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Series 98 Pneumatic Scotch Yoke Actuator Operation and

1. DESCRIPTION MATERIAL DESCRIPTION MATERIAL 1 Yoke Housing Ductile Iron 1 27 Bushing Yoke Pin PTFE Bronze 2 2 Guide Rod Alloy Steel 1 28 Cap Screw Flat Head Hex Socket Stee 8 3 Housing Cover Ductile Iron 1 29 Position Indicator Plastic 1 4 Bushing Yoke PTFE Bronze 2 30 Cap Screw Flat Head Hex Socket Stee 1 5 O Ring Yoke Buna N 2 31 Adaptor Pressure Module Ductile Iron 1 6 O Ring Cover Buna N 1 32 Barrel Carbon Steel 1 7 Top Cover Ductile Iron 1 33 Piston Ductile Iron 1 8 O Ring Top Cover Buna N 1 34 End Cap Pressure Module Ductile Iron 1 9 Flanged Bushing PTFE Bronze 1 35 Piston Rod Alloy Steel 1 10 O Ring Accessory Drive Buna N 1 36 Bushing Adaptor PTFE Bronze 1 11 Accessory Drive Stainless Steel 1 37 Seal U Cup Buna N 1 12 Hex Bolt Stee 8 38 Split Collar Alloy Steel 4 13 Spring Washer Spring Steel 8 39 Tie Rod Steel 4 14 Set Screw Socket Head Stee 2 40 Locknut Nylok Steel 4 15 Dowel Pin Hardened Steel 4 41 O Ring Piston Rod Buna N 1 16 Socket Head Caps Screw Stee 4 42 Wear Ring PTFE 2 17 Socket Head Caps Screw Low Head Stee 1 43 Quad Seal Buna N 1 18 Seal Nut Stee 2 44 O Ring Barrel Buna N 2 19 Stop Bolt Stee 2 45 Retainer Ring Stainless Steel 1 20 Bre
2. Actuator part number and fail direction needs to be suitably changed on the name plate after completing any configuration change Refer to Technical Manual or contact factory for information 7 2 Double Acting to Spring Return 1 To convert the DA actuator to Spring Return SC or SO a Spring Module will need to be mounted opposite the Pressure Module with a Module Mounting Kit 2 If the Pressure Module needs to be shifted for the required configuration of the Spring Return actuator then first remove the Pressure Module from the actuator Follow the procedure in Section 6 4 to remove the Pressure Module and Section 6 6 for Reassembly of Actuator Skip this step if shifting the Pressure Module is not required 3 Remove the DA End Cover 52 refer to Drawing ES 00020 DA Assembly 4 Tighten the Studs from Module Mounting Kit into the Spring Module Adaptor applying thread lock compound on the threads Install the module O ring in adaptor groove 5 Follow steps in Section 6 6 for Reassembly of the Actuator 6 Set the travel Stop Bolts on the Torque Module as required for proper valve seating 7 Remove the air connection from the End Cap port of the Pressure Module and replace the connector with a breather filter 8 The Spring Return Actuator requires air connection only on the Adaptor port 7 3 Spring Return to Double Acting 1 Remove Spring Module from actuator refer to Section 6 3 2 Fit DA End
3. LE Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 3 Free the Extension Rod from the Jackscrew assembly apply a drop of medium strength thread lock compound on the extension rod threads and firmly tighten it into the threading in the Guide Block inside the Torque Module Refer to the piston rod tightening torque table under Section 15 2 N 4 Coat the extension rod with NLGI2 grease 5 Lubricate and place the flange O ring into the groove on the jackscrew assembly flange 6 Back off the jackscrew fully in the assembly and carefully slide the mounting flange of the jackscrew assembly on the extension rod Take care in locating the bushing and the flange seal on the extension rod All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r 2 Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 7 Slide the assembly to locate and mate the flanges Use the hardware supplied in the kit to fasten the assembly to the Torque Module flange 8 Install suitable size 3 2 manual valves on the pneumatic cylinder s ports which will either connect the ports to the air supply or vent them
4. e The actuator shall not be installed in hazardous areas incompatible with the defined gas groups and temperature class e When using manual override sandwich gearbox ensure the gearbox has over travel at least equal to that of the actuator The actuators can be mounted on valves in different positions but care shall be taken to reorient suitably some accessories like filter regulation units hydraulic override power pack reservoirs etc that are gravity dependent for functioning Before proceeding with installation check compatibility of the valve stem to the actuator bore The length size and configurations keyways double D square must match Additionally check compatibility of valve and actuator bolting pattern If using a mounting kit physically check the coupler to ensure it fits the actuator bore and the valve stem 1 Ensure the pressure module is depressurized completely by venting the ports to atmosphere and any power sources to accessories are disconnected 2 Ensure the valve and actuator are aligned to the same position i e valve closed actuator closed or both in open For spring return actuators align the valve to the fail safe position of the actuator If a sandwich gearbox manual override is used then make sure it is also aligned with the valve and actuator position All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of
5. indicates a potentially hazardous situation which if not avoided may result in minor or used without the safety alert symbol indicates a potential situation which if not avoided may result in an undesirable result or state including property damage 1 2 Qualified Personnel A qualified person in terms of this document is one who is familiar with the installation commissioning and operation of the product and who has appropriate qualifications such as Is trained in the operation and maintenance of pneumatic pressure equipment and systems in accordance with established safety practices Is trained or authorized to energize de energize ground tag and lock electrical circuits and equipment in accordance with established safety practices Is trained in the proper use and care of personal protective equipment PPE in accordance with established safety practices Is trained in first aid In cases where the device is installed in a potentially explosive hazardous location is trained in the operation commissioning and maintenance of equipment in hazardous locations All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 3 detailed knowledge and experience with their application r 2 0 INTRODUC
6. 4 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r 3 Secure the valve bolt the mounting bracket to the valve and fit the coupler shaft on the valve stem when using mounting kit Ensure the actuator s bore and seating face are clean and coat the valve stem adaptor with a suitable oil grease Position the actuator to align the valve stem or coupler shaft with the yoke bore and slide the actuator on until the actuator seats on the bracket mounting surface or on the valve top flange in case of direct mounting 4 When using a manual override sandwich gearbox between the actuator and valve first couple and fix the gearbox on the valve following the gearbox installation procedure Back off the gearbox travel stop bolts Mount the actuator on the gearbox with the coupler shaft and bolt up the actuator on the gearbox flange 5 In order to align the bolt holes it may be necessary to loosen the valve bracket bolting slightly The actuator mounting bolts should easily thread into the actuator base without side loading on the bracket or the valve top flange If needed turn the actuator a bit and or adjust the actuator travel stops Bolt up the actuator to the bracket gearbox flange valve as the case may be 6 Before operating the actuator disengage the manual overrid
7. Bray Series 98 Pneumatic Scotch Yoke Actuator Operation and Maintenance Manual Your Global Flow Control Partner Ey CE Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual TABLE OF CONTENTS LO Detinition Ot TEMS iaa a ee ee ee A A we A RO OS wR Ow OEE ii 3 1 1 Hazard free Use 3 1 2 Qualified Personnel 2 2 a a a a a a L 3 ZOINMIAUICION y ea Oe oe AAA AAA 4 ANISTON lt mesias sonar ae eH A RAR AAA RARAS 4 4 0 Operation Guidelines lt lt 2 5 625 228 ee 56465 O28 45 ori A A 5 5 0 Spring Return Pneumatic Actuator Assembly Drawing and Materials of Construction 6 6 0 Maintenance 2 4 4 4 6 6 044 4 64 444664404444 56h404 4446844655464 44 405 8 6 1 Lubricants and Maintenance Consumables o o 8 6 2 Disassembly Service amp Reassembly of Modules 2 a o 8 Sapa Moddle 22 20 Gee ee eee eee ee ee oe e ee Chee A 8 6 3 1 Removing the Spring Mod le s s eos eor Lorea ESE E SSG EPP eGR SS 8 6 3 2 Service 8 Reassembly of the Spring Module 2 o 0 o 9 6 4 Pressure Module 2 0 cc hd pba ee aa A AAA 9 6 4 1 Removing the Pressure Module from Actuator 2 2 0 2 2 o 9 6 4 2 Disassembling the Pressure Module a aa ee 9 6 4 3 Service 8 Reassembly of the Pressure Module 2 a ee 9 6 5 Torque Module 25 2524 4844684 Seba ee ea de abb ee eed gabe eee ees 11 6 5 1 Disassembling the Torque Module a25 4i6843 8464884
8. Disengaged piston rod broken connection jammed Refer to Maintenance section for module actuator disassembly mechanism procedures to disassemble appropriate module for inspection Valve problem jammed Refer to valve manufacturer s IOM Fails to go to the Altered schematics Check if the control circuit is as per the supplied schematic Correct the failsafe position circuit if altered Control component malfunction failure Check and replace Choked exhaust silencer foreign object blocking Remove vent to confirm normal operation Clean replace exhaust exhaust line silencer Spring rod disengaged connection broken Refer to Maintenance section for module actuator disassembly procedures to disassemble appropriate module for inspection Valve problem jammed Refer to valve manufacturer s IOM All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r POTENTIAL MISUSE Use in unintended conditions Supply pressure greater than the actuator MOP to compensate for valve problems incorrect selection Actuator subjected to temperatures out of permissible imits Used with operating media that does not conform to specification Lifting actuator valve accessories ass
9. 18 7 15 3 22 8 29 5 5 1 1 0 14 1 6 0 1 5 6 8 16 3 8 3 10E4 E40 E35 5153518 541578 538201 552831 1738 slau 69 31 22 18 91 02 3 351 SHS 5 1 10 17 8 7 0 ETS SS E ils ISO Base F16 F12 73E2 F16 F12 1526 427 427 400 201 402 723 326 300 288 420 18 249 63 5 15 88 78 Sy 12 14E3 F25 16 1843 542 542 477 235 470 896 342 307 390 498 130 18 276 76 2 19 05 93 300 145 24E3 F30 25 223578 033 NOS SH 550 62 911 582 1148 397 364 491 605 130 25 334 114 3 25 4 131 350 186 F35 30 F40 F35 Refer ES drawings for dimensions of specific models CYLINDER PORT SIZE Cylinder Size 12 16 24 28 36 Ports NPT 1 4 3 8 1 2 3 4 ala 1 5 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 26 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 14 0 SERIES 98 GENERAL SPECIFICATIONS AND FEATURES GENERAL SPECIFICATIONS RANGE ISO Rated Torque Spring End Torque Spring End Torque isle Maximum Over Travel Model Mounting q Nm Lb in foot Stem Height
