DFAMM-01

DIA-FLO ® & PURE-FLO ® ITT INDUSTRIES VALVES AND VALVE ACTUATORS ARE DE-
SIGNED AND MANUFACTURED USING GOOD WORKMANSHIP AND
MATERIALS, AND THEY MEET ALL APPLICABLE INDUSTRY STAN-

Diaphragm Valves 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

Instruction Manual COMPANY VALVE ENGINEER.

MISAPPLICATION OF THE PRODUCT MAY RESULT IN INJURIES
OR PROPERTY DAMAGE. A SELECTION OF VALVE COMPONENTS

With Dia-Flo Actuator ® OF THE PROPER MATERIAL CONSISTENT WITH THE PARTICULAR
PERFORMANCE REQUIREMENTS, IS IMPORTANT FOR PROPER
APPLICATION.
This manual provides installation and maintenance EXAMPLES OF THE MISAPPLICATION OR MISUSE OF ITT IN-
DUSTRIES VALVES INCLUDE USE IN AN APPLICATION IN WHICH
instructions for DIA-FLO ACTUATOR operated THE PRESSURE/TEMPERATURE RATING IS EXCEEDED OR FAIL-
DIA-FLO/PURE-FLO diaphragm valves. URE TO MAINTAIN VALVES AS RECOMMENDED.
IF VALVE EXHIBITS ANY INDICATION OF LEAKAGE, DO NOT OP-
If additional information is required, contact: ERATE. ISOLATE VALVE AND EITHER REPAIR OR REPLACE.

Engineered Valves
33 Centerville Road
Lancaster, PA 17603
(717) 509-2200
Attention: Sales Department

CONTENTS 6. TRAVEL STOPS

1.0 INSTALLATION 7. HANDWHEEL OPENING DEVICE
2.0 OPERATION & ADJUSTMENT 8. WRENCH OPENING DEVICE
3.0 MAINTENANCE 9. COMBINATION HANDWHEEL OPENING OR
4.0 ACCESSORIES WRENCH OPENING WITH ADJUSTABLE OPENING
4.1 PRESSURE CAP STOP
4.2 TRAVEL (CLOSING) STOP ADJUSTMENT 10. HANDWHEEL CLOSING DEVICE AND
4.3 HANDWHEEL OPENING DEVICE OPERATION ADJUSTABLE OPENING STOP
4.4 WRENCH OPENING DEVICE OPERATION 11. LIMIT SWITCHES - PUSHBUTTON TYPE
4.5 COMBINATION HANDWHEEL OR WRENCH 12. LIMIT SWITCHES - WESTLOCK PROXIMITY TYPE
OPENING DEVICE WITH ADJUSTABLE OPEN- 13. POSITIONERS (TOP MOUNTED)
ING STOP 14. PTFE DIAPHRAGM DETAIL
4.6 HANDWHEEL CLOSING DEVICE AND
ADJUSTABLE OPENING STOP 1.0 INSTALLATION
4.7 MICROSWITCH LIMIT SWITCHES - NOTE: WELD END VALVES
ADJUSTMENT Weld end valves for schedule 10 and heavier pipe re-
4.8 WESTLOCK MODULE 3 LIMIT SWITCHES quire bonnet and diaphragm removal prior to welding
4.9 POSITIONERS (TOP MOUNTED) 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
TABLES equipment only without removing the diaphragm.
1. BONNET FASTENER TORQUES Manual welding requires bonnet and diaphragm re-
2. VALVE AND ACTUATOR TRAVEL moval for all pipe schedules.
3. ACTUATOR INTERNAL DATA NOTE: GLASS LINED BODIES
4. VALVE OPERATING PRESSURES Glass lined bodies have special installation instruc-
5. O-RING SIZES tions - See section 1.3.
FIGURES NOTE: SOLID PLASTIC VALVES
1. GLASS LINED BODY INSTALLATION Solid Plastic Valves are not recommended for installation
2. VALVE DIAPHRAGM IDENTIFICATION in plastic lined piping systems. Also note threaded inserts
3. ACTUATOR DIAPHRAGM IDENTIFICATION are supplied in the base of the valve body and should be
4. ACTUATOR DRAWINGS used for bracketing/supporting valves in accordance with
5. POSITION INDICATORS 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
 stem between 0 and 30 degrees above horizon- 3.7 or 3.8. On sealed bonnet valves, back off the
tal. (After draining, a small pocket of fluid may v-notch vent plug two or three turns.
remain in the valve.) Note: Pure-Flo valves have
either raised hash marks (castings) or small  WARNING:
machined dots (forgings) on the valve body to When the process fluid is hazardous or corro-
indicate the correct drain angle. Locate these sive, extra precautions should be taken. The
marks at the 12 o’clock position to achieve the user should employ appropriate safety
optimum drain angle. devices and should be prepared to control a
1.2 Prior to pressurization (with the valve open), leak of the process fluid. Fluid weeping from
tighten the bonnet nuts in a crisscross pattern the plug indicates a diaphragm failure.
in accordance with Table 1. Retightening 24 Replace diaphragm immediately. Failure to
follow these instructions could result in
hours after the system reaches operating
serious personal injury or death and property
temperature and pressure is recommended. If damage.
leakage occurs at the body/diaphragm seating
area, immediately depressurize system and 3.2 Air pressure from the bonnet weep hole may
tighten bonnet nuts as noted above. If leakage indicate o-ring failure. Follow applicable replace-
continues, diaphragm replacement is required. ment instructions given below.
Follow applicable steps in Section 3.5, 3.6, 3.7 3.3 If valve diaphragm flange area leaks, depres-
or 3.8. surize system and open valve slightly, using
1.3 INSTALLATION - GLASS LINED VALVE BODIES handwheel/wrench opening device (if equipped
It is extremely important that all glass lined or local bleed type regulator. Tighten bonnet nuts
valves be installed with proper end flange as described in Section 1.2. If leakage continues,
gaskets and that proper torque be applied to diaphragm replacement is required.
the bolts in correct sequence. The use of PTFE 3.4 Lubrication
plastic envelope gaskets with soft insert Standard lubricants are Sunoco 991EP for
materials is recommended. See Figure 1 for Dia-Flo valves and Chevron Poly FM2 (FDA Com-
pliant) for Pure-Flo valves. Actuators equipped
proper bolt torque and sequence.
with a lube fitting should be lubricated
1.4 The travel stop, if equipped, is factory set and every 6 months. Actuators without lube fittings
should not require adjustment at time of instal- should be lubricated in the spindle/adapter
lation. However, if adjustment is required, see bushing/o-ring area whenever the actuator is
section 4.2. disassembled.
1.5 Maximum valve operating pressures are shown 3.5 Double Acting (See Figure 4(A))
in Table 4. Consult factory or Engineering 3.5.1 Valve Diaphragm Replacement
Catalog for vacuum operation. 3.5.1.1 Disconnect air lines. Remove bon-
1.6 Air line connections should be made up with net bolts and nuts. Lift actuator and
care as damage may occur to the standard bonnet assembly from valve body.
aluminum actuator covers. Connection size is 3.5.1.2 Unscrew diaphragm from com-
1/4" NPT for #12 through #75 and 1/2" for #101 pressor by turning counterclockwise.
through #250. 3.5.1.3 For PTFE diaphragm assemblies
2. OPERATION & ADJUSTMENT only: replace backing cushion and
2.1 The Dia-Flo actuator is a spring-and-diaphragm, PTFE diaphragm. Invert PTFE
or double acting diaphragm, pneumatic actua- diaphragms prior to installation
tor. The actuator model number is located on in tube nut. (To invert, hold edge
the ITT i.d. tag. The model number is a four or of diaphragm with fingers while
five digit number defining the actuator as pressing in the center of the dia-
follows: phragm face with thumbs.)
XXYYY 3.5.1.4 Screw new diaphragm into com-
if XX = 31 Direct Acting (Spring to pressor until hand tight, then back
Open) off until bolt holes in diaphragm and
if XX = 32 Reverse Acting (Spring to bonnet flange register.
Close) 3.5.1.5 Replace actuator and bonnet
if XX = 33 Double Acting assembly on body and tighten
YYY = Nominal Size. Available sizes bonnet bolts with a wrench, criss-
(approximate effective diaphragm area): crossing from corner to corner.
#12, 25, 50, 75, 101, 130, 250. For two digit See Table 1 for torques.
sizes, the final Y is left off. 3.5.2 Actuator Diaphragm Replacement
2.2 Maximum permitted air supply pressure is 85 3.5.2.1 Disconnect air lines. Remove actua-
psig (586 kPa). tor bolts and nuts. Remove top cover.
2.3 For operation and adjustment of actuator 3.5.2.2 Remove spindle nut, diaphragm
accessories, see Section 4. top plate and actuator diaphragm.
2.4 Valve and actuator travel are shown in Table 2. 3.5.2.3 Install new diaphragm. Reassembly
For any combination, the actual travel is the is the reverse of the above. Apply
lesser of the two. Loctite 242 or equivalent on spindle
3. MAINTENANCE threads when installing spindle nut.
3.1 Periodically inspect condition of external valve 3.5.3 Spindle O-Ring Replacement
parts. Replace all parts showing excessive 3.5.3.1 Disconnect air lines, remove actua-
wear or corrosion. Leakage from the bonnet tor and bonnet assembly as a unit
weep hole indicates diaphragm rupture. For from valve body and dismantle ac-
diaphragm replacement, see Section 3.5, 3.6, tuator following instructions above

