42000 Series Rotary Eccentric-Plug Valve Instructions

Transcription

1 Instruction Manual April Series Rotary Eccentric-Plug Valve Instructions Contents Introduction... 1 Specifications... 1 Installation... 2 Maintenance... 4 Introduction This instruction manual applies only to the Series control valves with Size 10, 25, or 54R actuators. The is an eccentric rotary plug control valve designed to handle a broad range of industrial and general service applications. Refer to separate instruction manuals for the digital valve Table 1. Specifications End Connections Mates with ANSI Class 150 or 300 1", 1-1/2", 2", 3", 4" and 6" raised-face flanges or DIN DN25, DN40, DN50, DN80, DN100, and DN150 PN10-16 or PN25-40 flanges Process Pressures and Temperatures (1) Consistent with ANSI Class 150 or 300 unless limited by valve material temperature limits Valve Material Temperature Limits (1) WCC Steel Valve Metal Seat 440C SST Bushings (standard): -20 to 750 F (-29 to 400 C) PEEK/PTFE Bushings (optional): -20 to 500 F (-29 to 260 C) Alloy 6 Bushings (optional): -20 to 750 F (-29 to 400 C) PTFE Seat All Bushing options: -20 to 450 F (-29 to 232 C) CF8M (316 Stainless Steel) Valve Metal Seat PEEK/PTFE Bushings (standard): -100 to 500 F (-73 to 260 C) Alloy 6 Bushings (optional) -320 to 750 F (-196 to 400 C) PTFE Seat PEEK/PTFE Bushings (standard): -100 to 450 F (-73 to 232 C) Alloy 6 Bushings (optional) -320 to 450 F (-196 to 232 C) Figure Series Control Valve controller and other accessories. Use this instruction manual only if you are trained or experienced in the use and maintenance of automatic control valves. If you have any questions, contact your nearest sales office before proceeding. Ambient Temperature Limits (1) Actuator: -40 to 150 F (-40 to 66 C) Type 863 and 865 Positioner: -10 to 150 F (-23 to 66 C) Type 3710 and 3720 Positioner: -40 to 180 F (-40 to 80 C) Type 3660 and 3661 Positioner: -40 to 180 F (-40 to 80 C) FIELDVUE Controller: -40 to 180 F (-40 to 82 C) Shutoff Classification (ANSI/FCI and IEC 534-4) Metal Seats: Class IV PTFE Seats: Class VI Positioner Input Signals Type 865-3, (2) (Direct-Acting Only): 3-15 psig ( bar) Type 863-3, (2) (Direct-Acting Only): 4-20 ma dc Type 3710 (Direct or Reverse Acting): 3-15, 3-9, or 9-15 psig ( , or bar) equal % or linear cams Type 3720 (Direct or Reverse Acting): 4-20, 4-12, or ma equal % or linear cams Type 3660 (2) (Direct or Reverse Acting): 3-15, 3-9, or 9-15 psig ( , or bar) equal % Type 3661 (2) (Direct or Reverse Acting): 4-20, 4-12, or ma equal % FIELDVUE Controller: See separate instruction manual Maximum Supply Pressures Refer to Table 7 Flow Direction Flow into seat ring end of valve (flow tends to open) (1) Also, do not exceed any other limit in codes, standards or this publication. (2) Available on 54R actuator only. H.D. BAUMANN, INC. 2000; All Rights Reserved

2 Installation Only personnel qualified through training or experience should install, operate, and maintain this valve body and related equipment. If there are any questions concerning these instructions, contact your Baumann sales office or sales representative before proceeding. Avoid personal injury or property damage resulting from the sudden release of pressure, do not install the valve assembly where service conditions could exceed the limits given on the appropriate nameplates or the mating pipe flange rating. Use pressurerelieving devices as required by government or accepted industry codes and good engineering practices. CAUTION! When ordered, the valve configuration and construction materials were selected to meet particular pressure, pressure drop, temperature and controlled fluid conditions. Since some body/trim material combinations are limited in their pressure drop and temperature range capabilities, do not apply any other conditions to the valve without first contacting the Baumann sales office or sales representative 1. If the valve body is to be stored before installation, protect the flange mating surfaces and keep the body cavity dry and clear of foreign material. 2. Install a three-valve bypass around the control valve assembly if continuous operation will be necessary during inspection and maintenance of the valve body. 3. The series valve body is normally shipped as part of a control valve assembly, with a power actuator mounted on the valve body. If the valve body and actuator have been purchased separately or if the actuator has been removed from the valve body, mount the actuator according to the actuator mounting procedure before installing the valve body. 4. Before starting the actual installation of the valve body, determine the proper installation orientation of the valve plug and actuator. See tables 3 and 4. Note Standard flow direction is into the seat ring end of the valve (flow tends to open). 5. Insert gaskets. Avoid injury from contact with moving parts or from pinching between parts stay clear of valve parts when moving the plug. Use hoists and rigging that are capable of handling the weight of the package. Stay clear in case chains or slings slip. Note For best shutoff performance, installation with the shaft horizontal is recommended. 6. Install the flange gaskets and insert the valve body between the mating pipeline flanges. Use flat sheet gaskets compatible with the process media, or spiral wound gaskets with compression-controlling center rings. 7. For all bodies, install the line bolts and nuts; then, tighten them using accepted bolting procedures. These procedures include, but are not limited to, lubricating the line bolts and hex nuts and tightening the nuts in a crisscross sequence to ensure proper gasket load. A series valve shaft is not necessarily grounded when installed in a pipeline unless the valve shaft is electrically bonded to the valve body.

