ITT Dia-Flo Instruction Manual

Dia-Flo

Instruction Manual

®

Paint Tote Valve, Quarter Turn

TABLE OF CONTENTS

PAGE SECTION

3 0.0 GENERAL INFORMATION

4 1.0 INSTALLATION

5 2.0 OPERATION

6 3.0 MAINTENANCE

8 4.0 ACCESSORIES

9 Figure 1 Tote Valve Assembly

10 Figure 2 Tote Valve Dimensional Data

0

1

2

3

4

2 DV-1/4 Turn IOM - 11/06

0.0 GENERAL INFORMATION

The latest edition of this manual can be found on the
website listed within this manual.

! WARNING

s

The safety precautions in these operating
instructions are specially marked with the
standard symbol for danger when
non-observance could result in personal injury,
loss of life or property damage.

! CAUTION

l

Non-observance of these safety precautions
can endanger the valve and its functions.

0.1.1 QUALIFICATIONS AND TRAINING
OF PERSONNEL

The personnel responsible for operation,
maintenance, inspection and assembly must be
appropriately qualified.

The operating company must precisely define the
responsibilities, competence and supervision of the
personnel. If the personnel lack the necessary
knowledge, they are to be trained and instructed. If
required this can be carried out by the
manufacturer/supplier of the valve by order of the
operating company. Furthermore, the operating
company is to ensure that the contents of the
operating instructions have been fully understood by
the personnel.

OPERATOR

If hot or cold components of the valves are a

-

source of danger, these components must be
secured against contact by operating company.

Contact guard for moving parts may not be

-

removed when valve is in operation.
Do not hang items off the valves. Any

-

accessories must be firmly or permanently
attached.

Do not use the product as a step or hand hold.

-

Do not paint over identification tag, warnings,

-

notices or other identification marks associated
with the product.

Plastic PTFE diaphragms emit toxic fumes due

-

to thermal decomposition at temperatures of
716°F (380°C) or greater.

0.1.5 SAFETY PRECAUTIONS FOR
MAINTENANCE, INSPECTION AND
ASSEMBLY

Work on externally actuated valves should only be
carried out when the valve is removed from service.
Valves that have been exposed to harmful media
such as caustic chemicals must be decontaminated.

On completion of work, all safety and protective
equipment must immediately be fitted again or
reactivated.

Before the re-operation, attention should be paid to
the points in the following sections.

0.1.2 DANGERS THROUGH
NON-OBSERVANCE OF THE SAFETY
PRECAUTIONS

The non-observance of the safety precautions can
result in the endangering of lives as well as the
environment and the valve. The non-observance of
the safety precautions can lead to the loss of all
claims for damages.

Non-observance can result in the following:

-

Failure of important functions of the valve/plant.

-

Endangering of lives by electrical, mechanical
and chemical influences.

-

Endangering the environment through leakage
of dangerous materials.

Personal injury or property damage.

0.1.3 SAFETY AWARENESS AT WORK

Attention must be paid to the safety precautions in
these operating instructions, the current national
regulations concerning the prevention of accidents as
well as any labor, company and safety-regulations of
the operating company.

0.1.4 SAFETY PRECAUTIONS FOR THE
OPERATING COMPANY / INDIVIDUAL

0.1.6 UNAUTHORIZED
RECONSTRUCTION AND MANUFACTURE
OF SPARE PARTS

Reconstruction or modification of the valve is only
admissible after consultation with the manufacturer.

Genuine spare parts and accessories authorized by
the manufacturer serve to maintain safety. The use of
other parts can annul all liability for the
consequences.

Manufacturer's parts are not to be used in conjunction
with products not supplied by the manufacturer. The
use of manufacturer's parts with products not supplied
by the manufacturer can annul all liability for the
consequences.

0.1.7 INADMISSIBLE MODES OF
OPERATION

The operational reliability of the valve supplied is only
guaranteed when used as designated. The operating
limits given on the identification tag and in the data
sheet may not be exceeded under any circumstances.

If the product label is missing or worn contact
manufacturer at the address listed within this manual
for specific instructions.

DV-1/4 Turn IOM - 11/06 3

0.2 TRANSPORT AND STORAGE

! WARNING

s

The universally recognized technical standards
and the regulations regarding prevention of
accidents must be observed at all times when
handling.

