 7 4 6 2 Operation of Handwheel Closing Device or adjustable opening stop when used as manual override 4 6 2 1 Vent air from actuator Loosen jam nut 4 6 2 2 Rotate handwheel or hex head bolt clockwise to close valve Tighten jam nut MicroS witch Limit Switches Model Nos BZE6 2RN BAF1 2RN DTE6 2RN DTF2 2RN EXQ EXDQ Adjustment See Figure 11 This section provides instructions for adjustment of the above switches when mounted to the actuator covers not yoke mounted These switches are pushbutton type actuated by a lever attached to the actuating rod On 12 actuators the actuating rod is attached directly to the actuator diaphragm plate On sizes 25 250 the actuating rods are spring loaded Contact with the diaphragm plate occurs only during the la
7. are shown in Table 2 For any combination the actual travel is the lesser of the two MAINTENANCE 3 1 Periodically inspect condition of external valve parts Replace all parts showing excessive wear or corrosion Leakage from the bonnet weep hole indicates diaphragm rupture For diaphragm replacement see Section 3 5 3 6 3 2 3 3 3 4 3 5 3 7 or 3 8 On sealed bonnet valves back off the v notch vent plug two or three turns A WARNING When the process fluid is hazardous or corro sive extra precautions should be taken The user should employ appropriate safety devices and should be prepared to control a leak of the process fluid Fluid weeping from the plug indicates a diaphragm failure Replace diaphragm immediately Failure to follow these instructions could result in serious personal injury or death and property damage Air pressure from the bonnet weep hole may indicate o ring failure Follow applicable replace ment instructions given below If valve diaphragm flange area leaks depres surize system and open valve slightly using handwheel wrench opening device if equipped or local bleed type regulator Tighten bonnet nuts as described in Section 1 2 If leakage continues diaphragm replacement is required Lubrication Standard lubricants are Sunoco 991EP for Dia Flo valves and Chevron Poly FM2 FDA Com pliant for Pure Flo valves Actuators equipped with a lube fitting should be lubricated eve
8. cap and pressurize actuator Repeat this process as necessary until valve does not leak Handwheel Opening Device Operation Figure 7 The purpose of the optional handwheel opening device is to open a reverse acting 3200 series actuator in the event of a diaphragm or plant air failure Loosen jam nut Rotate handwheel counterclock wise to open Rotate clockwise to return the valve to the closed position Note Handwheel must be returned precisely to its original position to maintain proper travel stop adjustment See Section 4 2 to adjust travel stop Wrench Opening Device Operation The purpose of the optional wrench opening device is to open a reverse acting 3200 series actuator in the event of an actuator diaphragm or plant air failure 4 4 3212 Wrench Opening Device Figure 9 b 4 4 1 1 Remove pressure cap Loosen jam nut 4 4 1 2 Rotate stop nut clockwise to open valve Rotate stop nut counterclock wise to return valve to the closed position Note Travel stop adjust ment is recommended at this time See Section 4 2 4 4 1 3 Tighten jam nut and install pressure Cap 4 4 2 3225 32130 Wrench Opening Device Figure 8 4 4 2 1 Remove safety cap Loosen jam nut 4 4 2 2 Rotate adjusting bushing clockwise to open valve Rotate adjusting 4 5 4 6 bushing counterclockwise to return valve to the closed position Note Travel stop adjustment is recom mended at this time See Section 4 2 to adjust travel stop 4 4 2 3
9. have special installation instruc tions See section 1 3 NOTE SOLID PLASTIC VALVES Solid Plastic Valves are not recommended for installation in plastic lined piping systems Also note threaded inserts are supplied in the base of the valve body and should be used for bracketing supporting valves in accordance with cGMP s 1 INSTALLATION 1 1 Dia Flo diaphragm valves may be installed in any orientation For horizontal piping systems to be drained through the valve install the valve A ITT Industries Engineered for life 2 1 2 1 3 1 4 1 5 1 6 stem between 0 and 30 degrees above horizon tal After draining a small pocket of fluid may remain in the valve Note Pure Flo valves have either raised hash marks castings or small machined dots forgings on the valve body to indicate the correct drain angle Locate these marks at the 12 o clock position to achieve the optimum drain angle Prior to pressurization with the valve open tighten the bonnet nuts in a crisscross pattern in accordance with Table 1 Retightening 24 hours after the system reaches operating temperature and pressure is recommended If leakage occurs at the body diaphragm seating area immediately depressurize system and tighten bonnet nuts as noted above If leakage continues diaphragm replacement is required Follow applicable steps in Section 3 5 3 6 3 7 or 3 8 INSTALLATION GLASS LINED VALVE BODIES It is extremely important that a
