DIA-FLO & PURE-FLO Diaphragm Valves Instruction Manual With
Contents
1. 24 NY BR 1 Ky NS AN ae SPRING I WASHER RETAINING RING FIGURE 11 B MICROSWITCH LIMIT SWITCHES 25 250 14 BRACKET COVER SCREW TRIGGER BRACKET WESTLOCK MODULE3 PROXIMITY SWITCH MODIFIED A 4 2 LY IS TAS BRACKET VALVE OPEN SWITCH VALVE CLOSED SWITCH VIEW A A BACK OF SWITCH DETAIL FIGURE 12 WESTLOCK MODULE 3 PROXIMITY SWITCH INSTRUMENT 1 4 NPT S 7 z Z 222 am cm 2 zb ST SSS E ZZ 5 gt LLJ LL INSTRUMENT AIR AIR MOTOR 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 Note2. pom WCW rss SSS O RING B FIGURE 4 D 4 SPRING ROD ADJUSTING BUSHING SAFETY CAP SPRING ROD ADJ BUSHING JAM NUT CULUMN NUTS T NS N I SPRING COVER SPRING CASE S n SPRING CAP SCREW SPINDLE CONN as lt rm LUCK WASHER 22 UPPER COVER A ff EN 7 Seg DIAPHRAGM HEX NLIT S g Oe VR lt O RING B Vy a O RING A Vas SPINDLE HEX NUT n a n He COMPRESSOR VALVE DIAPHRAGM FIGURE 4 E 3250 3275 32101 32250 TOP COVER HEX HEAD SCREW SPINDLE NUT L K lt DIAPHRAGM PLATE ACTUATOR DIAPHRAGM TOW Ag ACTUATOR BOLTS amp NUTS a SPRING WA SPINDLE SA O RING A LUBE FITTING r CDMPRESSUR 2 VALVE DIAPHRAGM v ULLA 77 242 gt BONNET BOLTS amp NUTS lt VALVE BODY 2 FIGURE 4 F FIGURE 4 G 3112 3125 COLUMN NUTS ae NSS LL d to CAP SCREW esse PRING COVER Why 2 GASKET nE HEX NUT hg JAM NUT Vat JAM NUT ao x Hl SPRING SEAT Ji SPRING PLATE NM ADJ BUSHING SPRING CASE STI ADJ BUSHING COLUMN rn SPINDLE EXT d HI SPRING SPINDLE CDUPLING CAP SCREW Es PRING SEAT OT LOCK WASHER Am Aem lt LL Ll ACTUATOR PLATE a ee NS DIAPHRAGM ee WS SPLNOLE SS IS O RING B E e A BONNET
3. Y 2 O RING A LUBE FITTING M ME SPINDLE n Ift GF COMPRESSOR VALVE DIAPHRAGM BONNET BOLTS amp NUTS 20 Z VALVE BODY 7 2 FIGURE 4 A 3312 33250 TOP COVER SPRINGS SPINDLE NUT DIAPHRAGM PLATE at Ware ACTUATOR BOLTS amp NUTS a er hn wee ACTUATOR DIAPHRAGM PTF Teed D RING A LUBE FITTING 2 SPINDLE 1 COMPRESSOR UDT 2 EZ NES Ene SS VALVE DIAPHRAGM BOLTS amp NUTS VALVE BUDY FIGURE 4 B 3212 N SPINDLE NUT E Ke DIAPHRAGM PLATE ae il MIN S ACTUATOR DIAPHRAGM Wy t 7 29 Za ACTUATUR BDLTS amp NUTS FIGURE 3 ACTUATOR DIAPHRAGM IDENTIFICATION Diaphragms Actuator Diaphragms Size 12 25 50 75 101 130 250_ A 6w 9 13 144 2176 maximum recommended air pressure 85 psi SAFETY SPRING ROD JAM NUT ADJUSTING BUSH NUT 72 h TOP COVER 277 Z N 785 7 2 2 SPRINGS Y 4 2 SPRING NUT SPRING SEAT CES SS ACTUATOR NUTS 2 AND BULTS S 7 2 2 SS ZZ Suse J 27 s lt ACTUATOR DIAPHRAGM O RING 2 22 O RING B BONNET BOLTS AND NUTS 2 y 2 DIAPHRAGM FIGURE 4 C 3225 JAM NUT SSNS NU 7 COLUMN ASSESS 1
4. O RING ae Ss SA HEX NUT a ESSE COMPRESSOR SS WAP P 9 Z I Np Re amp SSS 2 VALVE DIAPHRAGM FIGURE 4 l 31101 31250 PRESSURE CAP FIGURE 4 H SPINDLE EXT 3150 JZ JAM NUT ES INDICATOR HOUSING O RING 110 2 O RING 113 INDICATOR TUBE 2 INDICATUR ROD T a7 SPRING COVER D RING 115 in at 5 SPACER 0 RSS O RING 110 gt s LUN RETAINING RING MAGNET HOLDING CRUCIBLE MACHINE SCREW TOP COVER TA AES Th gt 1 AP Z FIGURE 5 A FIGURE 5 B FIGURE 6 25 250 PRESSURE CAP amp TRAVEL STOPS POSITION INDICATOR POSITION INDICATOR 3100 amp 3300 SERIES 9 CY ROD SPRING HT JAM NUT JAM NUT ROD SPRING H A ADJ BUSHING Ce Iz CAP SCREW 4 A 1 LOCK WASHER 2 2 THRUST WASHER THRUST WASHER 7 ASX 2 7 pO N 4 SPRINGS 7 N SPRINGS 2 7 TOP COVER N TOP COVER Y N N CONNECTOR EN N CONNECTOR 2 E COUPLING Ane COUPLING INH SPRING SEAT INSO K SPRING SEAT oh TH TH S FIGURE 7 FIGURE 8 HANDWHEEL OPENING DEVICE WRENCH OPENING DEVICE 3200 SERIES 3200 SERIES SPINDLE EXT JAM NUT HANDWHEEL SET SCREW SHIM WASHER HANDWHEEL BUSHING RACE THRUST JAM NUT WRENCH OPENING NLT NS 4 5
