Swagelok DF Series Operating instructions

DF Series Diaphragm Valve
Service Instructions
The valves are shown with
tube butt weld ends. These
instructions also apply to
valves with any other end
connection.
Contents
Tool Requirements
WARNING
Before servicing any installed valve, you must
●depressurize the system
● cycle valve.
WARNING
Residual material may be left in valve and
system.
• Tool Requirements
• Operation
• Installation
• Panel Mounting (Round Handle Valves)
• Welding
• Testing
• Maintenance
• Kit Contents
• Replacing Diaphragms, Upper Assembly, or
Body Assembly
• Handle Replacement
• Round Handle
• Integral Lockout Handle
• Accessories for Pneumatic Valves
• Indicator Switch Kit Contents
• Indicator Switch Installation
Pneumatically
Actuated Valve
Manually Actuated
(Round Handle)
Valve
Manually Actuated
(Integral Lockout
Handle) Valve
Part Tool Size
Bonnet nut Open-end extension
1 5/16 in.
Torque wrench 0 to 600 in.·lb (0 to 67.8 N·m,
0 to 691 cm·kg)
VCR®ttings
Open-end wrench
Male 15/16 in.
Female 1 1/16 in.
"H" Type VCR ttings Male 5/8 in.
Female 3/4 in.
Nut / lock washer
(round handle only)
Nut driver
11/32 in.
Sleeve hex
(Integral lockout handle only)
Open-end extension or hex
socket (deep well) 18 mm
Set screw
(Integral lockout handle only)
Hex wrench
3/32 in.

2
Operation
Manually Actuated (Round Handle) Valve Pneumatically Actuated Valve
Air Inlet: Apply
70 psig (4.9 bar)
to actuate
CAUTION
Do not turn the handle past three-quarters
turn or valve could be damaged.
Manually Actuated (Integral
Lockout Handle) Valve
Turn counterclockwise
three-quarters turn to
open
Turn clockwise
three-quarters turn to
close
To lock in the closed
position, pull up on
handle. Insert padlock
(0.18 in. minimum
shank diameter)
through the hole.
Note: Hole diameter is
0.33 in. (8.3 mm).
Turn counterclockwise
three-quarters turn to
open
Turn clockwise
three-quarters turn to
close
CAUTION
Do not turn the handle past three-quarters
turn or valve could be damaged.
Normally Open
Pneumatic Valve
Normally Closed
Pneumatic Valve

3
To maintain original cleanliness, all valves are
packaged in double bags. Remove outer bag
prior to entering cleanroom. Remove inner bag in
cleanroom.
Installation
Panel Mounting (Round Handle Valve)
1. Close the valve.
2. Pry upward on the cap insert to remove it.
3. Remove the nut/lock washer.
4. Lift upward on the round handle to remove it.
5. Pry upward on the outside edge of the base,
opposite the bonnet tab, and remove.
6. Remove the panel nut.
7. Insert the valve through the panel.
8. Using the flow direction arrow on the valve,
orient the valve to the proper flow direction.
9. Install the panel nut.
10. Position the slot in the base over the bonnet
tab, then press the base onto the bonnet.
11. Slide the round handle onto the valve.
Position the handle to center the C on the
base in the window.
Note: If the C cannot be centered in the
window, offset the C slightly to the right
(toward the word Open).
12. Install the nut/lock washer and tighten to
25 in.·lb (2.8 N·m, 28.8 cm·kg).
13. Press the cap insert into place on the round
handle.
Window
Slot for
bonnet tab
Pry upward on
this edge
Cap insert
Nut/lock washer
Round handle
Base
Panel nut
Bonnet tab
Bonnet nut
Panel
Valve
Flow direction arrow

4
All Valves
1. With the valve in the open position, verify that
flow passes through the valve.
2. With the valve in the closed position, verify
that no flow passes through the valve.
3. Test the diaphragm seal and the seat seal for
leakage by performing an inboard helium leak
test to a rate of 1 10–9 std cm3/s.
4. Test the seat seal for leakage at the
application pressure.
Manually Actuated (Round Handle) Valves
1. Turn the handle to the open position, then
the closed position to test for proper three-
quarters turn operation.
Manually Actuated (Integral
Lockout Handle) Valves
1. Turn the handle to the open, then the closed
position to test for proper three-quarters turn
operation.
2. With the valve in the closed position, pull
up on the handle to test for proper locking
function.
Welding
location
Purge Gas Flow
Welding
location
Purge Gas Flow
Testing
Welding (All Valve Types)
CAUTION
Disassembly of the valve is not required
for inline welding if proper precautions are
taken. If the valve is disassembled, cover
the sealing surfaces to protect them from
nicks and weld spatter.
 WARNING
Welding should be done by qualified
personnel as outlined in Section IX of the
ASME Boiler Code.
1. If necessary, use a heat sink to prevent
excessive heating of internal components.
2. Actuate the valve to the OPEN position.
3. Connect the purge gas supply so that the gas
exits out of the valve port being welded.
CAUTION
Use a high quality purge gas to maintain
cleanliness and reduce welding
discoloration.
4. Perform the weld.
5. With the valve in the open position, purge the
valve and system of contamination.
6. Test the valve for proper operation and
leak-tight integrity. See Testing.

