AAMM-01
®
®
Pure-Flo and Dia-Flo
Advantage® Actuator
Maintenance Manual
This manual provides installation and maintenance instructions for ADVANTAGE® ACTUATOR operated
diaphragm valves. If additional information is required, please contact:
ITT Industries
33 Centerville Road
Lancaster, PA 17603
(717) 509-2200
Attention: Sales Department
CONTENTS:
FIGURES:
1.0 Advantage® Installation
2.0 Advantage® Operation & Adjustment
3.0 Advantage® Maintenance
4.0 Advantage® Accessories
4.1 Travel (Closing) Stop Adjustment
4.2 Manual Over-Ride (Open) and
Adjustable Opening Stop
1. Actuator Drawings
2. Accessories:
- Travel Stops
- Manual Over-Ride (Open) with
Adjustable Opening Stop
- Manual Over-Ride (Close) with
Adjustable Opening Stop
3. Switch Pack 2.0
4.3 Manual Over-Ride (Close) and
Adjustable Opening Stop
3A. Switch Pack 2.5
5.0 Switch Pack 2.0
6.0 Switch Pack 2.5
3B. Switch Pack 3.0
4. Positioner
7.0 Switch Pack 3.0
8.0 Positioner
5. Valve Diaphragm Identification
6. PTFE Diaphragm Detail
7. Advantage Assembly & Disassembly Fixture
TABLES:
WARNING
1. Fastener Torques
ITT INDUSTRIES VALVES AND VALVE ACTUATORS ARE DESIGNED AND
MANUFACTURED USING GOOD WORKMANSHIP AND MATERIALS, AND
THEY MEET ALL APPLICABLE INDUSTRY STANDARDS. THESE VALVES ARE
AVAILABLE WITH COMPONENTS OF VARIOUS MATERIALS, AND THEY
SHOULD BE USED ONLY IN SERVICES RECOMMENDED IN OUR PRODUCT
CATALOG OR BY A COMPANY VALVE ENGINEER.
2. Actuator Travel and Weights
3. Actuator Internal Data
4. O-Ring Sizes
MISAPPLICATION OF THE PRODUCT MAY RESULT IN INJURIES OR PROP-
ERTY DAMAGE. A SELECTION OF VALVE COMPONENTS OF THE PROPER
MATERIAL CONSISTENT WITH THE PARTICULAR PERFORMANCE REQUIRE-
MENT, IS IMPORTANT FOR PROPER APPLICATION.
EXAMPLES OF THE MISAPPLICATION OR MISUSE OF ITT INDUSTRIES
VALVES INCLUDE USE IN AN APPLICATION IN WHICH THE PRESSURE/TEM-
PERATURE RATING IS EXCEEDED OR FAILURE TO MAINTAIN VALVES AS
RECOMMENDED.
IF VALVE EXHIBITS ANY INDICATION OF LEAKAGE, DO NOT OPERATE.
ISOLATE VALVE AND EITHER REPAIR OR REPLACE.
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3.6.1.5 Replace actuator assembly on body
and tighten bonnet bolts with a
wrench, crisscrossing from corner to
corner. See Table 1 for recommended
torques.
3.3 Diaphragm-Flange Leakage
If valve diaphragm flange area leaks, depressurize
system and open valve slightly, using the wrench
opening device (3” & 4”Series 47 only, DIN 80 & 100
only) or a local bleed type regulator. Tighten bonnet
bolts as described in Section 1.2. If leakage contin-
ues, valve diaphragm replacement is required.
3.6.1.6 Travel stop, if equipped, must be reset
at this time to assure proper closure.
See Section 4.1.
3.4 Lubrication
Standard lubricant is Chevron Poly FM2 (FDA
Compliant) for all Pure-Flo® valves (1/4” through 4”,
DIN 8 - 100) and 1/4” through 2” (DIN 8 - 50)
Dia-Flo® valves. Sunoco 991EP is standard for 3” or
4” (DIN 80 or 100) Dia-Flo® valves. The 3” & 4” (DIN
80 & 100) unit requires Never-Seez on the adjusting
bushing/spindle threaded joint and on the travel stop
nuts/adjusting bushing threaded joint. Actuators
should be lubricated in the spindle/o-ring area when-
ever the actuator is disassembled.
3.6.2 Actuator Diaphragm Replacement:
(1/4” through 2”, DIN 8 - 50)
3.6.2.1 Disconnect air lines. Remove actuator
bolts and remove top cover.
3.6.2.2 Remove indicating spindle, diaphragm
top plate and actuator diaphragm.
3.6.2.3 Install new diaphragm top hat up, use
Blue Loctite #242 on the indicating
spindle.
3.5 Advantage® Actuator to Valve Body
Mounting Instructions
For double acting (A3YY) and spring-to open (A1YY)
actuators, regulate air pressure in upper cover to
extend the compressor and assemble valve
diaphragm. Correctly position the diaphragm with
bolt holes then back the regulator off until the
diaphragm just rest against the lower cover.
Spring-to close (A2YY) units require air pressure reg-
ulated in the lower cover to properly locate the valve
diaphragm.
3.6.2.4 Assemble top cover, using care to keep
the air fitting in line with the lower
cover air fitting.
3.6.2.5 See Table #1 for fastener
torques.
3.6.3 Actuator Diaphragm Replacement:
(3” & 4” Series 47, DIN 80 & 100)
1/4” through 2” (DIN 8 - 50):
3.6.3.1Disconnect air lines. It is best to
remove the bonnet bolts, lift actuator
assembly from the valve body and
move the unit to a bench. Remove
clear plastic cap, travel stop nuts,
roller-bearing/races, actuator bolts and
nuts. Remove top cover.