0.2.1 TRANSPORT

The goods have to be carefully handled in order to
prevent damage.

The end flange caps supplied are to be fitted to the
valve as applicable.

0.2.2 UNPACKING

Unpack the shipment, check to make sure that all
contents are present and undamaged.

0.2.3 STORAGE

If the valve is not to be installed immediately following
delivery, it must be properly stored.

Storage should be in a dry room at a temperature as
constant as possible. Product should not be stacked
on top of one another.

Storage over a longer period may necessitate
individual moisture proof packing. This is dependent
on the local conditions.

0.2.4 DISPOSAL, RECYCLE OR RETURN
SHIPMENT

The personnel responsible for disposal of the product
or associated components are to comply with
federal, state and local requirements.

If the return shipment is required, contact
manufacturer at the address listed on backpage for
specific instructions.

! WARNING

s

The operator of valves used for aggressive or
toxic media such as caustic chemicals must
ensure that these are well flushed and cleaned
before being handed to the maintenance
personnel. This is particularly important when
returning to the product manufacturer,
disposing of or recycling the product or its
component parts. MSDS are required for
authorization to return valves to the
manufacturer.

1.0 INSTALLATION

1.1 BONNET ASSEMBLY TO BODY INSTALLATION

This section to be followed when assembling a bonnet
assembly including diaphragm and backing cushion to
a valve body.

1.1.1 Prior to assembly to the body, the
diaphragm/backing cushion should be resting flat
against the bonnet flange. The compressor should be
extending just short of the full closed position. Rotate
the input shaft to achieve this position.

1.1.2 Position the bonnet over the studs and onto the
body. Drop washers over the studs.

1.1.3 After the bonnet assembly is positioned over the
studs and rests against the body, lightly lubricate the
studs with Chevron Poly FM2 just above the bonnet
flange (i.e. the location at which the nut will engage the
stud when tight against the bonnet).

1.1.4 Assemble nuts finger tight. Final tightening of
bonnet fasteners shall be done by hand. Pneumatic
tools are not permitted. Bring the torque up gradually
with at least 3 passes on each nut. Nuts shall be
tightened in a crisscross pattern, so as to compress
the diaphragm evenly. Tighten nuts securely to 10
ft-lbs (120 in-lbs, 13.5 N-m).

! CAUTION

l

Nut assembly torque requirement of 10 ft-lbs
(120 in-lbs, 13.5 N-m) is critical to the success
of the valve's sealing function. Excessive
torque decreases the valve's sealing function
and increases the amount of effort required to
actuate the valve.

4 DV-1/4 Turn IOM - 11/06

1.2 TOTE VALVE TO TOTE TANK INSTALLATION

This section to be followed when assembling a
tote valve to a tote tank.

1.2.1 Prior to pressurization (with the valve
slightly open), verify the torque applied to the
bonnet to body nuts per Section 1.1.4.

1.2.2 Assembly of tote valve to tote tank requires
an o-ring be located in the flange to create a seal
as shown below. This o-ring (#336) is to be
provided by the user to insure chemical
compatibility.

1.2.3 Position the tote valve over the studs mounted in the
tote tank’s flange. Make sure that the valve’s outlet port
does not extend beyond the footprint of the tote tank.

1.2.4 Secure the tote valve to the tote tank using washers
and nuts. Washers and nuts are to be provided by the
user to insure chemical compatibility. Tighten nuts per
user’s torque specification.

1.3 Maximum valve operating pressure is 14 psig (0.97
bar) at 100% pressure drop (DP). A pressure drop of
100% DP is when pressure is only acting on one side of

the diaphragm when the valve is closed and the outlet is
open to atmospheric pressure.

1.4 Cam-Lok cap/cover is to be placed on the valve’s
outlet port when the tote tank contains fluid. This Cam-Lok
cap/cover is to be provided by the user to insure chemical
compatibility.

2.0 OPERATION

2.1 The valve is closed with a quarter turn (90°)
clockwise rotation of the input shaft, opened with
a counterclockwise rotation. The valve is only
intended for manual actuation. Do not attempt to

exceed the quarter turn (90°) rotation limit. A
lever/handle capable of mating with the 0.50”
(12.7 mm) square drive on the valve’s input shaft
is to be used. This lever/handle is to be provided
by the user. It is recommended that this
lever/handle be at least 14” (355.6 mm) long.