10. 00021 drawing for more information All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 16 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual ITEM DESCRIPTION MATERIAL QTY ITEM DESCRIPTION MATERIAL QTY 1 Yoke Housing Ductile Iron 1 26 Bushing Guide Rod PTFE Bronze 2 2 Guide Rod Alloy Steel 1 27 Bushing Yoke Pin PTFE Bronze 2 3 Housing Cover Ductile Iron 1 28 Cap Screw Flat Head Hex Socket Stee 8 4 Bushing Yoke PTFE Bronze 2 29 Position Indicator Plastic 1 5 O Ring Yoke Buna N 2 30 Cap Screw Flat Head Hex Socket Stee 1 6 O Ring Cover Buna N 1 31 Adaptor Pressure Module Ductile Iron 2 7 Top Cover Ductile Iron 1 32 Barrel Carbon Steel 2 8 O Ring Top Cover Buna N 1 33 Piston Ductile Iron 2 9 Flanged Bushing PTFE Bronze 1 34 End Cap Pressure Module Ductile Iron 2 10 O Ring Accessory Drive Buna N 1 85 Piston Rod Alloy Steel 2 1 Accessory Drive Stainless Steel 1 36 Bushing Adaptor PTFE Bronze 2 12 He
11. 1 61 Nut Steel 12 30 Cap Screw Flat Head Hex Socket Steel 1 62 Spring Washer Spring Steel 12 Sil Adaptor Pressure Module Ductile Iron 1 e53 ES O Ring Module Buna N 2 32 Barrel Carbon Steel 1 64 Load Ring Carbon Steel 1 For reference only Please refer to current revision of ES 00019 drawing for more information Parts in Seal Kits Ake Parts in Repair Kits All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r 6 0 MAINTENANCE Series 98 actuators are designed for long service periods between maintenance in demanding conditions However a preventative maintenance program is essential for ensuring good performance safe operation extended life of equipment and to avoid expensive down time The service conditions load and cycling frequency may vary largely which would require the maintenance program to be suitably designed with sound judgment of the working conditions Contact manufacturer for assistance In general the scheduled service shall include replacement of all seals and wear parts Seals shall be replaced if the actuator is in storage or inactive for long periods of time 6
12. 1 Lubricants and Maintenance Consumables The Standard actuators use following lubricants contact factory for information on high low temperature actuator lubricants Shell Alvania EP2 LF grease for the Torque amp Spring Modules Molykote 55 for the Pressure Module ISO Grade 32 hydraulic fluid for hydraulic override Thread lock compound Loctite 243 or equivalent Thread Sealant Loctite 577 or equivalent Commercial leak check fluid Snoop or equivalent Anti seize compound Loctite 77164 or equivalent 6 2 Disassembly Service amp Reassembly of Modules caution Prior to disassembly of the actuator disconnect all air and electrical supplies from actuator remove the relevant accessories from actuator and dismount actuator from valve or override gearbox if present NOTICE Replacement of the press fitted bushings may require workshop infrastructure to remove the worn bearings from their housing and to press fit new ones without damaging the housings We recommend sending the actuator or module to our factory for overhauls major repairs Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual References Drawing ES 00019 Spring Return Actuator Assembly Drawing ES 00020 DA Assembly Drawing ES 00021 DD Assembly Refer to the Bray website for current revisions of the drawings 6 3 Spring Module Follow the sequence of steps as described below Injury or
13. E4 100 000 506 571 621 649 1000 1135 1225 Actuator lifting lugs are only for lifting the stand alone actuator not for the complete assembly All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 25 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual r 13 0 SERIES 98 DIMENSIONS Q ACCESSORY DRIVE DETAILS M5 y 7 00 STEM BORE DETAIL TOP VIEW RIGHT VIEW e LEFT VIEW T FRONT VIEW Model ISO Base A B D E F G H J K E M N E Q R S i U 45E2 F16 F12 52 8 14 8 14 8 14 2 6 3 12 5 26 2 9 4 9 7 9 4 13 1 0 7 8 5 2 0 0 5 2 3 dl 3 8 73E2 F16 F12 60 1 16 8 16 8 15 8 1S Wet3 2h Wl MESA Wiles les gt 0 7 9 8 2 5 0 625 Shi 7 8 ll 14E3 F25 16 72 6 21 3 21 3 18 8 9 3 18 5 35 3 13 5 12 1 154 19 6 5 1 0 7 10 9 3 0 0 75 3 7 11 8 5 7 24E3 F30 25 QO 251 Ail Zl WS 22198 245724 Wee Wels Wes 28s Del 1 135 4 5 1 0 52 8 Thee 45E3 F35 30 113 3 33 3 33 3 25 8 14 3 28 6 589
14. Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 5 0 Spring Return Pneumatic Actuator Assembly Drawing and Materials of Construction a EH EA Gh 9 D ae D mA 6 B A AY NE 64 Y A A o O a S Nee eet I N YN A VA Nee i P F i KA EAD o Hy Wt VRE NE 7 be 7 ALAS y ZN E g y A Aa QA qT PER Y Y U WW Y ly A NJ Ah N IA On KA AN E AR S HA a Nea sx mai ENPN Z S Z gist Wo did DETAIL E For reference only Please refer to current revision of ES 00019 drawing for more information All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual ITEM DESCRIPTION MATERIAL QTY ITEM DESCRIPTION MATERIAL QTY 1 Yoke Housing Ductile Iron 1 33 Piston Ductile Iron 1 2 Guide Rod Alloy Steel 1 34 End Cap Pressure Module Ductile Iron 1 3 Housing Cover Ductile Iron 1 35 Piston Rod Alloy Steel 1 4 Bushing Yoke PTFE Bronze 2 36 Bushing Adaptor PTFE Bronze 2 5 E O
15. and Maintenance Manual 5 With a socket spanner located on the hex head of the hydraulic cylinder s piston loosen and disengage the piston rod from the Guide Block in the Torque Module 6 Remove the fasteners holding the hydraulic cylinder s flange on the Torque Module end 7 Take the cylinder assembly off the Torque Module 15 4 2 Servicing Hydraulic Cylinder 1 Drain the oil from the rod side of the cylinder and pull the barrel with the piston and the piston rod out of the cylinder head 2 Pull the barrel off the piston remove the old seals and wear band Thoroughly wash clean all parts 3 Inspect the barrel and the piston for any damage or scoring Repair replace any damaged parts 4 Replace the seals wear rings guide bushings o rings on the cylinder head and end caps Reassemble the cylinder and install it on the Torque Module as described in the Installation Section 5 Flush clean the hydraulic fluid reservoir and tubing Fill fresh fluid to required level before testing the operation of the override as described in installation section 15 5 Servicing Hand Pump Unit Refer to the hand pump unit manufacturer s service manual for maintenance instructions All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solel
16. consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 19 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 11 0 TECHNICAL DATA 11 1 Double Acting Actuators Model Maximum Operating Pressure Volume Actuator Weight Assembly Weight approx 4 a w Jackscrew w Hydraulic Symmetrical Canted Cu in Lts erent evans psi bar psi bar Rod End Cap End Rod End Cap End Lbs Kg Lbs Kg Lbs kg DA 45E2 08 150 10 3 150 103 322 346 53 5 143 65 207 94 45E2 09 144 9 9 119 8 2 417 442 6 8 7 2 152 69 216 98 45E2 10 117 8 0 96 6 6 519 560 8 5 9 2 172 78 236 107 l 45E2 12 81 5 6 67 4 6 750 831 12 3 13 6 209 95 273 124 45E2 14 59 4 1 49 3 4 1020 1135 16 7 18 6 267 121 331 150 DD 45E2 08 92 6 3 76 5 2 669 669 11 0 11 0 203 92 45E2 09 72 5 0 60 4 1 858 858 14 1 14 1 220 100 45E2 10 59 4 0 48 3 3 1079 1079 17 7 17 7 260 118 45E2 12 41 2 8 1581 1581 25 9 25 9 335 152 DA 73E2 10 150 10 3 127 8 7 621 668 10 2 11 0 245 111 331 150 359 163 73E2 12 107 7 4 88 6 1 902 985 14 8 16 2 280 127 366 166 395 179 73E2 14 78 5 4 65 44 1227 1347 20 1 22 1 331 150 417 189 445 202 l 73E2 16 60 4 1 49 3 4
17. models The hydraulic override cylinders are designed for 3 000 psi max working pressure and provide adequate thrust to output the required valve torque The operating pressure required is set on the hand pump assembly through a built in relief valve 15 1 Installation Series 98 standard actuators with hydraulic overrides are shipped pre assembled with the cylinder hand pump bypass valves and tubing complete The hand pump unit is selected factory installed and the hydraulic pressure valve set per the application No additional customer installation adjustment is usually required Actuators in service without this override option can be retrofitted with the override kit as described below 15 1 1 Installing Hydraulic Override on Spring Return Actuators 1 Disconnect air pressure and electrical power from actuator 2 In fail safe position of the actuator remove the end cover plate retaining the O ring on the End Cap 3 Firmly thread the studs 10 supplied with the override mounting kit into the thrust base With the piston rod fully retracted insert the Hydraulic Cylinder into the Spring Module positioning the air venting plug at the top Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual Secure the cylinder flange on the thrust base of the Spring Module with the spring washers and nuts from the override mounting kit Thread in the hydraulic connector into the cylinder p
18. screw head Replace the flanged bushing and the O rings in the Top cover and fit it back on the Housing Cover with the Top Cover Bolts Fit the indicator on the drive shaft Apply anti seize compound on the stopper bolt threads and thread them with the Lock Nuts into the Torque Module Housing 6 6 Reassembly of Actuator I 2 12 Secure the Torque Module on its base Back off the travel Stop Bolts 19 fully and manually turn the Yoke to the side on which the Pressure Module is to be fixed Lift the Pressure Module lubricate and place the module flange O ring in the groove Degrease the Piston Rod threads apply a drop of thread lock compound on the threads and locate the module on the Torque Module s mounting flange Carefully guide the Studs into the flange and center the module on the spigot Fasten the modules with Spring Washers and Stud Nuts refer to the tables for torque values Take the Plug End Cover off the End Cap of the Pressure Module and couple the Piston Rod threads to the Guide block using an extended socket or tube spanner Refer to the tables in Section 10 for torque values Install the Plug or End Cover with thread sealant and apply low pressure air 5psi on the End Cap port till the Yoke reaches end of stroke Restrain the Guide Bar from sliding out of the Housing while stroking 10 11 12 13 Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual For D
