Bray Series 98 Scotch Yoke Pneumatic Actuator Operations and Maintenance Manual

Series 98

Pneumatic Scotch Yoke Actuator

Operation and Maintenance Manual

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

TABLE OF CONTENTS

1.0 - Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Hazard-free Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.0 Spring Return Pneumatic Actuator Assembly Drawing and Materials of Construction . . . . . . . . . . . 6

6.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.1 Lubricants and Maintenance Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.2 Disassembly, Service & Reassembly of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.3 Spring Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.3.1 Removing the Spring Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.3.2 Service & Reassembly of the Spring Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.4 Pressure Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.4.1 Removing the Pressure Module from Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.4.2 Disassembling the Pressure Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.4.3 Service & Reassembly of the Pressure Module . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.5 Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.5.1 Disassembling the Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.5.2 Service & Reassembly of the Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.6 Reassembly of Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.0 Field Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.1 Fail Safe Condition (for Spring Return Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.2 Double Acting to Spring Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.3 Spring Return to Double Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Bolting Torques and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

10.1.a - Pressure Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

10.1.b - Pressure Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

10.2 - Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

10.3 - Spring Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

10.4 - Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 detailed knowledge and experience with their application.

1

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

11.0 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

11.1 - Double Acting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

11.2 - Spring Return Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

12.0 Module Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

13.0 Series 98 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

14.0 Series 98 General Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

15.0 Hydraulic Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

15.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

15.1.1 Installing Hydraulic Override on Spring Return Actuators . . . . . . . . . . . . . . . . . . . 28

15.1.2 Operation - Spring Return Hydraulic Override . . . . . . . . . . . . . . . . . . . . . . . . 29

15.2 Installing Hydraulic Override on DA Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

15.2.1 Operation – DA Hydraulic Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.3 Maintenance of Hydraulic Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.3.1 Spring Return Hydraulic Override Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.3.2 Disassembly of Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.3.3 Servicing Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.4 DA Override Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.4.1 Disassembly of Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15.4.2 Servicing Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

15.5 Servicing Hand Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

16.0 Jackscrew Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16.1.1 Installing DA Jackscrew Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16.1.2 Operating DA Jackscrew Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

16.2 Installing SR Jackscrew Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

16.2.1 Operating SR Jackscrew Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

17.0 Extended Stoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

17.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

17.1.1 Installing Extended Stopper for Torque Module . . . . . . . . . . . . . . . . . . . . . . . 35

17.1.2 Adjusting Extended Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

17.2 Installing Extended Stopper for Spring Module. . . . . . . . . . . . . . . . . . . . . . . . . . . 36

17.2.1 Adjusting Extended Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Trouble Shooting Potential Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2

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

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

Read and Follow These Instructions

Save These Instructions

1.0 - DEFINITION OF TERMS

indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

used without the safety alert symbol indicates a potential situation which, if not avoided, m ay result in an undesirable result or state, including property damage.

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.

• 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.

• 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.

• 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.

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 detailed knowledge and experience with their application.

3

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

2.0 INTRODUCTION

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 operating 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.

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-actuatoraccessory assembly.

NOTICE

• 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.

• The actuator shall not be installed in hazardous areas incompatible with the defined gas groups and temperature class.

• 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.

4

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

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 override, 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.

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 mentioned 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.

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 detailed knowledge and experience with their application.

5

R

DIVISION

BTSI

THIRD ANGLE

PRIMARY UNITS

MM

CUSTOMER ERN DRAWING NO.

GENERAL ASSEMBLY, SERIES 98,

SPRING RETURN PNEUMATIC ACTUATOR

5.0 Spring Return Pneumatic Actuator Assembly Drawing and

Materials of Construction

44 32 33 43

34

42

44

31

2

25

26 56

47

B

54 52

48

51

49

46

40

39

D

C

50

63

35 63

66

62 61 60

A

1

60 61 62

18

19

27

6

64

28 24 3

22

23

5

21

12 13

4

17

53

11

30

29 14

36

54 37

A

7 16

15

20

36

4

SECTION A-A

8

5

10

9

68

70

65

45

38

DETAIL B

41

38

59

DETAIL C

57 58

67

E

55

6

DETAIL D

DETAIL E

69

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

ITEM

1

2

DESCRIPTION

Yoke Housing

Guide Rod

3 Housing Cover

4 ** Bushing (Yoke)