3 Table 2. Approximate Valve and Actuator Weights APPROXIMATE VALVE WEIGHT APPROXIMATE VALVE SIZE ACTUATOR Class 150 Class 300 PN ACTUATOR WEIGHT SIZE in DN Pounds Kilograms Pounds Kilograms Pounds Kilograms Pounds Kilograms 1 1-1/ R Table 3. Actuator Orientations for Size 10 and 25 Actuators (shown with actuator in front of valve) Mounting Option Air-to-Open (ATO) Fails Closed Flow Direction Actuator In Front Of Pipeline Air-to-Close (ATC) Fails Open 1 Standard Table 4. Actuator Orientations for Size 54R Actuator (shown with actuator in front of valve) Air-to-Open - (ATO) - Fails Closed Air-to-Close - (ATC) - Fails Open Standard Standard

4 Maintenance Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations: Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure from both sides of the valve. Drain the process media from both sides of the valve. Vent the pneumatic actuator loading pressure. Avoid injury from contact with moving parts or from pinching between parts stay clear of valve parts when moving the plug. Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. Maintenance Notes Review these notes and refer to the illustrations before attempting any maintenance. Packing Maintenance Key numbers are referenced in figure 19 unless otherwise indicated. Note Both the standard braided PTFE/Graphite packing and the optional ENVIRO-SEAL packing systems can be used in vacuum service. It is not necessary to reverse the ENVIRO-SEAL PTFE v-rings. Stopping Leakage All maintenance procedures in this section may be performed with the valve body in the line. Leakage around the packing can be stopped by tightening the packing box nuts (figure 2). If packing leakage cannot be stopped in this manner, replace the packing according to the "Replacing Packing" procedure below. If the packing is relatively new and tight on the valve shaft, and if tightening the packing nuts does not stop leakage, it is possible that the valve shaft is worn or nicked so that a seal cannot be made. If the leakage comes from the outside diameter of the packing, it is possible that the leakage is caused by nicks or scratches on the packing box wall. Inspect the shaft and packing box wall for nicks or scratches when performing the following procedures. Replacing Packing Note If the valve has ENVIRO-SEAL live-loaded packing installed, see the Fisher Controls instruction manual entitled ENVIRO-SEAL Packing System for V-Line and edisc Rotary Valves. The actuator must be removed if replacing the packing or if the metal packing parts need to be replaced. 1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body and drain the process media from both sides of the valve. If using a power actuator, also shut off all pressure lines to the power actuator, and release all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. 2. If necessary, remove the actuator as outlined in the actuator sections of this manual. 3. Remove the packing box nuts(18), packing flange(14) and packing follower(13). 4. Remove the old packing rings(12). Do not scratch the valve shaft or packing box wall; scratching these surfaces could cause leakage. Clean all accessible metal parts and surfaces to remove particles that would prevent the packing(12) from sealing. 5. Install the new packing rings(12) being sure to offset the splits in the adjacent packing rings to avoid forming a leak path. Slide the stack into the packing box as far as it will go while being careful to avoid trapping air among the rings. 6. Install the packing follower(13), packing flange(14) and Packing Box Nuts Valve Mounting Bolts Figure 2. Packing Adjustment

5 Braided PTFE/Graphite Split Rings Valve Size 1" - 3" 4" & 6" Kit P/N 42000T T002 Figure 3 Standard Packing System PTFE ENVIRO-SEAL Graphite ENVIRO-SEAL Valve Size 1" - 3" 4" & 6" Valve Size 1" - 3" 4" & 6" Repair Kit P/N RRTYX RRTYX Repair Kit P/N 13B8816X032 13B8816X092 Retrofit Kit P/N RRTYXRT0022 RRTYXRT0052 Retrofit Kit P/N RRTYXRT0322 RRTYXRT0352 * Order ENVIRO-SEAL packing kits through Fisher Controls. Note that the packing flange in the retrofit kits is not used on the series. Figure 4 Optional Packing Systems packing box nuts(18), and tighten them on far enough to stop leakage under normal conditions. 7. Mount the actuator while referring to the actuator mounting procedures this manual. Complete the adjusting actuator travel procedure in this manual before installing the valve in the pipeline. This is necessary due to the measurements that must be made during the actuator adjustment process. 8. When the control valve is being put back into operation, check the packing follower(13) for leakage, and retighten the packing box nuts(18) as necessary. Seat Ring Maintenance Key numbers referenced in figure 19 unless otherwise indicated. This procedure is to be performed if the control valve is not shutting off properly, if the port diameter is to be changed by installing a different seat ring, or if seat ring inspection is necessary. The actuator and valve body must be removed from the pipeline; however, the actuator may remain mounted to the valve during this procedure. A special tool is required to remove the seat ring retainer. A tool can be machined using the dimensions shown in figure 5 and table 5. During disassembly, handle the retainer and seat ring carefully. Critical areas that must be protected are the threads and inner surface of the retainer, the sealing surfaces of the gaskets, and the shutoff surface of the seat ring. A new seat ring gasket is required whenever the seat ring is removed. Other parts in good condition can be reused. Disassembly Before removing the seat ring retainer(2), mark the location of the alignment notch in the seat ring(3) in relation to the alignment notch in the body bore(figure 6). Note Exact alignment of the notches is not required. The notches show approximate alignment only. To remove the seat ring retainer(2), seat ring(3), and gasket(4), use the retainer tool on the retainer to unscrew it. After the seat ring retainer is removed, the seat ring and gasket can be lifted out of the valve body. Lapping Seating Surfaces The seat ring(3) and plug(5) can be lapped to restore shutoff if there is minor wear. Lap outside the body using fine grinding compound. Toggle and turn the plug(5) against the seat ring(3) until complete line contact is restored. Reassembly 1. Clean all parts that are to be replaced. 2. Install the plug(5) before installing the seat ring(3). Insert the seat ring gasket(4) (with mylar surface up) and then the seat ring(3). 3. Apply anti-seize compound to the gasket(4) surface of the seat ring(3). Line up the notch in the seat ring(3) with the mark you made in the body bore(figure 6). The seat ring(3) is now within a few degrees of the correct position. 4. Apply anti-seize compound to retainer threads and to the underside of retainer. Initially tighten the seat ring retainer(2) to compress the gasket(4). 5. Loosen the seat ring retainer(2).

