Instruction Manual
D103352X012
Baumann™ Pneumatic Actuators
Contents
Introduction 1...................................
Scope of Manual 1.............................
Design Notes 2...............................
Installation 2
Attaching an Air-to-Retract (ATR)
Actuator to a Valve - Part 1 3.....................
Bench Range Adjustment -
Air-to-Retract (ATR) Actuator 3...................
Attaching an Air-to-Retract (ATR)
Actuator to a Valve - Part 2 4.....................
Attaching an Air-to-Extend (ATE)
Actuator to a Valve - Part 1 4.....................
....................................
Bench Range Adjustment -
Air-to-Extend (ATE) Actuator 5....................
Attaching an Air-to-Extend (ATE)
Actuator to a Valve - Part 2 5.....................
Spring Replacement, Changing Bench Range 6......
Maintenance 6
Field Conversion - ATE to ATR or ATR to ATE 6.......
Removing the Actuator from the Valve 7..........
Disassembling the Actuator 8...................
Reassembling the ATE Actuator 8................
Reassembling the ATR Actuator 9................
Actuator Maintenance 9........................
Handwheel Operation 9.........................
Parts Ordering 24
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Introduction
The Baumann multiple-spring diaphragm actuators are powerful and compact devices designed to operate control
valves, louvers, dampers or mechanical speed adjusting devices. The actuators can provide either direct air-to-extend
action (ATE) or reverse air-to-retract action (ATR). When an ATE actuator is installed on a typical Baumann valve, it
provides an air-to-close (ATC) or fail-open function. When an ATR actuator is installed, it provides an air-to-open (ATO)
or fail-closed function. The design features exceptionally low hysteresis due to the absence of side loads imposed by
misalignment of single coiled springs. The use of multiple springs also offers a substantially lower profile.
The units include zinc-plated, epoxy-coated steel diaphragm cases and an epoxy-coated ductile-iron yoke. Stainless
steel diaphragm cases, actuator stems, and yokes are available for Baumann size 32 and 54 actuators. The Baumann
size 16 actuator comes standard with a stainless steel yoke and epoxy-coated steel diaphragm case. All remaining
metal parts are made of either stainless or zinc plated steel for optimum corrosion resistance.
All actuators are suitable for a standard ambient temperature range of -29 to 71_C (-20 to 160_F); for higher
temperature service, an optional design is available, consult your Emerson sales office
Scope of Manual
This instruction manual includes installation, maintenance, and parts information for Baumann pneumatic actuators.
Do not install, operate, or maintain Baumann actuators 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 sales office before proceeding.
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Baumann Pneumatic Actuators
October 2020
Instruction Manual
D103352X012
Design Notes
The same basic actuator may be configured in several ways. Variations may produce either a 7.9 mm (5/16 inch), 12.7
mm (1/2 inch), or 19.1 mm (3/4 inch) stroke. The spring tables list the nominal bench spring ranges. Each line in the
table lists the high and low limits for the signal air pressure, measured in bar and pounds per square inch (psi). These
signal pressures produce the rated stroke lengths when the actuator is not loaded. The signal air connections use 1/4
NPT fittings, and are located in both the lower (key 43) and upper (key 44) diaphragm cases. Use the lower connection
for an air-to-retract (ATR) actuator and the upper connection for an air-to-extend (ATE) actuator. The signal air
pressure must not exceed 2.4 bar (35 psi). Higher pressures may cause the diaphragm to leak.
Installation
WARNING
Always wear protective gloves, clothing and eyewear when performing any installation operations to avoid personal injury.
To avoid personal injury or property damage resulting from the bursting of pressure retaining parts, be certain the service
conditions do not exceed either the valve body rating or the flange joint rating, or other limits given on the nameplate. Use
pressure‐relieving or pressure‐limiting devices to prevent the service conditions from exceeding these limits.
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 on page 6
in this manual.
CAUTION
Often, these types of actuators are attached to valves which include a stainless steel stem and valve seat. When assembling
or adjusting the actuators, never turn the valve stem when the plug is touching the valve seat. If the two stainless steel
parts rotate while they are touching, they can be damaged very easily.
When adjusting the valve stem (key 5), 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
together. This will allow you to turn the stem by turning the locknuts with a wrench.
WARNING
Personal injury or equipment damage caused by sudden release of pressure or bursting of parts may result if the valve
assembly is installed where service conditions could exceed the limits given in the product literature, the limits on the
appropriate nameplates, or the mating pipe flange rating. Use pressure-relieving devices as required by government or
accepted industry codes and good engineering practices. If you cannot determine the ratings and limits for this product,
contact your Emerson sales office
Personal injury could result from packing leakage. The packing might require some readjustment to meet specific service
conditions.