5 * O-Ring (Yoke)

6 *

7

8 *

O-Ring (Cover)

Top Cover

O-Ring (Top Cover)

MATERIAL

Ductile Iron

Alloy Steel

Ductile Iron

PTFE Bronze

Buna-N

Buna-N

Ductile Iron

Buna-N

17

18

19

14

15

16

20

21

9 ** Flanged Bushing

10 * O-Ring (Accessory Drive)

11 Accessory Drive

12

13

Hex Bolt

Spring Washer

Set Screw, Socket Head

Dowel Pin

Socket Head Caps Screw

Seal Nut

Stop Bolt

Breather Vents

Yoke

PTFE Bronze

Buna-N

Stainless Steel

Steel

Spring Steel

Steel 2

Hardened Steel 4

Steel 4

Socket Head Caps Screw, Low Head Steel

Steel

Steel

Carbon Steel

Ductile Iron

1

1

1

2

2

1

1

1

8

8

1

1

1

1

2

2

QTY .

1

1

28

29

30

31

32

22 ** Slider Block

23 Yoke Pin

24 Retainer Plate

25 Guide Block

26 ** Bushing (Guide Rod)

27 ** Bushing (Yoke Pin)

Cap Screw, Flat Head, Hex Socket

Position Indicator

Cap Screw, Flat Head, Hex Socket

Adaptor, Pressure Module

Barrel

Bronze

Alloy Steel

Plastic

Carbon Steel

PTFE Bronze

PTFE Bronze

Steel

Plastic

Steel

Ductile Iron

Carbon Steel

8

1

1

1

1

1

2

2

2

1

2

54

55

56

57

58

59 *

60

61

62

63 *

64

49

50

51

52

53

46

47

48

43 *

44 *

45

ITEM

33

34

DESCRIPTION

Piston

End Cap, Pressure Module

38

39

40

35 Piston Rod

36 ** Bushing (Adaptor)

37 * Seal, U-Cup

41 *

42 *

Split Collar

Tie Rod

Locknut, Nylok

O-Ring (Piston Rod)

Wear Ring

Quad Seal

O-Ring (Barrel)

Retainer Ring

Pipe Plug

Adaptor, Spring Module

Pipe

End Cap, Spring Module

Spring Guide

Button

Spring, Compression

Lifting Lug

Spring Rod

End Cover

Retainer Ring

Spring Washer

Hex Bolt

O-Ring (End Cover)

Stud

Nut

Spring Washer

O-Ring (Module)

Load Ring

* Parts in Seal Kits

*

&

** Parts in Repair Kits

1

1

9

1

1

1

1

1

1

2

1

4

4

4

1

2

1

2

1

QTY

.

1

1

4

4

1

12

12

1

1

1

12

2

1

MATERIAL

Ductile Iron

Ductile Iron

Alloy Steel

PTFE Bronze

Buna-N

Alloy Steel

Steel

Steel

Buna-N

PTFE

Buna-N

Buna-N

Stainless Steel

Carbon Steel

Carbon Steel

Carbon Steel

Carbon Steel

Carbon Steel

Plastic

Alloy Steel

Carbon Steel

Alloy Steel

Carbon Steel

Stainless Steel

Spring Steel

Steel

Buna-N

Steel

Steel

Spring Steel

Buna-N

Carbon Steel

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.

7

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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 f requenc y 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.

6.1 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 & 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 & 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).

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

WARNING

Follow the sequence of steps as described below. Injury or 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.

CAUTION

Never try to loosen the Spring Rod without completely relieving the spring load on it.

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.

3. Remove the Extended Stopper/ override assembly, if present, from the Spring Module by unfastening the bolts holding the assembly on the End Cap.

8

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

WARNING

The Spring Module is welded into an integral component and the internal components cannot be disassembled.

Spring within is under compression. Never attempt to modify or cut open this module.

4. To take the Spring Module off the actuator, unscrew the

End Cover Bolts (58), remove the End Cover (55) and the O-ring (59). Using an extended socket spanner /tube spanner, unscrew and disconnect the Spring Rod (54) from the Guide Block (25) in Torque Module. A retainer ring on the threaded side of the Spring Rod stops it from being taken out of the Spring Module.

