ITT Engineered Valves Advantage 2.1 User manual

Maintenance Manual
Advantage® 2.1 Actuator

Table of Contents
1 Introduction and Safety ....................................................................................................................................2
1.1 Safety message levels .............................................................................................................................. 2
1.2 User health and safety .............................................................................................................................. 2
2 Product Description ..........................................................................................................................................4
2.1 Actuator identification ................................................................................................................................ 4
2.2 Bonnet description..................................................................................................................................... 5
2.3 Valve diaphragm identification...................................................................................................................6
3 Maintenance....................................................................................................................................................... 7
3.1 Precautions ............................................................................................................................................... 7
3.2 Inspection .................................................................................................................................................. 7
3.3 Tighten the bonnet fasteners..................................................................................................................... 7
3.3.1 Fastener torque table for valve body to topworks ...........................................................................8
3.4 Disassemble the valve .............................................................................................................................. 8
3.5 Replace the valve diaphragm....................................................................................................................8
3.6 Adjust the travel (closing) stop ................................................................................................................ 10
3.7 Change the compressor, tube nut, and snap ring ................................................................................... 11
3.8 Replace the spindle o-rings..................................................................................................................... 11
3.9 Lubrication requirements.........................................................................................................................12
3.10 Replace the actuator diaphragm and spring for fail open actuator........................................................ 12
3.11 Replace the actuator diaphragm and spring for fail close actuator ....................................................... 13
3.12 Replace the actuator diaphragm for double acting actuator.................................................................. 14
3.13 Tighten the actuator cover to cover fasteners .......................................................................................15
3.13.1 Fastener torque table for actuator cover to cover .......................................................................15
4 Parts Listing and Cross-Sectional Drawings................................................................................................ 16
4.1 Advantage 2.1 actuator parts .................................................................................................................. 16
5 Certifications ...................................................................................................................................................17
5.1 Declaration of Conformity........................................................................................................................17
5.2 Declaration of Incorporation .................................................................................................................... 19
Table of Contents
Advantage® 2.1 Actuator Maintenance Manual 1

1 Introduction and Safety
1.1 Safety message levels
Definitions
Safety message level Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or
serious injury
WARNING:
A hazardous situation which, if not avoided, could result in death
or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result in minor
or moderate injury
ELECTRICAL
HAZARD:
The possibility of electrical risks if instructions are not followed in a
proper manner
NOTICE:
• A potential situation which, if not avoided, could result in an
undesirable result or state
•A practice not related to personal injury
1.2 User health and safety
General precautions
This product is designed and manufactured using good workmanship and materials, and meets all appli-
cable industry standards. This product should be used only as recommended by ITT.
WARNING:
•Misapplication of the valve can result in injury or property damage. Select valves and
valve components of the proper materials and make sure that they are consistent with
your specific performance requirements. Incorrect application of this product includes but
is not limited to:
• Exceeding the pressure or temperature rating
• Failing to maintain this product according to the recommendations
• Using this product to contain or control media that is incompatible with the materials
of construction
Qualifications and training
The personnel responsible for the assembly, operation, inspection, and maintenance of the valve must
be appropriately qualified. The operating company must do the following tasks:
• Define the responsibilities and competency of all personnel handling this equipment.
• Provide instruction and training.
1 Introduction and Safety
2 Advantage® 2.1 Actuator Maintenance Manual