Apply a dab of Dow Corning® 111, which has FDA
compliance to Title 21 CFR 175.300, to the lead
thread of each lower cover insert. (DO NOT
OVER-LUBRICATE.) No lubricants are permissible
on the diaphragm seal face or body interior/seal
area.
Assemble valve body using the torques shown in Table
1.
3.6.3.2 Remove adjusting bushing, spindle
nut, diaphragm top plate and actuator
diaphragm.
3.6 Double Acting
(REMOVE ALL LINE PRESSURE)
3.6.1 Valve Diaphragm Replacement
3.6.3.3 Install new diaphragm, top hat up.
Reassembly is the reverse of the above,
use Blue Loctite #242 on the spindle
nut. Be sure to set the adjusting bush-
ing at the correct position 4.06”
(10.31 cm) from top of the spindle nut
to bottom of adjusting bushing), see
Figure 1. See Table 1 for fastener
torques.
3.6.1.1 Disconnect air lines. Remove bonnet
bolts, lift actuator assembly from valve
body.
3.6.1.2 Unscrew diaphragm from compressor
by turning counterclockwise.
3.6.1.3 For PTFE assemblies only: Replace back-
ing cushion and PTFE diaphragm.
Note: To engage the threads of the
diaphragm stud invert the PTFE
diaphragm. To invert the diaphragm,
press on the center of the
(3” & 4” Series 33, DIN 80 & 100)
3.6.3.4Disconnect air lines. It is best to
remove the bonnet bolts, lift actuator
assembly from the valve body and
move the unit to a bench. Remove
actuator bolts and remove top cover.
diaphragm face with thumbs while
holding the edge of the diaphragm
with fingers.
3.6.3.5 Remove extension spindle, both nuts,
diaphragm top plate and actuator
diaphragm.
3.6.1.4 Screw new diaphragm into compressor
until hand tight. DO NOT OVERTIGHT-
EN. Then back off until bolt holes in
diaphragm and bonnet flange align.
3.6.3.6Install new diaphragm, top hat up. Be
sure the diaphragm is positioned so
the diaphragm bolt holes line up with
3
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the cover bolt holes with no stretching
of the diaphragm. The compressor
extends 0.72” from the bonnet face in
this relaxed position, reference p. 10
for a view of the compressor position.
Re-assembly is the reverse of the
above, use Blue Loctite #242 on the
spindle nut. See Table 1 for fastener
torques.
Advantage Act. lower cover. Do not
apply excessive air pressure that
results in inversion of the diaphragm.
3.7.1.7 Replace actuator assembly on body,
and tighten bonnet bolts hand tight.
3.7.1.8 Tighten bonnet bolts with a wrench,
crisscrossing from corner to corner.
See Table 1 for recommended
torques.
3.6.4 Spindle O-Ring Replacement
(All Sizes)
3.7.1.9 Apply sufficient air pressure to the
lower cover to fully open the valve. If
necessary, retighten bonnet bolts.
3.6.4.1 Disconnect air lines, remove actuator
assembly from valve body and disman-
tle actuator following instructions
above for removing actuator
diaphragm.
3.7.1.10 Travel stop (Closing Stop), if
equipped, must be reset at this time
to assure proper closure. See Section
4.1.
3.6.4.2 Withdraw valve diaphragm, compres-
sor and spindle assembly from the
bonnet.
3.7.2 Actuator Diaphragm or Spring Replacement:
(1/4” through 2”, DIN 8 - 50) If present, the switch pack-
age must be removed.
3.6.4.3 Remove old o-rings, taking care not to
damage machined surfaces. Lubricate
new o-rings per Section 3.4 and install
in grooves. Reassemble reversing the
above instructions. Care must be used
on the Bio-Tek to align the compressor
T-slot with molded tabs in lower cover.
Spring-to-Close actuators contain powerful springs
and should not be disassembled unless properly fix-
tured.
One fixture exists for 1/2”, 3/4”, and 1” (DIN 15, 20, 25)
sizes, and another one for 1.5” and 2” (DIN 40 and 50)
sizes. No special fixtures are required for the 3” & 4” (DIN
80 & 100) sizes. Consult factory for details, see Figure 7.
3.7 Reverse Acting
(REMOVE ALL LINE PRESSURE)
3.7.1 Valve Diaphragm Replacement
3.7.2.1 Remove actuator from the valve body.
Apply air to lower cover to simplify dis-
assembly, then release air.
3.7.1.1 Load the bottom chamber of the actu-
ator with sufficient air to partially open
valve. This will ease the spring tension
holding the valve diaphragm to the
body weir.
3.7.2.2 Remove valve diaphragm and plastic
indicator spindle plug (found on the
1/4” through 2” (DIN 8 - 50) spindles),
both unthread by turning counter-
clockwise.
3.7.1.2 Remove the bonnet bolts. Lift actuator
assembly from valve body. Release air
and disconnect air line.
3.7.2.3 Position actuator centrally in fixture,
locating the compressor over the cor-
rect spacer in the fixture lower plate.
3.7.1.3 Unscrew diaphragm from compressor
by turning counterclockwise.
3.7.2.4 Drop the stem guide through center of
fixture handwheel and position in actu-
ator indicator spindle #10-24 UNC
3.7.1.4 For PTFE assemblies only: Replace back-
ing cushion and PTFE diaphragm.
Note: To engage the threads of the
diaphragm stud invert the PTFE
diaphragm. To invert the diaphragm,
press on the center of the
tapped hole (former plug location).
3.7.2.5 Turn handwheel clockwise until stop
rests on actuator top cover.
diaphragm face with thumbs while
holding the edge of the diaphragm
with fingers.
3.7.2.6 Remove all cover to cover
caps, bolts, and washers.
3.7.1.5 Screw new diaphragm into compressor
by turning hand tight. DO NOT OVER-
TIGHTEN. Then back off until bolt
holes in diaphragm and bonnet flange
register.