10. inch Replace actuator and bonnet as sembly on body and tighten bon net bolts hand tight Release air pressure and tighten bonnet bolts with a wrench criss crossing from corner to corner See Table 1 for recommended torques Apply air and open valve If neces sary retighten bonnet bolts 3 6 1 10 Travel stop if equipped must be reset at this time to assure proper closure See Section 4 2 3 6 2 Actuator Diaphragm or Spring Replacement 3212 3 6 2 1 3 6 2 2 3 6 2 3 3 6 2 4 Remove four bolts and nuts at equal spacing around actuator cover and replace with four threaded rods approximately 6 inches long secured by nuts on top and bottom of actuator flange Remove the remaining bolts and nuts that clamp the actuator dia phragm Turn the threaded rod nuts counterclockwise equally to gradu ally relax spring s Remove springs spindle nut upper plate and actuator diaphragm Replace parts and reverse instruc tions for reassembly Apply Loctite 242 on spindle nut 3 6 3 Actuator Diaphragm or Spring Replace ment 3225 3 6 3 1 3 6 3 2 3 6 3 3 3 6 3 4 3 6 3 5 3 6 3 6 Remove safety cap and jam nut from top of spring rod Apply air to bottom chamber until valve is in open position Tighten adjusting bushing until springs are compressed then re lease air in bottom chamber If the actuator diaphragm is so badly rup tured that it is not possible to open the valve with air in the lower ch
11. 36 1799 MEXICO Insurgentes Sur No 600 4 P Co Del Valle C P 03100 Mexico D F Phone 52 5 669 5002 Fax 52 5 669 5289 PUERTO RICO P O Box 1225 Hato Rey PR 00919 Phone Fax 787 703 0402 EUROPE Richards Street Kirkham Lancashire PR4 2HU England Phone 44 1772 682696 Fax 44 1772 686006 HONG KONG Ground Floor Times Tower 928 Cheung Sha Wan Road Kowloon Hong Kong Phone 852 2741 6302 Fax 852 2741 6605 Gu Industries Engineered for life
12. DFAMM 01 DIA FLO amp PURE FLO Diaphragm Valves Instruction Manual With Dia Flo Actuator This manual provides installation and maintenance instructions for DIA FLO ACTUATOR operated DIA FLO PURE FLO diaphragm valves If additional information is required contact ITT INDUSTRIES VALVES AND VALVE ACTUATORS ARE DE SIGNED AND MANUFACTURED USING GOOD WORKMANSHIP AND MATERIALS AND THEY MEET ALL APPLICABLE INDUSTRY STAN DARDS THESE VALVES ARE AVAILABLE WITH COMPONENTS OF VARIOUS MATERIALS AND THEY SHOULD BE USED ONLY IN SER VICES RECOMMENDED IN OUR PRODUCT CATALOG OR BY A COMPANY VALVE ENGINEER MISAPPLICATION OF THE PRODUCT MAY RESULT IN INJURIES OR PROPERTY DAMAGE A SELECTION OF VALVE COMPONENTS OF THE PROPER MATERIAL CONSISTENT WITH THE PARTICULAR PERFORMANCE REQUIREMENTS IS IMPORTANT FOR PROPER APPLICATION EXAMPLES OF THE MISAPPLICATION OR MISUSE OF ITT IN DUSTRIES VALVES INCLUDE USE IN AN APPLICATION IN WHICH THE PRESSURE TEMPERATURE RATING IS EXCEEDED OR FAIL URE TO MAINTAIN VALVES AS RECOMMENDED IF VALVE EXHIBITS ANY INDICATION OF LEAKAGE DO NOT OP ERATE ISOLATE VALVE AND EITHER REPAIR OR REPLACE Engineered Valves 33 Centerville Road Lancaster PA 17603 717 509 2200 Attention Sales Department CONTENTS 1 0 INSTALLATION 2 0 OPERATION amp ADJ USTMENT 3 0 MAINTENANCE 4 0 ACCESSORIES 4 1 PRESSURE CAP 4 2 TRAVEL CLOSING STOP ADJ USTMENT 4 3 HANDWHEEL OPENING DEVICE OPERATION 4 4 WRENCH OPENI
13. INGS 7 N N TOP COVER N N JS N CONNECTOR N E N za COUPLING N J SPRING SEAT LESS D N mmn FIGURE 7 HANDWHEEL OPENING DEVICE 3200 SERIES MAGNET HOLDING CRUCTBLE MACHINE SCREW TOP COVER SCREW I CAP SCREW HEX NUT ij Kb A M EZA N N 5 ll SPRING PLATE 5 SL ADJ BUSHING SPINDLE EXT SPRING GASKET S LIPPER NR ACTUATOR PLATE HEX NU E _ 2 DIAPHRAGM 9 SPINDLE SPRING CASE CAP SCREW LUCK WASHER ELE EAE EE OEE Ao N gm gt m H ML JAN O RING B O RING COMPRESSOR BDNNET HEX NUT e VALVE DIAPHRAGM FIGURE 4 1 31101 31250 PRESSURE CAP SPINOLE EXT JAM NUT O RING SPRING COVER FIGURE 6 PRESSURE CAP amp TRAVEL STOPS 3100 amp 3300 SERIES LOCK WASHER THRUST WASHER NAI NISN Pre SPRINGS TOP COVER VA 227 en 2 CONNECTOR 5 24122 iN COUPLING SPRING SEAT I IN SN S 6 S FIGURE 8 WRENCH OPENING DEVICE 3200 SERIES SPINDLE EXT JAM NUT HAND WHEEL SET SCREW SHIM WASHER HANDWHEEL BUSHING RACE THRUST NEEDLE BEARING RETAINING RING JAM NUT WRENCH OPENING NLIT BUSHI