• Ensure that the contents of the operating instructions have been fully understood by the personnel.
Instruction and training can be carried out by either ITT or the reseller of the valve by order of the operat-
ing company
WARNING:
California Proposition 65 Cancer http://www.P65Warnings.ca.gov. Plastics in product contain
Glass Wool Fibers, known to the State of California to cause cancer. Wash hands after han-
dling.
Non-compliance risks
Failure to comply with all safety precautions can result in the following conditions:
•Death or serious injury due to electrical, mechanical, and chemical influences
• Environmental damage due to the leakage of dangerous materials
• Product damage
• Property damage
• Loss of all claims for damages
Operational safety precautions
Be aware of these safety precautions when operating this product:
• Do not leave hot or cold components of the product unsecured against contact if they are a source
of danger.
• Do not remove the contact guard for moving parts when the product is in operation. Never operate
the product without the contact guard installed.
• Do not hang items from the product. Any accessories must be firmly or permanently attached.
• Do not use the product as a step or hand hold.
• Do not paint over the identification tag, warnings, notices, or other identification marks associated
with the product.
Maintenance safety precautions
Be aware of these safety precautions when performing maintenance on this product:
• You must decontaminate the product if it has been exposed to harmful substances such as caustic
chemicals.
Use of unauthorized parts
Reconstruction or modification of the product is only permissible after consultation with ITT. Genuine
spare parts and accessories authorized by ITT serve to maintain safety. Use of non-genuine ITT parts
can annul liability of the manufacturer for the consequences. ITT parts are not to be used in conjunction
with products not supplied by ITT as this improper use can annul all liability for the consequences.
Unacceptable modes of operation
The operational reliability of this product is only guaranteed when it is used as designated. The operating
limits given on the identification tag and in the data sheet may not be exceeded under any circumstan-
ces. If the identification tag is missing or worn, contact ITT for specific instructions.
1.2 User health and safety
Advantage® 2.1 Actuator Maintenance Manual 3

2 Product Description
2.1 Actuator identification
Design Overview
The actuator is a spring or double acting pneumatic actuator.
To determine if you have an Advantage actuator or an Advantage actuator 2.1 locate the spindle com-
pressor connection and determine if you have a pin connection or modular compressor design.
Figure 1: Pin connection for Advant-
age actuator
Figure 2: Compressor
for Advantage 2.0 ac-
tuator
Figure 3: Modular compressor
with snap ring retention for Ad-
vantage 2.1 actuator
Model number
The actuator model number is located on the ITT identification tag. The model number is a four digit
number defining the actuator as follows.
Table 1: Actuator
Code Description
B Advantage 2.1 actuator
Table 2: Mode of operation
Code Description
1 Fail open (spring to open, air to close) (direct acting)
2 Fail close (spring to close, air to open) (reverse acting)
3 Double acting (air to open, air to close)
Table 3: Actuator series
Code*1 Actuator series*2
03, 04 3
05, 06 5
08, 09 8
16, 17 16
*1 For fail close actuators, codes are specific spring combinations.
*2 Series number equates tp diaphragm effective area.
2 Product Description
4 Advantage® 2.1 Actuator Maintenance Manual

Table 4: Examples
Model number Description
B308 Advantage 2.1 actuator, double acting, series 8
B216 Advantage 2.1 actuator, fail close, series 16 with a spring set
Identification tag
Line Description
1 Valve serial number
2 Valve size and model number
3 Valve diaphragm type
4 Maximum recommended actuation pressure
2.2 Bonnet description
Non-Sealed bonnet
The non-sealed bonnet has a weep hole that indicates a diaphragm failure by allowing process fluid that
accumulates in the bonnet to pass through the hole.
Sealed bonnet
The sealed bonnet uses a special “V-notch” vent plug, which permits leak detection.
Bonnet
weep hole
V-notch vent plug
(Sealed bonnet only)
Figure 4: Weep hole and V-notch vent plug
2.2 Bonnet description
Advantage® 2.1 Actuator Maintenance Manual 5

2.3 Valve diaphragm identification
Diaphragm tab codes
All diaphragm materials and physical properties are batch traceable via permanent codes molded into
the diaphragm tabs. The molding date, grade of diaphragm, and size provide traceability to original batch
records.
1. Date code
2. Supplier code
Figure 5: Elastomer diaphragm front
1. Valve size
2. Grade of diaphragm
Figure 6: Elastomer diaphragm back
1. Material code
2. Date code
Figure 7: PTFE diaphragm
2.3 Valve diaphragm identification
6 Advantage® 2.1 Actuator Maintenance Manual