3.7.2.7 Turn handwheel counterclockwise until
spring load is relieved.
3.7.2.8 Remove top cover, lift out spring(s),
unthread indicator spindle, remove top
actuator plate and diaphragm.
3.7.1.6 Connect air line to lower air chamber
and load chamber with sufficient air
to move the diaphragm upward until
the backing cushion or elastomer
diaphragm rests against the
3.7.2.9 Replace parts using the following pro-
cedure: Place the correct spacer,
dependent on valve size, over the pin
in the fixture lower plate. The 1 1/2”
4
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and 2” (DIN 40 & 50) sizes require four
(4) threaded rod guides in the lower
cover prior to assembly. Position the
actuator sub-assembly, including
3.7.3.6 Unthread adjusting bushing, this
relieves the spring load, until it is free
of the valve spindle. Remove the
adjusting bushing/spring plate sub-
assembly and the springs. Remove
spindle nut, top actuator plate and
actuator diaphragm.
spring(s) and top cover, over the spacer
(i.e., the compressor rests on the spac-
er). Drop the stem guide through cen-
ter of the fixture handwheel, actuator
top cover, and locate in the actuator
indicator. Position the upper actuator
cover so the 1/8” NPT inlets in the
upper and lower covers are in line and
the rod guides slide through the clear-
ance holes. Turn the handwheel clock-
wise to compress the spring(s) until
the covers almost touch. Remove the
four(4) threaded rod guides. Start the
cover bolts and then continue to com-
press the spring(s) until the covers
touch. Place remaining washers and
bolts in top cover and tighten bolts to
torques shown in Table 1.
3.7.3.7Install new diaphragm, top hat up. Be
sure the diaphragm is positioned so
the diaphragm bolt holes line up with
the cover bolt holes with no stretching
of the diaphragm. The compressor
should extend 0.72” from the bonnet
face in this relaxed position, reference
p. 10 for a view of the compressor
position. Re-assembly is the reverse of
the above, use Blue Loctite #242 on
the spindle nut. Thread the adjusting
bushing down until it shoulders. A gap
will exist between the covers until
properly bolted together using a criss-
cross pattern. Use three long bolts to
pull down the upper cover and pinch
the diaphragm. Tighten the standard
cover bolts, replace the three long
bolts and complete the assembly. See
Table 1 for fastener torques.
3.7.3 Actuator Diaphragm or Spring Replacement
(3” & 4” Series 47, DIN 80 & 100)
If present, the switch package must be removed.
3.7.3.1Disconnect air lines. It is best to
remove the bonnet bolts, lift actuator
assembly from the valve body and
move the unit to a bench. Remove
clear plastic cap, travel stop nuts,
roller-bearing and races.
3.7.4 Spindle O-Ring Replacement (All sizes)
3.7.4.1 Disconnect air lines. Remove actuator
from valve body and dismantle actua-
tor following instructions above for
removing actuator diaphragm and
springs.
3.7.3.2 Turn adjusting bushing clockwise until
contact is made with spring package,
record the number of turns. Remove
actuator bolts and nuts, lift off top
cover. Unscrew spring package from
valve spindle by turning counterclock-
wise.
3.7.4.2 Withdraw valve diaphragm, compres-
sor and spindle assembly from the
bonnet.
3.7.4.3 Replace o-rings and reassemble by
reversing the instructions and follow-
ing the steps for replacing a valve
diaphragm. Care must be used on the
Bio-Tek to align the compressor T-slot
with molded tabs in lower cover.
Lubricate o-rings prior to installation
per Section 3.4.
3.7.3.3 Remove spindle nut, diaphragm top
plate and actuator diaphragm.
3.7.3.4 Install new diaphragm, top hat up.
Reassembly is the reverse of the above,
use Blue Loctite #242 on the spindle
nut. If the original spring package is
used, turn the adjusting bushing coun-
terclockwise the number of turns
recorded in 3.7.3.2. only after assem-
bling the top cover and fasteners.
Should replacement of the spring
package be required, simply thread the
new spring package onto the valve
spindle. A gap may exist between the
covers until properly bolted together
using a crisscross pattern. See Table 1
for fastener torques.
3.8 Direct Acting
(REMOVE ALL LINE PRESSURE)
3.8.1 Valve Diaphragm Replacement
3.8.1.1 Disconnect air lines. Remove bonnet
bolts, lift actuator assembly from valve
body. Pressurize actuator by applying
air to upper cover, extending compres-
sor and diaphragm.
(3” & 4” Series 33, DIN 80 & 100)
3.8.1.2 Unscrew diaphragm from compressor
by turning counterclockwise.
3.7.3.5Disconnect air lines. It is best to
remove the bonnet bolts, lift actuator
assembly from the valve body and
move the unit to a bench. Remove
actuator bolts and remove top cover.
3.8.1.3 For PTFE assemblies only: Replace back-
ing cushion and PTFE diaphragm.
Note: To engage the threads of the
diaphragm stud invert the PTFE
diaphragm. To invert the diaphragm,
press on the center of the
5
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diaphragm face with thumbs while
holding the edge of the diaphragm
with fingers.
and compress the spring until the actu-
ator plate shoulders on the spindle.
Use care to insure the spindle goes
through the actuator plate center hole.
Slide the actuator diaphragm over the
valve spindle using care to insure the
top hat is in the upper cover. Position
the actuator diaphragm so the bolt
clearance holes line up with thread-
ed inserts in lower cover. Place an
actuator plate, concave side up, over
the valve spindle. Apply Blue Loctite
#242 and thread the indicating spindle
on the valve spindle by hand. Turn the
handwheel counterclockwise to
3.8.1.4 Screw new diaphragm into compressor
until hand tight. DO NOT OVERTIGHT-
EN. 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 assembly
on body, and tighten bonnet bolts
hand tight.