6 6. With the plug(5) gently closed, shine a light into the outlet of the valve. Slowly rotate the seat ring(3) on the plug(5) and watch for light shining between the plug(5) and seat ring(3). When there is no light shining between, the seat ring(3) is aligned. 7. Making sure the seat ring(3) does not move, tighten the seat ring retainer(2) as recommended in table 5. If the seat ring(3) moves, loosen the seat ring retainer(2), reposition the seat ring(3), and re-tighten. Figure 5. Seat Ring and Seat Ring Retainer Wrench Lug Style 1 Lug Style 2 Lug Style 4 Seat Ring Tool Retainer Tool Table 5. Seat Ring and Seat Ring Adaptor Tools (Critical Dimensions are Shown as an Upper and Lower Limit) VALVE SIZE Lug INCHES in DN Style G H A B C D E F Min Sq Seat Ring Tool / / Retainer Tool MILLIMETERS A B C D E F G Min H Sq

7 Table 6. Recommended Torque VALVE SIZE RECOMMENDED SEAT RING RETAINER TORQUE Notches in Body and Seat Ring Show Approximate Alignment Inches mm Lbf Ft N m 1 1-1/ Figure 6. Shown with Plug Opened Approximately 10 Degrees Valve Plug, Shaft, and Bushings Maintenance Key numbers are referenced in figure 19 unless otherwise indicated. Perform this procedure to replace the valve plug, shaft, or bushings. These parts are independently replaceable. Disassembly To avoid personal injury resulting from contact with edges of the valve plug and seat ring during plug rotation, stay clear of the plug edges when rotating the plug. To avoid damage to tools, valve parts, or other items resulting from the valve plug rotation, keep tools and other property away from the edges of the plug. 1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. If using a power actuator, also shut-off all pressure lines to the power actuator, release all pressure from the actuator. Use lockout procedures to be sure that the above measures stay in effect while you work on the equipment. 2. With the valve body out of the pipeline, remove the actuator in accordance to the Actuator Removal instructions. 3. Loosen the packing box nuts(18). If the packing(12) is to be reused, do not remove it. However, it is recommended that the packing(12) be replaced whenever the shaft(7) is removed. 4. Rotate the plug(5) to the fully open position. 5. Remove the packing box nuts(18), lockwashers(19), and packing flange(14) from the packing box studs(17). 6. Remove packing follower(13), packing(12), packing box ring(23), spacer(11) and retainer(10). 7. Remove retention bolt(20); then, slide shaft(7) out of body(1) and remove plug(5) and bushings(8 & 9). 8. Remove seat ring(3) and seat ring retainer(2) as outlined in the Seat Ring Maintenance section of this manual. Assembly 1. Insert bushings(8 & 9) 2. Slide plug(5) into body(1) and insert shaft(7), packing box ring(23), and the two piece stepped retainer(10) into body(1) and plug(5), making sure that the thicker end of the retainer(10) goes in first. Fasten the retention bolt(20) and gasket(21) in place. When placing plug(5) on shaft(7), make sure to orientate the plug(5) with the slot at the end of the shaft(7) so that the slot and the plug(5) are both vertical. 3. Insert packing(12), making sure to alternate splits in rings. 4. Insert packing follower (13) with the o-ring side going into the body(1) first. 5. If the mounting bracket(15) was removed, slide it over the shaft(7). Put LOCTITE onto the valve mounting screws(16) and attach the mounting bracket(15) using the valve mounting screws(16). Slide the packing flange(14) onto the packing box studs(17). Place the lockwashers(19) and the packing box nuts(18) onto the packing box studs(17) and tighten. 6. To ensure proper plug and seat ring alignment, refer to the Seat Ring Maintenance section of this manual.