14. NG ADJUSTER JAM NUT WRENCH OPENING DEVICE DETAIL SPRING COVER RETAINING NUT SPACER SPRING SEAT CONNECTOR FIGURE 9 A COMBINATION WRENCH OR HANDWHEEL OPENING DEVICE WITH ADJUSTABLE OPENING STOP 3225 32130 HANOWHEEL ADJUSTING SCREW JAM NUT PRESSURE CAP arth 3 TTA f LESS FEA FIGURE 9 B COMBINATION WRENCH OPENING DEVICE AND ADJUSTABLE OPENING STOP 3212 EP pee BRE HANDWHEEL SPTROL PIN JAM NUT ADJUSTING SCREW OPENING STOP JAM NUT THREDSEAL PRESSURE CAP SPIROL PIN JAM NUT SPINDLE EXT ADJUSTABLE OPERATING ROO SWITCH SWITCH ACTUATOR MOUNTING BRACKET INN AT ROD GUIDE O RING RETAINING RING ANCHOR PLATE ACTUATOR PLATE FIGURE 11 A FIGURE 10 WASHER MICROSWITCH LIMIT DETAIL A HANDWHEEL CLOSING DEVICE AND ADJUSTABLE OPENING STOP SWITCHES 3100 amp 3300 SEHIES 12 ACTUATOR TRIGGER SWITCH ACTUATOR LOCK WASHER MICRO SWITCH DETAIL B FIGURE 11 B MICROSWITCH LIMIT SWITCHES 25 250 TRIGGER BRACKET BRACKET COVER SCREW WESTLOCK MOOULE3 PROXIMITY SWITCH MODIFIED gt VALVE DPEN gt SWITCH LAST TT QU VALVE CLOSED SWITCH VIEW BACK DF SWITCH DETAIL WESTLOCK MODULE 3 PROXIMITY SWITCH INSTRUMENT 1 4 NPT ib d WSS Rts Vf AO D wen e m
15. NG DEVICE OPERATION 4 5 COMBINATION HANDWHEEL OR WRENCH OPENING DEVICE WITH ADJ USTABLE OPEN ING STOP 4 6 HANDWHEEL CLOSING DEVICE AND ADJ USTABLE OPENING STOP 4 7 MICROSWITCH LIMIT SWITCHES ADJ USTMENT 4 8 WESTLOCK MODULE 3 LIMIT SWITCHES 4 9 POSITIONERS TOP MOUNTED TABLES 1 BONNET FASTENER TORQUES 2 VALVE AND ACTUATOR TRAVEL 3 ACTUATOR INTERNAL DATA 4 VALVE OPERATING PRESSURES 5 O RING SIZES FIGURES 1 GLASS LINED BODY INSTALLATION 2 VALVE DIAPHRAGM IDENTIFICATION 3 ACTUATOR DIAPHRAGM IDENTIFICATION 4 ACTUATOR DRAWINGS 5 POSITION INDICATORS Holland APPLIED TECHNOLOGIES Indianapolis e Chicago e San Juan www hollandapt com 800 800 8464 TRAVEL STOPS HANDWHEEL OPENING DEVICE WRENCH OPENING DEVICE COMBINATION HANDWHEEL OPENING OR WRENCH OPENING WITH ADJ USTABLE OPENING STOP 10 HANDWHEEL CLOSING DEVICE AND AD USTABLE OPENING STOP 11 LIMIT SWITCHES PUSHBUTTON TYPE 12 LIMIT SWITCHES WESTLOCK PROXIMITY TYPE 13 POSITIONERS TOP MOUNTED 14 PTFE DIAPHRAGM DETAIL mue ea 1 0 INSTALLATION NOTE WELD END VALVES Weld end valves for schedule 10 and heavier pipe re quire bonnet and diaphragm removal prior to welding in line See Section 3 5 3 6 3 7 or 3 8 Schedule 5 and lighter pipe and tubing may be welded with automatic equipment only without removing the diaphragm Manual welding requires bonnet and diaphragm re moval for all pipe schedules NOTE GLASS LINED BODIES Glass lined bodies
16. Tighten jam nut and install safety Cap Combination Handwheel or Wrench Opening Device with Adjustable Opening Stop Figure 9 A 4 5 1 3225 32130 Operation of Wrench Opening Device 4 5 1 1 Loosen jam nut 1 4 5 1 2 Rotate wrench opening nut clock wise to open valve Rotate counter clockwise to return valve to the closed position Tighten jam nut Note Travel stop adjustment is recommended at this time See Section 4 2 to adjust travel stop 4 5 2 3225 32130 Operation of Handwheel Opening Device Figure 9 A 4 5 2 1 Loosen jam nut 1 above hand wheel 4 5 2 2 Rotate handwheel counterclock wise to open valve Rotate clock wise to return valve to the closed position Tighten jam nut 1 Note Travel stop adjustment is recom mended at this time See Section 4 2 to adjust travel stop 4 5 3 3225 32130 Operation of Adjustable Open ing Stop 4 5 3 1 Loosen jam nut 2 above spring cover 4 5 3 2 Using air pressure and bleed type regulator open valve to desired position 4 5 3 3 Rotate adjusting bushing clock wise until resistance is felt 4 5 3 4 Tighten jam nut 2 Opening stop is now set Handwheel Closing Device and Adjustable Open ing Stop Figure 10 3100 amp 3300 series These options are very similar Both use an adjust ing screw to either limit valve opening travel or manually stroke the valve to the closed position The handwheel closing device simply uses a handwheel rather than a hex head to rotate the Screw