3 Maintenance
3.1 Precautions
WARNING:
•All procedures must be performed by qualified personnel.
• When the process fluid is hazardous, thermal (hot or cold), or corrosive, take extra pre-
cautions. Employ the appropriate safety devices and be prepared to control a process
media leak.
• Always wear protective clothing and equipment to safeguard the eyes, face, hands, skin,
and lungs from the fluid in the line.
• Do not disassemble the actuator in the field. The actuator contains energized springs
which can cause injury. The product is designed to be recycled in its entirety.
CAUTION:
•Disconnect electrical, pneumatic, and hydraulic power before servicing actuator or auto-
mation components.
3.2 Inspection
Inspection area What to look for Action if problem is found
External valve parts Excessive wear or corrosion • Replace the affected parts
•Contact ITT to obtain replace-
ment parts or for specific in-
structions
Non sealed bonnet Fluid weeping from the plug Replace the valve diaphragm
Sealed bonnet Fluid weeping from the plug
Loosen the v-notch vent plug 2-3
turns to check
Replace the valve diaphragm
Actuator's bonnet weep hole and air
ports
Air pressure Contact ITT for specific instructions
Topworks Spindle binding, excessive noise, or
dried lubricant
Contact ITT for specific instructions
Diaphragm and valve body Leakage between the diaphragm and
valve body
Tighten the bonnet fasteners
For more information, see:
•3.5 Replace the valve diaphragm on page 8
•3.3 Tighten the bonnet fasteners on page 7
3.3 Tighten the bonnet fasteners
CAUTION:
Do not tighten fasteners while the system is pressurized or at elevated temperatures (greater
than 38°C | 100°F).
3 Maintenance
Advantage® 2.1 Actuator Maintenance Manual 7

1. Depressurize the system.
2. Use regulated air pressure to position diaphragm so that valve is slightly open.
You may need to use air pressure to actuate the valve.
3. Tighten the bonnet fasteners in a crisscross pattern.
For more information, see 3.3.1 Fastener torque table for valve body to topworks on page 8.
4. Make multiple crisscross passes to build up torque to the final table value. Make additional criss-
cross passes using final table values to evenly tighten each fastener to within 5% of torque value.
5. Retighten the bonnet fasteners as noted above at ambient conditions after the system has cycled
through operating pressure and temperature.
6. Monitor the valve for leakage:
If leakage ... Then ...
Occurs at the body/bonnet
flange sealing area
Depressurize the system and retighten the bonnet fasteners as noted
above.
Continues Depressurize the system and retighten the bonnet fasteners as noted
above. (maximum 3rd re-torque)
Continues Replace the valve diaphragm.
For more information, see 3.5 Replace the valve diaphragm on page 8.
3.3.1 Fastener torque table for valve body to topworks
Values given are for lubricated fasteners.
Valve size Bolt size PTFE diaphragm Elastomer diaphragm
DN Inch Metric Imperial N-m in-lb N-m in-lb
Bio-Tek
(8, 10, 15)
Bio-Tek
(0.25, 0.375,
0.50)
M4 #6 2.3-2.8 20-25 2.3-2.8 20-25
15 0.50 M6 1/4" 2.8-6.8 25-60 2.3-4.5 20-40
20 0.75 M6 1/4" 5.7-9.1 50-65 2.3-5.7 20-50
25 1.00 M8 5/16" 7.4-11.3 65-90 5.1-7.9 45-70
40 1.50 M10 3/8" 23-25 200-225 8.5-14.7 75-130
50 2.00 M12 7/16" 25-31 225-275 11-20 100-180
3.4 Disassemble the valve
1. Remove all line pressure.
2. If the actuator mode of operation is fail open or fail close, then load the actuator with air.
If the actuator mode of operation is ... Then ...
Fail open Load the actuator with sufficient air to partially close the valve.
Fail close Load the actuator with sufficient air to partially open the valve.
3. Remove the bonnet fasteners.
4. Lift the topworks assembly from the valve body.
5. If the actuator mode of operation is fail open, then remove pressure load from the actuator.
3.5 Replace the valve diaphragm
1. Disassemble the valve.
For more information, see 3.4 Disassemble the valve on page 8.
2. Unscrew the diaphragm from the compressor by turning the diaphragm counterclockwise.
3.4 Disassemble the valve
8 Advantage® 2.1 Actuator Maintenance Manual