3.8.1.6 Tighten bonnet bolts with a wrench,
crisscrossing from corner to corner. See
Table 1 for recommended torques.
remove the load and remove the actu-
ator from the fixture. Clamp the slot-
ted plate in a vise and pull so the actu-
ator slips free. Tighten the indicator
spindle with a wrench using care to
insure the actuator diaphragm remains
properly aligned.
3.8.1.7 Release air and permit the valve to
open. If necessary, retighten bonnet
bolts.
3.8.1.8 Travel stop, if equipped, must be reset
at this time to assure proper closure.
See Section 4.1.
3.8.2.4 Position the upper actuator cover so
the 1/8” NPT inlets in the upper and
lower covers are in line.
3.8.2 Actuator Diaphragm or Spring Replacement:
(1/4” through 2”, DIN 8 - 50)
3.8.3 Actuator Diaphragm or Spring Replacement:
(3” & 4” Series 47, DIN 80 & 100) If present,
switch package must be removed.
If present, the switch package must be removed.
Spring-to-Open actuators contain powerful
springs and should not be disassembled unless
properly fixtured.
3.8.3.1Disconnect air lines. It is best to
remove the bonnet bolts, lift actuator
assembly from the valve body and
move the unit to a bench.
One fixture exists for the 1/2”, 3/4”, and 1“ (DIN 15,
20, 25) sizes, and one for 1 1/2” and 2” (DIN 40
and 50) sizes.
3.8.3.2 Remove clear plastic cap, travel stop
nuts and roller bearing/races.
No fixture required for 3” & 4”(DIN 80 & 100).
Consult factory for details, see Figure 7.
3.8.3.3 Remove actuator bolts and nuts, lift off
top cover.
3.8.2.1 Remove cover bolts and lift off top
cover.
3.8.3.4 Remove adjusting bushing, spindle nut
(under load due to spring force),
diaphragm plates, actuator diaphragm
and spring.
3.8.2.2 Caution: actuator plates are under
load. Loosen the indicator spindle two
turns before placing centrally in the fix-
ture, locating the compressor over the
correct spacer in the fixture lower
plate. Place the slotted fixture plate
and spacer plate on the actuator top
plate; turn the fixture handwheel
clockwise to remove the load from the
indicator spindle. Remove the spindle
and turn the handwheel counterclock-
wise until the spring load is relieved.
Use care - the diaphragm may pinch
the spindle thread and restrict spring
extension. Examine the diaphragm
through hole for damage and replace,
if necessary.
3.8.3.5 Using replacement parts, reverse
instructions for reassembly. Use Blue
Loctite #242 on the spindle nut. Be
sure to set the adjusting bushing at
the correct location (4.06” (10.31 cm)
from top of the spindle nut to bottom
of adjusting bushing), see Figure 1.
(3” & 4” Series 33, DIN 80 & 100)
3.8.3.6Disconnect air lines. It is best to
remove bonnet bolts, lift actuator
assembly from the valve body and
move the unit to a bench. Remove
actuator bolts an remove top cover.
3.8.2.3 Place the spring in the lower cover and
set an actuator plate, concave side
3.8.3.7 Remove extension spindle, both nuts,
diaphragm top plate, actuator
diaphragm and spring.
down, over the valve spindle. Position
in the fixture over the spacer and place
the slotted fixture plate on the actua-
tor plate. Set the spacer plate on top,
turn the fixture handwheel clockwise
3.8.3.8 Reassembly is the reverse of the above,
6
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use Blue Loctite #242 on the spindle
nut. The diaphragm is to be assembled
top hat up. See Table 1 for fastener
torques.
4.2.1 Operation of Manual Over-ride (Open): (3” &
4” Series 47 only, DIN 80 & 100 only)
4.2.1.1 Remove switch Package if present.
4.2.1.2 Release any air pressure in top cover.
3.8.4 Spindle O-Ring Replacement (All sizes)
3.8.4.1 Disconnect air lines. Remove actuator
from valve body and dismantle actua-
tor following instructions above for
removing actuator diaphragm and
spring.
4.2.1.3 Remove clear plastic cap and loosen
jam nuts.
4.2.1.4 Use a wrench to hold the adjusting
bushing from rotating, turn the lowest
jam nut clockwise. This opens the valve
0.056” (1.42 mm) per rotation. Rotate
the nut counterclockwise to return
valve to closed position. Note: Travel
stop adjustment is recommended at
this time. See Section 4.1 to adjust
travel stop.
3.8.4.2 Withdraw valve diaphragm, compres-
sor and spindle assembly from the
bonnet.
3.8.4.3 Replace o-rings and reassemble by
reversing the instructions and follow-
ing the steps for replacing a valve
diaphragm. Care must be used on the
Bio-Tek® to align the compressor T-slot
with molded tabs in lower cover.
Lubricate o-rings prior to installation
per Section 3.4.
4.2.1.5 Tighten jam nuts together and assem-
ble plastic cap.
4.2.2 Operation of Adjustable Opening Stop:
(1/4” through 2”, DIN 8 - 50)
4
ACCESSORIES
4.2.2.1 Remove switch package if present.
4.1 Travel (Closing) Stop Adjustment
This feature is standard on 3” - 4” Series 47 (DIN
80-100) actuators and optional on the 1/4” - 2” (DIN
8-50). It is not available on 3” - 4 “ Series 33 (DIN
80-100).
4.2.2.2 Using air pressure and bleed type regu-
lator, open valve to desired position.
4.2.2.3 Rotate adjusting bushing counterclock-
wise until resistance is felt.
The purpose of the travel stop is to prevent over-
loading of the diaphragm, thus prolonging
diaphragm life. Travel stops are factory set and
do not require routine adjustment. However, with
replacement of valve diaphragms, travel stop
adjustment is recommended.