17. a ber then it will be necessary to use the adjusting bushing as a jack screw to compress the springs with out the air assist Remove actuator nuts and bolts re leasing top cover containing spring assembly Remove spindle nut releasing top plate and actuator diaphragm To remove springs clamp upper cover flange in vice jaws and rotate adjusting bushing counterclockwise to relax springs Replace parts and reverse instruc tions for reassembly Apply Loctite 242 on spindle nut 3 6 4 Actuator Spring Replacement 3250 amp 3275 3 6 4 1 3 6 4 2 To replace spring remove four nuts from columns safety cap and jam nut from top of spring rod Remove adjusting bushing spring cover and springs Replace parts and reverse instruc tions for reassembly 3 6 5 Actuator Diaphragm Replacement 3250 amp 3275 3 6 5 1 3 6 5 2 To replace actuator diaphragm re move actuator bolts and nuts re leasing actuator top cover Remove spindle nut and top diaphragm plate Replace parts and reverse instruc tions for reassembly Apply Loctite 242 on spindle nut 3 6 6 Spindle O Ring Replacement 3212 3225 3250 amp 3275 3 6 6 1 3 6 6 2 3 6 6 3 3 7 Reverse Acting Figure 4 E Disconnect air lines Remove actu ator and bonnet assembly from valve body and dismantle actuator following instructions above for re moving actuator diaphragm and Springs Withdraw valve diaphragm com pressor and spindle asse
18. atings In addition a solenoid valve may be at tached directly to the switch enclosure via the solenoid s conduit connection The solenoid leads may then be terminated at the switch terminal strip 4 8 2 Adjustment 4 8 2 1 Open valve Remove the four screws holding the bracket cover to the bracket Remove bracket cover 4 8 2 2 Loosen jam nuts on valve open Switch trigger and slide to bottom of slot Tighten jam nuts A horizon tal distance of 1 16 to 1 8 should be maintained between the trigger and the switch 4 8 2 3 Attach continuity tester to valve open switch contacts 4 8 2 4 Loosen setscrew Slide trigger bracket assembly up until switch contacts change state Tighten Setscrew 4 8 2 5 Close valve Loosen jam nuts on valve closed switch trigger 4 8 2 6 Attach continuity tester to valve closed switch contacts Slide valve closed switch trigger down until switch contacts change state 4 8 2 7 Tighten jam nuts Switches are now set 4 8 2 8 Install bracket cover and four SCrews 4 9 Positioners See Figure 13 4 9 1 4 9 2 Scope Top mounted positioners listed below 4 9 1 1 Moore 73N12F 3100 amp 3300 Series Actuators 4 9 1 2 Moore 73NB 3200 Series Actuators 4 9 1 3 ITT Conoflow GC31 3100 amp 3300 Series Actuators 4 9 1 4 ITT Conoflow GC33 3200 Series Actuators Supply and Instrument Pressures 4 9 2 1 Instrument input pressure range as specified 3 15 psi standard 3 9 psi 6
19. be used using the lifting eyelets located near the top of the spring casing A WARNING Spring casing must be lifted up over spindle extension Be care ful not to bend spindle exten sion Failure to follow these in structions could result in property damage and or moderate per sonal injury Spring s are captured in spring casing and are not re movable If spring replacement is necessary replace entire casing assembly 3 7 2 10 Remove hex nuts from hex head cap screws around periphery of actuator cover by rotating nuts counterclockwise 3 7 2 11 Lift off upper actuator cover 3 7 2 12 Rotate spindle connector counter clockwise to remove from actuator spindle This has been assembled with Loctite sealant and may re quire extra torque or slight heat to release the sealant 3 7 2 13 Remove upper actuator plate 3 7 2 14 Remove actuator diaphragm and replace with new one 3 7 2 15 To reassemble reverse the above procedure Use air pressure instead of adjusting bushing to take load off of valve diaphragm Apply Loctite 242 on spindle threads when instal ling spindle connector Adjust travel stop per section 4 2 3 7 3 Spindle O Ring Replacement 3 7 3 1 Remove pressure from line contain ing valve and disconnect air line to lower cover 3 7 3 2 Remove valve bonnet and actuator from valve body and disassemble in accordance with Section 3 7 2 steps 1 thru 13 3 7 3 3 Lift off actuator diaphragm and remove l
20. e for a given span may also be suppressed or shifted to the desired range by means of the zero adjusting screw 4 9 6 Maintenance A clean oil and moisture free air supply will reduce maintenance problems The supply air filter should be blown down on a routine basis The filter element should be examined periodically and replaced if necessary No lubrication is required on the valve posi tioner The system should be shut down or the valve isolated from the system before service or removal of the positioner is ac complished For additional maintenance activities refer to the manufacturer s service manual TABLE 1 TABLE 2 BONNET FASTENER TORQUES IN INCH POUNDS VALVE AND ACTUATOR TRAVEL Bonnet Metal Plastic NIPWSIPE E Actual travel for any valve and actuator combination is the lesser of the Glass Lined Straightway Weir amp valve or actuator travel listed below Except Lined ERG Tt tt WE Actuator Size 12 25 50 75 101 130 250 Valve Size Yo 1 1 1 2 Xk 3 4 6 8 10 12 Stroke s Phe l s Y s 12 8 2 s 3 ls 4 js 558 6 2 Stroke for 3 4 flanged weir valve is 1 2 except solid plastic STRAIGHTWAY Actuator NOTES 1 Torque may be exceeded by up to 10 pu lc c 2202 2 Bolt tension developed using torque wrenches can vary widely Stroke Je 2 3 3 3e 37 depending fastener condition wrench accuracy degree lubrication and technique If fastener yielding or gal