5. Sling and support the Spring Module and remove the

Module’s mounting flange Stud Nuts (61) and Lock washers (62). Spring Module can now be pulled off 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 & Reassembly of the Spring

Module

Ensure that a correct Repair Kit is on hand, prior to disassembly.

1. Take the Retainer Ring (56) off and pull the Spring Rod out from the cover end.

2. Replace the Bushing (Adaptor) (36), clean and lubricate the Spring Rod and slide it back in.

3. Install the Retainer Ring back in the Spring Rod groove.

4. Fit the Module back on Torque Module with new O-ring

(63).

5. Fit End Cover back with new O-ring (59).

6.4 Pressure Module

6.4.1 Removing the Pressure Module from

Actuator

1. 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.

2. Apply low pressure air to the adaptor port to move the piston to end cap side.

3. Depressurize and remove the Plug (46) (or cover plate) on the End Cap (34).

4. Use an extended socket or tube spanner and unscrew the Piston Rod (35) from the Guide Block (25) in Torque

Module.

5. Sling and support the Pressure Module. Remove the

Adaptor Stud Nuts (61) and Lock washers (62). Pressure

Module can now be pulled off the Torque Module.

Pull off the module carefully so as not to damage the threads on the Piston Rod and studs on the Adaptor.

6. Ensure the Module sealing O-ring (63) is retained in the groove.

6.4.2 Disassembling the Pressure Module

1. Secure the Module and unscrew the Tie Rod Nuts (40).

2. Gently tap the End Cap (34) off the cylinder Barrel (32) with a plastic mallet and remove the End Cap.

3. Slide the Barrel over and off the Adaptor (31) and Piston

(33), being careful not to scratch or dent the honed and chrome plated surface of the barrel.

4. Take the Piston Assembly off the Adaptor, taking care not to damage the threads.

5. Tie Rods (39) may be unscrewed from the Adaptor Plate.

6. Remove the Retainer Ring (45) and take the Split Collars

(38) off the Piston Rod (35) upper groove. Pull the Piston

Rod off the Piston and remove the Split Collars from the lower groove.

6.4.3 Service & Reassembly of the Pressure

Module

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.

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.

9

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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.

Adaptor. Beware of the pinch points between the Piston and the Adaptor while lowering the Piston Assembly on the Adaptor inner face.

2. Lubricate the piston rod U-cup Seal (37) and insert it in the groove in Adaptor Plate with the seal lip towards piston side.

3. Lubricate and install the Adaptor O-ring (44).

8. Lubricate and install the Wear Bands (42) and the Piston

Quad Seal (43) on the Piston.

9. Carefully lift and slide in the Barrel over the Piston Wear

Bands, Quad Seal and Adaptor O-ring and push it down on to the Adaptor.

4. Lubricate the piston rod O-ring (41) and install in the groove on the piston rod.

R

PRIMARY UNITS

6. Install the Split Collars on the upper groove similarly and

10. Thread the Tie Rods into the Adaptor, use thread lock compound on the threads.

BTSI

11. Lubricate the inside of the Barrel and slide in the End

5. Grease and slip in the Split Collars on the Piston Rod lower groove and slide in the Piston Rod (hex side) through the Piston till the split collars locate in the counter bore in the piston.

Cap, aligning the ports on the Adaptor and the End

Cap.

12. Fasten the assembly with Tie Rod Nuts tightened to the recommended torque. (Refer to Section 10 Bolting

Torque Tables)

04/15/2015 1 OF 2 2 secure it by the Spiral Retainer Ring.

Assembly through the Rod Seal and Bushing in the

13. Lift the Module using lifting eye bolts threaded into the

End Cap and place it horizontally. Put back the Plug/End

Cover on the End Cap to test the module.

44 32 33 43 42 44

31

2

25

26

34

46

40

39

66

62 61 60

D

C

28

63 35

A

24 3

1

60 61 62

56

64

47

B

18

19

63

22

23

5

21

27

54 52

6

48

50

12 13

4

17

53

11

51

49

E

55

10

30

29 14 A

7 16

15

20

36

54 37 36 detailed knowledge and experience with their application.