5. 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 cap and pressurize actuator Repeat this process as necessary until valve does not leak Handwheel Opening Devi
6. 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 425 250 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 ratings In addition a solenoid valve may be at tached directly to the switch enclosure via the
7. DEVICE OPERATION 4 5 COMBINATION HANDWHEEL OR WRENCH OPENING DEVICE WITH ADJUSTABLE OPEN ING STOP 4 6 HANDWHEEL CLOSING DEVICE AND ADJUSTABLE OPENING STOP 4 7 MICROSWITCH LIMIT SWITCHES ADJUSTMENT 4 8 WESTLOCK MODULE 3 LIMIT SWITCHES 4 9 POSITIONERS TOP MOUNTED TABLES BONNET FASTENER TORQUES 2 VALVE AND ACTUATOR TRAVEL 3 ACTUATOR INTERNAL DATA 4 VALVE OPERATING PRESSURES 5 O RING SIZES F 1 GLASS LINED BODY INSTALLATION 2 VALVE DIAPHRAGM IDENTIFICATION 3 ACTUATOR DIAPHRAGM IDENTIFICATION 4 ACTUATOR DRAWINGS 5 POSITION INDICATORS TRAVEL STOPS HANDWHEEL OPENING DEVICE WRENCH OPENING DEVICE COMBINATION HANDWHEEL OPENING OR WRENCH OPENING WITH ADJUSTABLE OPENING STOP 10 HANDWHEEL CLOSING DEVICE AND ADJUSTABLE OPENING STOP 11 LIMIT SWITCHES PUSHBUTTON TYPE 12 LIMIT SWITCHES WESTLOCK PROXIMITY TYPE 13 POSITIONERS TOP MOUNTED 14 PTFE DIAPHRAGM DETAIL 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 have special installation instruc tions See section 1 3 NOTE SOLID PLASTIC VALVES Solid Plastic V
8. 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 3 7 1 3 7 2 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 assembly from the bonnet Replace o ring s and reassemble by reversing the instructions and f
9. 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 4 9 3 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 8200 Series Actuators Supply and Instrument Pressures 4 9 2 1 Instrument input pressure range as specified 3 15 psi standard 3 9 psi 6 30 psi and others are optional 4 9 2 2 Supply pressure 3 psi above re quired actua
10. 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 MicroSwitch Limit Switches Model Nos BZE6 2RN BAF1 2RN DTE6 2RN DTF2 2RN 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 last 1 4 of travel 4 7 1 Adjustment 12 Actuator 4 7 1 1 Loosen lever adjustment screws Open valve
11. 3 Remove spindle nut 8125 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 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 diaphragm com pressor and spindle assembly from the bonnet 3 8 4 3 Replace o ring and reassemble by reversing the instru