4.2.2.4 Opening stop is now set. NOTE: VALVE
CLOSED SWITCH REQUIRES ADJUST-
MENT.
4.2.3 Operation of Adjustable Opening Stop:
(3” & 4” Series 47, DIN 80 & 100)
4.1.1 All Operating Modes:
4.2.3.1 Remove switch package if present.
4.2.3.2 Remove clear plastic cap.
4.1.1.1 Remove switch Package if present.
4.1.1.2 Release air pressure in actuator covers.
4.1.1.3 Remove clear plastic cap.
4.2.3.3 Using air pressure and bleed type regu-
lator, open valve to desired position.
4.2.3.4 Rotate adjusting bushing counterclock-
wise until resistance is felt. Count and
record the number of turns.
4.1.1.4 To adjust travel (closing) stop, first
loosen jam nuts and back off one turn.
If double or direct acting, apply
enough pressure in top cover to close
the valve. While preventing the adjust-
ing bushing from rotating, turn lower
nut clockwise until valve leaks. Then
turn lower nut counterclockwise until
valve stops leaking while continuing to
insure the adjusting bushing does not
rotate. Tighten jam nuts together, the
travel stop is now set. Replace plastic
cap.
4.2.3.5 Loosen the two jam nuts and turn the
lower nut clockwise the same number
of turns recorded above. Lock the nuts
together. Note: Travel stop adjust-
ment is recommended at this time.
See Section 4.1 to adjust travel stop.
4.2.3.6 Replace cap.
4.3 Combination Manual Over-ride (Close) and
Adjustable Opening Stop
4.2 Combination Manual Over-ride (Open) and
Adjustable Opening Stop
(Wrench closing not available on 1/4” through
2”, DIN 8 - 50 or 3” & 4”, DIN 80 & 100, Series 33.)
(Manual Over-ride (Open) not available on 1/4”
through 2”, DIN 8 - 50 or 3” & 4”, DIN 80 - 100
Series 33.)
4.3.1Operation of Manual Over-ride (Close):
(3” & 4” Series 47 (DIN 80 & 100)
Direct & Double only)
7
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ADVANTAGE® ACTUATOR
FIGURE 1
3
⁄
4”-2”
1
1
2
⁄
4”- ⁄
”
1/4” - 2”
(DIN 8-50)
“D”
“C”
“TOP VIEW”
“C”
“A/B”
“E”
SPRING TO CLOSE AIR TO OPEN
LOW PROFILE
DOUBLE ACTING
&
SPRING TO OPEN AIR CLOSE
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ADVANTAGE® ACTUATOR
3” - 4” (SERIES 47)
(DIN 80-100)
QUANTITY
REQUIRED,
1 FOR DIR. ACT.
2 FOR DBL ACT.
1
⁄
4” NPI
“A/B”
1
⁄
4” NPI
FURNISHED WITH
DIR. ACT. ONLY
DOUBLE & DIRECT
ACTING
REVERSE ACTING
TRAVEL, STOP, ADJUSTABLE OPENING
STOP & MANUAL OVER-RIDES
FIGURE 2
*
*
*
3” - 4” (SERIES 47)
(DIN 80-100)
*
*
PLASTIC CAP
(TRANSPARENT)
TRAVEL
STOP
NUTS
ROLLER BEARING
& RACES
O-RING
TOP
COVER
O-RING
*
THRUST
SPRING
WASHER
PLUNGER
ADJUSTING
BUSHING
VALVE
SPINDLE
* RECOMMENDED SPARE PARTS
9
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ADVANTAGE® ACTUATOR
3” - 4” (SERIES 33)
(DIN 80-100)
QTY. REQUIRED
1 FOR REV. ACT
REVERSE ACTING
QTY. REQUIRED,
1 FOR DIR. ACT.
2 FOR DBL. ACT.
FURNISHED
WITH DIR.
ACT. ONLY
REVERSE ACTING
ACTUATOR DIAPHRAGM REPLACEMENT
DOUBLE & DIRECT
ACTING
10
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4.3.1.1 If present, the switch package must be
removed.
5.2.3Thread on the adapter, insure that the O-Ring
is in place at the base of the adapter.
4.3.1.2 Release any air pressure in bottom
cover.
5.2.4Slide the switch sub assembly down over the
adapter, position the conduit entrances in the
location most desirable, (45˚ increments), press
down and tighten the set screw located on the
side of the lower housing to lock the unit in
place. The set screw torque should not exceed
5 in-lbs (.656 Joules).
4.3.1.3 Remove clear plastic cap.
4.3.1.4 Use a wrench to turn the adjusting
bushing counter clockwise to close the
valve (record the number of turns).
Turn the adjusting bushing clockwise
the same number of turns to return
valve to open position.
5.2.5Holding the lower housing stationary unscrew
the top switch package cover and wire to the
terminal strip (Reference factory wiring decal).
Verify the switches operate correctly by cycling
the valve, see 5.3 for switch adjusting proce-
dure. Screw the switch package cover on,
insure the O-Ring remains in the groove.
4.3.1.5 Tighten Travel Stop nuts and assemble
plastic cap.
5
SWITCH PACK 2.0
5.3 Setting Switches
(The switch package is not autoclavable,
maximum temperature is 150˚ F 65.5˚C)
(Switches and Positioners cannot be used
together)
(Switches are identified with decal)
5.3.1Remove top switch package cover.
5.3.2Place valve in full open position.
Retrofit - The switch package as received from
the factory is pre-set, only minimal adjustment
is required to adapt to the actuator.
5.3.3Connect test device to terminal strip on con-
nections identified for SW (open) switch. The
switch type, inductive proximity versus dry con-
tact mechanical, determines the type of test
device required. Contact switches use a tradi-
tional volt meter with resistance capability to
verify continuity, inductive proximity switches
cannot use this method. Proximity switches
require an inductive proximity tester, such as
Pepperl+Fuch’s model #1-1305, which supplies
the proper load and supply voltage to the
switch. Inductive proximity switches must be
energized with the correct load and supply
voltage to sense the target.