19. test the module 44 62 43 42 A 9 e Oe on A SS 62 Y A N Q as G6 y lt x SS SESS ESSE SESS SESE SSS SESS ESS ___ _ _ _ _ gt PRE Q QQ ___0_ ESEESSSSSSSS gt Sos OY AN ig a AND De NANI FS a Y IN h ALYS AP i ln UN 69 p A SA A a q Ws k Le N N A ION ye A NY RQP S DA EY Y Le gt lt Me SSSR sN 63 65 z 7 63 wr WY FIZIZIZ ES Wr tN yyy Pay mm SS o y SECTION A A All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual Bray 14 Apply 10 15 psi air pressure to ports alternately to check for smooth stroking for 5 10 cycles and then raise to 80 psi and hold the pressure to check for any leaks past the Piston through the Rod Seal and the Barrel O rings NOTICE For smaller models up to 14E3 this can be done by hand Larger models may require use of a hoist to support the weight of the Yoke sub assembly For this remove the Screw 17 off the Yoke and fit an eye bolt in place Leak test the piston seal by bubble test at 80 psi pressure and for other seals check visually usin
20. to atmosphere The ports must be vented when operating the manual override Refer to Figure C 3 WAY MANUAL VALVES Ale el us Figure C 16 1 2 Operating DA Jackscrew Override 1 To test operate the override shut off the main air supply and turn the 3 position valves on the cylinder ports to vent the ports to atmosphere Pull Disengage Push Engage Turn the hand wheel on the jackscrew assembly to move the screw forward until it touches the extension rod s end Push the T handle into the jackscrew head to couple it with the extension rod Turn the hand wheel to turn the actuator in required direction see direction markers on the hand wheel After completing the manual override stroke disengage the coupler by pulling out the T handle Back off the jackscrew completely before restoring pneumatic operation NOTICE The jackscrew is not designed as an extended travel stop It must be taken to fully backed off position for the actuator to work normally in automatic mode Turn the 3 position valves to connect the air supply to restore automatic operation N caution The extension rod moves back and forth in normal operation Do not remove any protective covers on the DA jackscrew assembly without ensuring the air supply is cut off and that the automatic operation of actuator is disabled All information herein is proprietary and confidential and may not be copied or reproduced w
21. 094 Hydraulic Override Assembly SR ES 00095 Jackscrew Assembly DA Direct Drive ES 00105 Jackscrew Assembly DA Gear Drive ES 00106 Jackscrew Assembly SR Direct ES 00113 Jackscrew Assembly SR Gear Drive ES 00114 Sandwich Gearbox ES 00126 Extended Stoppers SR ES 00127 Extended Stoppers DA ES 00201 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 37 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual TROUBLE SHOOTING POTENTIAL PROBLEMS FAULT POSSIBLE CAUSES RECOMMENDED ACTIONS Erratic Movement Inconsistent supply dirty operating media clogged Check media supply pressure and line filters correct as necessary filters Refer to Introduction section in this manual for operating media requirements Inadequate lubrication Disassemble and lubricate Refer to Maintenance section in this manual for lubricant specs Worn damaged parts Disassemble and inspect Replace worn damaged parts Refer to Disassembly Service amp Reassembly of Modules section in this manual Seal set due to long periods of inactivity Operate for 5 10 cycles and check Replace seals if not resolved Refer to the procedures under Pressure Module
22. 1588 1766 26 0 29 0 399 181 485 220 514 233 DD 73E2 10 77 53 64 4 4 1289 1289 Ziel 21 1 344 156 73E2 12 54 3 7 44 3 0 1887 1887 30 9 30 9 414 188 l DA 14E3 12 150 10 3 142 9 8 1071 1152 17 6 18 9 386 175 534 242 558 253 14E3 14 127 8 7 104 Ez 1458 1574 23 9 25 8 437 198 584 265 608 276 14E3 16 97 6 7 80 5 5 1890 2061 31 0 33 8 507 230 655 297 679 308 14E3 18 Wi 58 63 4 3 2421 2626 39 7 43 1 591 268 739 335 763 346 14E3 20 62 4 3 51 3 5 2978 3300 48 8 54 1 721 327 869 394 893 405 1p gt 143 12 87 6 0 72 4 9 2223 2223 36 5 36 5 536 243 14E3 14 64 4 4 52 3 6 3032 3032 49 7 49 7 637 289 14E3 16 49 3 4 40 2 8 3951 3951 64 8 64 8 778 353 DA 24E3 14 150 10 3 134 9 2 1831 1954 30 0 32 0 657 298 873 396 910 413 24E3 16 124 8 6 102 7 1 2387 2560 39 2 42 0 721 327 937 425 974 442 24E3 18 98 6 8 81 5 6 3059 3255 50 2 53 4 800 363 1016 461 1054 478 24E3 20 80 5 5 66 4 5 3750 4084 61 5 67 0 941 427 1157 525 1195 542 24E3 22 66 4 5 54 SIJ 4561 5012 74 8 82 2 1041 472 1257 570 1294 587 24E3 24 55 3 8 46 3 1 5452 5917 89 4 97 0 1208 548 1424 646 1462 663 l DD 24E3 14 82 5 6 67 4 6 3785 3785 62 1 62 1 886 402 24E3 16 63 4 3 52 3 5 4948 4948 81 1 81 1 1014 460 24E3 18 49 3 4 6314 6314 103 5 103 5 1173 532 24E3 20 40 2 8 7834 7834 128 5 128 5 1455 660 DA 45E3 18 150 10 3 123 8 5 3722 3895 61 0 63 9 1105 501 1457 661 l 45E3 20 121 8 4 100 6 9 4584 4878 752 80 0 1241 563 1594 723 45E3 22 100 6 9 83 5 7 5591 5973 91 7 98 0 1345 610 169
23. 22 14E3 20 91 6 3 80 55 2978 48 8 1173 532 1287 584 1281 581 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 22 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 11 2 Spring Return Actuators Cont Model Maximum Operating Pressure Volume Actuator Weight Assembly Weight approx Spring Symmetrical Canted Rod End w Jackscrew Override w Hydraulic Override a psi bar psi bar Lbs Kg Lbs Kg 24E3 14 150 10 3 150 10 3 1387 629 1389 630 24E3 16 150 10 3 138 9 5 1451 658 1453 659 24E3 18 126 8 7 109 75 1530 694 1532 695 24E3 20 1 102 7 0 88 6 1 1671 758 1673 759 24E3 22 84 5 8 73 5 0 1770 1772 804 24E3 24 71 4 9 61 4 2 1938 1940 880 24E3 14 150 10 3 150 10 3 1407 1407 638 24E3 16 150 10 3 145 10 0 1470 667 24E3 18 132 9 1 114 7 9 1550 703 24E3 20 106 ES 92 6 4 1691 767 24E3 22 88 6 1 76 5 2 1790 812 24E3 24 74 511 64 4 4 1958 888 24E3 14 150 10 3 150 10 3 1433 650 24E3 16 150 10 3 150 10 3 1497 679 24E3 18 139 9 6 122 8 4 1576 715 24E3 20 3 113 7 8 99 6 8 1717 779 24E3 22 93 6 4 81 5 6 1817 824 24E3 2
24. 3 319 714 324 73E2 10 150 10 3 150 10 3 621 10 2 538 244 604 274 615 279 73E2 12 150 10 3 141 ciy 902 14 8 573 260 639 290 650 295 73E2 14 117 8 1 103 TN 1227 20 1 624 283 690 313 701 318 73E2 16 90 6 2 79 5 4 1588 26 0 692 314 758 344 769 349 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 21 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 11 2 Spring Return Actuators Cont Maximum Operating Pressure Volume Actuator Weight Assembly Weight approx Symmetrical Canted Rod End w Jackscrew Override w Hydraulic Override psi bar psi bar Cu In Lts Lbs Kg Lbs Kg 14E3 12 150 10 3 150 10 3 1071 842 855 388 14E3 14 150 10 3 137 915 1458 893 906 411 14E3 16 122 8 4 105 7 2 1890 963 977 443 14E3 18 96 6 6 83 5 7 2421 1047 1060 481 14E3 20 78 5 4 67 4 6 2978 1177 1190 14E3 12 10 3 1071 869 877 14E3 14 10 3 9 8 1458 919 928 14E3 16 14E3 18 14E3 20 14E3 12 14E3 14 14E3 16 14E3 18 14E3 20 14E3 12 14E3 14 14E3 16 14E3 18 14E3 20 14E3 12 14E3 14 14E3 16 14E3 18 113 7 8 99 6 8 2421 39 7 1043 473 1157 525 1151 5
25. 4 78 5 4 68 47 1984 900 24E3 14 150 10 3 150 10 3 1490 676 24E3 16 150 10 3 150 10 3 1554 705 24E3 18 145 10 0 127 8 8 1634 741 24E3 20 sl 117 8 1 103 TA 1775 805 24E3 22 97 6 7 85 5 8 1874 850 24E3 24 81 5 6 71 4 9 5452 89 4 1885 855 2079 943 2041 926 24E3 16 150 10 3 150 10 3 2387 39 2 1400 635 1596 724 1556 706 24E3 18 150 10 3 133 9 2 3059 50 2 1479 671 1675 760 1636 742 24E3 20 5 122 8 4 108 7 4 3750 61 5 1620 735 1817 824 1777 806 24E3 22 101 6 9 89 6 1 4561 74 8 1720 780 1916 869 1876 851 24E3 24 84 5 8 75 5 1 5452 89 4 1887 856 2083 945 2044 927 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 23 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 11 2 Spring Return Actuators Cont Maximum Operating Pressure Volume Actuator Weight Assembly Weight approx Symmetrical Canted Rod End w Jackscrew Override w Hydraulic Override psi bar psi bar Cu In Lts Lbs Kg Lbs Kg 45E3 18 150 10 3 150 10 3 3722 61 0 2418 1097 45E3 20 150 10 3 134 9 2 4584 115 2 2555 1159 45E3 22 128 8 8 110 7 6 5591 91 7 2659 1206 45E3 24 107 7 4 93
26. 4254 244 8845 11 6 5 2 Service 8 Reassembly of the Torque Module 2 02004 11 6 6 Reassembly of ACtualOr 2 22 24ck8 eee 48 RRR ER ER DE RR eee eee eS 12 THE CONVEISIONS lt lt 2 042844 naar O44 oe ew SB Ae A A 13 7 1 Fail Sate Condition for Spring Return Actuators 2 240 6 a a 13 7 2 Double Acting to Spring Return lt 4 242 lt 44 6 4564464464444 4464444 445444 13 7 3 Spring Return to Double Acting 2 24 6 24 oe ou be RE 0040 SORE ERE Bo A 13 8 0 Pneumatic Actuator Double Acting Single Cylinder Assembly and Materials of Construction 14 9 0 Pneumatic Actuator Double Acting Dual Cylinder Assembly and Materials of Construction 16 10 0 Belting Torques aNd 10GlS oss Soe ae deen Be gt ee eS wee Pee eS OPE OS ee SS 18 TO a Pressure WioduIe ss et a oe ee ke ee oe De de ee eee ee Pale Boe De we ee d 18 10 1 b Pressure Module ain de soso rra A A SHAE Se EO 18 IO 2 enue IOUS dre eee ee eS PAE ee 18 10 3 Spring Mod le gt s osos tera aa pee ee eee giv ee baer eed bebe ds 19 10 4 Actuator Assembly ars AAA A 19 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 1 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuat
27. 6 4 6676 109 5 2829 1283 45E3 28 79 5 4 68 4 7 9074 148 8 3256 1477 45E3 18 10 3 3722 61 0 2469 1120 45E3 20 10 3 9 5 4584 75 2 2606 1182 45E3 22 9 1 7 9 5591 91 7 2709 1229 45E3 24 7 6 6 6 6676 109 5 2879 1306 45E3 28 45E3 18 45E3 20 45E3 22 45E3 24 45E3 28 45E3 18 45E3 20 45E3 22 45E3 24 45E3 28 45E3 18 45E3 20 45E3 22 5 149 10 2 131 9 0 5591 91 7 2776 1259 3025 1372 45E3 24 125 8 6 110 7 6 6676 109 5 2945 1336 3194 1449 45E3 28 91 6 3 80 5 5 9074 148 8 3373 1530 3622 1643 10E4 22 150 10 3 150 10 3 6875 112 8 4153 1884 4429 2009 10E4 24 150 10 3 150 10 3 8173 134 0 4330 1964 4605 2089 10E4 28 1 143 9 8 123 8 4 11049 181 2 4815 2184 5090 2309 10E4 32 109 ES 94 6 4 14589 2398 5370 2436 5646 2561 10E4 36 86 5 9 74 5 1 18327 300 6 6078 2757 6354 2882 10E4 22 150 10 3 150 10 3 6875 112 8 4297 1949 4572 2074 10E4 24 150 10 3 150 10 3 8173 134 0 4473 10E4 28 2 147 10 1 126 8 7 11049 181 2 4958 10E4 32 112 7 7 97 6 7 14589 239 3 5514 10E4 36 88 6 1 76 58 18327 300 6 6221 2822 6497 2947 10E4 22 150 10 3 150 10 3 6875 112 8 4594 2084 4870 2209 10E4 24 150 10 3 150 10 3 8173 134 0 4771 2164 5046 2289 10E4 28 3 150 10 3 135 9 3 11049 181 2 5256 2384 5531 2509 10E4 32 119 8 2 103 7 1 14589 2398 5811 2636 6087 2761 10E4 36 94 6 5 82 5 6 18327 300 6 6519 2957 6795 3082 10E4 22 150 10 3 150 10 3 6875 112 8 4793 2174 5068 2299 10E4 24 150 10 3 150 10 3 8173 134 0 4969 2254 5245 2379 10E4 28 4 150 10 3 141 97 11049 181 2 5454 2474 5730 2599 10
28. 8 770 45E3 24 84 5 8 69 4 8 6676 7068 109 5 115 9 1515 687 1867 847 45E3 28 62 4 3 51 3 5 9074 9699 148 8 159 1 1942 881 2295 1041 DD 45E3 18 US 52 62 4 3 7617 7617 124 9 124 9 1543 700 45E3 20 61 4 2 50 3 5 9462 9462 155 2 155 2 1817 824 45E3 22 50 3 5 41 2 9 11564 11564 189 7 189 7 2024 918 l 45E3 24 42 2 9 13745 13745 225 4 225 4 2363 1072 l DA 10E4 22 150 10 3 150 10 3 6875 7205 112 8 118 2 2092 949 2698 1224 10E4 24 150 10 3 126 8 7 8173 8504 134 0 139 5 2269 1029 2875 1304 10E4 28 113 7 8 93 6 4 11049 11713 181 2 192 1 2754 1249 3360 1524 10E4 32 86 5 9 71 4 9 14589 15908 239 3 260 9 3309 1501 3915 1776 10E4 36 68 4 7 56 3 9 18327 19859 300 6 325 7 4017 1822 4623 2097 1 gt 10E4 22 92 6 3 76 5 2 14080 14080 230 9 230 9 2873 1303 10E4 24 77 53 64 4 4 16676 16676 273 5 273 5 3225 1463 10E4 28 57 3 9 47 B2 22763 22763 37323 373 3 4195 1903 10E4 32 43 3 0 30497 30497 500 2 500 2 5306 2407 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 20 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 11 2 Spring Return Actuators Maximum Operating Pressure Actuator Weight