4

68

SECTION A-A

10

9

8

5

70

65

45

38

DETAIL B

41

38

59

DETAIL C

57 58

67

DETAIL D

DETAIL E

NOTE: REFER SHEET 2 FOR BILL OF MATERIALS

69

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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.

Leak test the piston seal by bubble test at 80 psi pressure and for other seals check visually using commercial leak check fluids (Snoop or equivalent).

Leakage rate after hold down time shall not be much 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.

15. If no abnormalities are seen, the Module is ready for assembly on the Torque Module.

6.5 Torque Module

6.5.1 Disassembling the Torque Module

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 from the Torque Module.

For DA actuators, remove the end cover on the Torque

Module.

1. Disconnect the Piston Rod (35) and the Spring Rod (54) from the Guide Block prior to disassembly.

2. Remove the position Indicator (29), if provided.

3. Remove Top Cover Bolts (16) and the Top Cover (7).

4. Take off the Accessory Drive Shaft Assembly (11) from top of the Yoke.

5. Remove the Housing Cover Bolts (12) and Lock Washers

(13).

6. Tighten the two Set Screws (14) on the Housing Cover

(3), half turn at a time alternately till the Housing Cover is separated enough to pry off the Housing with a blunt tool.

7. Gently tap with plastic hammer or pull off the Guide Bar

(2) from the Guide Block (25) and the Housing (1).

8. Rotate and center the Yoke Assembly, move the

Guide Block towards the Yoke center and lift the Yoke

Assembly out of Housing.

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.

9. Secure the Yoke Assembly and remove the Retainer

Plate Screws (28) and the Retainer Plate (24).

10. Pull out the Yoke Pin (23), and the upper Slider Block

(22).

11. 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 and Housing Cover, if replacement is required.

13. The Yoke Bushing (4) in the Housing and the Housing

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 & Reassembly of the Torque

Module

Note: Thoroughly clean/degrease all components prior to assembly.

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

(24) with Screws (28), applying a drop of thread lock compound on the screw threads.

3. Flip the Yoke over, grease the bottom slot and the Slider

Block (22) generously and slide the Slider Block into the slot.

4. Grease the Guide Block bushings and slide the Guide

Block between the arms of the Yoke aligning the Yoke

Pin bushings with the lower Slider Block pin hole.

5. Grease the Yoke Pin (23) and slide it through the upper slot in the Yoke and the Guide Block pin bearings, locating it in the lower Slider Block hole. Push the Yoke

Pin down to touch the bottom Retainer Plate.

6. Grease the upper slot and the Slider Block and slide it down on the Yoke Pin through the upper slot till it rests 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 detailed knowledge and experience with their application.

11

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

8. Lubricate and Install the Yoke O-ring (5) in the Housing and grease the bushing and the Yoke seating raised face.

9. 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.

10. Grease and slide in the Guide Bar (2) through the

Housing and Guide Block.

11. 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.

12. 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.

13. Locate the Accessory Drive Shaft Assembly on the top of the Yoke, locating the plate slot into the screw head.

14. 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.

15. 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

1. Secure the Torque Module on its base.

2. 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.

3. 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.

4. Carefully guide the Studs into the flange and center the module on the spigot.

5. Fasten the modules with Spring Washers and Stud Nuts, refer to the tables for torque values.

6. 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.

7. 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.

8. For DA 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.

9. 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.

10. 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.

11. Fix the End Cover with O-ring on the Spring Module (or the Extended Travel Stop/Jackscrew Assembly/Hydraulic override cylinder, if provided).

12. Set the Travel Stops to previously marked positions.

13. Test the actuator for smooth operation at the Maximum

Operating Pressure, as noted on the nameplate.

12

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

7.0 FIELD CONVERSIONS

7.1 Fail Safe Condition (for Spring Return

Actuators)

Prior to configuration change, 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.

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.

NOTICE

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 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 detailed knowledge and experience with their application.

13

R

DIVISION

BTSI

THIRD ANGLE

PRIMARY UNITS

MM

IOM/MANUALS

CUSTOMER ERN

164104

RELEASED BTSI Deepak Divakaran

04/15/2015

DRAWING NO.