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 the removing actuator diaphragm. 3.6.3 Actuator Diaphragm or Spring Replace-
3.5.3.2 Withdraw valve diaphragm, com- ment - 3225
pressor and spindle assembly from 3.6.3.1 Remove safety cap and jam nut
the bonnet. from top of spring rod. Apply air to
3.5.3.3 Remove old o-ring, taking care not bottom chamber until valve is in
to damage machined surfaces. Lu– open position.
bricate new o-ring per Section 3.4 3.6.3.2 Tighten adjusting bushing until
and install in groove. Reassemble springs are compressed, then re-
reversing the above instructions:
lease air in bottom chamber. (If the
3.6 Reverse Acting - 3212, 3225, 3250, 3275 -
actuator diaphragm is so badly rup-
See Figures 4(B), 4(C), 4(D)
3.6.1 Valve Diaphragm Replacement tured that it is not possible to open
3.6.1.1 Load the bottom chamber of the the valve with air in the lower cha-
actuator with sufficient air to par- ber, then it will be necessary to use
tially open valve. This will ease the the adjusting bushing as a jack-
spring tension holding the valve screw to compress the springs with-
diaphragm to the body weir. out the air assist.)
3.6.1.2 Remove the bonnet bolts and nuts. 3.6.3.3 Remove actuator nuts and bolts, re-
Lift actuator and bonnet assembly leasing top cover containing spring
from valve body. Release air and assembly.
disconnect air line. 3.6.3.4 Remove spindle nut, releasing top
3.6.1.3 Unscrew diaphragm from compres- plate and actuator diaphragm.
sor by turning counterclockwise. 3.6.3.5 To remove springs, clamp upper
3.6.1.4 For PTFE assemblies only: Replace cover flange in vice jaws and rotate
backing cushion and PTFE dia- adjusting bushing counterclockwise
phragm. Note: It may be difficult to relax springs.
to engage the threads of the dia-
3.6.3.6 Replace parts and reverse instruc-
phragm stud without inverting the
diaphragm. To invert diaphragm, tions for reassembly. Apply Loctite
press on the center of the dia- 242 on spindle nut.
phragm face with thumbs while 3.6.4 Actuator Spring Replacement - 3250 & 3275
holding the edge of the dia- 3.6.4.1 To replace spring, remove four nuts
phragm with fingers. from columns, safety cap and jam
3.6.1.5 Screw new diaphragm into com- nut from top of spring rod. Remove
pressor by turning hand tight. Then adjusting bushing, spring cover and
back off until bolt holes in dia- springs.
phragm and bonnet flange register. 3.6.4.2 Replace parts and reverse instruc-
3.6.1.6 Connect air line to lower air cham- tions for reassembly.
ber and load chamber with suffi- 3.6.5 Actuator Diaphragm Replacement - 3250 &
cient air to move the compressor 3275
approximately 1/8 of an inch. 3.6.5.1 To replace actuator diaphragm, re-
3.6.1.7 Replace actuator and bonnet as- move actuator bolts and nuts re-
sembly on body, and tighten bon- leasing actuator top cover. Remove
net bolts hand tight.
spindle nut and top diaphragm plate.
3.6.1.8 Release air pressure and tighten
3.6.5.2 Replace parts and reverse instruc-
bonnet bolts with a wrench, criss-
crossing from corner to corner. See tions for reassembly. Apply Loctite
Table 1 for recommended torques. 242 on spindle nut.
3.6.1.9 Apply air and open valve. If neces- 3.6.6 Spindle O-Ring Replacement - 3212, 3225,
sary, retighten bonnet bolts. 3250 & 3275
3.6.1.10 Travel stop, if equipped, must be 3.6.6.1 Disconnect air lines. Remove actu-
reset at this time to assure proper ator and bonnet assembly from
closure. See Section 4.2. valve body and dismantle actuator
3.6.2 Actuator Diaphragm or Spring Replacement following instructions above for re-
- 3212 moving actuator diaphragm and
3.6.2.1 Remove four bolts and nuts at springs.
equal spacing around actuator 3.6.6.2 Withdraw valve diaphragm, com-
cover and replace with four pressor and spindle assembly from
threaded rods approximately 6 the bonnet.
inches long, secured by nuts on top 3.6.6.3 Replace o-ring(s) and reassemble
and bottom of actuator flange. by reversing the instructions and
3.6.2.2 Remove the remaining bolts and
following the steps for replacing a
nuts that clamp the actuator dia-
valve diaphragm. Lubricate o-ring(s)
phragm. Turn the threaded rod nuts
counterclockwise equally to gradu- prior to installation per Section 3.4.
ally relax spring(s). 3.7 Reverse Acting - 32101, 32130, 32250 (see
3.6.2.3 Remove springs, spindle nut, upper Figure 4(E))
plate and actuator diaphragm. 3.7.1 Valve Diaphragm or Spring Replace-
3.6.2.4 Replace parts and reverse instruc- ment - see 3.6.1.
tions for reassembly. Apply Loctite 3.7.2 Actuator Diaphragm Replacement
242 on spindle nut. 3.7.2.1 Remove pressure from line

