Emerson Fisher Baumann 81000 Instruction Manual
Contents
1. 1 Remove the actuator by unscrewing the yoke drive nut key 9 and lifting off the complete actuator assembly This keeps the actuator assembly intact and calibrated to the factory setting Refer to actuator instructions Instruction Manual 81000 Valve D103366X012 May 2012 2 Remove the bolts key 13 and lift the bonnet yoke assembly key 2 with the diaphragm key 5 and O ring key 15 from the valve body key 1 Lift out the spring key 6 3 Remove the O ring key 15 and diaphragm key 5 Wipe with a clean soft cloth and examine for wear 4 Inspect the valve body sealing surfaces Refer to the Lapping the Valve Seat procedure in this instruction manual Lapping the Valve Seat If valve seat leakage becomes excessive it may be necessary to lap the valve seat 1 Use a good quality lapping compound with a mixture that contains 280 to 600 grit Apply at several spots around the plug seating surface refer to figure 5 2 Thoroughly lap the valve body on a flat preferably cast iron surface plate 3 Clean the seats thoroughly after lapping 4 Inspect the diaphragm key 5 and replace if necessary Bonnet Maintenance 1 Remove the actuator by unscrewing the yoke drive nut key 9 and lifting off the complete actuator assembly Hold the flattened portions of the bonnet yoke key 2 in a vise and unscrew the valve bonnet key 8 using a 2 1 4 inch wrench Remove and inspect the bearing cartridge assembly key 4 and O ring key2. 35 mm NPS 1 4 12 7 mm NPS 1 2 BAUMANN WEIGHT a l o BESACE Ene I 81000 Valve Instruction Manual May 2012 D103366X012 Neither Emerson Emerson Process Management nor anv of their affiliated entities assumes responsibilitv for the selection use or maintenance of anv product Responsibilitv for proper selection use and maintenance of anv product remains solelv with the purchaser and end user Baumann Fisher and FIELDVUE are marks owned bv one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes onlv and while everv effort has been made to ensure their accuracv thev are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates eS Singapore 128461 Singapore 2009 2012 Fisher Controls International LLC All rights reserved
3. H T T ea f os j ea j osa E H S K eT Ta om o n2 os om0 oms s500 na enans s03 1 Add the suffix of the letter H to the valve body part number when N10276 Nickel Alloy material is specified 2 Refer to key 5 in table 1 for the appropriate closure diaphragm 81000 Valve Instruction Manual May 2012 D103366X012 Figure 8 81000 Angle Valve with Baumann 16 Figure 10 Baumann 16 Actuator with FIELDVUE Actuator and FIELDVUE DVC6000 Digital Valve DVC6000 Digital Valve Controller Top View Controller inch NOTE BAUMANN 16 ACTUATOR REQUIRES inch 77mm 3 Inches VERTICAL CLEARANCE Figure 9 81000 Inline Valve with Baumann 16 Figure 11 Baumann 16 Actuator with Fisher Actuator and FIELDVUE DVC6000 Digital Valve 3660 3661 and 67CFR Airset Controller 159 3660 3661 Pal POSITIONER 1 2 NPT NOTE BAUMANN 16 ACTUATOR REQUIRES 77mm 3 Inches VERTICAL CLEARANCE inch E1331 E1327 Instruction Manual 81000 Valve D103366X012 Mav 2012 Figure 12 Baumann 16 Actuator with FIELDVUE Figure 13 Baumann 16 Actuator with FIELDVUE DVC2000 Digital Valve Controller DVC2000 Digital Valve Controller Top View 159 6 3 mm inch 166 6 52 ____m 10016 34 inch NOTE BAUMANN 16 ACTUATOR REQUIRES NOTE BAUMANN 16 ACTUATOR REQUIRES E1330 77mm 3 Inches VERTICAL CLEARANCE E1328 77mm 3 Inches VERTICAL CLEARANCE Table 3 Baumann 81000 Valve Weights Table 4 Baumann Actuator Weights 6
4. in the upper diaphragm case For an air to retract actuator air to open action connect the actuating air pressure line to the 1 4 NPT in the lower diaphragm case See figures 2 and 3 2 Use 6 4 mm 1 4 inch O D tubing or equivalent for all air lines If the air line exceeds 8 m 25 ft in length 9 5 mm 3 8 inch tubing is preferred Air pressure should not to exceed 2 5 bar 35 psig Flow Direction There are two possible ways to pass fluid through the valve see figures 6 and 7 In the flow to open mode fluid enters from Port A to Port B In the flow to close mode fluid enters from Port B to Port A Each flow direction has its advantages and disadvantages The following guide will make a selection easier Use Flow From Port B toA e In vacuum applications with spring P N 81168Z vacuum on down stream e With fluids that have a tendency to cavitate e In applications where inlet pressure is low and no seat spring can be tolerated When self cleaning operation is required for removal of solid particles in flow stream Use Flow From Port Ato B When valve has to fail close in case of bursting or damage to the sealing diaphragm Disassembly A WARNING If there is evidence of process fluid under pressure leaking from the joint retighten the valve body joint nuts and return to the Warning at the beginning of the Maintenance section to provide proper steps have been taken to isolate the valve and relieve process pressure