12. 4 WRENCH OPENING DEVICE DETAIL x NEEDLE BEARING I RETAINING RING 4 BUSHING ADJUSTER JAM NUT 155555 SPRING COVER o rc v RETAINING NUT SPACER SPRING SEAT CONNECTOR COUPLING BAZAN AAW oI va IAIN om L L L FIGURE 9 A COMBINATION WRENCH OR HANDWHEEL OPENING DEVICE WITH ADJUSTABLE OPENING STOP 3225 32130 INS Z A m SSS HANDWHEEL ADJUSTING SCREW 2 mis ZA HA ALA S H 22 gt d Wk N rm xin rim EN on A 1 5 LL s CE V 5555224 UW FIGURE 9 B COMBINATION WRENCH OPENING DEVICE AND ADJUSTABLE OPENING STOP 3212 gt Ce gi aes pt r4 HANDWHEEL SPIROL PIN JAM NUT ADJUSTING SCREW ADJUSTABLE JAM NUT OPENING THREDSEAL STOP PRESSURE CAP SS SPINDLE EXT p SPIROL PIN an Tp JAM NUT 12 Z OPERATING ROD MICRO SWITCH SWITCH ACTUATOR MOUNTING BRACKET WANG rL S 17 T Z2 ROD GUIDE O RING RETAINING RING ANCHOR PLATE ACTUATOR PLATE FIGURE 11 A WASHER FIGURE 10 MICROSWITCH LIMIT DETAIL A HANDWHEEL CLOSING DEVICE AND ADJUSTABLE OPENING STOP SWITCHES 3100 amp 3300 SERIES 12 ACTUATOR pen TRIGGER SWITCH ACTUATOR LOCK WASHER MICRO SWITCH
13. ACTING ACTUATORS ACTUATOR VALVE SIZES SIZE 1 2 2 1 2 35 3150 114 116 E 214 214 214 326 326 31130 TWO REQUIRED 238 31250 214 TWO REQUIRED 238 Used with sealed bonnet only Two required if sealed bonnet is used DIRECT ACTING ACTUATORS VALVE SIZES Two required if sealed bonnet is used 10 FIGURE 1 INSTALLATION GLASS LINED BODIES Important It is extremely important that all glass lined valves be installed with proper end flange gaskets and that proper torque be applied to the bolts in correct se quence The use of PTFE plastic envelope gaskets with soft insert materials is recommended See proper bolt torque and sequence at right PROPER BOLTING RECOMMENDED SEQUENCE TORQUE Valves Ib Ft 00 50 01 50 20 30 02 00 02 50 30 60 ny ANA 03 00 04 00 40 70 Se 06 00 55 110 08 00 60 110 VALVE END FLANGE FIGURE 2 VALVE 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 For 00 75 with flanged ends use 01 00 diaphragm except for solid plastic For 01 25 solid plastic uses 01 50 diaphragm TOP COVER d T eA LOWER COVER e
14. 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 ADJUSTMENT 3 0 MAINTENANCE 4 0 ACCESSORIES 4 1 PRESSURE CAP 4 2 TRAVEL CLOSING STOP ADJUSTMENT 4 3 HANDWHEEL OPENING DEVICE OPERATION 4 4 WRENCH OPENING
15. Maximum pressure rating for Dualrange Control Valves is 100 psi PAS bonnet required above 200 F 93 Z ive AZ n s ML MOY aN a SUPPLY 1 4 NPT 4424 BACKING CUSHION s GY ZZ SSSSS SG SAV R 2 DIAPHRAGM 1 WS E FIGURE 14 PLASTIC DIAPHRAGM DETAIL COMPRESSOR SPIROL PIN LINE PRESSURE PSIG LINE PRESSURE PSIG TEMPERATURE 60 71 83 93 CAN reel sister NUN T et BEBIVINGSENEEEEENI T RENTA d F TEMPERATURE 20 ES 107 121 WEIR VENES zoo E 1379 E maswa ER Htt ror HIGHER PRESSURE TEMPERATURE T NNS COMBINATIONS CONTACT ENGINEERED LLL IDE TL VAES SALES OFFICES um PE TTT TTT T TER LI RE IN og ASS EASES gt EE CELLLLDISSERICTTE DIREPTA CTT AN ARSENE dw T AED RU ER TRESS e CTT Re RAR LLLLLLLLLLLIT EEELPEL T Lu PC OY POE 6 8 100 10 140 10 10 20 22 TEMPERATURE F KPA G KPA G Engineered Valves For more information write to Engineered Valves Headquarters 33 Centerville Road PO 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 itt com 2001 ITT Industries ITT
16. alves 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 ITT Industries Engineered for life 1 2 1 3 1 4 1 5 1 6 stem between 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 all glass lined valves be installed with proper end flange gaskets and that proper torque be applied to the