8 Installing a Rotary Attenuator Disc (2" - 6" Only) Apply anti-seize thread compound on the disc threads. Proper flow is into the sharper edge of the attenuator disc (figure 7). Screw the disc into the outlet of the valve until the disc is flush or slightly recessed into the valve body. The disc should be snug in the body, however, high torque is not required as the disc is further retained between the valve body and downstream piping. To tighten the disc, insert a screwdriver into one of the installation slots and tap on the screwdriver to tighten. Be sure the disc does not extend beyond the mating surface of the flange. Installation Slot Disc Side with Sharper Edges Flow Installation Slot Gasket Mating Flange Figure 7. Optional Rotary Attenuator Disc Actuator Removal, Mounting, Spring Adjustments, and Changing Fail Mode (For Size 10 & 25 Actuators Only) Key numbers are referenced in figure 12 unless otherwise indicated. To make removal and reinstallation of actuator parts easier, attach flexible tubing to the power module(100). Apply air pressure to remove spring force and position the actuator at approximately mid travel. When required, it is recommended that the power module (100) be replaced as a complete unit. If you wish to replace individual power module parts, ask your sales office for separate instructions. Removal (Air Supply Required) 1. Using flexible tubing from an external air supply to the actuator power module, apply slight pressure to the actuator to move the actuator to approximately mid travel. 2. Remove locknut(23), and travel indicator pointer. 3. Remove the socket head cap screws(19) holding the actuator to the mounting bracket(15)(figure 19) on the valve body(1)(figure 19). 4. Slide the actuator off the valve shaft. Mounting 1. Manually rotate the valve shaft(7)(figure 19) and valve plug(5)(figure 19)to approximately mid travel. 2. Using flexible tubing from an external air supply to the actuator power module(100), apply slight pressure to the actuator to move the actuator to approximately mid travel. 3. Slide actuator onto the valve shaft(7)(figure 19). 4. Attach the actuator to the mounting bracket(15)(figure19) by installing the socket head cap screws(19)(figure 19), while holding the actuator to the valve mounting bracket(15) (figure 19). 5. Install the travel indicator pointer, and locknut(23). 6. Torque the locknut(23) to 25 lbf ft (34 N m) for size 10 actuators and 40 lbf ft (54.23 N m) for size 25 actuators.

9 Spring Adjustments and Changing Fail Mode (Applies to Size 10 & 25 Actuators ONLY) Table 7. Setting Actuator Spring Compression AIR-TO-OPEN AIR-TO-CLOSE 1 Loosen locknut(21) and turn adjusting bolt(22) all the way in. Loosen locknut(21) and turn adjusting bolt(22) out until spring preload is relieved. Apply beginning bench range pressure directly to power module Apply ending bench range pressure directly to power module per 2 per chart below. chart below. 3 Back out adjusting bolt(22) until plug just begins to open. Turn in adjusting bolt(22) until plug just touches into seat. SUPPLY SUPPLY ACTUATOR BENCH RANGE SPRING* PRESSURE ACTUATOR BENCH RANGE SPRING* PRESSURE SIZE SIZE Psig Bar Psig Bar Psig Bar Psig Bar L L S S L L S S * "L" refers to the spring that accomodates lower air supplies. "S" refers to the standard spring that accomodates higher air supplies. Table 8. Setting Actuator Fail Safe Mode (Key numbers are referenced in figure 12 unless otherwise indicated) CHANGE ACTION ( AIR-TO-OPEN OR AIR-TO-CLOSE) With or Positioner With 3710 or 3720 Positioner With FIELDVUE Controller CHANGE MOUNTING POSITION (ROTATING THE ACTUATOR ON THE VALVE SHAFT TO ACCOMMODATE PIPING OR OPERATOR ACCESS) 1 Observe Warning and maintenance notes at beginning of Maintenance Section.Take the valve and actuator out of service. 2 Pressure the power module to remove the spring force and to move the actuator to approximately mid stroke. 3 4 Remove locknut (23), nameplate, travel indicator,pointer, and any accessories that are mounted to the shaft. Remove positioner and mounting parts from end of valve shaft. Remove locknut(23), nameplate, and travel indicator pointer. Remove socket head cap screws (19) and remove the entire actuator from the valve mounting bracket. Re-position the actuator end-for-end (do not rotate it around the shaft) Remove locknut (23), nameplate, travel indicator pointer and any accessories that are mounted to theshaft. Remove the alignment screw (18) from the housing. Remove locknut (23), nameplate, travel indicator, pointer, and any accessories that are mounted to the shaft. Disconnect the Fieldvue CAUTION! feedback lever from the Before removing the packing actuator lever(17) by sliding flange, ensure the valve body the spring loaded sleeve on has been removed from service the end of the feedback and all line pressure has been lever back against the spring. released. While doing this, slightly pull Remove the packing flange(14). feedback arm away from Remove the entire actuator and actuator lever to disengage bracket from the valve. Rotate connection. the actuator and bracket to the Unscrew cap screws (20) and desired position (remove and remove the outer housing. rotate packing flange studs as The Fieldvue can remain necessary). attached to the housing. Turn power module end-forend and reassemble. New tubing is required between the Fieldvue and power module. 6 Position the valve plug at approximately mid travel before putting the actuator back on the valve. 7 Recommended torque for the locknut(23) is 25 lbf ft (34 N m) for size 10 actuators and 40 lbf f (54.23 N m) for size 25 actuators. 8 Re-adjust spring compression; as outlined in table 7. 9 Recalibrate positioner according to calibration procedures in this manual