5. of parts Before performing any maintenance operations Do not remove the actuator from the valve while the valve is still pressurized Always wear protective gloves clothing and eyewear when 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 on both sides of the valve Drain the process media from both sides of the valve Depending on the actuator construction it will be necessary to manage the pneumatic actuator spring pre compression It is essential to refer to the relevant actuator instructions in this manual to perform safe removal of the actuator from the valve Use lock out procedures to be sure the above measures stay in effect while you work on the equipment The valve packing box may contain process fluids that are pressurized even when the valve has been removed from the pipeline Process fluids may spray out under pressure when removing the packing hardware or packing rings or when loosening the packing box pipe plug Check with your process or safety engineer for any additional measures that must be taken to protect against process media Note Whenever a gasket seal is disturbed by removing or shifting gasketed parts install a new gasket during
6. qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding a EMERSON www Fisher com Process Management 81000 Valve Instruction Manual May 2012 D103366X012 A WARNING Always wear protective gloves clothing and eyewear when performing any installation operations to avoid personal injury Personal injury or property damage caused by sudden release of pressure or bursting of pressure retaining parts may result if service conditions exceed those for which the product was intended To avoid injury or damage provide a relief valve for over pressure protection as required by government or accepted industry codes and good engineering practices Check with your process or safety engineer for any additional measures that must be taken to protect against process media If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual CAUTION This valve is intended for a specific range of pressures temperatures and other application specifications Applying different pressures and temperatures to the valve could result in parts damage malfun
7. 49 2 Reinsert the parts O ring key 49 and bearing cartridge assembly key 4 ensuring the bearings extend below the side plate of the bearing cartridge assembly key 4 and contact the piston subassembly key 3 With the plunger key 10 removed screw the bonnet key 8 onto the yoke key 2 There should be no binding or galling Tighten the bonnet with a wrench until there is metal to metal contact 3 Insert the plunger key 10 and push it in and out The piston subassembly key 3 should travel easily up and down Calibration 1 Reassemble the valve by inserting the spring key 6 O ring key 15 and diaphragm key 5 into the valve body 2 Replace the bonnet yoke assembly key 2 and install the bolts key 13 and tighten Add the jam nut key 27 and travel indicator disk key 58 to the plunger key 10 Line up the plunger key 10 in the bearing cartridge assembly key 4 Screw the actuator onto the plunger key 10 until the actuator yoke touches the bonnet key 8 Lock the actuator with the drive nut key 9 3 To prevent damage to the plunger key 10 or the bearing cartridge subassembly key 4 be sure the hex jam nut key 27 is not tightened against the travel indicator key 58 CAUTION To prevent damage to the plunger key 10 or bearing cartridge subassembly key 4 be sure the hex jam nut key 27 is not tightened against the travel indicator key 58 Do Not Attempt to Rotate the Plunger key 10 1 For
8. Instruction Manual 81000 Valve D103366X012 May 2012 Baumann 81000 Mikroseal Control Valve Contents Figure 1 Baumann 81000 Control Valve Introduction 0 ee ccc eee eee eee nee 1 Scopeoi Manual ce sie nit aa e ip 1 Satety Pre alitionis eurrera rarae 2 WSS e 2 n TaLe TTT 3 Installation a H 6 4 Z ta ib a bare da 3 PALF IDEN 6 32 ee a oot ote ae ken me ada bnadi ede 4 HOw Direction 67T Re TE Ze ead CU ee ede 4 DISASSEMIDIY sorrir usini an eased des pees 4 Lapping the Valve Seat 0 0 e eee eee 5 Bonnet Maintenance 0 0 eee eee 5 Calibratioai oie dre C aed eee eases 5 Parts OrdeninG on b0i lt dcwhel oat aewaheierkeeoese 6 Dimensions and Weights 000 10 NPS 1 2 Inline Valve with NPS 1 4 Angle Valve Baumann 16 Actuator and with Baumann 16 Actuator FIELDVUE DVC2000 Digital Valve Controller Introduction The Baumann 81000 Mikroseal control valve figure 1 is excellent for throttling of liquid or gaseous media A low friction mechanical force amplifying mechanism is used to reduce the travel of the pneumatic or electric actuators This mechanism moves the closure diaphragm precisely against the valve orifice to throttle or stop the passing fluid Scope of Manual This instruction manual includes installation maintenance and parts information for the Baumann 81000 Mikroseal control valve Do not install operate or maintain Baumann 81000 control valves without being fully trained and
