ITT Industries Pure-Flo Advantage Actuator

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Summary

Installation

Dia-Flo Diaphragm Valve Orientation

Describes correct orientation for draining Dia-Flo diaphragm valves.

Bonnet Bolt Tightening

Instructions for tightening bonnet bolts and re-tightening recommendations.

Travel Stop Adjustment

Notes on factory setting and adjustment of the closing travel stop.

Maximum Operating Pressure

Specifies maximum valve operating pressure and temperature limitations.

Air Line Connections

Details on air line connection sizes and care for actuator covers.

Lifting Procedures for 3 and 4 Actuators

Instructions on safe lifting for specific actuator models using an eye bolt.

Actuator Air Inlet Positioning

Guidance on repositioning air inlets for stainless steel bonnet actuators.

Operation and Adjustment

Actuator Model Identification

Explains how to identify actuator models based on the ITT i.d. tag.

Maximum Air Supply Pressure

Specifies the maximum permitted air supply pressure for the actuator.

Maintenance

Periodic Inspection

Guidelines for routine inspection of external valve parts and identifying leaks.

Pressurized Bonnet Leaks

How to identify and address leaks from the pressurized bonnet.

Diaphragm-Flange Leakage

Procedures for addressing leaks in the diaphragm flange area.

Lubrication Recommendations

Specifies lubricants for various valve parts and actuators.

Actuator to Valve Body Mounting

Instructions for mounting the actuator to the valve body, including diaphragm placement.

Double Acting Valve Diaphragm Replacement

Step-by-step guide for replacing the diaphragm in double acting actuators.

Spindle O-Ring Replacement (All Sizes)

Instructions for replacing O-rings on the actuator spindle for all sizes.

Reverse Acting Valve Diaphragm Replacement

Detailed procedure for diaphragm replacement in reverse acting actuators.

Actuator Diaphragm;Spring Replacement (1;4-2)

Procedure for replacing diaphragm or spring in smaller actuators.

Actuator Diaphragm;Spring Replacement (3-4 Series 47)

Guide for replacing diaphragm/spring in larger Series 47 actuators.

Spindle O-Ring Replacement (All sizes)

Replacement of spindle O-rings for all actuator sizes.

Direct Acting Valve Diaphragm Replacement

Steps for replacing the diaphragm in direct acting actuators.

Actuator Diaphragm;Spring Replacement (1;4-2)

Steps to replace diaphragm or spring in smaller direct acting actuators.

Actuator Diaphragm;Spring Replacement (3-4 Series 47)

Procedure for replacing diaphragm or spring in larger Series 47 actuators.

Spindle O-Ring Replacement (All sizes)

Instructions for replacing spindle O-rings across all actuator sizes.

Accessories

Travel (Closing) Stop Adjustment

Details on adjusting the travel stop to prevent diaphragm overloading.

Manual Override & Opening Stop Operation

Instructions for operating manual override and adjustable opening stop.

Manual Override (Close) & Opening Stop

Guidance on using manual override for closing and adjustable opening stop.

Switch Pack 2.0 Installation and Settings

Field Mounting Switch Pack 2.0 (1;4-2, 3-4 Series 33)

Steps for mounting Switch Pack 2.0 on various actuator sizes.

Field Mounting Switch Pack 2.0 (3-4 Series 47)

Specific mounting instructions for Switch Pack 2.0 on Series 47 actuators.

Setting Switches

Procedure for setting switches on the Switch Pack 2.0.

Switch Pack 3.0 Installation and Settings

Field Mounting Switch Pack 3.0 (1;4-1)

Instructions for mounting Switch Pack 3.0 on smaller actuators.

Setting Switches

Guide for setting switches on Switch Pack 3.0.

Field Mounting Switch Pack 3.0 (1;4-2)

Mounting procedure for Switch Pack 3.0 on 1/4" through 2" actuators.

Setting Switches

Steps for adjusting switches in Switch Pack 3.0.

Positioner Installation and Adjustment

Positioner Scope and Models

Lists positioner models and their general scope of application.

Supply and Instrument Pressures

Specifies required instrument and supply air pressures for positioners.

Positioner Description

Explains the function and operation of direct and reverse acting positioners.

Positioner Installation

Instructions for connecting supply and instrument air to the positioner.

Positioner Adjustment

Details on making zero adjustments for the positioner.

Positioner Maintenance

Recommendations for maintaining the valve positioner and air supply.

The Pure-Flo and Dia-Flo Advantage® Actuator is a pneumatic actuator designed for use with diaphragm valves. It is available in spring-and-diaphragm (direct or reverse acting) and double-acting configurations. The actuator's model number, found on the ITT i.d. tag, defines its type (Advantage® Actuator), acting mode (Direct Acting - Spring to Open, Reverse Acting - Spring to Close, or Double Acting), nominal size (effective diaphragm area in square inches), and spring package (60 PSI, 80 PSI, or 90 PSI).

Function Description:

The Advantage® Actuator controls the opening and closing of diaphragm valves by converting pneumatic pressure into mechanical force. In spring-and-diaphragm configurations, air pressure acts on a diaphragm to overcome or assist a spring, moving the valve stem. Double-acting actuators use air pressure on both sides of the diaphragm for precise control. The actuator can be equipped with accessories such as travel stops, manual over-rides (open or close), adjustable opening stops, switch packs, and positioners to enhance its functionality and control.