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.
before proceeding.
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Attaching an Air-to-Retract (ATR) Actuator to a Valve - Part 1
Follow these instructions when assembling the actuator to a valve or other device which provides a positive stop in one
direction.
1. Before starting, identify and locate these parts on the valve assembly, figure 1: stem locknuts (key 27), travel
indicator (key 58), bonnet (key 8), yoke drive nut (key 9), and plug and stem assembly (keys 4 and 5). Refer to the
assembly instructions for the appropriate Baumann control valve.
2. Place the valve body (key 1) in a vise. Clamp the flat end faces of the valve. DO NOT CLAMP THE SIDES OF THE
VALVE. This may distort the shape of the casting, and ruin the valve.
3. Begin to attach the actuator to the valve body, figures 1 and 2 through figure 14, depending on actuator type. The
yoke drive nut (key 9) and travel indicator (key 58) must be removed from the valve body assembly. The hole at the
bottom of the actuator yoke (key 17) should fit over the top of the valve stem (key 5). Tilt the top of the actuator
back at an angle so you can access the top of the valve stem (key 5).
4. Position the drive nut (key 9) over the valve stem (key 5) with the flat side facing up. (The rounded side should face
down, toward the top surface of the yoke.)
5. Thread the two locknuts (key 27) onto the valve stem (key 5). Turn both nuts down as far as possible. Lock nuts
together using two wrenches to counter-tighten them. By turning the locked nuts with a wrench, you can turn the
valve stem without damaging the surface of the stem.
6. Place the travel indicator (key 58) over the valve stem (key 5).
7. If applicable, loosen shaft collar (key 25), figure 6, and turn clockwise until it reaches the bottom of the actuator
stem (key 26).
8. Apply anti-seize compound to the first few threads of the valve stem (key 5). Turn the actuator counterclockwise to
locate the first thread on the stem. Thread stem into the actuator a half turn.
9. Apply 1 bar (15 psi) to the signal air port in the lower diaphragm case (key 43). The bottom of the yoke will drop
down and touch the top of the valve bonnet (key 8).
10. By hand, tighten the drive nut (key 9).
11. Using a wrench on the counter-tightened nuts (key 27), turn the stem (key 5) up until you feel a resistance.
12. Using a hammer and punch, tighten the drive nut (key 9).
13. Next, make the bench range adjustment. See the next section.
Bench Range Adjustment Air-to-Retract (ATR) Actuator
This adjustment sets the valve so that it opens and closes at the correct signal air pressures. On an air-to-retract
actuator, when the pressure reaches the low end of the range, the valve should just begin to open. Once the bench
range has been set correctly, the valve should be completely open when it receives full signal air pressure, and the
valve travel should also be correct. The spring tables list the possible pressure ranges for different valve configurations.
The signal pressure at the low end of the range is dependent on the springs used in the actuator. In order to make this
adjustment, you will need an adjustable source of compressed air ranging from 0 to 1 bar (0 to 15 psi) for Baumann 16
and 32 actuators, 0 to 1.4 bar (0 to 20 psi) for Baumann 54 and 70 actuators with a 1/4 NPT external connector.
1. Connect the air source to the signal air port in the lower diaphragm case (key 43). Begin at 0 bar (0 psi) and
gradually increase the pressure. Notice the pressure at the point when the valve stem (key 5) just begins to move.
a. If the pressure at this point is too low (lower than the recommended bench initials shown in the spring tables),
the actuator and stem assembly should be longer. Turn the valve stem (key 5) out of the actuator stem (key 26)
1/2 turn.
b. If the pressure at this point is too high, the actuator and stem assembly should be shorter. Turn the valve stem
(key 5) into the actuator stem (key 26) 1/2 turn.
2. Adjust the length of the valve stem (key 5) as described above. Always turn the valve stem (key 5) using a wrench on
the two counter-tightened nuts (key 27). Never turn stems while the plug is on the seat.
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3. You may have to repeat steps 1 and 2 several times to get the correct setting.
Instruction Manual
D103352X012
CAUTION
Remember that the valve stem (key 5) cannot be allowed to turn against the valve seat when the two parts are touching.
Before you make any adjustment, apply 1 bar (15 psi) to the actuator. This will lift the valve stem away from the seat, and
help prevent damage.
Attaching an Air-to-Retract (ATR) Actuator to a Valve - Part 2
1. Once the bench range has been adjusted correctly, you can complete the assembly. Apply 1 bar (15 psi) to the
signal port on the actuator.