29. A models refer to Drawing ES 00020 DA Assembly fit the DA End Cover 52 with O ring 47 in the groove using Bolts 51 Nuts 50 and Spring Washers 49 Skip to step 12 For DD models mount the second Pressure Module on the other side of Torque Module following relevant actions from steps 3 through 7 Skip to step 12 For Spring Return Models mount the Spring Module on the other side of the Torque Module in same manner as the Pressure Module and couple the Spring Rod to Guide Block just as was done with the Piston Rod Always ensure to tighten the Piston and the Spring Rod to the recommended torque Fix the End Cover with O ring on the Spring Module or the Extended Travel Stop Jackscrew Assembly Hydraulic override cylinder if provided Set the Travel Stops to previously marked positions Test the actuator for smooth operation at the Maximum Operating Pressure as noted on the nameplate All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 7 0 FIELD CONVERSIONS 7 1 Fail Safe Condition for Spring Return Actuators Prior to configuration change
30. Assembly Weight approx Symmetrical Canted Rod End w Jackscrew Override w Hydraulic Override psi bar psi bar Lbs Kg Lbs Kg 45E2 08 150 10 3 150 10 3 304 138 45E2 09 150 10 3 150 10 3 y 313 142 45E2 10 146 10 0 125 8 6 333 151 45E2 12 101 7 0 87 6 0 370 168 45E2 14 74 5 1 63 4 4 428 194 45E2 08 10 3 10 3 E 315 143 45E2 09 10 3 10 3 y 324 147 45E2 10 10 3 915 344 156 45E2 12 108 74 93 6 4 750 12 3 355 161 381 173 45E2 14 79 5 4 69 47 1020 16 7 412 187 439 199 45E2 08 150 10 3 150 10 3 322 5 3 295 134 353 160 45E2 09 150 10 3 150 10 3 417 6 8 304 138 362 164 45E2 10 3 150 10 3 148 10 2 519 8 5 324 147 381 173 45E2 12 Wy 8 1 103 Tal 750 12 3 362 164 419 190 45E2 14 86 5 9 a5 5 2 1020 16 7 419 190 476 216 45E2 09 150 10 3 150 10 3 417 6 8 324 147 384 174 45E2 10 150 10 3 150 10 3 519 8 5 344 156 403 183 45E2 12 j 121 8 4 107 7 4 750 12 3 381 173 441 200 45E2 14 89 6 1 79 5 4 1020 16 7 439 199 498 226 73E2 10 536 243 73E2 12 i 571 259 73E2 14 622 282 73E2 16 690 313 73E2 10 538 244 73E2 12 y i 573 260 73E2 14 105 73 91 6 3 1227 20 1 547 248 611 277 624 283 73E2 16 80 55 70 4 8 1588 26 0 615 279 679 308 692 314 73E2 10 150 10 3 150 10 3 621 10 2 483 219 549 249 560 254 73E2 12 150 10 3 133 9 2 902 14 8 518 235 584 265 595 270 73E2 14 i 111 FT 98 6 7 1227 20 1 569 258 635 288 646 293 73E2 16 85 519 75 Sil 1588 26 0 637 289 70
31. Cover with O ring and fasteners from the DA Cover Kit 3 Adjust travel Stop Bolts as required 4 Remove the breather filter from the End Cap of the Pressure Module and connect suitable connector for connecting the air line from the direction control valve All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 13 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 8 0 Pneumatic Actuator Double Acting Single Cylinder Assembly and Materials of Construction AAA anaes S Le N Nu a Sen NW Rwy Z SES Li e Ne RNS AO SS SECTION A A For reference only Please refer to current revision of ES 00020 drawing for more information All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 14 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual
32. E4 32 123 8 5 108 7 4 14589 239 3 6010 2726 6285 2851 10E4 36 97 6 7 85 De 18327 300 6 6717 3047 6993 3172 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 24 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 12 0 MODULE WEIGHTS MODULE WEIGHTS APPROX Lbs are on Torque Pressure Modules Size Inch Spring Modules Nm Module 8 9 e e 2g 22 2 as 2 3 1 2 3 4 5 45 E2 4 500 84 60 68 88 126 183 134 146 152 172 73 ED 7 300 146 99 134 185 254 214 216 238 293 14 E3 14 000 236 150 201 271 355 485 362 384 403 430 452 24E3 24 000 428 a8 23 37 3 Sie Gils veo 575 593 619 677 679 45 E3 45 000 666 439 575 679 849 1276 1065 1116 1259 1369 1431 10E4 100 000 1312 780 957 1442 1997 2705 2061 2205 2502 2701 MODULE WEIGHTS APPROX Kg Spring Modules Model Torq Nm 45 E2 4 500 2 3 4 5 66 69 78 98 24 000 45 E3 45 000 10
33. Ring Yoke Buna N 2 ay ES Seal U Cup Buna N 1 6 O Ring Cover Buna N 1 38 Split Collar Alloy Steel 4 7 Top Cover Ductile Iron 1 39 Tie Rod Steel 4 8 O Ring Top Cover Buna N 1 40 Locknut Nylok Steel 4 9 Flanged Bushing PTFE Bronze 1 abl O Ring Piston Rod Buna N 1 10 O Ring Accessory Drive Buna N 1 42 Wear Ring PTFE 2 11 Accessory Drive Stainless Steel 1 aa Quad Seal Buna N 1 12 Hex Bolt Stee 8 44 O Ring Barrel Buna N 2 13 Spring Washer Spring Steel 8 45 Retainer Ring Stainless Steel 1 14 Set Screw Socket Head Stee 2 46 Pipe Plug Carbon Steel 1 15 Dowel Pin Hardened Steel 4 47 Adaptor Spring Module Carbon Steel 1 16 Socket Head Caps Screw Stee 4 48 Pipe Carbon Steel 1 17 Socket Head Caps Screw Low Head Stee 1 49 End Cap Spring Module Carbon Steel 1 18 Seal Nut Stee 2 50 Spring Guide Carbon Steel 19 Stop Bolt Stee 2 51 Button Plastic 9 20 Breather Vents Carbon Steel 1 52 Spring Compression Alloy Steel 21 Yoke Ductile Iron 1 53 Lifting Lug Carbon Steel 1 22 Slider Block Bronze 2 54 Spring Rod Alloy Steel 23 Yoke Pin Alloy Steel 1 55 End Cover Carbon Steel 1 24 Retainer Plate Plastic 2 56 Retainer Ring Stainless Steel 25 Guide Block Carbon Steel 1 57 Spring Washer Spring Steel 4 26 Bushing Guide Rod PTFE Bronze 2 58 Hex Bolt Steel 4 27 Bushing Yoke Pin PTFE Bronze 2 Es O Ring End Cover Buna N 1 28 Cap Screw Flat Head Hex Socket Steel 8 60 Stud Steel 12 29 Position Indicator Plastic
34. TION The instructions and guidelines in this manual enable competent technicians to install operate adjust and carry out routine maintenance activities on Series 98 pneumatic actuators Responsibility lies with the user to follow the instructions in this and in any additional documentation related to the product and accessories supplied with it User shall ensure the equipment is installed and operated in the environment that it is intended for and effective protections are provided against exposure to pressure and temperature in excess of maximum rating Failing to do so may affect the product warranty Only trained personnel aware of precautions in hazardous environments and health and safety in the workplace should service the equipment Series 98 Actuators are designed for quarter turn rotary valves in configurations as DA Double Acting with a single cylinder DD Double Acting with dual cylinders SC Spring Return Fail Close CW SO Spring Return Fail Open CCW Two output torque characteristic profiles are available in the form of Symmetrical Yoke and Canted Yoke Standard actuators have a mounting base to ISO 5211 MSS mounting base is available as an option Mounting of the shaft driven accessories is per VDE 3845 NAMUR standard The maximum operating pressure of the Series 98 Pneumatic Scotch Yoke Actuators range from 40 to 150 psig depending upon the size and configuration Refer to the MOP maximum operati
35. WM m dy To operate the override turn the 3 2 way valve on the pressure module to vent the cylinder port to atmosphere and Close the pressure release valve PRV on the hand pump manifold Operating the Hand Pump on the power pack extends the Hydraulic cylinder s piston rod and pushes the Spring Rod while compressing the spring and operates the actuator manually Opening the pressure release valve relieves the hydraulic pressure to reservoir The spring returns the piston rod of override cylinder to retracted position and the actuator to fail safe position To restore normal pneumatic operation turn the pressure release valve to full Open and switch the 3 2 way valve on pneumatic cylinder to connect the cylinder port to the air supply pressure 3 1 ALR tyler F T PE Y Y NY F POWER PACK E 15 2 Installing Hydraulic Override on DA Actuator Turn the actuator so that the guide block is at the cover end side of the Torque Module and ensure it stays in this position after disconnecting air pressure and electrical power from actuator Remove the DA cover from the torque module and mount the DA hydraulic override cylinder assembly with the hardware supplied in mounting kit Make sure to install the O ring on the mounting f
36. and lock washers from the mounting kit All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 35 detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 17 1 2 Adjusting Extended Stopper Connect air supply to the rod end side port of the pneumatic cylinder adjust the extended stopper screw to 4 required position and reverse the actuator direction to stop movement by the extended stopper Confirm position and tighten the seal nut to lock the position 5 Tighten the nuts with spring washers refer to Table 10 4 for tightening torque for the nut size 17 2 1 Adjusting Extended Stopper 1 Connect air supply to the rod end side Adaptor port of the pneumatic cylinder tighten the extended stopper screw to approximately required position Release air so that the actuator will reverse direction by the spring action and stop against the extended stopper Repeat to get to final position NOTICE 2 Confirm position and tighten the seal nut to lock the position The Extended Stopper is not designed as a jackscrew Do not use this to manually override the actuator Always adjust the stopper with no load o
37. assemblies Actuator weight is printed on the name plate for ready reference Refer to Operation Guidelines section of this manual Pressurizing pneumatic cylinder to aid spring may cause over load on valve stem and actuator parts resulting in damages to valve actuator Do not substitute the vent provided on cap end port of cylinder with a pipe fitting See Safety Information section Do not permit anyone other than qualified technicians who have read and fully understood the installation and maintenance instructions to perform any maintenance adjustments on the actuator Refer to Disassembly Service amp Reassembly of Modules section of this manual Under no circumstances shall attempt be made to disassemble the pressure module or any fastener plug be loosened without isolating supply pressure and venting the cylinder ports to atmosphere Never operate the actuator in partially disassembled condition or with the Spring Module Pressure Module end plate removed Strictly prohibit change of any component design or adding spacers to increase the spring end load The Spring Rod thread engagement will be compromised and this can have disastrous consequences resulting in equipment damage and or severe personal injury RESIDUAL RISKS This document does not cover every detail about every version of the product described It cannot take into account every potential occurrence in installation operation maintenance and use All infor