10 Accessories Mounting, Calibration, and Removal (For Size 10 & 25 Actuators Only) I/P or P/P Positioner Key numbers are referenced in figure 9 unless otherwise indicated. Mounting 1. Screw the output/mounting(1) fitting into the mounting plate(2); then, screw the fitting(1) and plate(2) into the power module. 2. Slide the feedback rod(3) into the actuator. Screw the zero adjusting nut(4) into the actuator just enough to engage the threads. 3. Be sure the lock ring(5) is on the feedback rod(3). Screw the positioner onto the zero adjusting nut(4) and attach the mounting plate(2) to the positioner. Calibration 1. Change the zero by first attaching an air supply to the positioner. 2. Loosen the two cap screws(6) that attach the positioner to the mounting plate(2). 3. Rotate the zero adjustment nut(4) on the feedback rod(3) to change the zero. Tighten the cap screws(6) after each adjustment. Repeat as necessary. Span is controlled by the positioner spring and is not adjustable. Removal 1. Remove mounting plate(2); then, unscrew the positioner from the zero adjusting nut(4). 2. Remove locknut from feedback rod(3); then, unscrew the zero adjustment nut(4) from the actuator. 3. Slide the feedback rod out of the actuator P/P or 3720 I/P Positioner Key numbers are referenced in figure 10 unless otherwise indicated. Mounting 1. Attach mounting plate(1) to actuator housing with the flathead screws(3). 2. Mount the coupler(7) onto the slotted end of the valve shaft. 3. Attach positioner to the mounting plate(1) with the socket head cap screws(4) and lockwashers making sure to align the positioner on coupler. Calibration Refer to Fisher instruction manual, form number 5300 for calibration instructions. Removal 1. Remove the socket head cap screws(4); then, remove the positioner from the mounting plate(1). FIELDVUE Controller Key numbers are referenced in figure 11 unless otherwise indicated. Note DO NOT remove linkage from the back of the FIELDVUE unit as it has been pre-calibrated at the factory. Mounting 1. Loosely screw in the mounting screw on the back of the Fieldvue unit that will mate with the slotted hole in the housing. 2. Guide the connecting rod(7) into the actuator housing. Hold the Fieldvue up to the housing and hook the Fieldvue onto the housing using the installed screw and tighten in place with the remaining mounting screws(2). 3. With the actuator locknut and nameplate removed, attach the connecting rod(7) to the standoff(1) on the actuator lever(17)(figure 10) using the spring-loaded latching sleeve. 4. Replace nameplate, travel indicator pointer, and locknut(23). 5. Recommended torque for the actuator locknut is 25 lbf ft (34 N m) for size 10 actuators and 40 lbf ft (54.23 N m) for size 25 actuators. Calibration Refer to Fisher instruction manual, form number 5335 for calibration instructions. Removal The FIELDVUE controller bolts directly to the actuator housing. 1. Remove the tubing from the back of the FIELDVUE and actuator power module. 2. Remove locknut(23), travel indicator pointer, and nameplate. 3. Disconnect the FIELDVUE connecting rod(7) from the actuator locking bar standoff(1) by holding the connecting rod(7) with needle-nose pliers and pulling the connector lock back against the spring force towards the FIELDVUE. Slide the connecting rod(7) off of the locking bar standoff(1). Leave linkage attached to the FIELDVUE. 4. Remove the bottom two and the upper right socket head cap screws(2) and pull off the FIELDVUE unit.

11 Pneumatic Connections Electrical Connections W6886/IL W6886/IL Avoid injury or damage from uncontrolled process. Use only clean, dry, oil-free, noncorrosive gas for supply pressure. Refer to industry standards. Baumann has no technical basis to recommend filtration required for all applications, but a 40-micron filter should suffice for most applications. Avoid injury or damage from fire or explosion of flammable gas or contact with toxic or reactive gas. Provide ventilation to remove harmful gas. Connect supply and input signal to the controller or positioner. For FIELDVUE digital valve controllers and 3710/3720 positioners, also refer to the separate instruction manual. For the positioners, connect input signal to the signal port and supply pressure to the supply port. Avoid injury from discharge of static electricity. Ground the controller in accordance with instructions in the controller instruction manual. Avoid injury from fire or explosion. Confirm that all hazardous area requirements have been met. Consult the controller instruction manual or your sales office. Do not apply power when wiring covers are open. For intrinsically safe installations, refer to drawings and instructions provided by the barrier manufacturer. For FIELDVUE digital valve controllers and 3710/3720 positioners, refer to the separate instruction manuals. For the Type positioner, connect the black wire to the negative (-) terminal and the red wire to the positive (+) terminal. If the valve does not respond as expected, the problem might be incorrect connections to the positioner, switches, or actuator. If the valve does not operate smoothly, the problem might be packing adjustment that is too tight or obstructions to plug movement. M Figure 8. Size 10 Actuator shown with Travel Stop Table 9. Size 10 Actuator with Travel Stop ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Hex Head Cap Screw 18-8 SST Locking lever CF Locking Lever Nut 18-8 SST 42767

12 M42802 Figure 9. Size 25 Actuator shown with positioner Table 10. Size 10 and 25 Actuator with 863-3/865-3 Positioner ITEM QTY DESCRIPTION MATERIAL PART NUMBER Size 10 Size Output / Mounting Fitting 316 SST Mounting Plate 18-8 SST Feedback Rod 316 SST Zero Adjusting Nut 303 SST Lock Ring PH15-7MO Cap Screws 18-8 SST Housing A356-T6 Aluminum Figure 10. Size 10 Actuator shown with 3720 positioner Table 11. Size 10 and 25 Actuator with 3710/3720 Positioner ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Mounting Plate 18-8 SST Spacer 18-8 SST Socket Flat Head Screw 18-8 SST Socket Head Cap Screw 18-8 SST Washer, Split 304 SST Nut 18-8 SST Coupler 18-8 SST 42910

13 M Figure 11. Size 10 Actuator shown with FIELDVUE Digital Valve Controller Table 12. Size 10 and 25 Actuator with FIELDVUE Digital Valve Controller ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Standoff 18-8 SST 42794A 2 3 Socket Head Cap Screw 18-8 SST Fieldvue Cover 302/304 SST Pointer 18-8 SST Pan Head Screw 18-8 SST Connecting Rod Subassembly SAE12 L14 / 18-8 SST Hex Head Cap Screw 18-8 SST Jam Nut 18-8 SST Socket Set Screw 18-8 SST Take-Off Arm 304 SST Gauge

14 M42001 Figure 12. Size 10 and 25 Actuator M Figure 13. Size 25 Actuator shown with Handwheel (Handwheel s/a for size 25 actuator - P/N 42890) M Figure 14. Size 10 Actuator shown with Handwheel (Handwheel s/a for size 10 actuator - P/N T001)