2. Using two wrenches, unlock the two counter-tightened nuts (key 27). There are flats on the actuator stem (key 26).
Hold these flats with a wrench and, one at a time, turn each nut up as far as possible. Counter-tighten the two nuts
together again.
3. Reduce the air pressure to 0 bar (0 psi). Loosen the screws (key 57) which hold the travel indicator scale (key 56) in
place. Set the scale so the lowest line matches the level of the travel indicator washer.
4. Set the air pressure to the high end of the valve's operating pressure. The travel indicator should move through the
full rated travel of 7.9, 12.7, or 19.1 mm (5/16, 1/2, or 3/4 inch).
Note
The shaft collar (key 25), if applicable, can be set at intermediate positions to provide a minimum opening valve travel stop
following calibration.
Attaching an Air-to-Extend (ATE) Actuator to a Valve - Part 1
Follow these instructions when assembling the actuator to a valve or another device which provides a positive stop in
one direction. (Baumann 70 actuator is ATR only.)
1. Before starting, identify and locate these parts on the valve assembly, figure 1: stem locknuts (key 27), travel
indicator (key 58), bonnet (key 8), yoke drive nut (key 9), and plug and stem assembly (keys 4 and 5). Refer to the
assembly instructions for the appropriate Baumann control valve.
2. Place the valve body (key 1 in a vise. Clamp the flat end faces of the valve. DO NOT CLAMP THE SIDES OF THE VALVE.
This may distort the shape of the casting, and ruin the valve.
3. Begin to attach the actuator to the valve body. The yoke drive nut (key 9) and travel indicator (key 58) must be
removed from the valve body assembly. The hole at the bottom of the actuator yoke (key 17) should fit over the top
of the valve stem (key 5). Tilt the top of the actuator back at an angle so you can access the top of the valve stem
(key 5).
4. Position the drive nut (key 9) over the valve stem (key 5) with the flat side facing up. (The rounded side should face
down, toward the top surface of the yoke.)
5. Thread the two locknuts (key 27) onto the valve stem (key 5). Turn both nuts down as far as possible. Lock nuts
together using two wrenches to counter-tighten them. By turning the locked nuts with a wrench, you can turn the
valve stem without damaging the surface of the stem.
6. Place the travel indicator (key 58) over the valve stem (key 5).
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Instruction Manual
D103352X012
7. If applicable, loosen shaft collar (key 25, figure 6) and turn clockwise until it reaches the bottom of the actuator
stem (key 26).
8. Apply anti-seize compound to the first few threads of the valve stem (key 5). Place the actuator over the top of the
valve bonnet (key 8). The yoke of the actuator will make contact with the top of the bonnet (key 8). Extend the valve
stem (key 5) into the actuator stem (key 26). Turn the stem (key 5) until it comes to a stop, then back off 1/2 turn.
9. By hand, tighten the drive nut (key 9).
10. Using a wrench on the counter-tightened nuts (key 27), turn the stem (key 5) up until you feel a resistance.
11. Using a hammer and punch, tighten the drive nut (key 9).
12. Next, make the bench range adjustment. See the next section.
Baumann Pneumatic Actuators
October 2020
Bench Range Adjustment Air-to-Extend (ATE) Actuator
This adjustment sets the valve so that it opens and closes at the correct signal air pressures. On an air-to-extend
actuator, when the pressure reaches the high end of the range, the valve should be completely closed. Once the bench
range has been set correctly, the valve should be completely open when it receives the low reading for the signal air
pressure, and the valve travel should also be correct. The spring tables list the possible pressure ranges for different
valve configurations. The signal pressure at the high end of the range is dependent on the springs used in the actuator.
In order to make this adjustment, you will need an adjustable source of compressed air ranging from 0 to 1 bar (0 to 15
psi) for Baumann 16 and 32 actuators, or 0 to 1.4 bar (0 to 20 psi) for Baumann 54 and 70 actuators with a 1/4 NPT
external connector.
1. Connect the air source to the signal air port in the upper diaphragm case (key 44). Gradually increase the pressure
toward the high rating listed in the appropriate spring table. Notice the pressure at the point when the valve is fully
seated, and the valve stem (key 5) stops moving.
a. If the pressure at this point is too high, the actuator and stem assembly should be longer. Turn the valve stem
(key 5) out of the actuator stem (key 26) 1/2 turn.
b. If the pressure at this point is too low, the actuator and stem assembly should be shorter. Turn the valve stem
(key 5) into the actuator stem (key 26) 1/2 turn.