2.2 Properly support the lever/handle against the
input shaft during actuation as shown below. Lack
of support may allow the lever/handle to
disengage from the input shaft during actuation
which can cause damage to the input shaft’s
square drive.

DV-1/4 Turn IOM - 11/06 5

2.3 The valve position is visible based on the position
of the groove at the end of the input shaft and lock
plate as shown below.

3.0 MAINTENANCE

2.4 The valve shall lock itself in the open or closed
position. If a secondary lock is desired in the open or
closed position, a pin, tie-wrap or other suitable
securing device may be placed thru the locking plate’s
and bonnet half’s ¼” (6.35 mm) thru hole.

ALL MAINTENANCE PROCEDURES MUST BE
PERFORMED BY QUALIFIED PERSONNEL.
MAINTENANCE DONE BY PERSONNEL NOT
QUALIFIED TO PERFORM IT COULD RESULT IN
PERSONAL INJURY, DEATH OR PROERTY
DAMAGE.

3.1 PERIODIC INSPECTION

! WARNING

s

When the process fluid is hazardous or
corrosive, extra precautions should be taken.
The user should employ appropriate safety
devices and should be prepared to control a
leak of the process fluid. Failure to follow these
instructions could result in serious personal
injury or death, and property damage.

3.2 BONNET TO BODY INTERFACE LEAKAGE

If leakage occurs at the body/diaphragm seating area,
immediately depressurize system, open valve slightly
and tighten nuts per Section 1.1.4. If leakage
continues, diaphragm replacement is required per
Section 3.6.

! WARNING

s

Remove all line pressure.

Periodically inspect condition of external valve parts.
Replace all parts showing excessive wear or
corrosion. Contact manufacturer at the address listed
on the back page of this manual in order to obtain
replacement parts or for specific instructions.

3.3 BONNET ASSEMBLY LEAKAGE

If leakage is occurring thru the bonnet assembly the
diaphragm has ruptured and must be replaced per
Section 3.6.

6 DV-1/4 Turn IOM - 11/06

3.4 LEAKAGE THRU THE OUTLET WHEN CLOSED

If leakage is occurring thru the body’s outlet when the
bonnet assembly is in the closed position the
diaphragm may be worn. The diaphragm must be
replaced per Section 3.6.

3.5 EXCESSIVE TORQUE TO ACTUATE VALVE

If more than 60 ft-lbs (81.3 N-m) of torque is required
to actuate the valve verify that the bonnet nuts are
tightened to a torque of 10 ft-lbs (120 in-lbs, 13.5
N-m).

3.6 DIAPHRAGM REPLACEMENT

Elastomer diaphragms are not intended to be used
with the quarter turn tote valve. Replacement
diaphragm should be identical in size and grade as
the original diaphragm.

3.6.1 Remove pressure/fluid from the tote tank
containing the valve. The diaphragm can be replaced
with the valve on the tank or after removing the valve
from the tote tank if desired.

3.6.2 Partially opened the valve by rotating the input
shaft counterclockwise. This will ease the pressure
being exerted by the compressor holding the valve
diaphragm to the body weir.

3.6.3 Remove the bonnet nuts. Lift bonnet assembly
from valve body. If the valve is mounted to the tank
support the bonnet assembly as the nuts are
removed.

3.6.4 Unscrew diaphragm from compressor by turning
counterclockwise. Note: Fine bronze shavings may be
present in the bonnet assembly due to component
wear. Clean out these shavings once diaphragm and
backing cushion are removed.

!! CAUTION

l

Nut assembly torque requirement of 10 ft-lbs
(120 in-lbs, 13.5 N-m) is critical to the success

of the valve’s sealing function. Excessive
torque decreases the valve’s sealing function
and increases the amount of effort required to
actuate the valve. If the proper amount of

torque is applied to the bonnet nuts but the
valve requires excessive torque to actuate
contact manufacturer at the address listed on
back page for specific instructions.