3
 containing valve and disconnect air ing valve and disconnect air line to
line to lower cover. lower cover.
3.7.2.2 Remove safety cap and hex jam nut 3.7.3.2 Remove valve bonnet and actuator
from spring rod by rotating counter- from valve body and disassemble in
clockwise. accordance with Section 3.7.2,
3.7.2.3 Remove adjusting bushing by rotat- steps 1 thru 13.
ing counterclockwise. Place a ball 3.7.3.3 Lift off actuator diaphragm and
thrust bearing over spring rod and remove lower actuator plate.
replace adjusting bushing. An 3.7.3.4 Slide diaphragm, compressor and
Aetna #E-33 (2-1/2" i.d. x 4" o.d. x valve spindle down out of the bon-
13/16" high) is recommended. net as a unit.
3.7.2.4 Engage adjusting bushing on 3.7.3.5 Replace o-rings in adapter bushing.
spring rod and rotate clockwise Lubricate o-rings per Section 3.4.
until it engages ball thrust bearing 3.7.3.6 To reassemble, reverse above pro-
and is tightened down against top cedures.
of spring casing. 3.8 Direct Acting (See Figures 4(F), 4(G), 4(H), 4(I))
3.7.2.5 Continue to rotate adjusting bush- 3.8.1 Valve Diaphragm Replacement
ing clockwise an additional 1/4" 3.8.1.1 Disconnect air lines. Remove bon-
down spindle extension. net bolts and nuts. Lift actuator and
3.7.2.6 Remove bonnet nuts by rotating bonnet assembly from valve body.
counterclockwise and lift valve Pressurize actuator, extending
bonnet, including diaphragm and compressor and diaphragm.
the actuator from valve body. 3.8.1.2 Unscrew diaphragm from compres-
3.7.2.7 Rotate adjusting bushing counter- sor by turning counterclockwise.
clockwise and remove from spring 3.8.1.3 For PTFE assemblies only: Replace
rod. Remove ball thrust bearing. backing cushion and PTFE dia-
3.7.2.8 Remove hex head cap screw and phragm. Note: It may be difficult
spring lock washers around base of to engage the threads of the dia-
spring casing by rotating counter- phragm stud without inverting
clockwise. the diaphragm. To invert dia-
3.7.2.9 Lift off spring casing containing phragm, press on the center of
spring. This is a heavy unit. It is the diaphragm face with thumbs
suggested that a chain fall be used, while holding the edge of the dia-
using the lifting eyelets located near phragm with fingers.
the top of the spring casing. 3.8.1.4 Screw new diaphragm into com-
 WARNING pressor until hand tight. Then back
Spring casing must be lifted up off until bolt holes in diaphragm
over spindle extension. Be care- and bonnet register.
ful not to bend spindle exten- 3.8.1.5 Reduce air pressure until back of
sion. Failure to follow these in- diaphragm is flat against bonnet.
structions could result in property Replace actuator and bonnet as-
damage and/or moderate per- sembly on body, and tighten bon-
sonal injury. Spring(s) are captured net bolts hand tight.
in spring casing and are not re- 3.8.1.6 Tighten bonnet bolts with a wrench,
movable. If spring replacement is crisscrossing from corner to corner.
necessary, replace entire casing See Table 1 for torques.
assembly. 3.8.1.7 Release air and open valve. If ne-
cessary, retighten bonnet bolts.
3.7.2.10 Remove hex nuts from hex head 3.8.2 Actuator Diaphragm or Spring Replace-
cap screws around periphery of ment - 3112 & 3125
actuator cover by rotating nuts 3.8.2.1 Vent air pressure and disconnect
counterclockwise. air line.
3.7.2.11 Lift off upper actuator cover. 3.8.2.2 Remove actuator bolts and nuts.
3.7.2.12 Rotate spindle connector counter- 3.8.2.3 Remove spindle nut (3125: Remove
clockwise to remove from actuator hex-head screw, relaxing spring),
spindle. This has been assembled diaphragm plates, actuator dia-
with Loctite sealant and may re- phragm and spring.
quire extra torque or slight heat to 3.8.2.4 Using replacement parts, reverse
release the sealant. instructions for reassembly. Apply
3.7.2.13 Remove upper actuator plate. Loctite 242 on spindle nut.
3.7.2.14 Remove actuator diaphragm and 3.8.3 Actuator Diaphragm or Spring Replace-
replace with new one. ment - 3150, 31101, 31130, 31250
3.7.2.15 To reassemble, reverse the above To replace springs:
procedure. Use air pressure instead 3.8.3.1 Vent air pressure and disconnect
of adjusting bushing to take load off air line.
of valve diaphragm. Apply Loctite 3.8.3.2 3150: Remove four nuts and spring
242 on spindle threads when instal- cover from columns.
ling spindle connector. Adjust travel 31101-31250: Remove cap screws
stop per section 4.2. and nuts from around cap.
3.7.3 Spindle O-Ring Replacement 3.8.3.3 Remove jam nut from spindle. Turn
3.7.3.1 Remove pressure from line contain- adjusting bushing counterclock-
wise, relaxing spring.
4
 3.8.3.4 Remove spring seat and spring. 4.2.1.3 3225-32250: Remove safety shield
3.8.3.5 Assemble in reverse order. by loosening the two mounting
To replace actuator diaphragm, screws.
perform steps 1 through 5 above; 4.2.1.4 To adjust travel (closing) stop, loosen
then, jam nut. Turn adjusting bushing or
3.8.3.6 Remove actuator bolts and nuts, stop nut clockwise (or turn hand-
releasing actuator upper cover. wheel counterclockwise) until valve
3.8.3.7 Unscrew spindle coupling to re- leaks. Then turn counterclockwise
move diaphragm plates and actu- (or turn handwheel clockwise) until
ator diaphragm. the valve just stops leaking. Tighten
3.8.3.8 Replace parts, including gaskets, jam nut. Travel stop is now set.
and reverse instructions for reas- 4.2.2 Direct and Double Acting
sembly. Apply Loctite 242, to The travel stop (code ATS) is housed within a
spindle threads (#12, 50-250) or pressure cap, which is pressurized along with
hex head bolt (#25), when installing the upper chamber. Note: If furnished with
spindle nut or spindle coupling. an adjustable opening stop (code TOHC)
3.8.4 O-Ring Replacement or handwheel closing device (code TOHC),
3.8.4.1 Disconnect air lines. Remove actu- these mechanisms will protrude through
ator and bonnet assembly from the top of the pressure cap. To adjust the
valve body and dismantle actuator travel stop, however, the pressure cap must
following above instructions for re- be removed.
moving actuator diaphragm. 4.2.2.1 Vent air from the upper chamber.
3.8.4.2 Withdraw valve diaphragm, com- Remove pressure cap by rotating
pressor and spindle assembly from counterclockwise. Loosen jam nut.
the bonnet. 4.2.2.2 Adjust travel stop nut until the gap
3.8.4.3 Replace o-ring and reassemble by below the nut is equal to the valve
reversing the instructions and fol- or actuator travel, whichever is less
lowing the steps for replacing a (Table 2). Tighten jam nut.
valve diaphragm. Lubricate o-rings 4.2.2.3 Install pressure cap, making sure
prior to installation per Section 3.4. o-ring is properly installed.
4. ACCESSORIES 4.2.2.4 Pressurize actuator. If valve leaks:
4.1 Pressure Cap (Figure 6) Repeat step 1. Back off stopnut
Pressure Caps are used with adjustable travel slightly by turning counterclock-
stops and other accessories. To remove pressure wise. Install pressure cap and
cap, ensure that upper chamber of actuator is un- pressurize actuator. Repeat this
pressurized. Rotate pressure cap counterclock- process as necessary until valve
wise to remove. does not leak.
Pressure Cap O-Rings: 4.3 Handwheel Opening Device Operation (Figure 7)
The purpose of the optional handwheel opening
Actuator Size O-Ring device is to open a reverse acting (3200 series)
#12 219 (213 with ductile iron cover) actuator in the event of a diaphragm or plant air
#25 220 failure.
All Others 333
4.2 Travel (Closing) Stop Adjustment (Note: Travel Loosen jam nut. Rotate handwheel counterclock-
Stops are standard on 3225-32250 and available wise to open. Rotate clockwise to return the valve
on all actuators.) to the closed position. Note: Handwheel must be
returned precisely to its original position to maintain
The purpose of the travel stop is to prevent over- proper travel stop adjustment. See Section 4.2 to
loading of the diaphragm, thus prolonging dia- adjust travel stop.
phragm life. Travel stops are factory set and do 4.4 Wrench Opening Device Operation
not require routine adjustment. However, with re- The purpose of the optional wrench opening device
placement of valve diaphragms, travel stop is to open a reverse acting (3200 series) actuator in
adjustment is recommended. Refer to Figure 6 for the event of an actuator diaphragm or plant air
all direct and double acting, and all #12 actuators. failure.
Refer to Figure 4 C, D & E for 3225-32250 actuators. 4.4.1 3212 Wrench Opening Device (Figure 9(b))
4.2.1 Reverse Acting 4.4.1.1 Remove pressure cap. Loosen jam
If actuator has handwheel (code HWO) nut.
(Figure 7) or wrench opening device 4.4.1.2 Rotate stop nut clockwise to open
(code WO) (Figure 8), this device also valve. Rotate stop nut counterclock-
serves travel stop function. wise to return valve to the closed
If 3212 actuator has adjustable opening position. Note: Travel stop adjust-
stop (code TOWO), the opening stop must ment is recommended at this time.
be removed. To remove opening stop ro See Section 4.2.
tate pressure cap counterclockwise and 4.4.1.3 Tighten jam nut and install pressure
lift off. For other sizes with combination cap.
hand-wheel/wrench opening device and 4.4.2 3225-32130 Wrench Opening Device
adjustable opening stop, see Section 4.5. (Figure 8)
4.2.1.1 Release any air pressure in bottom 4.4.2.1 Remove safety cap. Loosen jam
chamber. nut.
4.2.1.2 3212: Remove pressure cap by 4.4.2.2 Rotate adjusting bushing clockwise
rotating counterclockwise. to open valve. Rotate adjusting