5.1 Field Mounting (1/4” through 2”, DIN 8 - 50, 3” &
4”, DIN 80 & 100, Series 33)
5.1.1Remove the four(4) stainless steel screws on
the actuator top cover. Place the valve in the
open position.
5.1.2Remove the plastic plug from the indicating
spindle.
5.1.3Thread the switch indicating spindle into the
valve indicating spindle. Use Blue Loctite #242.
WARNING: DO NOT SHORT THE INDUCTIVE
PROXIMITY SWITCH BY DIRECTLY CONNECT-
ING A POWER SUPPLY, IRREPARABLE AND
IMMEDIATE DAMAGE CAN OCCUR TO THE
SWITCH.
5.1.4Mount the adapter, insure that both O-Rings
are on the adapter and lubricated with Dow
111. The correct torque is 5 in-lbs (.656 Joules).
5.1.5Slide the switch sub assembly down over the
adapter, position the conduit entrances in the
location most desirable, (45˚ increments), press
down and tighten the set screw located on the
side of the lower housing to lock the unit in
place. The set screw torque should not exceed
5 in-lbs (.656 Joules).
5.3.4Loosen the two (2) screws on the open switch
slightly.
5.3.5Use the adjusting screw accessible from the top
to move the switch up or down the bracket to
the optimum position. (Two turns past the trig-
ger location is recommended.)
5.1.6Holding the lower housing stationary, unscrew
the top switch package cover and wire to the
terminal strip (Reference factory wiring decal).
Verify the switches operate correctly by cycling
the valve, see 5.3 for switch adjusting proce-
dure. Screw the switch package cover on,
insure the O-Ring remains in the groove.
5.3.6Tighten the two (2) screws on the switch.
5.3.7Place the valve in the full closed position.
5.3.8Repeat the above steps for the SW (closed)
switch.
5.2 Field Mounting
5.3.9Replace the top switch package cover.
(3” and 4” Series 47, DIN 80 and 100)
6
SWITCH PACK 2.5
5.2.1Remove the clear plastic cap from the actuator.
(The switch package is not autoclavable,
maximum temperature is 150˚F, 65.5˚C)
(Switches and Positioners cannot be used
together)
5.2.2Thread the switch indicating spindle into the
valve indicating spindle. Use Blue Loctite #242.
11
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SWITCH PACK 2, SP2.0
FIGURE 3
“A”
9.75
5.29
BIO-TEK
THRU 02.00
DETAIL “B”
(BIO-TEK - 01.000)
DETAIL “B”
(03.000 & 04.000 SERIES 47)
“A”
NOTE:
1. RECOMMENDED SPARE PARTS ARE MARKED WITH AN
ASTERISK (*) ON THE LIST OF PARTS.
2. ▲- USED ON BIO-TEK - 01.000
+ - USED ON BIO-TEK - 02.000
- USED ON 1.500 & 02.000
- USED ON 03.000 & 04.000
∆ 3. SWITCHES
PROX P&F #NJ3-V3-Z
PROX P&F #NJ3-V3-N
PROX P&F #NJ3-V3-E
PROX P&F #NJ3-V3-E2
MECH #X97173-V3L (SIL CONT)
MECH #X97174-V3L (GOLD CONT)
▲ 4. USED ONLY WITH PROXIMITY SWITCHES.
5. USED ONLY WITH MECHANICAL SWITCHES
SEE DETA
WIRING LABELS (ITEM 31)
12
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turns past the trigger location is recommend-
ed.)
Retrofit - The switch package as received from
the factory is pre-set, only minimal adjustment
is required to adapt to the actuator.
6.2.5Place the valve in the full closed position.
6.2.6Replace the top switch package cover.
SWITCH PACK 3.0
6.1 Field Mounting (1/4” through 1”, DIN 8 - 25)
6.1.1Remove the four(4) stainless steel screws on
the actuator top cover. Place the valve in the
open position.
7
(The switch package is not autoclavable,
maximum switch temperature is 140˚F,
60˚C.) (Switches and Positioners cannot be
used together.)
6.1.2Remove the plastic plug from the indicating
spindle.
6.1.3Mount the adapter, insure that both 0-Rings
are on the adapter and lubricated with Dow
111. The correct torque is 5 in-lbs (.565 Joules).
Retrofit - The switch package as received from
the factory on valve assemblies is pre-set, only
minimal adjustment is required to adapt to the
actuator.
6.1.4Place the washer on the adapter. Thread the
switch indicating spindle (item 12) into the
actuator spindle. Use Blue Loctite #242.
7.1 Field Mounting (1/4” through 2”, DN 8 - 50)
7.1.1Remove the four (4) stainless steel screws on
the actuator top cover. Place the valve in the
open position.
6.1.5Slide the switch sub assembly down over the
adapter, position the conduit entrances in the
location most desirable, (45˚ increments), press
down and tighten the set screw located on the
side of the lower housing to lock the unit in
place. The set screw torque should not exceed
5 in-lbs (.565 Joules).
7.1.2Remove the plastic plug from the indicating
spindle.
7.1.3Insure all O-Rings are on the adapter and lubri-
cated with Dow 111. Slip the switch indicating
spindle, #10-24 UNC threads first, through the
adapter until the threads are exposed. Apply
Blue Loctite #242 to the threads, thread the
switch spindle into the actuator spindle until it
shoulders.
6.1.6Attach target assembly (item 9) to switch indi-
cating spindle (item 12) using shoulder screw
with Belleville washers in place. Use Blue
Loctite #242. Run field wires and conduit to
terminal strip. (Reference factory wiring tag.)
