Emerson Fisher Baumann 24003 User manual

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Baumann™ 24003 3-Way Control Valve
Contents
Introduction 1...................................
Scope of Manual 1.............................
Safety Precautions 2...........................
Educational Services 3.........................
Maintenance 3.................................
Installation 4..................................
Air Piping 4...................................
Disassembly 4................................
Lapping the Valve Seat 5.......................
Replacing Packing 5...........................
Reassembly 6.................................
Parts Ordering 6................................
Special ENVIRO-SEAL™ Packing Note 8.............
Dimensions and Weights 9.......................
Mixing and Diverting Applications 10..............
Figure 1. Baumann 24003 3-Way Valve
Stainless Steel 3-Way
Valve with Baumann
32 Actuator
Bronze 3-Way Valve with
Baumann 54 Actuator
and FIELDVUEtDVC2000
Digital Valve Controller
W9765
W9764
Introduction
The Baumann 24003 3-way control valve (figure 1) is ideally suited for control of flow and temperature where mixing
or diverting service is required.
Scope of Manual
This instruction manual includes installation, maintenance, and parts information for the Baumann 24003 3-way
control valve.
Do not install, operate, or maintain Baumann 24003 3-way control valves without being fully trained and 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.
Instruction Manual
D103357X012
24003 Valve
January 2014

Instruction Manual
D103357X012
24003 Valve
January 2014
2
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, malfunction 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.
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.
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.

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Educational Services
For information on available courses for the Baumann 24003 valve, as well as a variety of other products, contact:
Emerson Process Management
Educational Services - Registration
P.O. Box 190
Marshalltown, IA 50158-2823
Phone: [phone] or 641-754-3771
FAX: [phone]
e-mail: [e-mail]
Maintenance
WARNING
Avoid personal injury and property damage from sudden release of process pressure or bursting of parts. Before
performing any maintenance operations:
DDo not remove the actuator from the valve while the valve is still pressurized.
DAlways wear protective gloves, clothing, and eyewear when performing any maintenance operations.
DDisconnect 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.
DUse 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.
DDepending 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.
DUse lock-out procedures to be sure the above measures stay in effect while you work on the equipment.
DThe 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.
DCheck 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 reassembly. This provides a
good gasket seal because the used gasket may not seal properly.
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.

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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.
2. Install the valve so the controlled fluid will flow through the valve body in the direction indicated for either mixing or
diverting service (see table 1).
3. Athree-valvebypassmustbeusedtopermitremovalofthecontrolvalvefromthelinewithoutshuttingdownthe
system.
4. In case of a heat-insulated installation, insulate the valve body only, not the bonnet.
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 Port L), connect the actuating air pressure line to the 1/4 NPT opening in
the upper diaphragm case. For an air-to-retract actuator (air-to-open Port L) connect the actuating air pressure line
to the 1/4 NPT in the lower diaphragm case.
2. Use 6.4 mm (1/4 inch) O.D. tubing or equivalent for all air lines. If air line exceeds 8 m (25 ft) in length, 9.5 mm (3/8
inch) tubing is preferred. Air lines must not leak. Air pressure not to exceed 2.5 bar (35 psig).
CAUTION
DWhen assembling or disassembling the valve, do not turn the valve stem while the plug is touching the valve seat. This
can damage the valve's seating surface very quickly.
DWhen adjusting the valve stem, do not grip the stem directly with pliers or a wrench. This will damage the surface of the
stem, and cause damage to the packing in the valve. Instead, counter-tighten the two locknuts (key 27) on the stem
(key 5). This will allow you to turn the stem by turning the locknuts (key 27) with a wrench.
Disassembly
WARNING
When placing the valve in a vise, clamp the flat end faces of the valve. Do not try to clamp the rounded sides of the valve.
This will distort the shape of the casting, and damage the valve internals.
1. Mount the valve in a vise.
2. Remove the actuator, stem locknuts (key 27), travel indicator (key 58), and yoke drive nut (key 8). See the following
instruction manual (Baumann Actuator Instructions, D103352X012).