5
 bushing counterclockwise to return 4.6.2 Operation of Handwheel Closing Device (or
valve to the closed position. Note: adjustable opening stop when used as
Travel stop adjustment is recom- manual override):
mended at this time. See Section 4.6.2.1 Vent air from actuator. Loosen jam
4.2 to adjust travel stop. nut.
4.4.2.3 Tighten jam nut and install safety 4.6.2.2 Rotate handwheel (or hex head
cap. bolt) clockwise to close valve.
4.5 Combination Handwheel or Wrench Opening Tighten jam nut.
Device with Adjustable Opening Stop (Figure 9(A)) 4.7 MicroSwitch Limit Switches (Model Nos. BZE6-
4.5.1 3225-32130 Operation of Wrench Opening 2RN, BAF1-2RN, DTE6-2RN, DTF2-2RN, EXQ,
Device EXDQ) - Adjustment (See Figure 11)
4.5.1.1 Loosen jam nut (1). This section provides instructions for adjustment
4.5.1.2 Rotate wrench opening nut clock- of the above switches when mounted to the
wise to open valve. Rotate counter- actuator covers (not yoke mounted).
clockwise to return valve to the These switches are pushbutton type, actuated by
closed position. Tighten jam nut. a lever attached to the actuating rod. On #12
Note: Travel stop adjustment is actuators, the actuating rod is attached directly
recommended at this time. See to the actuator diaphragm plate. On sizes 25-250,
Section 4.2 to adjust travel stop. the actuating rods are spring loaded. Contact
4.5.2 3225-32130 Operation of Handwheel with the diaphragm plate occurs only during the
Opening Device (Figure 9(A)) last 1/4" of travel.
4.5.2.1 Loosen jam nut (1) above hand- 4.7.1 Adjustment (#12 Actuator)
wheel. 4.7.1.1 Loosen lever adjustment screws.
4.5.2.2 Rotate handwheel counterclock- Open valve.
wise to open valve. Rotate clock- 4.7.1.2 Move open switch operating lever
wise to return valve to the closed until open switch makes an audible
position. Tighten jam nut (1). Note: click. Tighten open switch lever
Travel stop adjustment is recom- adjustment screws.
mended at this time. See Section 4.7.1.3 Open switch is now set. Verify set
4.2 to adjust travel stop. point by checking continuity on
4.5.3 3225-32130 Operation of Adjustable Open- switch terminals.
ing Stop 4.7.1.4 Close valve and repeat the above
4.5.3.1 Loosen jam nut (2) above spring cover. procedure for the valve closed
4.5.3.2 Using air pressure and bleed type switch.
regulator, open valve to desired 4.7.2 Adjustment (#25-250 Actuator)
position. 4.7.2.1 Open valve slowly. Note: if actuat-
4.5.3.3 Rotate adjusting bushing clock- ing lever has previously been mis-
wise until resistance is felt. adjusted, lever may overtravel
4.5.3.4 Tighten jam nut (2). Opening stop switch and become damaged.
is now set. 4.7.2.2 Loosen lever attachment screws.
4.6 Handwheel Closing Device and Adjustable Open- Note: Actuating rod is spring
ing Stop (Figure 10) (3100 & 3300 series) loaded. If rod is not bearing
These options are very similar. Both use an adjust- against diaphragm plate, spring
ing screw to either limit valve opening travel or may force actuating rod entirely
manually stroke the valve to the closed position. within actuator. Actuator must be
The handwheel closing device simply uses a disassembled to retrieve.
handwheel rather than a hex head to rotate the 4.7.2.3 Move actuating lever until switch
screw. makes an audible click. Verify set-
4.6.1 Operation of Adjustable Opening Stop: point by checking continuity on
4.6.1.1 Use bleed type regulator and air switch terminals. Open switch is
supply to move valve to the de- now set.
sired position. Loosen jam nut. 4.7.2.4 Repeat the above procedure for the
4.6.1.2 Rotate adjusting screw or hand- valve closed switch. Same cautions
wheel clockwise until contact with apply.
the valve spindle is felt. Tighten 4.8 Westlock Module3 Proximity Switches - See
jam nut. Opening stop is now set. Figure 12
 WARNING 4.8.1 Description
If upper chamber is pressurized These proximity switches are actuated by
during this adjustment, leakage magnetic triggers. The triggers, along with
will occur past the adjusting sensing end of the switches, are inside a
spindle. Note that the adjusting protective metal enclosure. The switch
screw cannot be completely re- leads and all electrical terminations are in-
moved. Means are provided on side a separate, sealed, explosion proof
the inboard side of the adjusting enclosure. Refer to the manufacturer’s
screw to prevent removal.
Failure to follow these instruc- literature for the precise enclosure ratings.
tions could result in property In addition, a solenoid valve may be at-
damage and/or moderate per- tached directly to the switch enclosure via
sonal injury. the solenoid’s conduit connection. The
solenoid leads may then be terminated at
the switch terminal strip.