21. ling is ap Valve parent reduce torque accordingly and replace fasteners Size h 1 lh 2 2 2 3 4 6 8 10 12 3 Stainless steel studs bolts with stainless steel nuts have Stroke 5 2 5 6 1 4 Ife 2 he 25he 4i 6 4 Ph Th Carbowax 3350 applied at the factory Stainless steel studs bolts with bronze nuts have no lubricant Subsequent field lu bricant is not necessary For 3 4 w flanged ends use 1 data except solid plastic AIR MOTOR FLANGE BOLTING amp SPINDLE NUT TORQUES Air Motor Flange Spindle Size Bolt Torque Nut Torque in Ib in Ib 12 30 48 25 72 144 50 72 144 75 72 312 101 72 540 130 72 540 250 210 540 S pindle nuts should be assembled with 271 red Loctite TABLE 3 Actuator internal dimensions Effective Actuator Volume cu in Diaphragm Bottom Chamber Upper Chamber Air Double amp Reverse Actine Double Acting Direct Acting Size Connection in Open Closed Open Closed Open Closed 12 a 13 25 6 8 6 1 12 5 6 1 12 5 25 2 90 3 21 7 13 4 85 1 13 4 85 1 50 3 321 0 63 4 71 1 329 0 364 622 75 3 374 7 128 1 80 9 422 0 101 31 3 528 0 174 0 144 0 498 0 579 933 130 37 698 7 202 9 212 0 710 9 647 1146 250 45 3 250 1650 0 750 0 675 0 1760 0 1110 2195 Using stroke of largest valve for which actuator is suitable TABLE 4 VALVE OPERATING PRESSURES The operating pressures listed below have been set to provide long operating life Pressure tests indicate that ITT Dia Flo diaphragm valves withstand
22. ll glass lined valves be installed with proper end flange gaskets and that proper torque be applied to the bolts in correct sequence The use of PTFE plastic envelope gaskets with soft insert materials is recommended See Figure 1 for proper bolt torque and sequence The travel stop if equipped is factory set and should not require adjustment at time of instal lation However if adjustment is required see section 4 2 Maximum valve operating pressures are shown in Table 4 Consult factory or Engineering Catalog for vacuum operation Air line connections should be made up with care as damage may occur to the standard aluminum actuator covers Connection size is 1 4 NPT for 12 through 75 and 1 2 for 101 through 250 OPERATION amp ADJ USTMENT 2 1 2 2 2 3 2 4 The Dia Flo actuator is a spring and diaphragm or double acting diaphragm pneumatic actua tor The actuator model number is located on the ITT i d tag The model number is a four or five digit number defining the actuator as follows XXY Y Y if XX 231 Direct Acting Spring to Open if XX 232 Reverse Acting Spring to Close if XX 233 Double Acting YYY Nominal Size Available sizes approximate effective diaphragm area 12 25 50 75 101 130 250 For two digit sizes the final Y is left off Maximum permitted air supply pressure is 85 psig 586 kPa For operation and adjustment of actuator accessories see Section 4 Valve and actuator travel
23. mbly from the bonnet Replace o ring s and reassemble by reversing the instructions and following the steps for replacing a valve diaphragm Lubricate o ring s prior to installation per Section 3 4 32101 32130 32250 see 3 7 1 Valve Diaphragm or Spring Replace ment see 3 6 1 3 7 2 Actuator Diaphragm Replacement 3 7 2 1 Remove pressure from line containing valve and disconnect air line to lower cover 3 7 2 2 Remove safety cap and hex jam nut from spring rod by rotating counter clockwise 3 7 2 3 Remove adjusting bushing by rotat ing counterclockwise Place a ball thrust bearing over spring rod and replace adjusting bushing An Aetna 33 2 1 2 i d x 4 o d x 13 16 high is recommended 3 7 2 4 Engage adjusting bushing on Spring rod and rotate clockwise until it engages ball thrust bearing and is tightened down against top of Spring casing 3 7 2 5 Continue to rotate adjusting bush ing clockwise an additional 1 4 down spindle extension 3 7 2 6 Remove bonnet nuts by rotating counterclockwise and lift valve bonnet including diaphragm and the actuator from valve body 3 7 2 7 Rotate adjusting bushing counter clockwise and remove from spring rod Remove ball thrust bearing 3 7 2 8 Remove hex head cap screw and spring lock washers around base of spring casing by rotating counter clockwise 3 7 2 9 Lift off spring casing containing spring This is a heavy unit It is suggested that a chain fall