17. 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 21 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 cha ber then it will be necessary to use the adjusting bushing as a jack screw to compress the springs with
18. 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 ADJUSTMENT 2 1 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 XXYYY if XX 31 Direct Acting Spring to Open if 32 Reverse Acting Spring to Close if XX 33 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 2 2 Maximum permitted air supply pressure is 85 psig 586 kPa 2 3 For operation and adjustment of actuator accessories see Section 4 2 4 Valve and actuator travel are shown in Table 2 For any combination the actual travel is the lesser of the two MAINTENANCE 3 1 Peri
19. ce Operation Figure 7 The purpose of the optional handwheel opening device is to open a reverse acting 8200 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 1 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 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 Tighten jam nut and install safety 4 5 Combination Handwheel or Wrench Opening Device with Adjustable Opening St
20. ctions and fol lowing the steps for replacing a valve diaphragm Lubricate o rings prior to installation per Section 3 4 4 ACCESSORIES 4 1 4 2 Pressure Cap Figure 6 Pressure Caps are used with adjustable travel stops and other accessories To remove pressure 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 For other sizes with combination hand wheel wrench opening device and adjustable opening stop see Section 4 5 4 2
21. e 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 instructions above 3009 2 3 5 3 3 the removing actuator diaphragm Withdraw valve diaphragm com pressor and sp
22. fastener yielding or galling is ap Valve f I parent reduce torque accordingly and replace fasteners size h 1 E ug 2 3 4 6 8 10 12 3 Stainless steel studs bolts with stainless steel nuts have Stroke 5 32 5 6 1 4 17 2 25 6 2 hs 4 4 6 4 T he T Carbowax 3350 applied at the factory Stainless steel studs bolts with bronze nuts have no lubricant Subsequent field lu bricant is not necessary 2 4 w flanged ends use 1 data except solid plastic a r 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 Spindle nuts should be assembled with 271 red Loctite TABLE 3 Actuator internal dimensions Effective Actuator Volume cu in Diaphragm Bottom Chamber Upper Chamber Double amp Reverse Acting Direct Acting size Connection in Open Closed Open Closed Open Closed 12 5 8 1 4 11 5 13 25 6 8 6 1 12 5 6 1 12 5 25 2 1 4 22 5 90 3 21 7 13 4 85 1 13 4 85 1 50 3 1 4 50 321 0 63 4 71 1 329 0 364 622 75 3 1 4 75 374 7 128 1 80 9 422 0 101 1 2 100 528 0 174 0 144 0 498 0 579 933 130 31 2 1 2 130 698 7 202 9 212 0 710 9 647 1146 250 45 3 1 2 250 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
23. indle 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 1 Valve 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 inch Replace actuator and bonnet as sembly on body and tighten bon net bolts hand tight Release air pressure