ES-00020

SHEET

1 OF 2

REV.

2

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

DOUBLE ACTING, SINGLE CYLINDER

8.0 Pneumatic Actuator - Double Acting, Single Cylinder Assembly and

Materials of Construction

44 32 43 42 33 44

31

26

A

25

2

6

34

46

22

23

5

27

52

40

39

C

B

21

47

4

47

35

1

A

18

19

SECTION A-A

10

9

8

5

12 13

4

17

11

50 49 48 28 24 3 51 49 50

37 36

45

38

41

38

30

29

14 7

16

15

20

DETAIL B

55

DETAIL C

54

For reference only. Please refer to current revision of ES-00020 drawing for more information.

14

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.

56

53

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

ITEM

1

DESCRIPTION

Yoke Housing

2

3

Guide Rod

Housing Cover

4 ** Bushing (Yoke)

5

6

7

* O-Ring (Yoke)

* O-Ring (Cover)

Top Cover

8 * O-Ring (Top Cover)

9 ** Flanged Bushing

MATERIAL

Ductile Iron

Alloy Steel

Ductile Iron

PTFE Bronze

Buna-N

Buna-N

Ductile Iron

Buna-N

PTFE Bronze

13

14

15

10 * O-Ring (Accessory Drive)

11 Accessory Drive

12 Hex Bolt

16

17

Spring Washer

Set Screw, Socket Head

Dowel Pin

Socket Head Caps Screw

Buna-N

Stainless Steel

Steel

Spring Steel

Steel

8

2

Hardened Steel 4

Steel

Socket Head Caps Screw, Low Head Steel

4

1

1

1

8

18

19

20

Seal Nut

Stop Bolt

Breather Vents

21 Yoke

22 ** Slider Block

23 Yoke Pin

24

25

Retainer Plate

Guide Block

26 ** Bushing (Guide Rod)

Steel

Steel

Carbon Steel

Ductile Iron

Bronze

Alloy Steel

Plastic

Carbon Steel

PTFE Bronze

2

1

2

1

2

1

2

2

1

2

1

1

1

1

QTY.

1

1

1

2

31

32

33

34

35

ITEM DESCRIPTION

27 ** Bushing (Yoke Pin)

28

29

30

Cap Screw, Flat Head, Hex Socket

Position Indicator

Cap Screw, Flat Head, Hex Socket

MATERIAL

PTFE Bronze

Steel

Plastic

Steel

Adaptor, Pressure Module

Barrel

Piston

End Cap, Pressure Module

Piston Rod

Ductile Iron

Carbon Steel

Ductile Iron

Ductile Iron

Alloy Steel

47

48

49

44

45

46

50

51

52

39

40

41

36 ** Bushing (Adaptor)

37 * Seal, U-Cup

38 Split Collar

42

43

*

*

*

Tie Rod

Locknut, Nylok

O-Ring (Piston Rod)

Wear Ring

Quad Seal

* O-Ring (Barrel)

Retainer Ring

Pipe Plug

* O-Ring (Module)

Stud

Spring Washer

Nut

Stud

End Cover, DA

PTFE Bronze

Buna-N

Alloy Steel

Steel

Steel

Buna-N

PTFE

Buna-N

Buna-N

Stainless Steel

Carbon Steel

Buna-N

Steel

Spring Steel

Steel

Steel

Ductile Iron

2

6

18

2

1

1

18

6

1

4

4

1

2

1

1

1

4

1

1

1

1

1

QTY.

2

8

1

1

* Parts in Seal Kits

*

&

**

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

R

DIVISION

BTSI

THIRD ANGLE

PRIMARY UNITS

MM

CUSTOMER ERN

164104

DRAWING NO.

ES-00021

Bray Series 98 Pneumatic Scotch Yoke Actuator

IOM/MANUALS

GENERAL ASSEMBLY, SERIES 98,

PNEUMATIC ACTUATOR,

DOUBLE ACTING, DUAL CYLINDER

9.0 Pneumatic Actuator - Double Acting, Dual Cylinder Assembly and

Materials of Construction

44 43 42 44 42 43 44

47

2

25

A

47

26

44

C

46

46

B

34

33 32 31 35

18

19 1

A

48 50 49

28 24 3

35 31

48 50 49

32

33 34

40

39

40

39

27

22

23

5

21

4

6

SECTION A-A

10

9

8

5

12 52 13

51

17

11

30

29

14

36

7

16

15

20

37

DETAIL B

56

38

45

DETAIL C

55

53

56

54

41

38

16

54

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.