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3. Unscrew the bonnet (key 3) by turning in a counterclockwise direction from the valve body (key 1). Lift the bonnet
up and off the plug and stem assembly (key 4).
4. Unscrew the lower seat ring retainer (key 5) from the valve body (key 1) and remove the plug and stem assembly
(key 4) (see figure 2). Wipe the parts with a clean soft cloth and examine for signs of wear.
Lapping the Valve Seat
If valve seat leakage becomes excessive, it may be necessary to lap the valve seat.
Lapping is the process of mating the valve plug to the seat ring, with an abrasive to produce a close fit. When valve seat
leakage becomes excessive, lapping becomes necessary. The plug and seat ring seating surfaces should be free of
largescratchesordentsandthecontactsurfaceoftheseatsshouldbeasnarrowaspossible.
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.
2. Replace the plug and stem assembly (key 4) through the bottom of the valve body (key 1) and screw in the lower
seat ring retainer (key 5).
3. Place the bonnet (key 3) loosely into the valve body to serve as a guide during the lapping operation.
4. Rotate the plug and stem assembly (key 4), applying light pressure to the plug/seat mating surface.
5. Lap as little as possible. Excessive lapping will shoulder the seat ring, and will not improve the seating. Repeat for
the second seating surface.
6. Clean the valve seats and plug thoroughly when the lapping is complete.
Replacing Packing
Refer to figure 2 and the standard and optional packing constructions (figures 3, 4, and 5) to determine the packing
that has been preinstalled in your valve.
1. Mount the valve in a vise.
2. Remove actuator, stem locknuts (key 27), travel indicator (key 58), packing follower (key 7), and yoke drive nut (key
8) per actuator instructions D103352X012.
3. Unscrew the bonnet (key 3) by turning in a counterclockwise direction from the valve body (key 1). Lift the bonnet
up and off the plug and stem assembly (key 4). Push the old packing out from the underside of the bonnet (key 3).
4. Standard Spring Loaded PTFE V-Ring Packing (figures 2 and 3): Carefully insert each piece in exact order shown in
figure 3. Turn the packing follower (key 7) until it shoulders on the bonnet (key 3). This will compress the packing
spring (key 9) to enable constant stem sealing throughout packing life.
5. Molded Graphite Ribbon Packing (figure 4): Carefully insert each piece in exact order shown in figure 4. Hand
tighten the packing follower (key 7). Use a wrench to increase tightness by turning the nut an additional 60
degrees.
6. ENVIRO-SEAL Packing (figure 5): Carefully insert each piece in exact order asshowninfigure5.Tightenthepacking
follower (key 7) until the Belleville springs are compressed. This will be signaled by a significant increase in
resistance. Back off the follower 1/8 to 1/4 turn. A gap of approximately 1/16 inch between the packing follower
and the bonnet will ensure packingisseatedproperly.
CAUTION
Overtightening the packing may prevent stem movement and valve operation and result in equipment damage or loss of
control of the process.

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Reassembly
1. Place the plug and stem assembly (key 4) into the valve body (key 1) from the lower port and screw in the lower seat
ring retainer (key 5).
2. Place the bonnet (key 3) over the stem and tighten in place.
3. Insert the packing kit by following steps 4, 5, or 6 of Replacing Packing shown previously.
4. Place the actuator yoke over the stem and bonnet. While tilting the actuator back to allow access to the top of the
stem,placetheyokedrivenut(key8)overthestem.
5. Next, turn one locknut (key 27) onto the stem, turning it down as far as possible. Place the travel indicator (key 58)
over the stem and then turn the second locknut (key 27) down against the travel indicator (key 58). Counter turn
the locknuts to tighten securely.
See the following instruction manual (Baumann Actuator Instructions, D103352X012) for bench range adjustment.
CAUTION
When assembling or disassembling the valve, do not turn the valve stem while the plug is in contact with either seat. This
can damage the seating surface very quickly.
Table 1. Application Port(1)
Service Inlet Outlet
Diverting CUandL
Mixing UandL C
1. C = common port, U = upper port, L = lower port
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.
WARNING
Use only genuine Fisherrreplacement 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, and could cause personal injury and property damage.

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E1281 NPS 1/2 and 1 NPS 1-1/2 and 2
O-RING USED IN
STAINLESS STEEL VALVE
ASSEMBLY ONLY
L
U
C
L
U
C
Figure 2. Baumann 24003 Valve Cross-Sectional Views
Table 2. Baumann 24003 Common Parts(1)
KEY
NO. QTY DESCRIPTION
VALVE SIZE
DN 15 (NPS 1/2) DN 25 (NPS 1) DN 40 (NPS 1-1/2) DN 50 (NPS 2)
Bronze SST Bronze SST Bronze SST Bronze SST
1 1 Valve Body --- --- --- ---
2* 2
Seat Ring, Cv = 1.0 B1790450-01 B1790450-01 --- ---
Seat Ring, Cv = 2.0 B1790450-01 B1790450-01 --- ---
Seat Ring, Cv = 4.0 B1790552-01 B1790552-01 --- ---
Seat Ring, Cv = 10 --- B1790630-01 --- ---
Seat Ring, Cv = 20 --- --- B1790830-01 ---
Seat Ring, Cv = 40 --- --- --- C1790930-01
2B* 2O-Ring --- 04907134 --- 04907134 --- 04907144 --- 04907150
3 1 Bonnet --- --- --- ---
4* 1
Plug & Stem Assy, Cv = 1.0 B3880400 B3880400 --- ---
Plug & Stem Assy, Cv = 2.0 B3880401 B3880401 --- ---
Plug & Stem Assy, Cv = 4.0 B3880500 B3880500 --- ---
Plug & Stem Assy, Cv = 10 --- B3880600 --- ---
Plug & Stem Assy, Cv = 20 --- --- C3880900-02 ---
Plug & Stem Assy, Cv = 40 --- --- --- C3880900-01
5 1 Lower Seat Ring Retainer --- --- --- ---
6* 1Packing Kit See Packing Details on page 8
7 1 Packing Follower 24490-1
8 1 Drive Nut, Actuator Yoke 011757-003-153
27 2Stem Locknut 971514-002-250
58 1Travel Indicator 24299
1. Serial number of valve is required.