Verify the switches operate correctly by cycling
the valve, see 6.2 for switch adjusting proce-
dure. Screw the switch package cover on,
insure the O-Ring remains in the groove.
7.1.4Attach the adapter to the upper cover. The cor-
rect torque is 5 in-lbs (.565 Joules).
7.1.5Thread the appropriate switch actuator(s) on
the spindle.
6.2 Setting Switches
(Switches are identified with decal)
7.1.6Position the closed switch actuator approxi-
mately 0.14” (4 turns) from end of threads and
position the open switch actuator approximate-
ly 0.25” (7 turns) below the top of the spindle,
do not tighten the set screw.
6.2.1Remove top switch package cover.
6.2.2Place valve in full open position.
6.2.3Connect test device to terminal strip on con-
nections identified for open switch. The switch
type, inductive proximity versus dry contact
mechanical, determines the type of test device
required. Contact switches use a traditional
volt meter with resistance capability to verify
continuity, inductive proximity switches cannot
use this method. Proximity switches require an
inductive proximity tester, such as
7.1.7Remove the switch package top cover, slide the
sub assembly down over the adapter using
care not to damage the switch internals
(specifically the mechanical switch levers).
Position the conduit entrance in the location
most desirable, press down and tighten the set
screw located on the side of the lower housing
to lock the unit in place. Note that the plastic
adapter has two molded counterbores.
Pepperl+Fuch’s model #1 - 1350, which sup-
plies the proper load and supply voltage to the
switch. Inductive proximity switches must be
energized with the correct load and supply
voltage to sense the target.
Locating the set screw in one of these holes
provides maximum resistance to conduit rota-
tion. The set screw torque should not exceed 5
in-lbs. (.565 Joules).
WARNING: DO NOT SHORT THE INDUCTIVE
PROXIMITY SWITCH BY DIRECTLY CONNECT-
ING A POWER SUPPLY, IRREPARABLE AND
IMMEDIATE DAMAGE CAN OCCUR TO THE
SWITCH.
7.1.8Run field wires and conduit to the terminal
strips. Verify the switches operate correctly by
cycling the valve. See 7.2 for switch adjusting
procedure. Screw the switch package top cover
on.
6.2.4Use the switch actuator (item 7) accessible
from the top to set the optimum position. (Two
7.2 Setting Switches
13
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SWITCH PACK 2.5, SP2.5
FIGURE 3A
“A”
ASSEMBLE BELLEVILLE WASHERS IN
SERIES AS SHOWN
SEE DETAIL “B”
“A”
(3.70) DIA
NOTE:
DETAIL “B”
1. RECOMMENDED SPARE PARTS ARE MARKED WITH AN
ASTERISK (*) ON THE LIST OF PARTS.
▲ 2. SWITCHES
PROX P&F #NJ3-V3-Z
PROX P&F #NJ3-V3-N
PROX P&F #NJ3-V3-E
(3.32)
PROX P&F #NJ3-V3-E2
MECHANICAL X96324-UM (SIL CONT)
MECHANICAL X96325-UM (GOLD CONT)
▲ 3. USED ONLY WITH MECHANICAL SWITCHES.
SECTION “A-A”
WIRING DIAGRAM CARDS (ITEM 30)
14
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7.2.1Remove top switch package cover.
7.2.2Place valve in full open position.
8.1.1 Moore 73N12F (A100 & A300 Series Actuators)
(Direct Acting Positioner, Top Loading)
8.1.2 Moore 73NB (A200 Series Actuators) (Direct
Acting Positioner, Bottom Loading)
7.2.3Connect test device to terminal strip for open
switch. The switch type, inductive proximity
versus dry contact mechanical, determines the
type of test device required. Contact switches
use a traditional volt meter with resistance
capability to verify continuity, inductive proxim-
ity switches cannot use this method. Proximity
switches require an inductive proximity tester,
such as Pepperl+Fuch’s model #1-1350, which
supplies the proper load and supply voltage to
the switch. Inductive proximity switches must
be energized with the correct load and supply
voltage to sense the target.
8.1.3 Moore 73NFR (A100 & A300 Series Actuators)
(Reverse Acting Positioner, Top Loading)
8.2 Supply and Instrument Pressures
8.2.1Instrument input pressure range - as specified:
3-15 psi (.21 - 1.03 bar) (standard), 3-9 psi
(.21-.62 bar), 6-30 psi (.41-2.07 bar) and others
are optional.
8.2.2Supply pressure: 3 psi (.21 bar) above required
actuator pressure to a maximum of 90 psi (6.2
bar). A filtered air supply is recommended.
WARNING: DO NOT SHORT THE INDUCTIVE
PROXIMITY SWITCH BY DIRECTLY CONNECT-
ING A POWER SUPPLY, IRREPARABLE AND
IMMEDIATE DAMAGE CAN OCCUR TO THE
SWITCH.
8.2.3Caution: Pressure in excess of 90 psi (6.2
bar) to any connection may cause damage.
8.3 Description
7.2.4 Bio-1.50” (Two Switch Actuators)
The positioner is designed to operate a valve actua-
tor to maintain the valve in a position determined by
the control instrument. The above positioners are
direct acting - with an increase in instrument pres-
sure, the pressure to the actuator (positioner output)
will increase or reverse acting - with an increase in
instrument pressure, the pressure to the actuator
(positioner output) will decrease. On a bottom load-
ing positioner (73NB), output is connected to the
actuator lower chamber via an external tube.
Therefore, the valve will open as instrument pressure
increases. The 73NB is the only unit which can have
an O-ring in the actuator upper cover. All others
operate on the concept that air feeds the upper
cover by flowing down the indicating shaft and into
the cover. (This means that a field retrofit for
Double and Direct units must have the O-ring
removed and a special slotted adjusting bushing.)