9. an air to retract actuator air to open Apply 6 9 bar 100 psi air pressure or N2 to the normal valve inlet Apply 0 2 bar 3 2 psi air signal to the actuator Use 0 07 bar 1 psi signal to the actuator if the inlet pressure exceeds 6 9 bar 100 psi If the valve leaks slowly turn the actuator stem counterclockwise This will move the plunger key 10 down until leakage is below 1 cc min Lock the plunger key 10 in position with the jam nut key 81000 Valve Instruction Manual May 2012 D103366X012 27 Calibrate the travel scale and check for 12 7 mm 1 2 inch valve travel applv a 1 04 bar 15 psi signal Reverse the signal the plunger should move in the opposite direction with less than 0 014 bar 0 2 psi signal change 2 For an air to extend actuator air to close use the same procedure as in step one except apply 0 88 bar 12 8 psi to the actuator to calibrate the shut off position Parts Ordering When corresponding with your Emerson Process Management sales office about this equipment always mention the valve serial number When ordering replacement parts also specify the key number part name and desired material using the following parts tables A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher valve because they may void your warranty might adversely affect the performance of the valve an
10. ction of the control valve or loss of control of the process Do not expose this product to service conditions or variables other than those for which the product was intended If you are not sure what these conditions are you should contact your Emerson Process Management sales office for more complete specifications Provide the product serial numbers shown on the nameplate and all other pertinent information A WARNING If you move or work on an actuator installed on a valve with loading pressure applied keep your hands and tools away from the stem travel path to avoid personal injury Be especially careful when removing the stem connector to release all loading on the actuator stem whether it be from air pressure on the diaphragm or compression in the actuator springs Likewise take similar care when adjusting or removing any optional travel stop Refer to the relevant actuator Maintenance Instructions If hoisting the valve take care to prevent people from being injured in case the hoist or rigging slips Be sure to use adequate sized hoists and chains or slings to handle the valve A WARNING Personal injury could result from packing leakage Valve packing is tightened before shipment however the packing might require some readjustment to meet specific service conditions Instruction Manual 81000 Valve D103366X012 May 2012 Maintenance Avoid personal injury and property damage from sudden release of process pressure or bursting
11. d could cause personal injury and property damage Instruction Manual 81000 Valve D103366X012 May 2012 Figure 2 Air to Extend Air to Close Action Figure 4 1 8 Port 1 4 NPT OPENING W9916 Figure 3 Air to Retract Air to Open Action Figure 5 Seating Surfaces 1 4 NPT OPENING E1234 W9917 81000 Valve Instruction Manual May 2012 D103366X012 Figure 6 Baumann 81000 NPS 1 4 Angle Valve Bodv Figure 7 Baumann 81000 NPS 1 2 Inline Valve Bodv l FT m ii 58 R OO 8 E 324 O EBD Instruction Manual 81000 Valve D103366X012 May 2012 Table 1 Common Parts ae Part Number Valve Body Refer to table 2 Bonnet Yoke NPS 1 2 81306 Bonnet Yoke NPS 1 4 81302 3 5 Piston Subassembly NPS 1 2 81188 Piston Subassembly NPS 1 4 81170 e Bearing Cartridge Subassembly 81180 2 Closure Diaphragm NPS 1 2 316 Stainless Steel Closure Diaphragm NPS 1 2 N10276 Nickel Alloy Closure Diaphragm NPS 1 4 316 Stainless Steel Closure Diaphragm NPS 1 4 N10276 Nickel Alloy opo T o T C HIH T THT S rr E E pane NPS 1 2 Allen head Bolt 3 8 16x2 5 8 ao NPS 1 4 Allen head Bolt M8x30 ing Prange te O Ring NPS 1 2 Body dali a e T E Table 2 Baumann 81000 Valve Body and Plunger 81000 VALVE BODV 1 PLUNGER PLUG TRAVEL ORIFICE DIAMETER DIAPHRAGM TRAVEL KEY 1 KEY 10 Baumann Baumann 0 009 0 635 0 025 0 1778 0 007 81504 2 81558 2 81193 5 81933 5 0 026 0 063 0 1778 0 007 a 2 81557 2 81193 5 81933 5 B
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13. reassembly This provides a good gasket seal because the used gasket may not seal properly A WARNING Avoid personal injury or property damage by thoroughly cleaning the line of all dirt welding chips scale oil or grease and other foreign material Failure to do so could result in parts damage malfunction of the control valve or loss of control of the process Installation 1 Before installing the valve in the pipeline thoroughly clean the line of all dirt welding chips scale oil or grease and other foreign material A micron size filter is recommended upstream of the valve 2 Install the valve so that the controlled fluid will flow through the valve body in the direction selected from the guidelines shown below 3 Athree valve bypass must be used to permit removal of the control valve from the line without shutting down the system 81000 Valve Instruction Manual May 2012 D103366X012 A A pressure gauge may be installed in the 1 8 inch port in the bolted bonnet see figure 4 This gauge tells when leakage or breakage of the diaphragm has occurred A WARNING To avoid personal injury or property damage do not attempt to do any work on a valve while the system is in operation the valve must be isolated 100 from the active system and the isolated line voided of pressure and or hazardous fluids Air Piping 1 For an air to extend actuator air to close action connect the actuating air pressure line to the 1 4 NPT opening
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