24. long operating life Pressure tests indicate that ITT Dia Flo diaphragm valves withstand 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 12 1 2 27 8 Valve size Handwheel inches 5 1 1 2 3 4 10 12 For solid plastic valves see catalog p45 TABLE 5 A WEIR VALVE O RINGS For O Ring A or B see Figure 4 DOUBLE ACTING ACTUATORS ACTUATOR 2 1 we 11 Ms 214 214 214 33250 TWO REQUIRED B 238 Two required if sealed bonnet is used DIRECT ACTING ACTUATORS ACTUATOR 112 112 112 114 114 114 HEE B Used with sealed bonnet only Two required if sealed bonnet is used REVERSE ACTING ACTUATORS ACTUATOR oe 214 214 214 214 326 oe Ms 214 214 214 TWO 24 TWOREQURED 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 A 112 3312 o tp ttt tft tt tf ais A 114 114 116 116 214 3325 LI 33250 214 TWO REQUIRED 238 Two required if sealed bonnet is used DIRECT
25. 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 7 213 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 lower actuator plate 3 7 3 4 Slide diaphragm compressor and valve spindle down out of the bon net as a
26. odically 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 9 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 every 6 months Actuators without lube fittings should be lubricated in the spindle adapter bushing o ring area whenever th
27. ollowing the steps for replacing a valve diaphragm Lubricate o ring s prior to installation per Section 3 4 32101 32130 32250 see Valve Diaphragm or Spring Replace ment see 3 6 1 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 E 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 be used using the lifting eyelets located near the top of the spring casing A WARNING Spring casing
28. op 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 4 6 Handwheel Closing Device and Adjustable Open ing Stop Figure 10 8100 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 4 6 1 Operation of Adjustable Opening Stop 4 6 1 1 Use bleed type regulator and air supply to move valve
29. ro 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 Ta Plastic Actual travel for any valve and actuator combination is the lesser of the valve or actuator travel listed below Straightway Weir amp Except Glass Lined Straightway 40 18 40 80 40 WEIR BO Actuator 0 Size 12 25 50 15 101 130 250 48 100 Stroke 5 2 3 3 3 s 31 2 4 48 96 Valve 192 Size Vo 1 17 4 1 5227 3 4 6 8 10 12 Stroke 4 5 1 9 ie 1 8 13 8 19 8 2 8 45 3 5 s 61 2 192 Stroke for 3 4 flanged weir valve is 1 2 except solid plastic STRAIGHTWAY Actuator Size 12 25 50 75 101 130 250 1 Torque be exceeded by up to 10 UM gr 2 Bolt tension developed using torque wrenches can vary widely Stroke 2 3 3 3 s 3 2 4 fs depending on fastener condition wrench accuracy degree of lubrication and technique If
30. ry 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 stroke for a given span may also be suppressed or shifted to the desired range by means of the ze
31. tor 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 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 non hardening sealant is strongly recom mended Connect the positioner to a source of clean d
32. 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 amp 3125 3 8 2 1 Vent air pressure and disconnect air line 3 8 2 2 Remove actuator bolts and nuts 3 8 2
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