Double Acting (A300 Series) require the lower actua-
tor cover to be pre-loaded, use a bleed off type regu-
lator with gauge. (This is standard when ITT supplies
the assembly.)
7.2.4.1 Verify the switch package locking set
screw is tight.
7.2.4.2 Verify the circuit board is firmly seat-
ed.
7.2.4.3 For mechanical switches only, press on
the top of the circuit board to move it
toward the switch actuator. Thread the
switch actuator two (2) turns past the
initial switch indication.
7.2.4.4 Lock in place with the set screw on
switch actuator.
7.2.5 2.0” (One switch actuator)
7.2.5.1 Do not set the switch in the open
position, set the switch in closed posi-
tion. Follow 7.2.4 with the valve in full
closed position. Confirm open switch
functions in full open position only
after setting in closed position.
8.4 Installation
The only task is to connect the supply and instru-
ment air. All connections are 1/4” NPT. Use 1/4” O.D.
tubing for the instrument connection, either 1/4” or
3/8” O.D. (6.35 or 9.52 mm) tubing for the supply
connection. Blow out all piping before connections
are made to prevent the possibility of dirt or chips
entering the positioner. Use pipe sealant sparingly,
and then only on the male threads. A non-hardening
sealant is strongly recommended. Connect the posi-
tioner to a source of clean, dry oil-free air. A filtered
and regulated air source is recommended.
7.2.6Place the valve in the full closed position and
connect the appropriate test device to the ter-
minal strip for valve CLOSE switch. Repeat sec-
tion 7.2.4-7.2.5 for the valve CLOSED switch.
Note on SP 3.0 units, the closed switch actua-
tor must never hit the adapter in the closed
position with body attached.
8
POSITIONERS
(Switches and Positioners cannot be used
together)
Note: Synthetic compressor lubricants in the air
stream at the instrument may cause the position-
er to fail.
(A special adjusting bushing is required for 3”
& 4“ (DIN 80 & 100) Actuators with position-
ers)
Note that a cushion loading regulator is furnished
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 regula-
tor should be set at the minimum pressure required
to open the valve wide open. Typically, this is 10 psi
(0.69 bar) or less.
8.1 Scope: Top-mounted positioners listed below
15
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SWITCH PACK 3.0, SP3.0
FIGURE 3B
(ADAPTER)
ADVANTAGE
ACTUATOR
ASSEMBLE WITH LOCTITE
SEALANT #242 (BLUE)
(INDICATING
SPINDLE)
BIO-TEK - 1.00”
ADVANTAGE
ACTUATOR
ASSEMBLE WITH LOCTITE
SEALANT #242 (BLUE)
(INDICATING
SPINDLE)
1.50” & 2.00”
16
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8.5 Adjustment
The only adjustment that can be made on the posi-
tioner is a zero adjustment. The zero adjusting screw
is located under the positioner’s top cover. To make
this adjustment, set the instrument air pressure to
the midpoint of its span, and turn the zero adjust-
ment until the valve is at the mid-point of its stroke.
Refer to Table #2 for stroke information. 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 or opening may be
required at a specific instrument pressure. 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 zero adjusting screw.
8.6 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 nec-
essary. 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 accomplished.
For additional maintenance activities, refer to the
Manufacturer’s service manual.
17
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POSITIONER
FIGURE 4
3
⁄
4” - 4”
(DIN 20-100)
18
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FIGURE 5
VALVE DIAPHRAGM IDENTIFICATION
ELASTOMER - 1 PIECE, MADE OF RUBBER, WITH
MOLDED IN STUD. (SEE TABS)
19
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120
13.56
20
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TABLE 4
O RING CHART
ADVANTAGE ACTUATOR AND SWITCH PACKAGE, SP2
ACT SIZE
AXYY
ACTUATOR
UPPER
COVER
ACTUATOR
LOWER
COVER
LOW
PROFILE
BUSHING
ACTUATOR
SP2
BASE
•
SP2
SP2
CAP
•
ADAPTER/COVER UPPER COVER/
•
LOWER COVER
DWG. ITEM
13
7.9
14
N/A
N/A
N/A
N/A
N/A
#128
10
12
13
03
05
#110
#112
#112
#114
#208
#212
#110
#112
#112
#114
#214
#214
#110, #112
#112, #114
#112, #114
#114, #118
N/A
#117
#117
#117
#117
#117
#128
#116
#116
#116
#116
#116
#116
#152
#152
#152
#152
#152
#152
08
16
*33
*47
N/A
1) *FDA COMPLIANT BUNA N MATERIAL
2) STANDARD MATERIAL, UNLESS NOTED, IS FDA COMPLIANT VITON
21
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NOTES
22
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NOTES
23
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Pure-Flo Solutions Group
OFFICE LOCATIONS
Pure-Flo Solutions Group
Headquarters
Pure-Flo Sweden
For more information, please contact:
Engineered Valves Headquarters
33 Centerville Road, P.O. Box 6164
Lancaster, PA 17603-2064 USA
Formerly A.G. Johansons Metallfabrik
Box 26 Vasterasvagen 6
S-730 40 Kolbäck
33 Centerville Road
Lancaster, PA 17603
Phone 800-366-1111
Phone (717) 509-2200
Fax (717) 509-2336
Phone +46-220-403-20
Fax +46-220-405-23
or call:
(800) 366-1111
(717) 509-2200
Fax: (717) 509-2336
E-mail: engvalves_custserv@fluids.ittind.com
Pure-Flo California
Pure-Flo UK
Formerly Sinton Group
Richards Street
Formerly ITT Sherotec
725 East Cochran Street, Unit E
Simi Valley, CA 93065
Phone 800-926-8884
Phone (805) 520-7200
Fax (805) 520-7205
Kirkham, Lancashire
PR4 2HU, England
Phone +44-1772-682696
Fax +44-1772-686006
©2001 ITT Industries
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