2. Adjust the length of the valve stem (key 5) as described in the last step. Always turn the valve stem (key 5) using a
wrench on the two counter-tightened nuts (key 27).
CAUTION
Remember that the valve stem (key 5) cannot be allowed to turn against the valve seat when the two parts are touching.
Before you make any adjustment, be certain that there is no air signal to the actuator.
3. You may have to repeat steps 1 and 2 several times to get the correct setting.
Attaching an Air-to-Extend (ATE) Actuator to a Valve - Part 2
1. Once the bench range has been adjusted correctly, you can complete the assembly. Apply 0 bar (0 psi) to the signal
port on the actuator.
2. Using two wrenches, unlock the two counter-tightened nuts (key 27). There are flats on the actuator stem (key 26).
Hold the flats with a wrench and, one at a time, turn each nut up until you feel a resistance. Counter-tighten the two
nuts together again.
3. Apply 1 bar (15 psi) to the signal port. Loosen the screws (key 57) which hold the travel indicator scale (key 56) in
place. Set the scale so the lowest line matches the level of the travel indicator (key 58).
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4. Apply 0 bar (0 psi). The travel indicator (key 58) should move through the full rated travel of 7.9, 12.7, or 19.1 mm
(5/16, 1/2, or 3/4 inches).
Instruction Manual
D103352X012
Spring Replacement, Changing Bench Range
The springs inside the actuator can be replaced or changed if necessary. This is necessary if you want to change the
bench range - the range of pressures over which the actuator is designed to operate. The spring tables list the possible
spring combinations. To use the tables, identify the stroke and the pressure range for the new valve configuration. This
will tell you the part number and the quantity of the springs needed.
Figures 2 and 3 for Baumann 16 actuators, figures 4 and 5 for Baumann 32 actuators, figures 10 and 11 for Baumann
54 actuators, and figure 14 for Baumann 70 actuators show the correct assembly configurations for air-to-extend and
air-to-retract valves. Notice that both types include the same parts, but they are arranged differently. The following
sections detail the disassembly and assembly instructions.
Maintenance
WARNING
Avoid personal injury and property damage from sudden release of process pressure or bursting of parts. Before performing
any maintenance operations:
D Do not remove the actuator from the valve while the valve is still pressurized.
D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations.
D 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.
D 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.
D Vent the power actuator loading pressure and relieve any spring precompression.
D Use lock‐out procedures to be sure the above measures stay in effect while you work on the equipment.
D 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 when removing the packing hardware or packing rings, or when loosening the
packing box pipe plug.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.
Field Conversion - ATE to ATR or ATR to ATE
Except for the Baumann 70, these actuators can be changed in the field from air-to-extend (ATE) operation to
air-to-retract operation, or from ATR to ATE operation. If you are making this change without changing the bench
range, you can reuse the same parts. The parts are simply assembled in a different way. This is described in more detail
in the following sections. The following sections list the disassembly and reassembly instructions.
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Note
Baumann 70 actuator is available in ATR only.
Field conversion cannot be done on dual-stop actuators.
Baumann Pneumatic Actuators
October 2020
WARNING
To avoid personal injury or property damage due to actuator springs being under compression, remove the long cap screws
last.
The upper actuator casing may remain fixed to the diaphragm and lower casing during disassembly, even if the casing cap
screws have been loosened. If this happens, the actuator springs are still under compression. The upper casing could
suddenly come loose and jump, due to the compressed energy of the springs. If the upper casing is stuck to the diaphragm
and lower casing when you begin loosening the casing cap screws, pry the casings apart with a prying tool. Always be sure
that the springs are dispersing energy and the upper casing is moving against the long bolts during disassembly.
WARNING
To avoid personal injury or property damage by uncontrolled movement of the actuator yoke, loosen the body/yoke nuts or
bonnet/yoke nuts by following the instructions in the next step. Do not remove a stuck actuator by pulling on it with
equipment that can stretch or store energy in any other manner. The sudden release of stored energy can cause
uncontrolled movement of the actuator yoke.
Removing the Actuator from the Valve
1. For an air-to-retract (ATR) actuator: Apply 1 bar (15 psi) for Baumann 16 and 32 actuators, or 1.4 bar (20 psi) for
Baumann 54 and 70 actuators, to the signal air inlet located in the lower diaphragm case (key 43). This will lift the
plug and stem (4/5) away from the valve seat.
For an air-to-extend (ATE) actuator: Disconnect the signal air line connected to the upper diaphragm case (key 43).
This will assure that the actuator is vented and that the valve plug and stem (4/5) are fully lifted away from the valve
seat.