38. ather Vents Carbon Steel 1 46 Pipe Plug Carbon Steel 1 21 Yoke Ductile Iron 1 47 O Ring Module Buna N 2 22 Slider Block Bronze 2 48 Stud Steel 6 23 Yoke Pin Alloy Steel 1 49 Spring Washer Spring Steel 18 24 Retainer Plate Plastic 2 50 Nut Steel 18 25 Guide Block Carbon Steel 1 51 Stud Steel 6 26 Bushing Guide Rod PTFE Bronze 2 52 End Cover DA Ductile Iron 1 Parts in Seal Kits amp Parts in Repair Kits For reference only Please refer to current revision of ES 00020 drawing for more information All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application 15 Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 9 0 Pneumatic Actuator Double Acting Dual Cylinder Assembly and Materials of Construction 4 T 47 A BAI E ea 6185 1m 2 7 ngg IAS 7 SN Y OBA gt Sa t O m a A me e CLK NAO LZ u Ll 5 Sy FJ Y a 772 es T5 anni SSN RA ae For reference only Please refer to current revision of ES
39. ce Manual Read and Follow These Instructions Save These Instructions 1 0 DEFINITION OF TERMS WARNING injury CAUTION moderate injury NOTICE 1 1 Hazard free Use This device left the factory in proper condition to be safely installed and operated in a hazard free manner The notes and warnings in this document must be observed by the user if this safe condition is to be maintained and hazard free operation of the device assured e Take all necessary precautions to prevent damage due to rough handling impact or improper storage Do not use abrasive compounds to clean or scrape its surfaces with any objects Configuration and calibration procedures are described in this document Proper configuration and calibration is required for the safe operation of this product e The control system in which the unit is installed must have proper safeguards to prevent injury to personnel or damage to equipment should failure of system components occur e This document does not cover every detail about every version of the product described It cannot take into account every potential occurrence in installation operation maintenance and use If situations transpire that are not documented in sufficient detail please request the required information from the Bray Distributor or Representative responsible for your area indicates a potentially hazardous situation which if not avoided could result in death or serious
40. d off the Piston and remove the Split Collars from the lower groove 5 Fit End Cover back with new O ring 59 6 4 Pressure Module N caution Ensure the ports are vented to atmosphere before disassembly of Pressure Module Failure to do so could cause severe injury To take the Pressure Module off the Spring Return Actuator first the Spring Module must be removed or at least the Spring Rod must be disconnected from the Guide Block steps 1 4 as described in section 6 3 1 6 4 3 Service amp Reassembly of the Pressure Module NOTICE The wear parts all seals piston wear bands and rod guide bushings in the Repair Kit shall be replaced during the maintenance cycle Ensure the replacement seals are suitable for the service temperature The assembly of the Pressure Module is done in vertical orientation Use Dow Corning Molykote 55 lubricant in the Pressure Module All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray 1 To reassemble secure the Adaptor Plate horizontally after replacing the Bushing 36 with sufficient space below to accommodate the Piston Rod The rod seal groove side of the Adaptor faces upwards Bray Seri
41. damages may occur if critical steps are bypassed or shortcuts taken Never attempt to cut open the Spring Module welded assembly as the spring inside is energized and can cause fatal severe injury or extensive damages Note If the actuator is provided with a jackscrew or hydraulic override cylinder on the Spring Module first ensure to back off the override fully to unload it from any spring force Remove the override assembly before disassembling Spring Module 6 3 1 Removing the Spring Module Refer to the Spring Return Pneumatic Actuator Assembly drawing 1 Slacken the Spring Module side Travel Stop Bolt Lock Nuts 18 on the torque module and extended stopper if provided Apply air pressure to pressure module adaptor port rod end port raising pressure slowly enough to release spring force on the Travel Stop Bolt 19 2 Mark the set position and back off fully both the Stop Bolts and Extended Stopper Jackscrew if present and release air pressure This will relieve the spring preload AN CAUTION Never try to loosen the Spring Rod without completely relieving the spring load on it 3 Remove the Extended Stopper override assembly if present from the Spring Module by unfastening the bolts holding the assembly on the End Cap All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 8 BRAY INTERNATIONAL Inc The technical data herein
42. de Block to provide the rotation adjustment up to 45 degrees from the end A 90 degree extended stop is an option 17 1 Installation Extended Stoppers are usually factory installed on the actuator and adjusted to the angle per customer s requirement if supplied as a valve actuator package If supplied as fitted on stand alone actuator then the stoppers are backed off fully to permit installation at site on the valve and they must be adjusted after installation If a field retrofit is required on actuators without the extended stopper the installation instructions provide a guide for a qualified technician to install and adjust them 17 1 1 Installing Extended Stopper for Torque Module This Extended Stopper module is installed only on Single Cylinder DA actuators 1 Disconnect the air pressure and the electrical power from actuator 2 Remove the DA end cover from the actuator 3 Clean threads on the Guide Block Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 4 Apply medium strength thread lock compound to the threads of the Bolt 4 and thread it into the Guide Block and tighten to lock the Bolt on the Guide Block face 5 Loosen the Lock Nut and back off the Extended Stopper in the assembly 6 Lubricate and locate the flange O ring in the groove on the assembly s flange and mount the assembly on the torque module 7 Secure the assembly with the mounting bolts nuts
43. djusting the overload valve on the pump to limit the hydraulic pressure as per the MOP tables 15 3 Maintenance of Hydraulic Override The hydraulic system may require servicing only when testing the system indicates no build up of pressure or the cylinder seals leak 15 3 1 Spring Return Hydraulic Override Cylinder Leakage of hydraulic fluid past the piston seal can be a cause for failure to hold the position when operating the override Leakage can be confirmed if oil can be seen dripping out of the weep hole on the cylinder Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 15 3 2 Disassembly of Hydraulic Cylinder Ensure the hydraulic cylinder seal kit is on hand before disassembling the cylinder 1 Disconnect the air pressure and the electrical power from the actuator and ensure the actuator turns to the fail safe position 2 Disconnect the hydraulic tubing from the override cylinder port 3 Remove the nuts and spring washers from the studs 10 holding the cylinder flange on the Spring Module end 4 Pull the cylinder out of the Spring Module and inspect for leakage from the weep hole at the rod end Proceed to replace seals if leakage is confirmed 5 Secure the cylinder loosen and remove the rod end guide nut 6 Pull the piston assembly out of the cylinder 15 3 3 Servicing Hydraulic Cylinder 1 Remove the old seal and wear rings from the piston and thoroughly clean the cyli
44. e 5 Sling and support the Spring Module and remove the Pull off the module carefully so as not to damage the Module s mounting flange Stud Nuts 61 and Lock threads on the Piston Rod and studs on the Adaptor washers 62 Spring Module can now be pulled off the 6 Ensure the Module sealing O ring 63 is retained in the Torque Module Pull off the module carefully so as not to damage the threads on the Spring Rod and studs on the Adaptor 6 3 2 Service amp Reassembly of the Spring groove 6 4 2 Disassembling the Pressure Module 1 Secure the Module and unscrew the Tie Rod Nuts 40 Module 2 Gently tap the End Cap 34 off the cylinder Barrel 32 Ensure that a correct Repair Kit is on hand prior to luni E MI ERA a disassembly 3 Slide the Barrel over and off the Adaptor 31 and Piston 33 being careful not to scratch or dent the honed and 1 Take the Retainer Ring 56 off and pull the Spring Rod chrome plated surface of the barrel out from the cover end 4 Take the Piston Assembly off the Adaptor taking care 2 Replace the Bushing Adaptor 36 clean and lubricate not to damage the threads the Spring Rod and slide it back in Tie Rods 39 may be unscrewed from the Adaptor Plate 3 Install the Retainer Ring back in the Spring Rod groove Remove the Retainer Ring 45 and take the Split Collars 4 Fit the Module back on Torque Module with new O ring 38 off the Piston Rod 35 upper groove Pull the Piston 63 Ro
45. e if present The travel stops of the actuator shall limit the stroke and not those on the gearbox valve if present 7 Adjust the travel stop bolts of the actuator for the proper open and closed valve positions per valve manufacturer s recommendations Refer to the Series 98 specifications for the travel adjustment range for different models 8 Tighten the travel stop bolts lock nuts after adjusting the stop bolts Ensure the travel stops on gearbox or valve if provided are now adjusted and locked to fractionally lag the actuator s stop position 9 Ensure the manual overrides are set for the normal pneumatic operation before putting the actuator to test in power operation mode Refer to Sec 15 through 17 10 Stroke the actuator a few times at not more than MOP to check for proper and smooth operation If the actuator is equipped with a switchbox or other accessories adjust them at this time NOTICE It is recommended to ground the actuator assembly against any buildup of static electricity Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 4 0 OPERATION GUIDELINES Series 98 actuators operate well in both on off and modulating applications The accessories control elements tubing and fittings shall be chosen for adequate flow rates so as not to constrict flow or cause high pressure drop affecting the performance of the actuator Maximum Operating Pressure MOP of the actuator is m