6
 4.8.2 Adjustment applied directly to the actuator directly
4.8.2.1 Open valve. Remove the four through the actuator housing (no external
screws holding the bracket cover tubing). The valve will close as instrument
to the bracket. Remove bracket pressure is increased.
cover. 4.9.4 Installation
4.8.2.2 Loosen jam nuts on valve open The only task is to connect the supply and
switch trigger and slide to bottom instrument air. All connections are 1/4" NPT.
of slot. Tighten jam nuts. A horizon- See Figure 13. Use 1/4" O.D. tubing for the
tal distance of 1/16" to 1/8" should instrument connection, either 1/4" or 3/8"
be maintained between the trigger O.D. tubing for the supply connection. Blow
and the switch. out all piping before connections are made
4.8.2.3 Attach continuity tester to valve to prevent the possibility of dirt or chips en-
open switch contacts. tering the positioner. Use pipe sealant spar-
4.8.2.4 Loosen setscrew. Slide trigger ingly, and then only on the male threads. A
bracket assembly up until switch non-hardening sealant is strongly recom-
contacts change state. Tighten mended. Connect the positioner to a source
setscrew.
of clean, dry oil-free air. A filtered and regu-
4.8.2.5 Close valve. Loosen jam nuts on
lated air source is recommended. Note:
valve closed switch trigger.
Synthetic compressor lubricants in the
4.8.2.6 Attach continuity tester to valve
closed switch contacts. Slide valve air stream at the instrument may cause
closed switch trigger down until the positioner to fail.
switch contacts change state. Note that a cushion loading regulator is fur-
4.8.2.7 Tighten jam nuts. Switches are now nished with 3300 series actuators and a tee
set. in the supply connection is routed to this
4.8.2.8 Install bracket cover and four regulator, so an extra hookup is not required.
screws. The cushion loading regular should be set at
4.9 Positioners (See Figure 13) the minimum pressure required to open the
4.9.1 Scope: Top-mounted positioners listed valve wide open. Typically, this is 10 psi or
below less.
4.9.1.1 Moore 73N12F (3100 & 3300 Series 4.9.5 Adjustment
Actuators) The only adjustment that can be made on
4.9.1.2 Moore 73NB (3200 Series the positioner is a zero adjustment. The zero
Actuators) adjusting screw is located under the posi-
4.9.1.3 ITT Conoflow GC31 (3100 & 3300 tioner’s top cover. To adjust the zero, set the
Series Actuators) instrument air pressure to the mid-point of
4.9.1.4 ITT Conoflow GC33 (3200 Series its span, and turn the zero adjustment until
Actuators) the valve is at the mid-point of its stroke. (To
4.9.2 Supply and Instrument Pressures determine valve stroke, refer to Table 2.)
4.9.2.1 Instrument input pressure range - Recheck the setting accuracy by changing
as specified: 3-15 psi (standard), instrument air pressure to the maximum/
3-9 psi, 6-30 psi and others are minimum point to obtain full open/closed
optional. valve position.
4.9.2.2 Supply pressure: 3 psi above re-
quired actuator pressure to a max- In some cases, valve shut-off opening may
imum of 85 psi. A filtered air supply be required at a specific instrument pres-
is recommended. sure. To zero the positioner at this point, set
the instrument signal at the specific pressure
 WARNING and turn the zero adjustment screw until the
Pressure in excess of 85 psi to valve reaches the required position. A slight
any connection may cause dam- change of the instrument pressure should
age. Failure to follow these in- start to move the valve. The valve stroke for
structions could result in prop- a given span may also be suppressed or
erty damage and/or moderate shifted to the desired range by means of the
personal injury. zero adjusting screw.
4.9.3 Description 4.9.6 Maintenance
The positioner is designed to operate a valve A clean, oil and moisture free air supply will
actuator to maintain the valve in a position reduce maintenance problems. The supply
determined by the control instrument. The air filter should be blown down on a routine
above positioners are direct acting - with an basis. The filter element should be examined
increase in instrument pressure, the valve periodically and replaced if necessary. No
actuator pressure (positioner output) will in- lubrication is required on the valve posi-
crease. On a bottom loading positioner (73 tioner. The system should be shut down or
NB and GC33), output is connected to the the valve isolated from the system before
actuator lower chamber via an external tube. service or removal of the positioner is ac-
Therefore, the valve will open as instrument complished.
pressure increases. For additional maintenance activities, refer
On a top-loading positioner, the output is to the manufacturer’s service manual.