15 Table 13. Part Numbers for size 10 & 25 Actuators FIGURE ITEM QTY DESCRIPTION MATERIAL Inner Housing for use with FIELDVUE Controller Outer Housing for use with FIELDVUE Controller PART NUMBER Size 10 Size SST Ductile Iron SST Ductile Iron Housing for use with or SST Positioner Ductile Iron Key Pin PEEK Spring Standard Pressure Steel Low Pressure Steel Spring Button 304 SST Diaphragm Polyester Shroud Nylon Actuator Linkage Duplex ASTM A890 Gr4A Roller 440C SST Dowel Pin Stainless Steel Bushing Steel/Bronze Locking Bar Stainless Steel Cylinder/Housing Alignment Screw Stainless Steel Socket Head Cap Screw Stainless Steel Socket Head Cap Screw Stainless Steel M-1S 21 1 Hex Nut 304 SST Standard Pressure 304 SST Adjusting Bolt Low Pressure 304 SST Locking Nut Stainless Steel End Cap Vinyl Washer Polymer Handwheel Nut Polymer Blend Size 10 Power Module Size 25 Power Module Size 25 Power Module with Handwheel Standard Spring T001 Low Pressure Spring T002 Standard Spring T003 Low Pressure Spring T004 Standard Spring Consult Factory Low Pressure Spring Consult Factory 1 1 Handwheel Plastic / Steel Roll Pin Zinc Plated Handwheel Stem 316 SST Locking Lever CF Nut 18-8 SST 42767

16 Actuator Removal, Mounting and Changing Fail Mode (For Size 54 Actuator Only) Key numbers are referenced in figure 18 unless otherwise indicated. Removal (Air Supply Required) 1. Using flexible tubing from an external air supply to the actuator, apply slight pressure to the actuator to move the actuator to approximately mid travel. 2. Loosen linkage bolt(37); then, remove locknut(22), and travel indicator pointer(5). Slide the actuator off the valve shaft. Mounting 1. Manually rotate the valve shaft and valve plug to approximately mid travel. 2. Using flexible tubing from an external air supply to the actuator, apply slight pressure to the actuator to move to approximately mid travel. Slide actuator onto the valve shaft. 3. While holding the actuator to the valve mounting bracket, install the socket head cap screws(33) 4. Install the travel indicator pointer(5) and locknut(22). 5. Tighten locknut(22) to pull valve shaft securely into place, tighten linkage bolt(38). Changing Fail Mode 1. After removing the actuator from the valve, move ball bearing assembly to opposite side of bracket. 2. Once the ball bearing assembly is moved, mount the actuator on the opposite side of the ball bearing assembly. Disassembly 1. Disconnect air lines 2. Remove hex head cap screws(8), nuts(10) and upper actuator case(1), making sure to remove the two longer hex head cap screws last. 3. Remove diaphragm assembly; then, loosen and remove head bolt(26) from diaphragm plate(14). 4. Replace diaphragm(13) if needed. Note location of bolt holes and make sure the rolled portion of the diaphragm fits into the lower actuator case(2), but do not disturb springs(30). While holding the actuator stem(28) with a wrench, replace head bolt(26) and tighten. 5. Reassemble upper actuator case(1), making sure to replace the two longer hex head cap screws(8) first. Reassembly 1. Attach actuator stem(28) to diaphragm plate(14) using head bolt(26) and belleville washers(27). 2. Place springs(30) into lower diaphragm case. 3. Place diaphragm plate(14) over springs(30), and rotate diaphragm plate(14) back and forth until all springs are centered on guides (place 4 springs symmetrically). 4. Attach diaphragm(13) to diaphragm plate(14) with head bolt(26). Note: Holes to line up with lower actuator case(2). 5. Place upper actuator case(1) on top of lower actuator case(2) and tighten hex head cap screws(8) evenly, making sure to replace the the two longer hex head cap screws first. Push springs(30) down to allow screws(8) to engage with nuts(10). 6. Screw ball joint(35) into stem(28) until center of ball joint extends 3-7/32 from lower surface of actuator case(2), and lock with nut(18). Note: Ball joint should be perpendicular to valve stem axis. 7.Place pair of linkages(38) and washers(36) onto valve shaft (linkage pin to face towards valve). Insert screws(37) and partially engage nut(20) (linkage to hang loose). Note Orientation: extended side of linkage hubs to face outwards. 8. Apply air pressure to actuator to move to approximately mid travel and slide actuator and linkages(38) onto actuator stem(18). Note valve plug location for reassembly. Actuator stem(18) should be pushed down. 9. Align pointer(5) with name plate(6) in the closed valve plug position, and set lower hex head cap screw(12) (if required) to limit down travel. Adjusting Actuator Stem Length When replacing the actuator on an existing valve, it may be necessary to change the actuator stem length in order to seat the valve plug properly. Proceed as follows with actuator removed from valve. 1. Stroke actuator down, loosen jam nut(18) and turnbuckle(15) with linkages(38) in or out of actuator stem(28) to reach desired angular position of linkage. Note: correct linkage orientation is, pin to face valve. 2. Retighten nut(17), making sure ball joint is perpendicular to valve stem axis. Reassemble and tighten all parts in reverse order.