46. e Piston Rod 35 and the Spring Rod 54 from the Guide Block prior to disassembly Remove the position Indicator 29 if provided 1 Replace the bushings in the Housing the Housing Cover and the Guide Block with suitable pressing tools Contact factory for more information 2 Secure the Yoke and fit the bottom Retainer Plate 3 Remove Top Cover Bolts 16 and the Top Cover 7 24 with Screws 28 applying a drop of thread lock 4 Take off the Accessory Drive Shaft Assembly 11 from compound on the screw threads top of the Yoke 3 Flip the Yoke over grease the bottom slot and the Slider 5 Remove the Housing Cover Bolts 12 and Lock Washers T 22 generously and slide the Slider Block into the 13 6 Tighten the two Set Screws 14 on the Housing Cover 4 Grease the Guide Block bushings and slide the Guide Block between the arms of the Yoke aligning the Yoke 3 half turn at a time alternately till the Housing Cover Pin bushiras withthe lower Slicer Block pinhole is separated enough to pry off the Housing with a blunt 9 p tool 5 Grease the Yoke Pin 23 and slide it through the upper 7 Gently tap with plastic hammer or pull off the Guide Bar aa ie ne Yoke and the Guide Block pin bearings 2 from the Guide Block 25 and the Housing 1 locating it in the lower Slider Block hole Push the Yoke Pin down to touch the bottom Retainer Plate 8 Rotate and center the Yoke Assembly move the a eae 4 Guide Block towards
47. embly using ifting lugs on actuator that are meant only for the actuator Pressurizing cap end port on spring return actuators o overcome valve jamming or to compensate valve sealing problems aintenance by unauthorized personnel aintenance without de energizing Operating the actuator without end covers Altering the design to increase spring end load for compensating valve seating problems Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual PREVENTION MEASURES Refer to Introduction amp Installation sections in this manual and supporting product documentation If in doubt contact manufacturer Use of appropriate pressure limiting devices in the supply pressure line to limit the pressure o actuator s MOP is highly recommended and shall be ensured by the end user Refer to the aximum Operating Pressure sections in this manual Actuator MOP is printed on the name plate for ready reference Refer to name plate and to General Specifications section for the limits of service emperature of the supplied trim Ensuring the environmental conditions do not cause over he limit temperatures is end user s responsibility Clean dry media of instrumentation grade only shall be supplied Refer to Introduction section of this manual for specs Read Warnings in the Installation section of this manual and on the stickers pasted on actuators Use slings and tackles of sufficient capacity appropriately for lifting
48. entioned on the nameplate and shall not be exceeded Suitable pressure regulator and safety valve shall be incorporated in the supply line if the line pressure is higher than this N caution Do not pressurize from the cap end port of the spring return actuator This port is normally fitted with a breather filter If there is a possibility of the actuator being submerged temporarily in water due to flooding then this port must be provided with an extension pipe with the breather filter on the pipe end at a safe height above the water level Spring Return actuators work on air stroke or spring stroke by pressurizing or venting respectively the adaptor side port rod end side A 3 2 way valve is typically used DA models require alternate ports to be pressurized and vented for stroking A 5 2 or 5 3 way direction control valve or two 3 2 way valves may be used DD models have adaptor ports of the cylinders tubed in parallel with the end cap ports of the other side cylinder The two cylinders work simultaneously with cap end of one and rod end of the other pressurized at a time All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 5 detailed knowledge and experience with their application Bray Series 98
49. es 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual Adaptor Beware of the pinch points between the Piston and the Adaptor while lowering the Piston Assembly on the Adaptor inner face 8 Lubricate and install the Wear Bands 42 and the Piston 2 Lubricate the piston rod U cup Seal 37 and insert it in Quad Seal 43 on the Piston the groove in Adaptor Plate with the seal lip towards E piston side 9 Carefully lift and slide in the Barrel over the Piston Wear Bands Quad Seal and Adaptor O ring and push it down 3 Lubricate and install the Adaptor O ring 44 on to the Adaptor 4 Lubricate the piston rod O ring 41 and install in the 10 Thread ia Tie be ie the Adaptor use thread lock groove on the piston rod compound On tne teans o i 11 Lubricate the inside of the Barrel and slide in the End lower groove and slide in the Piston Rod hex side Cap h h the Piston till th lit collars in th mere de A A 12 Fasten the assembly with Tie Rod Nuts tightened to counter bore in the piston the recommended torque Refer to Section 10 Bolting 6 Install the Split Collars on the upper groove similarly and Torque Tables secure it by the Spiral Retainer Ring 13 Lift the Module using lifting eye bolts threaded into the 7 Lubricate the Piston Rod and carefully slide in the Piston Assembly through the Rod Seal and Bushing in the End Cap and place it horizontally Put back the Plug End Cover on the End Cap to
50. etting of the pump does not exceed the MOP setting refer to the table on DA Hydraulic MOP Use the plugged port on the pressure line Tee to connect a suitable pressure gage Set the pump relief valve to the MOP at the stroke end All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 29 detailed knowledge and experience with their application r MOP for DA Hydraulic Overrides Model MOP psi 1935 73 E2 bar 133 psi 2000 14 E3 bar 138 psi 2090 24 E3 bar 144 psi 2005 45 E3 bar 138 psi 2130 10 E4 bar 147 15 2 1 Operation DA Hydraulic Override 1 For Manual Override operation turn the 3 way valves on the pressure module to vent the cylinder ports to atmosphere and close the hydraulic bypass valve HBV Turn the lever on the direction control valve on the hand pump unit to select the direction of the actuator rotation and stroke the hand pump to reach the required valve position 2 To restore pneumatic operation turn the direction control valve to center position the HBV to Open position and switch the vent valves to connect the cylinder ports to the air supply lines caution Over thrust by the hydraulic override may cause actuator damage Prevent unsafe conditions and damage by a
51. g Hand PUMP UNIE esoo picha eee howe eh bb Se ae AE SE See 31 160 Jackscrewy Override s oscar Soe ee de a As Fae e 32 IS MISMO cerrar a AAA AAA AAA 32 16 1 1 Installing DA Jackscrew Override 0 o 32 16 1 2 Operating DA Jackscrew Override 2 ew eee ee ee ee RA ER EE E 33 16 2 Installing SR Jackscrew Override o 34 16 2 1 Operating SR Jackscrew Override 2 2 ee ee eR 34 17 0 Extended Stoppers oaoa 35 Ln staewONG e s 2 4 0248 2454 8 A II 35 17 1 1 Installing Extended Stopper for Torque Module o o o e 35 17 1 2 Adjusting Extended Stopper site ease he aa ARA A AA 36 17 2 Installing Extended Stopper for Spring Module 0 e 36 17 24 Adj sting Extended Stoppers lt 2 eea e eee SEES Seek Ev oe ee RES EES 36 Reference Drawings 44 so oo br eed Cae bee eee oe SS be ee eae Fees ob be 37 Trouble Shooting Potential Problems o lt 4 4 cae ee de RR RA eR we 38 For information on this product and other Bray products please visit us at our web page www bray com All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 2 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenan
52. g commercial leak check fluids Snoop or equivalent Leakage rate after hold down time shall not be much 9 Secure the Yoke Assembly and remove the Retainer 15 higher than 1 2 bubbles per minute with a 1 4 ID tube Stroke the piston a few times to set the seals if leakage is higher and repeat the bubble test If still not within the limits dismantle the module to examine the cause If no abnormalities are seen the Module is ready for assembly on the Torque Module Plate Screws 28 and the Retainer Plate 24 Pull out the Yoke Pin 23 and the upper Slider Block 22 Slide the Guide Block out of the Yoke 21 and remove the bottom Slider Block 12 Remove the Yoke sealing O rings 5 from the Housing 6 5 Torque Module and Housing Cover if replacement is required 6 5 1 Disassembling the Torque Module 13 The Yoke Bushing 4 in the Housing and the Housing NOTICE For SR actuators the Spring Module or the Pressure Module must be removed from the Torque Module to allow for removal of the Guide Bar and Yoke Assembly Cover the Guide Bar Bushing 26 and Yoke Pin Bushing 27 in the Guide Block are press fitted and may need suitable workshop tools for removal without damaging the housing 6 5 2 Service amp Reassembly of the Torque from the Torque Module Module For DA actuators remove the end cover on the Torque Note Thoroughly clean degrease all components prior to Module assembly Disconnect th
53. hread Spanner Size mm 17 19 19 24 24 30 30 36 36 46 36 46 46 335 410 610 330 540 685 Torque Nm 25 35 45 80 110 180 230 End Plug NPT Allen Key 755 1 1 1 i 1 End Plate Bolts M10 M10 M10 M10 M10 M10 M10 Spanner Size mm 17 17 17 17 17 17 17 Torque Nm Consumables Thread Sealant Loctite 577 Equivalent Thread Lock Loctite 234 Equivalent Lubricant Dow Corning Molykote 55 for standard actuators Refer to TS 00084 for Low High temperature trim lubricants 10 1 b Pressure Module MODEL Piston Rod Diameter inch 1 1 25 1 5 1 75 2 25 2 75 Rod Thread M24 x 2 M27 x2 M30 x 2 M36 x 3 M48 x 3 M60 x 4 Piston Rod Hex A F mm 21 26 32 36 46 55 Torque Nm 200 200 250 250 350 450 Piston Rod Minimum No of Turns 10 13 5 15 12 16 15 10 2 Torque Module MODEL 45 E2 Housing Cover Bolts Studs M8 M8 M10 M12 M12 M16 Spanner Size mm 18 13 17 19 19 24 Torque Nm 13 13 25 50 50 115 Retainer Plate Screws M5 M6 M6 M6 M6 M8 Allen Key mm 3 4 4 4 4 5 Acc Drive Screw M6 M6 M6 M8 M8 M10 Allen Key mm 5 5 5 6 6 8 Top Cover Bolts M6 M8 M8 M8 M8 M10 Allen Key mm 5 6 6 Spanner Size Metric 13 13 17 Consumables Thread Sealant Loctite 577 Equivalent Thread Lock Loctite 243 Equivalent Anti seize Loctite Ni Anti Seize Lubricant Shell Alvania Lead Free EP2 Grease for Standard Actuator Refe
54. is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual Bray J N WARNING The Spring Module is welded into an integral component and the internal components cannot be disassembled 6 4 1 Removing the Pressure Module from Actuator For Spring return actuators the spring rod shall be first disconnected following the steps 1 4 of 6 3 1 For Double acting actuators skip this step Spring within is under compression Never attempt to 2 l Apply low pressure air to the adaptor port to move the modify or cut open this module piston to end cap side 3 Depressurize and remove the Plug 46 or cover plate 4 To take the Spring Module off the actuator unscrew the on the End Cap 34 End Cover Bolts 58 remove the End Cover 55 and 4 Use an extended socket or tube spanner and unscrew the O ring 59 Using an extended socket spanner tube the Piston Rod 35 from the Guide Block 25 in Torque spanner unscrew and disconnect the Spring Rod 54 Module from the Guide Block 25 in Torque Module A retainer A ring on the threaded side of the Spring Rod stops it 5 Sling and support the Pressure Module Remove the from being taken out of the Spring Module Adaptor Stud Nuts 61 and Lock washers 62 Pressure Module can now be pulled off the Torque Modul