7
 TABLE 1 TABLE 2
BONNET FASTENER TORQUES IN INCH-POUNDS VALVE AND ACTUATOR TRAVEL
Bonnet Metal Plastic
All Weir & Glass Lined
Actual travel for any valve and actuator combination is the lesser of the
Body Straightway Weir & All valve or actuator travel listed below.
(Except Glass Lined) Straightway
Diaphragm Elastomer PTFE Elastomer PTFE All
Size
IN DN
1
/2 15 40 80 40 40 18
WEIR
3
/4* 20 48 80 48 80 18
Actuator
Size 12 25 50 75 101 130 250
1 25 48 100 48 80 25
11/4 32 48 100 48 80 — Stroke /8"
5
2" 3" 3" 31/8" 31/2" 45/8"
11/2 40 48 220 48 110 75
2 50 96 275 96 170 100 Valve
21/2 60 192 575 192 200 — Size 1
/2 3/4* 1 11/4 11/2 2 21/2 3 4 6 8 10 12
3 80 300 1000 300 300 420 **Stroke 1/4 3/8 1/2 5/8 13/16 11/8 13/8 15/8 21/8 31/8 45/8 55/8 61/2
4 100 192 575 192 360 180 *Stroke for 3/4" flanged weir valve is 1/2" except solid plastic.
6 150 480 1200 480 600 —
8 200 480 1200 480 600 —
10 250 480 1200 480 — —
12 300 480 1200 480 — —
STRAIGHTWAY
Actuator
NOTES:
Size 12 25 50 75 101 130 250
1) Torque may be exceeded by up to 10%.
2) Bolt tension developed using torque wrenches can vary widely Stroke /8"
5
2" 3" 3" 31/8" 31/2" 45/8"
depending on fastener condition, wrench accuracy, degree of
lubrication and technique. If fastener yielding or galling is ap- Valve
parent, reduce torque accordingly and replace fasteners. Size 1
/2 1 11/2 2 21/2 3 4 6 8 10 12
3) Stainless steel studs/bolts with stainless steel nuts have **Stroke 15
/32 /16
15
11/4 17/8 2 2 5/16 213/16 41/4 61/4 71/2 71/2
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 & SPINDLE NUT TORQUES