5
Body Assembly
Maintenance
Kit Contents
Diaphragms
Body Kit
Upper Assembly Kit
Pneumatically Actuated
Assembly
Manually Actuated
(Round Handle) Assembly
Diaphragm Kit
Replacing Diaphragms, Upper Assembly
or Body (All Valve Types)
Disassembly
CAUTION
Whenever the valve is disassembled, new
diaphragms must be installed.
1. Remove the valve from system if possible.
2. Place the valve in the open position. Normally
closed valves, apply 70 psig (4.8 bar) minimum
actuator pressure.
3. Loosen the bonnet nut.
4. Remove the upper assembly and both
diaphragms.
Body
Bonnet nut
Diaphragms
Manually
Actuated
Round Handle
Manually
Actuated
Integral Lockout
HandlePneumatically
Actuated
Upper
assembly
Manually Actuated
(Integral Lockout Handle)
Assembly
Pneumatically Actuated
Assembly
Manually Actuated
(Round Handle) Assembly

6
2. Place the upper assembly on the body.
•Pneumatically actuated assemblies: No
alignment is required.
•Manually actuated (round handle)
assemblies: Align the word open in the
handle window over the outlet port on the
body.
•Manually actuated (integral lockout
handle) assemblies: Align the word open
in the handle window over the outlet port
on the body.
Caution
Seal surfaces on the body, seat assembly,
and diaphragms must be clean before
reassembly. Particles can damage the seat
and seal surfaces.
1. Place the two new diaphragms inside the
lip on the body with the convex side of the
diaphragms facing up.
Outlet
port
Maintenance (contd)
Reassembly
3. Hold the upper assembly down firmly against
the body assembly and thread the bonnet nut
onto the body hand-tight.
4. Torque the bonnet nut to 550 in.·lb (62.1 N·m,
633 cm·kg).
5. Test the valve for proper operation and
leak-tight integrity. See Testing.
If a manual valve leaks across the seat, reset
handle. See Resetting the Round Handle or
Resetting the Integral Lockout Handle.
Resetting the Round Handle
1. With the handle in the open position, pry off
the cap insert and remove the
nut/lock washer.
2. Keep the handle splines engaged with the
upper assembly splines and lift the handle
up approximately 1/8 in. to allow the handle
stop to clear the bonnet tab.
3. Turn the handle clockwise until the valve is
fully closed.
4. Test the valve for proper operation and leak-
tight integrity. See Testing. Repeat steps 1
through 3 until valve passes testing.
Handle stop
Bonnet tab
Note: Base removed for clarity
Splines
Body
Lip
Diaphragm
Outlet
port

7
Resetting the Round Handle (contd)
5. Reposition the handle on the valve body,
making sure the C on the base is centered in
the window.
Note: If the C cannot be centered in the
window, offset the C slightly to the right
(toward the word OPEN)
6. Reinstall the nut/lock washer and torque to
25 in.·lb (2.8 N·m, 28.8 cm·kg).
7. Press the cap insert into place on the handle.
8. Reinstall valve in system.
Resetting the Integral Lockout Handle
1. With the handle in the closed position, loosen
the set screw using a hex wrench.
2. Lift up on handle and remove from valve.
3. Turn the sleeve hex counterclockwise one-
half turn.
Window
4. Turn the sleeve hex clockwise to the closed
position and torque to 25 in.·lb (2.8 N·m,
28.8 cm·kg).
5. Align the slot on the inside diameter of the
handle with the tab on the base and place
the handle on the valve.
5. Slide the handle down until the bottom of the
handle is level with the bottom of the base.
6. Tighten the set screw to 10 in.·lb (1.1 N·m,
11 cm·kg).
7. Test the valve for proper operation and leak-
tight integrity. See Testing.
If valve fails any of the testing, repeat steps 1
through 7.
Sleeve hex
Handle
Set screw
Valve
Handle
Set screw
Base
Handle
Slot
Tab
Base
Valve

Caution:
Do not mix or interchange parts with those of
other manufacturers.
CAUTION
Whenever the valve is disassembled, new
diaphragms must be installed.
Disassembly
1. If possible, remove the valve from the system.
2. Actuate the valve to the open position. Apply
70 psig (4.8 bar) minimum actuator pressure.
3. Loosen the bonnet nut.
4. Remove the upper assembly and both
diaphragms.
Reassembly
1. Using the modified actuator assembly,
reassemble the valve. See steps 1 through 4
of Maintenance Reassembly).
2. Thread the indicator switch into the
threaded hole on the cap until the plunger
rests on top of the internal piston.
3. Connect switch leads to a continuity tester.
4. Thread the indicator switch into cap until the
continuity tester indicates that the switch is
actuated.
5. Thread the jam nut against the cap and
tighten.
6. Test the valve for proper operation and
leak-tight intengrity. Test the indicator switch
by actuating the valve open and closed.
7. Install the valve into the system and connect
the switch wire leads.
Indicator Switch Installation
Accessories for Pneumatic Valves (Normally Closed Only)
Pneumatically Actuated Assembly
with Modied Cap Indicator Switch
Threaded hole for
indicator switch
Indicator Switch Kit Contents
Swagelok, VCR — TM Swagelok Company
© 1997, 2005, 2007 Swagelok Company
June 2007, Rev C
MS-CRD-0071
Indicator switch
Jam nut
Cap
Bonnet nut
Threaded hole
Upper assembly
Plunger
www.swagelok.com