55. ithout the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application 33 Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 16 2 Installing SR Jackscrew Override 1 Disconnect the air pressure and the electrical power from actuator and ensure the actuator is at its fail safe position 2 Remove the end cover on the Spring module Retain replace the cover O ring 6 Install a suitable 3 position manual valve to the pneumatic cylinder s rod end port Refer to Figure D 3 Apply a drop of thread lock compound on the mounting stud threads and firmly tighten them into the spring i E EXIT module end cap Figure D Ww 16 2 1 Operating SR Jackscrew Override 4 Back off the jackscrew fully in the assembly and mount 1 TO test operate the override shut off the main air the jackscrew assembly on the spring module end cap supply and turn the 3 position valve on the cylinder port thrust base to vent the cylinder port to atmosphere The actuator should move to its fail safe position 2 Turn the hand wheel on the jackscrew to advance the screw into the spring module see direction markers on the hand wheel 3 Resistance will be felt when the thrust head of the jackscrew touches the end of the spring
56. lange Remove the hydraulic cylinder s tie rod nuts and the end cap without disturbing the cylinder barrel With a suitable socket tube spanner located on the hex head at the piston end thread and tighten the piston rod into the threading on Guide Block inside the Torque Module Refer to the table below for tightening torque Hydraulic Piston Rod Tightening Torque Torque 132 148 200 14 E3 184 250 24 E3 184 250 EA SESION 2 10 E4 55 450 Replace the end cap taking care not to damage the cap seal and tighten the tie rod nuts of the hydraulic cylinder Install the 3 way valves rated for 150 psi 10 3 bar working pressure on the pneumatic cylinder ports Refer to Figure B and turn them to venting position Mount the hydraulic pump assembly on the Torque Module s rear accessories pad as described in previous section Tube the ports of the hydraulic cylinder to the direction control valve s ports on the hydraulic hand pump unit Refer to Figure B Fill the reservoir with clean hydraulic fluid till about 1 2 from the top Fit back the filler breather cap Turn the direction control valve on the hand pump unit to direct oil flow to one of the cylinder ports Loosen the corresponding vent plug on the cylinder and stroke the hand pump to vent out air in the lines Tighten the vent plug when no more air bubbles are seen Repeat the same for the other side of the cylinder Check and ensure the Hydraulic pressure s
57. mation herein is proprietary and confidential and may not be co BRAY INTERNATIONAL Inc The technical data herein is for general infor detailed knowledge and experience with their application pied or reproduced without the expressed written consent of mation only Product suitability should be based solely upon customer s All statements technical information and recommendations in this bulletin are for general use only Consult Bray representa tives or factory for the specific requirements and material se lection for your intended application The right to change or modify product design or product without prior notice is reserved Patents issued and applied for worldwide Bray is a registered trademark of Bray International Inc 2015 Bray International Inc All rights reserved OM_S98PSYA_05_04_ 2015 YOUR GLOBAL FLOW CONTROL PARTNER Bray Controls A Division of Bray International Inc 13333 Westland East Blvd Houston Texas 77041 Tel 281 894 5454 e www bray com
58. n it J N WARNING Never remove the assembly fasteners without first backing off the Extended Stopper fully to release any load on it 17 2 Installing Extended Stopper for Spring Module NOTICE This Extended Stopper module is installed on Spring Module s thrust base The Extended Stopper is not designed as a jackscrew Do not use this to manually override the actuator Always 1 Disconnect air pressure and any electrical power from adjust the stopper with no load on it actuator 2 Remove the end cover on the Spring Module 3 Thread in and tighten the studs from the mounting kit into the Spring Module thrust base Use thread lock WARNING Loctite 242 or equivalent Locate the end cover O ring in the groove Never remove the assembly fasteners without first backing 4 Back off the stopper bolt and mount the Extended off the Extended Stopper fully to release any load on it Stopper assembly on the Spring Module end cap All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 36 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual REFERENCE DRAWINGS Description Drg Hydraulic Override Assembly DA ES 00
59. nder and piston assembly 2 Replace the u cup seal and wear ring on the piston with new ones Lubricate the seal and the wear ring with clean hydraulic fluid and carefully slide the piston into the cylinder 3 Replace the seals and guide bushing on the rod side nut and install the nut 4 Flush clean the oil tank and tubing fill fresh hydraulic fluid and re mount the cylinder on the Spring module connect the tubing and vent out the air from the line as described in the Installation Section 5 Operate the hydraulic override to test for correct operation 15 4 DA Override Cylinder 15 4 1 Disassembly of Hydraulic Cylinder 1 Operate the actuator so that the hydraulic cylinder piston is at the cap end side 2 Shift the direction control valve on the hand pump unit to mid position disconnect the air pressure and the electrical power from actuator and ensure it stays in this position Disconnect the hydraulic tubing from the cylinder ports 4 Remove the tie rod nuts off the hydraulic cylinder and pull the end cap off the barrel All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 30 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations
60. ng pressure charts or the name plate on the actuator for the maximum operating pressure Operating media shall be clean and dry in accordance to ISO 8573 1 Class 2 3 4 filtered to 5 microns or better with pressure dew point of 20 C 4 F or at least 10 C 18 F below ambient temperature The user shall plan and implement a periodic maintenance program to ensure the service conditions continue as intended and the actuator is monitored and maintained per manufacturer s recommendations 3 0 INSTALLATION The S98 actuators are assembled tested and delivered per the configuration ordered The mounting of the actuator may be direct onto the valve or may require a mounting kit that would include a bracket coupler shaft with keys and hardware Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual WARNING Use appropriate tackles and slings to lift the actuator Refer to Technical Data table for the approximate actuator weight The lifting lugs provided are for lifting the actuator only and not for lifting the complete valve actuator accessory assembly NOTICE e The user shall ensure installation in intended service conditions and that the actuator is not covered with dirt dust or other substances that may affect any heat dissipation capability resulting in exceeding the maximum temperature rating of the actuator To prolong actuator seal life use only permitted media of recommended quality
61. on either side Mn Max m 1 1 1 Base Min z CONFIGURATIONS w fee acia Dt O OOOO OPERATING CONDITIONS Standard 20 F to 200 F 29 C to 93 C Temperature Range 7 j High Temp Up to 300 F 149 C Standard Options Contact factory for extended ranges Low Temp Down to 50 F 46 C COMPLIANCES Mounting dimensions options per ISO 5211 2001 E or MSS SP 101 1989 Shaft Driven Accessories Mounting as per NAMUR VDE In accordance with EN 15714 3 2009 IP66 IP67M per IEC 60529 All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 27 detailed knowledge and experience with their application r 15 0 HYDRAULIC OVERRIDE Hydraulic overrides on S98 actuators provide low effort high thrust in a compact size for manually operating the actuator The hydraulic override cylinders are single acting on the SR models and double acting on the DA models of the Actuators These are available on Models 73E2 through 10E4 The hydraulic override consists of a power pack with a hand operated high pressure pump and oil reservoir connected by tubing to the hydraulic override cylinder The hydraulic cylinder is mounted on the Spring Module end thrust base on SR models and on the Torque Module flange on the DA
62. or Operations and Maintenance Manual 11 0 Technical Datas o s 2 eo ee oboe 0444 9 6 Pe ee oe eh eee eae heb eee Os GS 20 11 1 Double Acting Actuators sedas ee SSK De AA Ree SS SH 20 11 2 Spring Return Actuators 3 eb Eee eee Eee rr Ee ee eS 21 120 Module Weights e r i e ee 64 68 4 SR SS Eee Beye bh bE ea OHS Ee Bee 25 12 0 Series 98 DIMENSIONS 3 lt 28 Sy ed eee Oe doe Bee eee eee eos kee eee ew 2S 2 26 14 0 Series 98 General Specifications and Features 2 2 oa a 27 15 0 Fiyoraulic OVEMIGe s s 252 24 208 cies naar A AAA 28 A 4 ae amp ee ete ee E ee ee ee se od 28 15 1 1 Installing Hydraulic Override on Spring Return Actuators oaoa a a 28 15 1 2 Operation Spring Return Hydraulic Override o o e 2 29 15 2 Installing Hydraulic Override on DA Actuator 2 ao a 29 15 2 1 Operation DA Hydraulic Override 22 224 824242464 24 e bee eee Ew E RS 30 15 3 Maintenance of Hydraulic Override as sc ciencias trek a beee Se baw Gaeta 30 15 3 1 Spring Return Hydraulic Override Cylinder 22 02022000 30 15 3 2 Disassembly of Hydraulic Cylinder 2 2 o o e 30 15 43 Servicing Hydraulic Cylinder s e s stan BER eee eRe Oe ed SRS SRE KEES 30 15 4 DA Override Cylinder 2 40452 4644 4 5 Pewee es og eee oes eee ee YE Se os 30 15 4 1 Disassembly of Hydraulic Cylinder 2 2 2 2 2444 eb a2 ee Ree Rew eR De KE ew 30 15 4 2 Servicing Hydraulic Cylinder 2 2 2 o e 31 153 Servicin