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

ITEM

1

DESCRIPTION

Yoke Housing

2

3

Guide Rod

Housing Cover

4 ** Bushing (Yoke)

5

6

7

* O-Ring (Yoke)

* O-Ring (Cover)

Top Cover

8 * O-Ring (Top Cover)

9 ** Flanged Bushing

MATERIAL

Ductile Iron

Alloy Steel

Ductile Iron

PTFE Bronze

Buna-N

Buna-N

Ductile Iron

Buna-N

PTFE Bronze

13

14

15

10 * O-Ring (Accessory Drive)

11 Accessory Drive

12 Hex Bolt

16

17

Spring Washer

Set Screw, Socket Head

Dowel Pin

Socket Head Caps Screw

Buna-N

Stainless Steel

Steel

Spring Steel

Steel

8

2

Hardened Steel 4

Steel

Socket Head Caps Screw, Low Head Steel

4

1

1

1

8

18

19

20

Seal Nut

Stop Bolt

Breather Vents

21 Yoke

22 ** Slider Block

23 Yoke Pin

24

25

Retainer Plate

Guide Block

Steel

Steel

Carbon Steel

Ductile Iron

Bronze

Alloy Steel

Plastic

Carbon Steel

1

2

1

2

1

2

2

1

2

1

1

1

1

QTY .

1

1

1

2

30

31

32

33

34

ITEM DESCRIPTION

26 ** Bushing (Guide Rod)

MATERIAL

PTFE Bronze

27 ** Bushing (Yoke Pin)

28 Cap Screw, Flat Head, Hex Socket

PTFE Bronze

Steel

29 Position Indicator Plastic

Cap Screw, Flat Head, Hex Socket

Adaptor, Pressure Module

Barrel

Piston

End Cap, Pressure Module

Steel

Ductile Iron

Carbon Steel

Ductile Iron

Ductile Iron

38

39

40

35 Piston Rod

36 ** Bushing (Adaptor)

37 * Seal, U-Cup

Split Collar

Tie Rod

Locknut, Nylok

41 * O-Ring (Piston Rod)

42 * Wear Ring

43 * Quad Seal

44 * O-Ring (Barrel)

45 Retainer Ring

46 Pipe Plug

47 * O-Ring (Module)

48 Stud

49

50

Spring Washer

Nut

Alloy Steel

PTFE Bronze

Buna-N

Alloy Steel

Steel

Steel

Buna-N

PTFE

Buna-N

Buna-N

Stainless Steel

Carbon Steel

Buna-N

Steel

Spring Steel

Steel

2

2

12

12

12

2

4

2

8

8

8

2

4

2

2

2

1

2

2

2

2

QTY .

2

2

8

1

* Parts in Seal Kits

*

&

**

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

8 9 10

Tie Rod Thread M10 M12 M12

Spanner Size, mm

Torque, Nm

End Plug, NPT

Allen Key

End Plate Bolts

Spanner Size, mm

Torque, Nm

Consumables

Thread Sealant

Thread Lock

Lubricant

17

25

1.25

.75”

19

35

1.5"

1”

19

45

1.5"

1”

12

M16

24

80

2"

1”

14

M16

24

110

2"

1”

16

M20

30

180

2"

1”

18

M20

30

230

M10

17

25

20

M24

36

335

M10

17

25

22

M24

36

410

M10

17

25

24

M30

46

610

M10

17

25

28

M24

36

330

M10

17

25

32

M30

46

540

M10

17

25

Loctite 577 / Equivalent

Loctite 234 / Equivalent

Dow Corning Molykote 55 (for standard actuators). Refer to TS-00084 for Low/High temperature trim lubricants