17 Table 14. Size 54R Actuator for General Utility Applications - Air Supply and Maximum Pressure Drops AIR-TO-OPEN AIR-TO-CLOSE Maximum Shutoff Pressure Maximum Shutoff Pressure ACTUATOR SIZE VALVE SIZE 1" DN25 TRIM CAPACITY BENCH RANGE (1) 3-15 psi ( bar) SIGNAL TO ACTUATOR WITH POSITIONER 20 psig (1.4 bar) AIR SUPPLY PRESSURE BENCH RANGE 3-15 psi ( bar) SIGNAL TO ACTUATOR WITH POSITIONER 20 psig (1.4 bar) AIR SUPPLY PRESSURE Cv Kv PSI BAR PSI BAR PSI BAR PSI BAR PSI BAR PSI BAR /2" DN R 2" DN " DN (1) Nominal bench spring range of 8-16 psi ( psi actual) bar ( bar actual). Note: Do not exceed valve pressure rating

18 Accessories Mounting, Calibration, and Removal (For Size 54 Actuator Only) I/P or P/P Positioner 3660 P/P or 3661 I/P Positioner Key numbers are referenced in figure 15 unless otherwise indicated. Mounting 1. Place back housing slot onto mounting block(2) and attach with washers(4) and cap screws(7). DO NOT TIGHTEN. Note: Be sure take-off pin assembly (36)(20) (21) (22) is resting on angle of take-off plate(7). 2. Use separate air source to stroke valve to mid-position. 3. Slide positioner onto cast mounting block(2) until feedback lever is horizontal. 6. Tighten mounting cap screws (3); then, remove air from actuator. Calibration For or 863-1, refer to Baumann instruction manuals, No IP:IM and No PP:IM for calibration instructions. For 3660 or 3661, refer to Fisher instruction manual, form number 5265 for calibration instructions. Removal 1. Remove mounting bolt(3); then, remove positioner from mounting block(2) P/P or 3720 I/P Positioner Key numbers are referenced in figure 16 unless otherwise indicated. Mounting 1. Attach mounting plate(1) to actuator tube bracket using the socket flat head screws(3), spacers(4), nuts(9), and washers(7). 2. Place the coupler(2) onto the slotted end of the valve shaft; then, Attach positioner to the mounting plate with the socket head cap screws(8), nuts(9)and washers(7) making sure to align the positioner on the coupler. Calibration Refer to Fisher instruction manual, form number 5300 for calibration instructions. Removal 1. Remove the socket head cap screws(8); then, remove the positioner from the mounting plate. FIELDVUE Controller Key numbers are referenced in figure 17 unless otherwise indicated. Note DO NOT remove linkage from the back of the FIELDVUE unit as it has been pre-calibrated at the factory. Mounting 1. Attach mounting plate(5) to the FIELDVUE using bolt(8). 2. Attach coupler(1) to positioner; then, mount the FIELDVUE to actuator tube bracket using the cap screws(3) and nuts(12). Before mounting, slide the two mounting spacers(6) over the four cap screws(3). CRITICAL FOR PROPER OPERATION! 3. Refer to FIELDVUE instruction manual form number 5335(section 6-8) on how to adjust the travel sensor in the FIELDVUE unit Calibration Refer to Fisher instruction manual, form number 5335 for calibration instructions. Removal 1. Remove the four bolts(3) and nuts(12); then, remove FIELDVUE from the actuator tube bracket. Pneumatic Connections Avoid injury or damage from uncontrolled process. Use only clean, dry, oil-free, noncorrosive gas for supply pressure. Refer to industry standards. Baumann has no technical basis to recommend filtration required for all applications, but a 40-micron filter should suffice for most applications. Avoid injury or damage from fire or explosion of flammable gas or contact with toxic or reactive gas. Provide ventilation to remove harmful gas. Connect supply and input signal to the controller or positioner. For FIELDVUE digital valve controllers, also refer to the separate instruction manual. For the positioners, connect input signal to the signal port and supply pressure to the supply port.

19 Electrical Connections Avoid injury from discharge of static electricity. Ground the controller in accordance with instructions in the controller instruction manual. Avoid injury from fire or explosion. Confirm that all hazardous area requirements have been met. Consult the controller instruction manual or your sales office. Do not apply power when wiring covers are open. For intrinsically safe installations, refer to drawings and instructions provided by the barrier manufacturer. For FIELDVUE digital valve controllers and 3710/3720 positioners, refer to the separate instruction manuals. For the Type positioner, connect the black wire to the negative (-) terminal and the red wire to the positive (+) terminal. If the valve does not respond as expected, the problem might be incorrect connections to the positioner, switches, or actuator. If the valve does not operate smoothly, the problem might be packing adjustment that is too tight or obstructions to plug movement. M Figure 15. Size 54 Actuator shown with and 3661 positioner Table 15. Size 54 Actuator with 863-1/865-1 and 3660/3661 Positioners ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Cover Plate 304 SST Mounting Block ASTM A Hex Head Cap Screw 304 SST Lockwasher 18-8 SST Cover Plate 304 SST Positioner Take Off-Plate 304 SST Cover Plate 304 SST Pan Head Screw 18-8 SST Insert Nylon Lock Nut 300 Series SST Hex Nut Stainless Steel Washer 300 Series SST Take-Off Pin 300 Series SST

20 Figure 16. Size 54 Actuator shown with 3720 positioner Table 16. Size 54 Actuator with 3710/3720 Positioner ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Mounting Plate 18-8 SST Coupler 18-8 SST Socket Flat Head Screw 18-8 SST Spacer 18-8 SST Pan Head Screw 18-8 SST Insert Nylon Washer 304 SST Socket Head Cap Screw 18-8 SST Nut 18-8 SST Cover Plate 304 SST Figure 17. Size 54 Actuator shown with FIELDVUE Digital Valve Controller Table 17. Size 54 Actuator with FIELDVUE Digital Valve Controller ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Coupler SST 17B2810X Bolt ASTM A582 S Hex Head Cap Screw 18-8 SST Spacer Steel Mounting Plate 18-8 SST Spacer 18-8 SST Pan Head Screw 18-8 SST Hex Head Cap Screw 18-8 SST Washer 304 SST Cover Plate 304 SST Nut 18-8 SST Insert Nylon