63. ort if not already fitted into the cylinder Use a commercial hydraulic fitting thread sealant Loctite 542 or equivalent Fit a 3 way valve rated for 150 psi 10 3 bar working pressure to the pneumatic module s port Refer to Figure A Turn the valve to venting position so that the pneumatic cylinder s port is connected to atmosphere Fit the hydraulic hand pump assembly bracket on the rear accessories mounting pad of the Torque Module with the 4 bolts supplied in the kit Tube the cylinder port to the pump outlet port as in Figure A The standard mounting as shown is for the actuator in horizontal orientation Special brackets for other orientations of the actuator can be supplied upon request On the Tee fitting at the pump outlet remove the plug and install a suitable pressure gage 0 4000psi 10 11 Remove the filler breather cap and fill the reservoir till about 1 2 from the top with hydraulic fluid ISO 32 grade for standard temperature service Install the breather cap on the reservoir do not substitute the breather cap with a plug Stroke the pump a few times with the pressure release valve on the pump open to bleed air out of pump Lightly loosen the air vent screw on the cylinder flange to bleed off air from the hydraulic lines Close the pressure release valve on the pump and stroke the hydraulic pump till the pressure builds up Tighten the vent plug when no more air bubbles bleed out The piston
64. r to TS00084 for Low High temperature trim lubricants All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 18 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 10 3 Spring Module MODEL Spring Rod Diameter inch Rod Thread M24 x 2 Spring Rod Hex A F mm 21 M27 x 2 M30 x2 M36 x 3 M48 x3 M60 x 4 26 32 36 46 55 Torque Nm Spring Rod Minimum No of Turns 10 13 5 15 12 16 15 End Cover Bolt M12 M12 M16 M16 M16 M20 Spanner Size mm 10 4 Actuator Assembly MODEL 45 E2 ISO Base F16 F12 F16 F12 Base Bolting Size M20 M12 M20 M12 Module Mounting Stud Nut Size M10 M12 F25 F16 F30 F25 F35 F30 F40 F35 M16 M20 M20 M16 M30 M20 M36 M30 M12 M16 M16 M24 19 24 24 36 Spanner Size Metric A 19 Torque Nm Consumables Thread Sealant Loctite 577 Equivalent Thread Lock Loctite 243 Equivalent Lubricant Shell Alvania Lead free EP2 Grease for Standard Actuator Refer to TS 00084 for Low High temp trim lubricants All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written
65. refer to the torque charts and ensure the actuator s torques would be suitable for the new application The fail safe direction on Series 98 spring return actuator can be reversed from fail CW to fail CCW and vise versa This requires interchanging the position of Pressure and Spring Modules NOTICE It is strongly recommended to take the actuator off the valve to do the fail safe reversal N CAUTION Never try to unscrew and remove the Spring Rod without completely relieving the spring load on it 1 Follow the steps for removing the Spring and Pressure Modules from the actuator as described in Sections 6 3 and 6 4 respectively 2 Switch the positions of the two modules mount the Pressure Module first Take care to seat the module sealing O ring properly in the groove Pressure Module will need to be flipped about its axis before mounting to get the ports to the front of the actuator 3 Follow instructions in Section 6 6 Reassembly of the Actuator 4 Mount the Actuator back on the valve gearbox and adjust the travel stop bolts as required for proper valve operation Tighten the Lock Nuts on the travel Stop Bolts 5 Check actuator for proper operation at the rated working pressure Fail Direction fr oy Actuator Configuration NOTICE
66. rod 4 Turning the hand wheel further will compress the spring and simultaneously turn the actuator NOTICE The spring constantly loads on the jackscrew and returns the actuator to fail safe state when the jackscrew is retracted Bring the actuator to fail safe position and 5 Locate the Jackscrew assembly flange into the studs and turn the 3 position valve on cylinder port to connect to fasten with the supplied nuts and lock washers air supply to restore auto operation mode caution Never disassemble the Jackscrew assembly with the spring load on the screw Severe injuries damage can result due to non compliance Retract the jackscrew completely to free the load before attempting any maintenance on the assembly All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 34 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application r 17 0 EXTENDED STOPPERS Extended Stoppers allow restriction of the actuator rotation angle higher than the travel stops provided on the Torque Module These Extended Stoppers modules fit on the Torque Module for single cylinder double acting actuators and on the Spring Module for the spring return actuators The standard extended stops restrict the linear stroke of the Gui
67. rod advances to press against the Spring Rod s end face and the thrust from the hydraulic pressure effects the override function Note the maximum hydraulic pressure setting for the actuator model refer to the SR Hydraulic MOP table Check the hydraulic pressure on the gage at the end of the actuator s stroke Refer to the hand pump service manual and adjust the overload valve setting on the pump to the MOP All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of 28 BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application Operations and Maintenance Manual Y Bray Series 98 Pneumatic Scotch Yoke Actuator MOP for SR Hydraulic Overrides Spring Number Model MOP A 2 3 4 5 psi 1585 1880 2425 2740 73 E2 bar 109 130 167 189 PS Ss ee Res a eo bar 91 105 122 156 187 ag PSI 1290 1530 1950 2260 2595 bar 89 105 134 156 179 psi 185 1415 1615 1855 2155 45 E3 bar 82 98 111 128 149 soga PSi_ 2465 3005 3630 4400 bar 170 207 250 303 15 1 2 Operation Spring Return Hydraulic Override fu CN i ie ew X
68. section in this manual for replacement and testing procedures Valve problem bearing seal friction damaged parts Refer to valve manufacturer s IOM O oo ooo ooo ooo Incomplete Stroke Stoppers set incorrectly Check and adjust Foreign object left inside during maintenance Disassemble inspect for damages and correct Manual override in wrong position Check and fully retract manual override devices for proper automatic Operation Valve problem Restriction friction incorrect valve Refer to valve manufacturer s IOM stopper Loss of power Supply pressure inadequate Check and correct supply pressure to operating pressure Inadequate flow Check flow control devices and adjust for sufficient flow Repair any kinked tubing Tubing or exhaust vents blocked Check and clean the vents silencers and tubing Pressure Module seals leaking Check leaks and replace seals Refer to the procedures under Pressure Module section in this manual for replacement and testing procedures Defective Accessories Inadequate capacity Refer to accessory manufacturer s IOM manual and specs Valve jammed or requires higher torque Refer to valve manufacturer s IOM No response to Altered schematic Check if the control circuit is as per the supplied schematic Correct the energizing circuit if altered Solenoid valve positioner control elements malfunction Check Refer to accessory manufacturer s IOM manual for troubleshooting
69. the Yoke center and lift the Yoke ee eae Upper alae do and slide ui down on the Yoke Pin through the upper slot till it rests Assembly out of Housing on the Guide Block 7 Fit the upper Retainer Plate to complete the Yoke Assembly All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s 11 detailed knowledge and experience with their application Bray 10 11 12 13 14 15 Lubricate and Install the Yoke O ring 5 in the Housing and grease the bushing and the Yoke seating raised face Carefully slide in the Yoke Assembly into the Housing bushing and push it down to seat it on the raised seating face in the Housing Grease and slide in the Guide Bar 2 through the Housing and Guide Block Screw in the accessory drive shaft assembly Screw 17 on top of the Yoke applying a drop of thread lock compound Grease the upper journal of the Yoke Lubricate and install the Yoke O ring and Cover O ring 6 in the Housing Cover and locate it on the Yoke upper journal and fit the Housing Cover on the Housing with the Cover Bolts 12 Ensure the set screws on the Housing Cover are backed off fully Locate the Accessory Drive Shaft Assembly on the top of the Yoke locating the plate slot into the
70. x Bolt Stee 8 37 Seal U Cup Buna N 2 3 Spring Washer Spring Steel 8 38 Split Collar Alloy Steel 8 14 Set Screw Socket Head Stee 2 39 Tie Rod Steel 8 15 Dowel Pin Hardened Steel 4 40 Locknut Nylok Steel 8 6 Socket Head Caps Screw Stee 4 41 O Ring Piston Rod Buna N 2 17 Socket Head Caps Screw Low Head Stee 1 42 Wear Ring PTFE 4 8 Seal Nut Stee 2 43 Quad Seal Buna N 2 9 Stop Bolt Stee 2 44 O Ring Barrel Buna N 4 20 Breather Vents Carbon Steel 1 45 Retainer Ring Stainless Steel 2 21 Yoke Ductile Iron 1 46 Pipe Plug Carbon Steel 2 22 Slider Block Bronze 2 47 O Ring Module Buna N 2 23 Yoke Pin Alloy Steel 1 48 Stud Steel 12 24 Retainer Plate Plastic 2 49 Spring Washer Spring Steel 12 25 Guide Block Carbon Steel 1 50 Nut Steel 12 Parts in Seal Kits amp Parts in Repair Kits For reference only Please refer to current revision of ES 00021 drawing for more information All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL Inc The technical data herein is for general information only Product suitability should be based solely upon customer s detailed knowledge and experience with their application 17 Bray Series 98 Pneumatic Scotch Yoke Actuator Operations and Maintenance Manual 10 0 BOLTING TORQUES AND TOOLS 10 1 a Pressure Module 9 10 Tie Rod T
71. y upon customer s 31 detailed knowledge and experience with their application r 16 0 JACKSCREW OVERRIDE Jackscrews provide an economical manual override option on the actuator for use in case of air failure These jackscrews come in two types direct hand wheel operated and bevel gearbox driven The direct hand wheel jackscrew has a rotating screw threading into a bronze nut when installed on the Torque module of DA actuators and on the Spring module of Spring Return actuators The hand wheel directly turns the screw or nut to move the jackscrew forward or back The bevel gearbox driven jackscrews are required to reduce the manual effort on larger actuator models and stiffer springs that require higher thrust to compress Here the screw translates with an anti rotation arrangement 16 1 Installation Jackscrew overrides are usually factory installed on the actuator Override units are shipped with the jackscrew assembly installed on the actuator so that the actuator is ready for installation in the auto operation mode No additional customer installation is required If a field retrofit is required on actuators without a manual override the installation instructions provide a guide for a qualified technician to install and operate the Jackscrew overrides 16 1 1 Installing DA Jackscrew Override 1 Disconnect the air pressure and the electrical power from actuator 2 Remove the DA end cover from the actuator re

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