24. mp 3125 3 8 2 1 Vent air pressure and disconnect air line 2 Remove actuator bolts and nuts 3 Remove spindle nut 3125 Remove hex head screw relaxing spring diaphragm plates actuator dia phragm and spring 3 8 2 4 Using replacement parts reverse instructions for reassembly Apply Loctite 242 on spindle nut Actuator Diaphragm or Spring Replace ment 3150 31101 31130 31250 To replace springs 3 8 3 1 Vent air pressure and disconnect air line 3 8 3 2 3150 Remove four nuts and spring cover from columns 31101 31250 Remove cap screws and nuts from around cap 3 8 3 3 Remove jam nut from spindle Turn adjusting bushing counterclock wise relaxing spring 3 8 2 3 8 2 3 8 3 4 Remove spring seat and spring 3 8 3 5 Assemble in reverse order To replace actuator diaphragm perform steps 1 through 5 above then 3 8 3 6 Remove actuator bolts and nuts releasing actuator upper cover 3 8 3 7 Unscrew spindle coupling to re move diaphragm plates and actu ator diaphragm 3 8 3 8 Replace parts including gaskets and reverse instructions for reas sembly Apply Loctite 242 to spindle threads 12 50 250 or hex head bolt 25 when installing spindle nut or spindle coupling 3 8 4 O Ring Replacement 3 8 4 1 Disconnect air lines Remove actu ator and bonnet assembly from valve body and dismantle actuator following above instructions for re moving actuator diaphragm 3 8 4 2 Withdraw valve diaph
25. non hardening sealant is strongly recom mended Connect the positioner to a source of clean dry oil free air A filtered and regu lated air source is recommended Note Synthetic compressor lubricants in the air stream at the instrument may cause the positioner to fail Note that a cushion loading regulator is fur nished with 3300 series actuators and a tee in the supply connection is routed to this regulator so an extra hookup is not required The cushion loading regular should be set at the minimum pressure required to open the valve wide open Typically this is 10 psi or less 4 9 5 Adjustment The only adjustment that can be made on the positioner is a zero adjustment The zero adjusting screw is located under the posi tioner s top cover To adjust the zero set the instrument air pressure to the mid point of its span and turn the zero adjustment until the valve is at the mid point of its stroke To determine valve stroke refer to Table 2 Recheck the setting accuracy by changing instrument air pressure to the maximum minimum point to obtain full open closed valve position In some cases valve shut off opening may be required at a specific instrument pres sure To zero the positioner at this point set the instrument signal at the specific pressure and turn the zero adjustment screw until the valve reaches the required position A slight change of the instrument pressure should start to move the valve The valve strok
26. nstructions above 3 5 3 2 3 9 9 3 the removing actuator diaphragm Withdraw valve diaphragm com pressor and spindle assembly from the bonnet Remove old o ring taking care not to damage machined surfaces Lu bricate new o ring per Section 3 4 and install in groove Reassemble reversing the above instructions 3 6 Reverse Acting 3212 3225 3250 3275 See Figures 4 B 4 C 4 D 3 6 1Valve Diaphragm Replacement 3 6 1 1 3 6 1 2 3 6 1 3 3 6 1 4 3 6 1 5 3 6 1 6 3 6 1 7 3 6 1 8 3 6 1 9 Load the bottom chamber of the actuator with sufficient air to par tially open valve This will ease the Spring tension holding the valve diaphragm to the body weir Remove the bonnet bolts and nuts Lift actuator and bonnet assembly from valve body Release air and disconnect air line Unscrew diaphragm from compres sor by turning counterclockwise For PTFE assemblies only Replace backing cushion and PTFE dia phragm Note It may be difficult to engage the threads of the dia phragm stud without inverting the diaphragm To invert diaphragm press on the center of the dia phragm face with thumbs while holding the edge of the dia phragm with fingers Screw new diaphragm into com pressor by turning hand tight Then back off until bolt holes in dia phragm and bonnet flange register Connect air line to lower air cham ber and load chamber with suffi cient air to move the compressor approximately 1 8 of an