Air Motor Flange Spindle
Size Bolt Torque Nut Torque*
(in-lb) (in-lb)
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
Air Area Double & Reverse Acting Double Acting Direct Acting
Size Stroke Connection (Sq. 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 31/8" 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 45/8" 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 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
Maximum pressure, psi Valve Size Maximum pressure, psi
Valve size Handwheel 1
/2, 1, 11/2, 2, 21/2, 3 100
(inches) operated 4 85
1
⁄4, ⁄8
3
200 6, 8 50
1
⁄2, 3⁄4, 1 200 10, 12 40
11⁄4, 11⁄2, 2 175
21⁄2 150
3 150
4 150
6 125
8 100
10, 12 65
For solid plastic valves, see catalog.
8
 TABLE 5(A)
WEIR VALVE O-RINGS
(For O-Ring A or B, see Figure 4)

DOUBLE ACTING ACTUATORS

ACTUATOR VALVE SIZES
SIZE 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 6 8 10 12
A 112 112 112 114 114 114 — — — — — — —
3312
B — — — — — — — — — — — — —
A* 114 114 114 114 116 116 214 214 214 — — — —
3325
B 326 326 326 326 326 326 326 326 326 — — — —
A* — — — — 116 116 214 214 214 214 — — —
3350
B — — — — 326 326 326 326 326 326 — — —
A* — — — — 116 116 214 214 214 214 — — —
3375
B — — — — 326 326 326 326 326 326 — — —
A — — — — 214 TWO REQUIRED
33101
B — — — — 238
A — — — — 214 TWO REQUIRED
33130
B — — — — 238
A — — — — 214 TWO REQUIRED
33250
B — — — — 238
* Two required if sealed bonnet is used.

DIRECT ACTING ACTUATORS

ACTUATOR VALVE SIZES
SIZE 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 6 8 10 12
A** 112 112 112 114 114 114 — — — — — — —
3112
B — — — — — — — — — — — — —
A* 114 114 114 114 116 116 214 214 214 — — — —
3125
B — — — — — — — — — — — — —
A* — — — — 116 116 214 214 214 214 — — —
3150
B — — — — 326 326 326 326 326 326 — — —
A — — — — 214 TWO REQUIRED
31101
B — — — — 238
A — — — — 214 TWO REQUIRED
31130
B — — — — 238
A — — — — 214 TWO REQUIRED
31250
B — — — — 238
** Used with sealed bonnet only.
* Two required if sealed bonnet is used.

REVERSE ACTING ACTUATORS

ACTUATOR VALVE SIZES
SIZE 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 6 8 10 12
A 112 112 112 114 114 114 — — — — — — —
3212
B — — — — — — — — — — — — —
A* 114 114 114 114 116 116 214 214 214 — — — —
3225
B 326 326 326 326 326 326 326 326 326 — — — —
A* — — — — 116 116 214 214 214 214 — — —
3250
B — — — — 326 326 326 326 326 326 — — —
A* — — — — 116 116 214 214 214 214 — — —
3275
B — — — — 326 326 326 326 326 326 — — —
A — — — — 214 TWO REQUIRED
32101
B — — — — 238
A — — — — 214 TWO REQUIRED
32130
B — — — — 238
A — — — — 214 TWO REQUIRED
32250
B — — — — 238
* Two required if sealed bonnet is used.