The replacement diaphragm should be identical in size and grade to the original diaphragm.
3. If replacing a PTFE diaphragm, then follow these steps.
a) Install the new elastomer backing cushion over the tube nut.
b) Invert the PTFE diaphragm by pressing the center of the diaphragm face with your thumbs
while holding the edge of the diaphragm with your fingers.
c) Engage the threads of the diaphragm into the tube nut by rotating clockwise.
d) Continue rotating the PTFE diaphragm clockwise into the compressor while securing the back-
ing cushion from rotating.
4. Rotate the diaphragm until hard stop or heavy resistance is achieved and additional force does not
significantly rotate the diaphragm into the compressor.
3.5 Replace the valve diaphragm
Advantage® 2.1 Actuator Maintenance Manual 9

5. If replacing a PTFE diaphragm, re-invert the diaphragm.
6. If the actuator mode of operation is fail open or fail close, select one of these steps.
If the actuator
mode of opera-
tion is ...
Then ...
Fail open Reduce the air pressure until the back of the diaphragm is flat against the bonnet.
Fail close 1. Connect the air line to the bonnet’s cylinder.
2. Load the chamber with sufficient air to move the diaphragm upward until
the back of diaphragm is flat against the bonnet. Do not apply excessive
air pressure that results in inversion of the diaphragm.
7.
For more information, see 3.3 Tighten the bonnet fasteners on page 7.
8. If the actuator mode of operation is fail open, then release the air, allowing the valve to open.
3.6 Adjust the travel (closing) stop
The travel stop is designed to prevent overloading of the diaphragm, thus prolonging diaphragm life.
Travel stops are factory set and do not require routine adjustment. However, travel stop adjustment is
recommended when replacing a valve diaphragm.
A travel stop is optional on series 3, 5, 8, and 16 actuators.
1. Release the air pressure in the actuator covers.
2. Loosen the jam nuts and back off one turn.
3. If the actuator is a double acting or fail open actuator, then apply enough pressure in the upper cov-
er to close the valve.
4. For all modes of operation, turn the lower nut clockwise while preventing the adjusting bushing from
rotating until the valve begins to leak.
3.6 Adjust the travel (closing) stop
10 Advantage® 2.1 Actuator Maintenance Manual

5. Turn the lower nut counterclockwise while continuing to prevent the adjusting bushing from rotating
until the valve stops leaking.
6. Tighten the jam nuts together.
3.7 Change the compressor, tube nut, and snap ring
To switch diaphragm types between EPDM and PTFE, the tube nut must be changed. Follow the steps
below before you switch diaphragm types.
1. Insert a screw driver or similar thin blade between compressor and bonnet flange.
Figure 8: Remove the compressor
2. Apply light pressure to back side of compressor finger.
3. Remove compressor and snap ring assembly.
Figure 9: Compressor assembly
4. Replace with new snap ring, tube nut and compressor (only 0.5 and 0.75" sizes). Do not re-use
snap ring.
3.8 Replace the spindle o-rings
1. Disconnect the air lines.
2. Remove any control packages.
3. Disassemble the valve.
For more information, see Disassemble the valve in this manual.
4. Disassemble the actuator.
3.7 Change the compressor, tube nut, and snap ring
Advantage® 2.1 Actuator Maintenance Manual 11