27. ower actuator plate 3 7 3 4 Slide diaphragm compressor and valve spindle down out of the bon net as a unit 3 7 3 5 Replace o rings in adapter bushing Lubricate o rings per Section 3 4 3 7 3 6 To reassemble reverse above pro cedures 3 8 Direct Acting See Figures 4 F 4 G 4 H 4 1 3 8 1 3 8 2 3 8 3 Valve Diaphragm Replacement 3 8 1 1 Disconnect air lines Remove bon net bolts and nuts Lift actuator and bonnet assembly from valve body Pressurize actuator extending compressor and diaphragm 3 8 1 2 Unscrew diaphragm from compres sor by turning counterclockwise 3 8 1 3 For PTFE assemblies only Replace backing cushion and PTFE dia phragm Note It may be difficult to engage the threads of the dia phragm stud without inverting the diaphragm To invert dia phragm press on the center of the diaphragm face with thumbs while holding the edge of the dia phragm with fingers 3 8 1 4 Screw new diaphragm into com pressor until hand tight Then back off until bolt holes in diaphragm and bonnet register 3 8 1 5 Reduce air pressure until back of diaphragm is flat against bonnet Replace actuator and bonnet as sembly on body and tighten bon net bolts hand tight 3 8 1 6 Tighten bonnet bolts with a wrench crisscrossing from corner to corner See Table 1 for torques 3 8 1 7 Release air and open valve If ne cessary retighten bonnet bolts Actuator Diaphragm or Spring Replace ment 3112 a
28. phragm Nii TOP COVER N 4 dorsi ab i WSS J LOWER COVER O RING A Y 1027222210 O RING B LUBE FITTING E SPINDLE 2 COMPRESSOR 922 VALVE DIAPHRAGM 2 227 BOLTS amp NUTS A VALVE BODY 2 Z FIGURE 4 A 3312 33250 TOP COVER SPRINGS SPINDLE NUT DIAPHRAGM PLATE Kee ACTUATOR BOLTS amp NUTS AE wur REE ACTUATOR DIAPHRAGM D RING A LUBE FITTING SPINDLE Dh tes 0 Yj COMPRESSOR VALVE DIAPHRAGM ENS AA BONNET BULTS amp NUTS Yj FIGURE 4 B 3212 VALVE BUDY X SPINDLE NUT LOS DIAPHRAGM PLATE Xe ae DLL 24 2725 ACTUATOR DIAPHRAGM ACTUATOR BOLTS amp NUTS Diaphragms Actuator Diaphragms Size 12 25 50 75 101 130 250 A Be 135e 14 15 Vae 1494s 217 Bolt Holes amp gt 27771 maximum recommended air pressure 85 psi SAFETY CAP SPRING ROD JAM NUT ADJUSTING BUSH NUT w TOP COVER SS WOO SPRINGS 2 SPRING NUT SPRING SEAT ACTUATOR NUTS AND BULTS ACTUATOR DIAPHRAGM O RING O RING B BUNNET BULTS AND NUTS DIAPHRAGM FIGURE 4 C 3225 SPRING ROD SAFETY CAP JAM NUT ADJUSTING BUSHING COLUMN NUTS SPRING COVER SPRING CASE SPRING RUD 0 BUSHING JAM NUT m v
29. pressures far in excess of their rated values The pressures listed below are applicable up to 120 F Valves at maximum pressures cannot be used at maximum temperatures IMPORTANT The actuator size being used may limit actual operating pressures Consult the Engineering Catalog for actuator sizing WEIR STRAIGHTWAY Tal Ub 2 2h 3 85 a 3 Maximum pressure psi Maximum pressure psi psi Valve size Handwheel Daw 200 TU Taz 2 10 12 Le E C NENNEN 10 12 For solid plastic valves see catalog TABLE 5 A WEIR VALVE O RINGS For O Ring A or B see Figure 4 DOUBLE ACTING ACTUATORS ACTUATOR 3325 2 Hs 116 5 326 3375 116 116 214 214 214 326 326 326 326 326 326 33250 214 TWO 4 1 TWOREQURED O O B 238 Two required if sealed bonnet is used DIRECT ACTING ACTUATORS ACTUATOR EA 2 114 114 114 3112 TWO REQUIRED TWO REQUIRED Used with sealed bonnet only Two required if sealed bonnet is used ACTUATOR SIZE 1 EIE 1 1 2 2 114 114 114 3095 114 114 114 114 116 116 214 214 5 5 326 326 326 326 326 326 326 326 3250 116 116 214 214 214 214 326 326 326 326 E 214 214 214 214 10 12 214 TWO REQUIRED B 238 32250 Two required if sealed bonnet is used TABLE 5 B STRAIGHTWAY VALVE O RINGS For O Ring A or B see Figure 4 DOUBLE ACT NG ACTUATORS ACTUATOR VALVE SIZES
30. r other sizes with combination hand wheel wrench opening device and adjustable opening stop see Section 4 5 4 2 1 1 Release any air pressure in bottom chamber 4 2 1 2 3212 Remove pressure cap by rotating counterclockwise 4 3 4 4 4 2 1 3 3225 32250 Remove safety shield by loosening the two mounting screws 4 2 1 4 To adjust travel closing stop loosen jam nut Turn adjusting bushing or stop nut clockwise or turn hand wheel counterclockwise until valve leaks Then turn counterclockwise or turn handwheel clockwise until the valve just stops leaking Tighten jam nut Travel stop is now set 4 2 2 Direct and Double Acting The travel stop code ATS is housed within a pressure cap which is pressurized along with the upper chamber Note If furnished with an adjustable opening stop code TOHC or handwheel closing device code TOHC these mechanisms will protrude through the top of the pressure cap To adjust the travel stop however the pressure cap must be removed 4 2 2 1 Vent air from the upper chamber Remove pressure cap by rotating counterclockwise Loosen jam nut 4 2 2 2 Adjust travel stop nut until the gap below the nut is equal to the valve or actuator travel whichever is less Table 2 Tighten jam nut 4 2 2 3 Install pressure cap making sure o ring is properly installed 4 2 2 4 Pressurize actuator If valve leaks Repeat step 1 Back off stopnut Slightly by turning counterclock wise Install pressure