21 Table 18. Size 54 Actuator Figure 18. Size 54 Actuator ITEM QTY DESCRIPTION MATERIAL PART NUMBER 1 1 Upper Actuator Case Carbon Steel Lower Actuator Case Carbon Steel Tube Bracket A500 Grade A Travel Scale ASTM A240 S Pointer 18-8 SST Jam Nut 18-8 SST Hex Head Cap Screw 304 SST Lock Washer 304 SST Nut 304 SST Hex Head Cap Screw 18-8 SST Diaphragm Nitril Rubber / Dacron Diaphragm Plate 1010 Carbon - Zinc Turnbuckle ASTM A582 S Shaft Collar 304 SST Lock Washer 304 SST Jam Nut 304 SST Flangette Stamping Zinc Plated Carbon Steel Nut (Nyloc) Zinc Plated Carbon Steel Ball Bearing Lock Nut (Nyloc) 18-8 SST Hex Head Cap Screw 304 SST Lockwasher 18-8 SST Nut 304 SST Head Bolt 304 SST Bellevue Washer 17-4 PH Actuator Stem 1075 Spring Steel Adapter Coupler ASTM A582 S Spring ASTM A108 G Hex Jam Nut 18-8 SST Washer 18-8 SST Socket Head Cap Screw 304 SST Nut M8 304 SST Ball Joint 4130 Steel Cadmium Plated Washer 18-8 SST Hex Head Cap Screw 18-8 SST Linkage 304 SST

22 Parts Lists Order parts using part numbers in the following lists. ALWAYS mention the serial number of the valve. Section A-A Figure 19. Typical Valve Assembly Table 19. Materials of Construction ITEM QTY DESCRIPTION MATERIAL 1 1 Valve Body WCC steel DIN steel CF8M / 316 stainless steel DIN stainless steel 2 1 Seat Ring Retainer CF8M / 316 stainless steel S31600 stainless steel (standard for all sizes) Seat Ring, Metal Solid Alloy 6 (optional for sizes1" & 1-1/2") Seat 3 1 S31600 stainless steel with CoCr-A (Alloy 6) seating surface (optional for sizes 2"- 6") Seat Ring, PTFE Seat S31600 stainless steel / PTFE insert 4 1 Gasket S31600 stainless steel (standard for sizes 1" & 1-1/2") Graphite (standard for sizes 2"- 6") 5 1 Valve Plug Solid Alloy 6 (standard for sizes 1" & 1-1/2") Chrome-plated CF8M (316 stainless steel) (standard for sizes 2"-6") CF8M / 316 stainless steel with CoCr-A (Alloy 6) overlay (optional for sizes 2"- 6") 6 1 Noise Attenuator Disc CF8M / 316 stainless steel (optional 2"- 6") 7 1 Shaft S31600 stainless steel (condition A) 8 1 Guide Bushing 440C stainless steel (standard for WCC valve body) PEEK/PTFE (standard for 316 stainless steel valve body, optional for WCC valve body) NACE compliant 9 1 Guide Bushing Alloy 6 (optional) NACE compliant 10 2 Shaft Retainer CF8M / 316 stainless steel 11 1 Spacer S31600 stainless steel 12 6 Packing Ring PTFE / graphite split ring 13 1 Packing Follower Assembly S30400 stainless steel, fiberglass/ptfe, fluoroelastomer o-rings 14 1 Packing Flange 18-8 stainless steel 15 1 Bracket CF8 (304 stainless steel) 16 2 Bolt 17 2 Packing Box Stud A193 B8M (stainless steel) 18 2 Hex Nut A194 Grade 8M (stainless steel) 19 2 Lock Washer S30400 stainless steel 20 1 Retention Bolt F738M Class A stainless steel 21 1 Gasket S31600 stainless steel 22 2 Spacer 18-8 stainless steel 23 1 Packing Box Ring S31600 stainless steel

23 Table 20. Part Numbers for Valve Parts VALVE SIZE ITEM QTY DESCRIPTION 1" 1-1/2" 2" 3" 4" 6" 1 1 Valve Body Specify Serial Number 2 1 Seat Ring Retainer Cv Kv P/N Cv Kv P/N Cv Kv P/N Cv Kv P/N Cv Kv P/N Cv Kv P/N 3* 1 Seat 316 SST 316 SST / PTFE Solid Alloy SST / CoCr- A (Alloy 6) * 1 Gasket Solid CoCr-A (1"-1-1/2") * 1 Plug 316 SST/ Chrome Plate SST/CoCr-A (2"-6" Optional) Noise Attenuator Disc Shaft * 1 Guide Bushing 440C Alloy PTFE / PEEK * 1 Guide Bushing 440C Alloy PTFE / PEEK * 2 Shaft Retainer Spacer * 6 Packing Ring * 1 Packing Follower Assembly Packing Flange Bracket Bolt 25836M-2S 25836M-2S 25836M-2S 25836M-2S Packing Box Stud Hex Nut 25705M 25705M 25705M 25705M Lockwasher Retention Bolt Gasket Spacer Packing Box Ring A6085X012 16A6085X012 * Indicates Recommended Spare Parts