2. For both types: Place a wrench on the flats of the actuator stem. With an additional wrench, engage the upper
locknut (key 27) on the stem and back out the stem about 6.4 mm (1/4 inch). (This procedure will prevent the
actuator stem from turning and causing damage to the diaphragm.)
3. Loosen the yoke drive nut (key 9).
4. Using the wrench to work against one of the counter-tightened nuts, turn the valve stem (key 5) completely down
until the end unthreads from the actuator stem (key 26).
5. Remove the travel indicator (key 58) from the valve stem (key 5). Loosen the locknuts (key 27) and remove them.
Remove the yoke drive nut (key 9).
6. Lift the actuator assembly off of the valve bonnet (key 8).
7. Disconnect airline from ATR actuators.
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Instruction Manual
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Disassembling the Actuator
1. Remove the actuator from the valve as described earlier.
2. Remove the cap screws (key 45) and nuts (key 46). Loosen the nuts from the cap screws gradually and evenly. Some
units may have a combination of longer and shorter screws. After removing the shorter screws, the remaining
longer screws must be loosened evenly. The springs put a lot of force on the diaphragm cases (keys 43 and 44). It is
important to release the spring tension gradually before you try to open them.
3. Remove the upper diaphragm case (key 44) and note the position of the parts inside. For the Baumann 70 actuator,
the upper diaphragm plate (key 40) must also be removed.
4. Except for the Baumann 16 actuator, lift out the actuator stem (key 26) with the diaphragm plate (key 40) and the
diaphragm (key 39). For the Baumann 16 actuator, loosen locknut (key 30) and remove the stem (key 26) through
the bottom.
5. For Baumann 32, 54, and 70 actuators, the lower part of the actuator stem (key 26) has flats. Use these flats to
clamp the lower end of the stem into a vise. Unscrew the nylon insert locknut (key 30). On an ATE unit, remove the
washer (key 112, key 116 for the Baumann 54 actuator), diaphragm (key 39), diaphragm plate (key 40), and for the
Baumann 32 actuator, stop cup (key 79). NOTE: There is not a stop cup for the Baumann 16 actuator. (An ATR unit
has the same parts, but they are attached in a different order.)
6. Replace the diaphragm (key 39) and the O-ring(s) (key 50) if these parts are damaged.
Reassembling the ATE Actuator
1. Use the flats on the actuator stem (key 26) to grip the lower end of the stem in a vise.
2. For the Baumann 32 actuator, place the stop cup (key 79) in position on the upper end of the stem. On an ATE
actuator, the stop cup faces down.
3. Place the diaphragm plate (key 40) on the upper end of the stem (key 26), also facing down.
4. Place the diaphragm (key 39) in position. The curved part of the diaphragm should open downward.
5. Place the washer (key 112, key 116 for the Baumann 54 actuator) over the opening in the diaphragm plate.
6. Thread the nylon insert locknut (key 30) onto the end of the stem (key 26) and tighten it.
7. Turn the assembly upside-down, and grip the nylon insert locknut (key 30) in the vise.
8. Place the springs (key 22) onto the diaphragm plate (key 40). Each spring should be centered on one of the raised
bosses on the plate.
9. Slide the stop collar (key 115) over the free end of the actuator stem (key 26).
10. Check to see that the O-ring (key 50) is in position on the actuator stem (key 26).
11. Apply some light grease to the O-ring (key 50) and to the surface of the actuator stem (key 26).
12. Slide the lower diaphragm case (key 43), with the actuator yoke (key 17) attached, over the actuator stem (key 26).
Make sure that the outer bolt holes of the lower diaphragm case (key 43) line up with the holes in the diaphragm
(key 39). If there is interference with any of the springs, rotate the case into another position.
13. Remove the assembly from the vise. Press on the diaphragm assembly slightly to compress the springs. Flip over
the assembly and reattach the upper diaphragm case (key 44). As you do this, be sure that all of the springs are
upright, and none of them are sitting on the bolt heads. Insert the cap screws (key 45) and tighten the nuts (key 46).
It may be necessary to compress the springs slightly to start the nuts. Tighten the nuts evenly, and cross from one
side of the assembly to the other as you tighten. This will ensure that the spring tension is taken up evenly.
14. Apply air pressure to the actuator and check for friction or leakage. The actuator should travel smoothly through
the entire travel range. Apply leak detection fluid to the area around the guide bushing (key 54). Also check for leaks
around the outer edge of the diaphragm (key 39).
15. Make the adjustments described in the section on Bench Range Adjustment - Air-to-Extend (ATE) Valve.
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