31. ragm com pressor and spindle assembly from the bonnet 3 8 4 3 Replace o ring and reassemble by reversing the instructions and fol lowing the steps for replacing a valve diaphragm Lubricate o rings prior to installation per Section 3 4 4 ACCESSORIES 4 1 Pressure Cap Figure 6 4 2 Pressure Caps are used with adjustable travel stops and other accessories To remove pressure cap ensure that upper chamber of actuator is un pressurized Rotate pressure cap counterclock wise to remove Pressure Cap O Rings Actuator Size O Ring 12 219 213 with ductile iron cover 25 220 All Others 333 Travel Closing Stop Adjustment Note Travel Stops are standard on 3225 32250 and available on all actuators The purpose of the travel stop is to prevent over loading of the diaphragm thus prolonging dia phragm life Travel stops are factory set and do not require routine adjustment However with re placement of valve diaphragms travel stop adjustment is recommended Refer to Figure 6 for all direct and double acting and all 12 actuators Refer to Figure 4 C D amp E for 3225 32250 actuators 4 2 1 Reverse Acting If actuator has handwheel code HWO Figure 7 or wrench opening device code WO Figure 8 this device also serves travel stop function If 3212 actuator has adjustable opening stop code TOWO the opening stop must be removed To remove opening stop ro tate pressure cap counterclockwise and lift off Fo
32. ry 6 months Actuators without lube fittings should be lubricated in the spindle adapter bushing o ring area whenever the actuator is disassembled Double Acting See Figure 4 A 3 5 1 Valve Diaphragm Replacement 3 5 1 1 Disconnect air lines Remove bon net bolts and nuts Lift actuator and bonnet assembly from valve body 3 5 1 2 Unscrew diaphragm from com pressor by turning counterclockwise 3 5 1 3 For PTFE diaphragm assemblies only replace backing cushion and PTFE diaphragm Invert PTFE diaphragms prior to installation in tube nut To invert hold edge of diaphragm with fingers while pressing in the center of the dia phragm face with thumbs 3 5 1 4 Screw new diaphragm into com pressor until hand tight then back off until bolt holes in diaphragm and bonnet flange register 3 5 1 5 Replace actuator and bonnet assembly on body and tighten bonnet bolts with a wrench criss crossing from corner to corner See Table 1 for torques 3 5 2 Actuator Diaphragm Replacement 3 5 2 1 Disconnect air lines Remove actua tor bolts and nuts Remove top cover 3 5 2 2 Remove spindle nut diaphragm top plate and actuator diaphragm 3 5 2 3 Install new diaphragm Reassembly is the reverse of the above Apply Loctite 242 or equivalent on spindle threads when installing spindle nut 3 5 3 Spindle O Ring Replacement 3 5 3 1 Disconnect air lines remove actua tor and bonnet assembly as a unit from valve body and dismantle ac tuator following i
33. st 1 4 of travel 4 7 1 Adjustment 12 Actuator 4 7 1 1 Loosen lever adjustment screws Open valve 4 7 1 2 Move open switch operating lever until open switch makes an audible click Tighten open switch lever adjustment screws 4 7 1 3 Open switch is now set Verify set point by checking continuity on switch terminals 4 7 1 4 Close valve and repeat the above procedure for the valve closed switch 4 7 2 Adjustment 4225 250 Actuator 4 7 2 1 Open valve slowly Note if actuat ing lever has previously been mis adjusted lever may overtravel switch and become damaged 4 7 2 2 Loosen lever attachment screws Note Actuating rod is spring loaded If rod is not bearing against diaphragm plate spring may force actuating rod entirely within actuator Actuator must be disassembled to retrieve 4 7 2 3 Move actuating lever until switch makes an audible click Verify set point by checking continuity on switch terminals Open switch is now set 4 7 2 4 Repeat the above procedure for the valve closed switch Same cautions apply 4 8 Westlock Module3 Proximity Switches See Figure 12 4 8 1 Description These proximity switches are actuated by magnetic triggers The triggers along with sensing end of the switches are inside a protective metal enclosure The switch leads and all electrical terminations are in side a separate sealed explosion proof enclosure Refer to the manufacturer s literature for the precise enclosure r
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