3.6.5 Replace backing cushion and plastic PTFE
diaphragm. Note: To engage the threads of the
diaphragm stud invert the plastic PTFE diaphragm. To
invert the diaphragm, press on the center of the
diaphragm face with thumbs while holding the edge of
the diaphragm with fingers.

3.6.6 Screw new diaphragm into compressor by
turning hand tight. Then back off until holes in
diaphragm and bonnet flange line up.

!! CAUTION

l

Do not overtighten diaphragm.

3.6.7 Assemble the bonnet to the body per Section

1.1.

Only Chevron Poly FM2 (silicone free) lubricant is
permitted on the tote valve's body studs. These are
the only components where lubricant is permitted on
the valve assembly. No lubrication shall be used in
the assembly of the quarter turn bonnet. No
lubrication shall be used on the diaphragm.

DV-1/4 Turn IOM - 11/06 7

3.7 LUBRICATION

3.8 BONNET ASSEMBLY - DISASSEMBLY / ASSEMBLY
PROCEDURE

Bonnet assembly is not intended to be disassembled
nor assembled in the field. Contact manufacturer at
the address listed on the back page for specific
instructions.

4.0 ACCESSORIES

4.1 NO ACCESSORIES ARE AVAILABLE FOR THIS PRODUCT.

8 DV-1/4 Turn IOM - 11/06

Figure 1:

TOTE VALVE ASSEMBLY

Item

1 Body

2 Bonnet Half

3 Bushing, Flanged

4 Bushing, Sleeve

5 Cam

6 Screw, Hex Head,

7 Compressor

8 Cover, Input Shaft

9 Backing Cushion

10 Plastic Diaphragm

11

12 Key

Description Material Quantity

Cap

Input Shaft

Stainless
Steel

Stainless
Steel

Bronze
Bronze
Copper

Infitrated
Steel

Stainless
Steel

Bronze
Stainless

Steel
EPDM
PTFE
Stainless

Steel
Steel

Item Description Material Quantity

1

2

2

1

1

4

1

1

1

1

1

1

13 Lock Plate Stainless

Steel

14 Washer, Spring

Lock
15 Tube Nut Brass 1
16 Nut, Hex Stainless

17 Ring, Retaining Stainless

18 Ring, Retaining Stainless

19 Pin, Roller Stainless

20 Spring Plunger Stainless

21 Stud Stainless

22 Washer, Plain Stainless

Stainless
Steel

Steel

Steel

Steel

Steel

Steel

Steel

Steel

1

4

4

2

1

1

2

4

4

Tote Valve Weight = 20 lbs (9.1 kg)
Bonnet Assembly Weight = 7 lbs (3.2 kg) (less items 1, 9, 10, 16, 21 and 22)

DV-1/4 Turn IOM - 11/06 9

TOTE VALVE DIMENSIONAL DATA

Figure 2:

(Dimensions shown below are in inches)

10 DV-1/4 Turn IOM - 11/06

THIS MANUAL PROVIDES INSTRUCTIONS FOR THE DIA-FLO®

1/4-TURN TOTE VALVE.

IF ADDITIONAL INFORMATION IS REQUIRED,

PLEASE CONTACT:

ITT INDUSTRIAL & BIOPHARM GROUP

33 CENTERVILLE ROAD P.O. BOX 6164

LANCASTER , PA 17603-2064 USA

OR CALL: [phone]

[phone]

FAX: [phone]

WEBSITE: WWW.ENGVALVES.COM

EMAIL: [e-mail]

! WARNING

s

Valves and related products are designed and
manufactured using good workmanship and
materials, and they meet all applicable industry
standards. These valves are manufactured with
various materials, and they should be used only
in services recommended by a company
engineer.

Misapplication of the product may result in
injuries or property damage. A selection of
valve and valve components of the proper
material and consistent with the particular
performance requirement is important for
proper application.

Examples of misapplication or misuse of any
products include use in an application in which
the pressure/temperature rating is exceeded or
failure to maintain valve or related product as
recommended and use of products to handle
caustic and/or hazardous substances when not
designed for that purpose.

If valve exhibits any indication of leakage, do
not operate. Isolate valve and either repair or
replace.

Form DVTQMM

© copyright 2006 Engineered Valves

a subsidiary of ITT Corporation