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Figure 3. Spring-Loaded PTFE V-Ring Packing Kit
P/N 24494T001
E1240
Table 3. Spring-Loaded PTFE V-Ring Packing Kit
P/N 24494T001
Key No. Description Material
9* Spring ASTM A313 S30200
14 Packing Set PTFE / carbon-filled PTFE
16 Washer ASTM A240 S31600
20 Spacer J-2000 (filled PTFE)
Figure 4. Molded Graphite (Flexible Graphite) Pack
ing Kit P/N 24492T001
E1241
Table 4. Molded Graphite (Flexible Graphite) Packing
Kit P/N 24492T001
Key No. Description Material
13 Bushing, qty 2 Carbon - Graphite
14 Packing Rings,
qty 4 Graphite
Figure 5. ENVIRO-SEAL Packing Kit
P/N 24490T001
E1248
Table 5. ENVIRO-SEAL Packing Kit P/N 24490T001
Key No. Description Material
13 Bushing, qty 2 Carbon Graphite
14 Packing Set PTFE / carbon-filled PTFE
17 Belleville Spring ASTM B637 N07718
18 Bushing PEEK
19 Washer, qty 2 Modified PTFE
Special ENVIRO-SEAL Packing
Note
The ENVIRO-SEAL PTFE packing system is suitable for
100 ppm environmental applications on services up to
51.7 bar (750 psig) and process temperatures ranging
from -46 to 232_C(-50to450_F).
For non-environmental applications, this packing
system offers excellent performance at the same
temperature range up to the maximum valve working
pressure.
Temperature limits apply to packing arrangements
only. Complete valve assembly temperature limits may
differ. Refer to appropriate pressure/ temperature
ratings.
Reference Fisher Packing Selection Guidelines for
Sliding-Stem Valves, bulletin 59.1:062, D101986X012.

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Figure 6. Dimensional Drawings
NOTE: ACTUATOR REMOVAL REQUIRES 115 mm (4.5 INCHES) VERTICAL CLEARANCE.
216
(48.5)
279
(411.0)
333
(413.1)
141
(5.5)
127
(5.0)
276
(10.9)
60
(2.4)
271
(10.7)
229
(9.0)
E1285
229
(9.0)
24003 3-WAY WITH BAUMANN 32 ACTUATOR
AND 3660/3661 POSITIONER
BAUMANN 54 ATO/FAIL
CLOSED ACTUATOR w/
HANDWHEEL
BAUMANN 70 ACTUATOR w/
FIELDVUE DVC6010 DIGITAL
VALVE CONTROLLER
BAUMANN 32 ATC/FAIL
OPEN ACTUATOR WITH
HANDWHEEL
BAUMANN 54 ATC / FAIL
OPEN ACTUATOR WITH
HANDWHEEL
160
(46.3)
163
(6.4)
160 (46.3)
130 (5.1)
MAX 71 (2.8)
MAX
94
(3.7)
279 (411.0)
279 (411.0)
152 (46.0)
BAUMANN 54 ACTUATOR w/
FIELDVUE DVC2000 DIGITAL
VALVE CONTROLLER
BAUMANN 32 ATO/FAIL
CLOSED ACTUATOR
WITH HANDWHEEL
31 (1.24)
152 (46.0)
BAUMANN 32 ACTUATOR
WITH ADJUSTABLE
OPEN/CLOSE DUAL
TRAVEL STOPS
mm
(inch)
A
B
C1
C
L
U
3/4 INCH
SQUARE
Table 6. Valve Dimensions and Weights, NPT Valve Bodies Only
VALVE SIZE VALVE BODY MATERIAL TRAVEL WEIGHT
Bronze, NPT Stainless Steel, NPT
DN NPS A B C1A B C1Inches lbs
15 1/2 4.875 2.75 2.75 4.8125 2.75 2.75 0.56 8
25 14.875 2.75 2.75 5.0 2.75 2.75 0.56 8
40 1-1/2 5.75 3.8125 3.3125 6.125 3.375 3.125 0.75 15
50 26.50 4.0 3.625 6.50 3.75 3.625 0.75 20

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Table 7. Actuator Weights
ACTUATOR TYPE WEIGHTS
kg lb
32 4.5 10
54 11.3 25
70 15.4 34
Table 8. Application Port(1)
Service Inlet Outlet
Diverting CUandL
Mixing UandL C
1. C = Common port, U = Upper port, L = Lower port
Figure 7. Mixing and Diverting Applications
E1286
C
U
L
L
U
C
DIVERTING
VALVE
COOL
WATER TEMPERED
WATER
HEAT EXCHANGER
RETURN
MIXING
VALVE
HEATING WATER