For more information, see Replace the actuator diaphragm and spring for proper mode of operation
(fail open, fail close, or double acting) in this manual.
5. Withdraw the valve diaphragm, compressor, and spindle assembly from the bonnet.
6. Replace the o-rings and lubricate the new o-rings.
For more information, see Lubrication requirements in this manual.
7. Replace the valve diaphragm, compressor, and spindle assembly on the bonnet. Care must be
used on the Bio-Tek to align the compressor T-slot with molded tabs in lower cover.
8. Reassemble the actuator.
For more information, see Replace the actuator diaphragm and spring for proper mode of operation
(fail open, fail close, or double acting) in this manual.
9. Reassemble the valve.
10. Reconnect the air lines.
11. If the actuator mode of operation is fail open or double acting, then follow the steps below:
a) Examine the actuator upper cover for leakage past the indicating spindle o-ring seal.
b) If leakage is present, then replace the spindle o-rings.
3.9 Lubrication requirements
Lubrication schedule
Remove residual grease prior to re-lubrication. Lubricate the spindle, o-rings, and mating surfaces when-
ever the topworks is disassembled.
Acceptable lubricants
Brand Lubricant type
Chevron FM ALC EP 2 (FDA Compliant)
Fuchs Cassida FM CSC EP2 (FDA Compliant)
3.10 Replace the actuator diaphragm and spring for fail open
actuator
One fixture exists for the series 3, 5, and 8 actuators and one for the series 16 actuator.
CAUTION:
Actuator plates are under load. Series 3, 5, 8, and 16 fail open actuators contain powerful
springs and should not be disassembled unless using ITT approved fixturing and fixturing
methods.
1. If present, remove the switch package.
2. Disconnect the air lines.
3. ITT recommends that the following steps be performed on a bench with the body removed from the
actuator:
a) Disassemble the valve.
For more information, see Disassemble the valve in this manual.
b) Unscrew the diaphragm from the compressor by turning it counterclockwise.
4. Remove the actuator fasteners and lift off the top cover.
5. Disassemble the actuator with a fixture:
a) Place the actuator in a fixture.
b) Loosen the indicator spindle two turns.
3.9 Lubrication requirements
12 Advantage® 2.1 Actuator Maintenance Manual

c) Place the actuator centrally in the fixture, locating the compressor over the correct spacer, de-
pendent on valve size, in the fixture lower plate.
d) Place the support plate and spacer plate on the actuator top plate.
e) Turn the fixture handwheel clockwise to remove the load from the indicator spindle.
f) Remove the spindle and turn the fixture handwheel counterclockwise until the spring load is re-
lieved.
Use care, as the spindle thread may pinch the actuator diaphragm and restrict spring extension.
6. Replace the actuator diaphragm and spring:
a) Place the spring in the lower cover and set an actuator plate, concave side down, over the
valve spindle.
b) Position the actuator in the fixture over the spacer.
c) Place the support plate on the actuator plate.
d) Set the spacer plate on top.
e) Turn the fixture handwheel clockwise and compress the spring until the actuator plate should-
ers on the spindle.
Use care to ensure the spindle goes through the actuator plate center hole.
f) Slide the actuator diaphragm over the valve spindle using care to ensure the top hat is in the
upper cover.
g) Position the actuator diaphragm so the bolt clearance holes line up with threaded inserts in low-
er cover.
7. Reassemble the actuator with a fixture:
a) Place an actuator plate, concave side up, over the valve spindle.
b) Prepare spindle nut surface with Loctite 7649 Primer N.
c) Apply Blue Loctite #242 and thread the indicating spindle on the valve spindle by hand.
d) Turn the fixture handwheel counterclockwise to remove the load and remove the actuator from
the fixture.
e) Clamp the slotted plate in a vise and pull so the actuator slips free.
f) Tighten the indicator spindle with a wrench using care to ensure the actuator diaphragm re-
mains properly aligned.
g) Position the upper actuator cover so the 1/8" NPT inlets in the upper and lower covers are in
line.
h) Tighten the actuator cover to cover fasteners.
For more information, see Tighten the actuator cover to cover fasteners in this manual.
3.11 Replace the actuator diaphragm and spring for fail close
actuator
One fixture exists for the series 3, 5, and 8 actuators and one for the series 16 actuator.
1. If present, remove the switch package.
2. Disconnect the air lines.
3. ITT recommends that the following steps be performed on a bench, with the body removed from the
actuator:
a) Disassemble the valve.
For more information, see Disassemble the valve in this manual.
3.11 Replace the actuator diaphragm and spring for fail close actuator
Advantage® 2.1 Actuator Maintenance Manual 13