Important Technical Specifications:

Maximum Valve Operating Pressure: 150 PSIG (10.34 bar) up to 100°F (38°C). Actuator size/configuration may limit actual operating pressure.
Maximum Permitted Air Supply Pressure: 90 psig (6.2 bar, 620 kPa). The actuator can withstand pressures well in excess of this rating without bursting, but maintaining operation at or below 90 psig ensures optimum life for operating components.
Air Line Connections: 1/8" NPT for 1/4" through 2" (DIN 8-50) sizes, and 1/4" NPT for 3" and 4" (DIN 80-100) sizes.
Switch Pack 2.0/2.5 Maximum Temperature: 150°F (65.5°C). Not autoclavable.
Switch Pack 3.0 Maximum Temperature: 140°F (60°C). Not autoclavable.
Positioner Instrument Input Pressure Range: Standard 3-15 psi (.21-1.03 bar), with optional ranges like 3-9 psi (.21-.62 bar) and 6-30 psi (.41-2.07 bar).
Positioner Supply Pressure: 3 psi (.21 bar) above required actuator pressure, up to a maximum of 90 psi (6.2 bar). A filtered air supply is recommended. Pressure in excess of 90 psi (6.2 bar) may cause damage to the positioner.

Usage Features:

Installation Flexibility: Dia-Flo® diaphragm valves can be installed in any orientation. For horizontal piping systems requiring drainage, the valve stem should be between 0 and 30 degrees above horizontal, aligning hash marks or machined dots on the valve body at the 12 o'clock position for optimum drainage.
Actuator Lifting: For 3" and 4" (Series 33 and 47) (DIN 80 and 100) Advantage® actuators, do not lift by air fittings. Use an eye bolt with a 0.625"-18 female thread attached to the adjusting bushing for lifting (Series 47 only).
Air Inlet Positioning: Stainless steel bonnet Advantage® Actuators (1/4"-2") (DIN 8-50) allow air inlets to be positioned in any quadrant by removing the actuator from the valve body, unthreading the bushing, and rotating the lower cover.
Travel (Closing) Stop: Standard on 3"-4" Series 47 (DIN 80-100) and optional on 1/4"-2" (DIN 8-50) actuators. Factory set to prevent diaphragm overloading and prolong life, but adjustment is recommended after diaphragm replacement.
Manual Over-ride (Open): Available on 3"-4" Series 47 (DIN 80-100) actuators. Allows manual opening of the valve.
Adjustable Opening Stop: Available on 1/4"-2" (DIN 8-50) and 3"-4" Series 47 (DIN 80-100) actuators. Allows setting a desired open position for the valve.
Manual Over-ride (Close): Available on 3"-4" Series 47 (DIN 80-100) Direct & Double only.
Switch Packs: Available in versions 2.0, 2.5, and 3.0. Provide feedback on valve position (open/closed). Not to be used with positioners.
Positioners: Top-mounted positioners (Moore 73N12F, 73NB, 73NFR) allow the valve actuator to maintain a position determined by a control instrument. Direct acting positioners increase pressure to the actuator with increased instrument pressure, while reverse acting positioners decrease pressure to the actuator with increased instrument pressure.

Maintenance Features:

Periodic Inspection: Regularly inspect external valve parts for wear or corrosion. Diaphragm rupture is indicated by leakage from the lower cover or bonnet weep hole. For sealed bonnet valves, fluid weeping from the v-notch vent plug indicates diaphragm failure.
Diaphragm Replacement: Detailed instructions are provided for replacing valve diaphragms in double-acting, reverse-acting, and direct-acting actuators, including specific steps for PTFE assemblies.
Actuator Diaphragm/Spring Replacement: Instructions vary by actuator size and series. Special fixtures may be required for spring-to-close actuators (1/2"-2" DIN 15-50).
Spindle O-Ring Replacement: Instructions cover all sizes, requiring actuator disassembly.
Lubrication: Standard lubricant is Chevron Poly FM2 (FDA Compliant) for Pure-Flo® and Dia-Flo® valves (1/4"-2" DIN 8-50). Sunoco 991EP is standard for 3" or 4" (DIN 80 or 100) Dia-Flo® valves. Never-Seez is used on adjusting bushing/spindle threaded joints and travel stop nuts/adjusting bushing threaded joints for 3" & 4" (DIN 80 & 100) units. Actuators should be lubricated in the spindle/o-ring area when disassembled. Dow Corning® 111 (FDA compliant) is applied to lower cover insert threads for 1/4"-2" (DIN 8-50) valves. O-rings should be lubricated prior to installation.
Fastener Torques: Specific torque values are provided in Table 1 for bonnet bolts and actuator cover bolts to ensure proper assembly and prevent leakage.
Positioner Maintenance: A clean, oil, and moisture-free air supply is crucial. The supply air filter should be blown down routinely and the filter element replaced periodically. No lubrication is required on the valve positioner. The system should be shut down or isolated before service or removal of the positioner.
Switch Pack Adjustment: Instructions for setting open and closed switch positions using a test device (volt meter or inductive proximity tester, depending on switch type).
Weld End Valves: Actuator removal is required for schedule 10 and heavier pipe welding. Schedule 5 and lighter pipe/tubing can be welded with automatic equipment without actuator removal, provided the valve is open and purged with inert gas. Manual welding always requires actuator removal.