9
 TABLE 5(B)
STRAIGHTWAY VALVE O-RINGS
(For O-Ring A or B, see Figure 4)

DOUBLE ACTING ACTUATORS

ACTUATOR VALVE SIZES
SIZE 1/2 1 1-1/2 2 2-1/2 3 4 6 8 10 12
A 112 — — — — — — — — — —
3312
B — — — — — — — — — — —
A* 114 114 116 116 214 — — — — — —
3325
B 326 326 326 326 326 — — — — — —
A* — 114 116 116 214 214 214 214 — — —
3350
B — 326 326 326 326 326 326 326 — — —
A* — 114 116 116 214 214 214 214 — — —
3375
B — 326 326 326 326 326 326 326 — — —
A — — — 214 TWO REQUIRED — — —
33101
B — — — 238 — — —
A — — — — 214 TWO REQUIRED — —
33130
B — — — — 238 — —
A — — — — 214 TWO REQUIRED
33250
B — — — — 238
* Two required if sealed bonnet is used.

DIRECT ACTING ACTUATORS

ACTUATOR VALVE SIZES
SIZE 1/2 1 1-1/2 2 2-1/2 3 4 6 8 10 12
A** 112 — — — — — — — — — —
3112
B — — — — — — — — — — —
A* 114 114 116 116 214 214 214 214 — — —
3125
B — — — — 326 326 326 326 — — —
A* — 114 116 116 214 214 214 214 — — —
3150
B — 326 326 326 326 326 326 326 — — —
A — — — — 214 TWO REQUIRED — — —
31101
B — — — — 238 — — —
A — — — — 214 TWO REQUIRED — — —
31130
B — — — — 238 — — —
A — — — — 214 TWO REQUIRED
31250
B — — — — 238
** Used with sealed bonnet only.
* Two required if sealed bonnet is used.

DIRECT ACTING ACTUATORS

ACTUATOR VALVE SIZES
SIZE 1/2 1 1-1/2 2 2-1/2 3 4 6 8 10 12
A* 114 114 — — — — — — — — —
3225
B 326 326 — — — — — — — — —
A* — 114 116 116 214 214 — — — — —
3250
B — 326 326 326 326 326 — — — — —
A* — 114 116 116 214 214 214 — — — —
3275
B — 326 326 326 326 326 326 — — — —
A — — — — 214 TWO REQUIRED — — —
32101
B — — — — 238 — — —
A — — — — 214 TWO REQUIRED — — —
32130
B — — — — 238 — — —
A — — — — 214 TWO REQUIRED
32250
B — — — — 238
* Two required if sealed bonnet is used.

10
 FIGURE 1 PROPER BOLTING RECOMMENDED
INSTALLATION — GLASS LINED BODIES SEQUENCE TORQUE
Valves (lb.-Ft.)
Important
00.50"-01.50" 20-30
It is extremely important that all glass lined valves be 02.00"-02.50" 30-60
installed with proper end flange gaskets and that 03.00"-04.00" 40-70
proper torque be applied to the bolts in correct se- 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
VALVE DIAPHRAGM IDENTIFICATION
ACTUATOR DIAPHRAGM IDENTIFICATION
ELASTOMER — 1 PIECE, MADE OF RUBBER, WITH MOLDED-IN STUD.
(SEE TABS) Diaphragms
Actuator Diaphragms
Size #12 #25 #50 #75 #101 #130 #250
A 6 5⁄8" 9 7⁄8" 13 5⁄16" 14" 1511⁄16" 14 9⁄16" 21 7⁄16"
Bolt Holes 12 18 NONE
maximum recommended air pressure: 85 psi

FIGURE 4(A)
3312-33250

FIGURE 4(B) FIGURE 4(C)

3212 3225

11
 FIGURE 4(D) FIGURE 4(E)
3250-3275 32101-32250

FIGURE 4(F) FIGURE 4(G)

3112 3125

12
 FIGURE 4(I)
31101-31250

FIGURE 4(H)
3150

FIGURE 5(A) FIGURE 5(B) FIGURE 6

3312 #25-#250 PRESSURE CAP & TRAVEL STOPS
POSITION INDICATOR POSITION INDICATOR 3100 & 3300 SERIES

FIGURE 7 FIGURE 8
HANDWHEEL OPENING DEVICE WRENCH OPENING DEVICE
3200 SERIES 3200 SERIES

13
 FIGURE 9(A)
COMBINATION WRENCH OR HANDWHEEL OPENING DEVICE FIGURE 9(B)
WITH ADJUSTABLE OPENING STOP COMBINATION WRENCH OPENING DEVICE AND
3225-32130 ADJUSTABLE OPENING STOP
3212

ADJUSTABLE
OPENING
STOP

FIGURE 11(A)
FIGURE 10 MICROSWITCH LIMIT
HANDWHEEL CLOSING DEVICE AND ADJUSTABLE OPENING STOP SWITCHES
3100 & 3300 SERIES #12 ACTUATOR

FIGURE 11(B) FIGURE 12

MICROSWITCH LIMIT SWITCHES WESTLOCK MODULE 3 PROXIMITY SWITCH
#25-#250

14
 FIGURE 14
PLASTIC DIAPHRAGM DETAIL

TEMPERATURE (° C)

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. (° F)
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)

15
Engineered Valves

For more information write to:

Engineered Valves Headquarters
33 Centerville Road, P.O. 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