b) Unscrew the diaphragm from the compressor by turning it counterclockwise.
4. Apply air to the lower cover to simplify disassembly from the body, then release the air.
5. Remove the valve diaphragm and plastic indicator spindle plug (found on the spindles) by turning
them counterclockwise.
6. Disassemble the actuator with a fixture:
a) Position the actuator centrally in a fixture, locating the compressor over the correct spacer in
the fixture lower plate.
b) Drop the stem guide through the center of the fixture handwheel and position it in the actuator
indicator spindle #10-24 UNC tapped hole (former plug location).
c) Turn the fixture handwheel clockwise until the stem rests on the actuator top cover.
d) Remove all the cover to cover caps, fasteners, and washers.
e) Turn the fixture handwheel counterclockwise until the spring load is relieved.
f) Remove the actuator upper cover, lift out spring(s), and unthread the indicator spindle.
g) Remove the top actuator plate and actuator diaphragm.
7. Replace the actuator diaphragm and spring:
a) Install the new actuator diaphragm (top hat up).
Be sure the diaphragm is positioned so the diaphragm bolt holes line up with the actuator cover bolt
holes with no stretching of the diaphragm.
b) If the spring needs to be replaced, then install a new spring.
c) If the spring does not need to be replaced, then install an old spring.
8. Reassemble the actuator with a fixture:
a) Place the correct spacer, dependent on valve size, over the pin in the fixture lower plate.
b) Position the actuator sub-assembly, including spring(s) and upper cover, over the spacer (the
compressor rests on the spacer).
c) Drop the stem guide through center of the fixture handwheel, actuator upper cover, and locate
it in the actuator indicator.
d) Position the actuator upper cover so the 1/8" NPT inlets in the upper and lower covers are in
line and the rod guides slide through the clearance holes.
e) Turn the handwheel clockwise to compress the spring(s) until the covers almost touch.
f) Remove the four threaded rod guides.
g) Start tightening the actuator cover fasteners and continue to compress the spring(s) until the
covers touch.
h) Place the remaining washers and fasteners in the top cover.
i) Tighten the actuator cover to cover fasteners.
For more information, see Tighten the actuator cover to cover fasteners in this manual.
3.12 Replace the actuator diaphragm for double acting actuator
1. If present, remove the switch package
2. Disconnect the air lines.
3. ITT recommends that the following steps be performed on a bench with the body removed from the
actuator:
a) Disassemble the valve.
For more information, see Disassemble the valve in this manual.
4. Remove the actuator fasteners and lift off the upper cover.
3.12 Replace the actuator diaphragm for double acting actuator
14 Advantage® 2.1 Actuator Maintenance Manual

5. Remove the actuator top plate and actuator diaphragm.
6. Remove the indicating spindle
7. Install the new actuator diaphragm (top hat up).
Be sure the actuator diaphragm is positioned so the diaphragm bolt holes line up with the cover bolt
holes with no stretching of the diaphragm.
8. Replace the actuator top plate and actuator diaphragm:
a) Prepare the spindle nut surface with Loctite 7649 Primer N.
b) Apply Blue Loctite #242 to the indicating spindle.
c) Replace the indicating spindle.
9. Assemble the upper cover using care to keep the air fitting in line with the lower cover air fitting.
10. Tighten the actuator cover to cover fasteners.
For more information, see Tighten the actuator cover to cover fasteners in this manual.
3.13 Tighten the actuator cover to cover fasteners
Tighten the bonnet fasteners in a crisscross pattern with proper torque.
1. Tighten the bonnet fasteners in a crisscross pattern in accordance with Fastener torque table for
actuator cover to cover.
2. Make multiple crisscross passes to build up torque to final table values.
3.13.1 Fastener torque table for actuator cover to cover
Actuator series Bolt size Torque
Imperial in-lb N-m
Series 3, 5, 8 #10 20 2.3
Series 16 1/4" 35 4.0
Values given are for lubricated fasteners.
Torques should be applied at near ambient conditions (less than 38ºC | 100ºF).
3.13 Tighten the actuator cover to cover fasteners
Advantage® 2.1 Actuator Maintenance Manual 15

4 Parts Listing and Cross-Sectional
Drawings
4.1 Advantage 2.1 actuator parts
List of parts
Figure 10: Fail closed actuator with compressor detail
Item Description
1 Tube Nut
2 Snap Ring
3 Backing Cushion
4 PTFE Diaphragm
5 Compressor
4 Parts Listing and Cross-Sectional Drawings
16 Advantage® 2.1 Actuator Maintenance Manual

5 Certifications
5.1 Declaration of Conformity
5 Certifications
Advantage® 2.1 Actuator Maintenance Manual 17

5.1 Declaration of Conformity
18 Advantage® 2.1 Actuator Maintenance Manual