36

M30

46

685

M10

17

25

10.1.b - Pressure Module

MODEL

Piston Rod Diameter, inch

Rod Thread

Piston Rod Hex A/F, mm

Torque, Nm

Piston Rod Minimum No. of Turns

45 E2

1

M24 x 2

21

200

10

73 E2

1.25

M27 x 2

26

200

13.5

14 E3

1.5

M30 x 2

32

250

15

24 E3

1.75

M36 x 3

36

250

12

45 E3

2.25

M48 x 3

46

350

16

10 E4

2.75

M60 x 4

55

450

15

18

10.2 - Torque Module

MODEL 45 E2

Housing Cover Bolts/Studs M8

Spanner Size, mm

Torque, Nm

Retainer Plate Screws

Allen Key, mm

Acc Drive Screw

Allen Key, mm

Top Cover Bolts

Allen Key, mm

Spanner Size, Metric

Consumables

Thread Sealant

Thread Lock

Anti seize

Lubricant

5

M6

5

13

13

M5

3

M6

73 E2

M8

13

13

M6

4

M6

5

M8

6

14 E3

M10

17

25

M6

4

M6

5

M8

6

Loctite 577 / Equivalent

Loctite 243 / Equivalent

Loctite Ni Anti Seize

Shell Alvania Lead Free EP2 Grease (for Standard Actuator).

Refer to TS00084 for Low/High temperature trim lubricants

24 E3

M12

19

50

M6

4

M8

6

M8

13

45 E3

M12

19

50

M6

4

M8

6

M8

13

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.

10 E4

M16

24

115

M8

5

M10

8

M10

17

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

10.3 - Spring Module

MODEL

Spring Rod Diameter, inch

Rod Thread

Spring Rod Hex A/F, mm

Torque, Nm

Spring Rod Minimum No. of Turns

End Cover Bolt

Spanner Size, mm

45 E2

1

M24 x 2

21

200

10

M12

19

73 E2

1.25

M27 x 2

26

200

13.5

M12

19

14 E3

1.5

M30 x 2

32

250

15

M16

24

24 E3

1.75

M36 x 3

36

250

12

M16

24

45 E3

2.25

M48 x 3

46

350

16

M16

24

10 E4

2.75

M60 x 4

55

450

15

M20

30

10.4 - Actuator Assembly

MODEL

ISO Base

Base Bolting Size

45 E2

F16/F12

M20/M12

Module Mounting Stud- Nut Size

Spanner Size, Metric

Torque, Nm

Consumables

Thread Sealant

Thread Lock

Lubricant

M10

17

40

73 E2

F16/F12

M20/M12

M12

19

70

14 E3

F25/F16

M16/M20

M12

19

70

Loctite 577 / Equivalent

Loctite 243 / Equivalent

Shell Alvania Lead free EP2 Grease (for Standard Actuator).

Refer to TS-00084 for Low/High temp trim lubricants.

24 E3

F30/F25

M20/M16

M16

24

165

45 E3

F35/F30

M30/M20

M16

24

165

10 E4

F40/F35

M36/M30

M24

36

545

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.

19

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

11.0 TECHNICAL DATA

DA

DD

45E2-08

45E2-09

45E2-10

45E2-12

45E2-14

45E2-08

45E2-09

45E2-10

45E2-12

DA

DD

73E2-10

73E2-12

73E2-14

73E2-16

73E2-10

73E2-12

DA

DD

14E3-12

14E3-14

14E3-16

14E3-18

14E3-20

14E3-12

14E3-14

14E3-16

DA

DD

24E3-14

24E3-16

24E3-18

24E3-20

24E3-22

24E3-24

24E3-14

24E3-16

24E3-18

24E3-20

DA

DD

45E3-18

45E3-20

45E3-22

45E3-24

45E3-28

45E3-18

45E3-20

45E3-22

45E3-24

DA

DD

10E4-22

10E4-24

10E4-28

10E4-32

10E4-36

10E4-22

10E4-24

10E4-28

10E4-32

11.1 - Double Acting Actuators

Model Maximum Operating Pressure

Symmetrical Canted

150

124

98

80

66

55

82

63

49

40

150

127

97

77

62

87

64

49 psi

150

144

117

81

59

92

72

59

41

150

107

78

60

77

54

150

150

113

86

68

92

77

57

43

150

121

100

84

62

75

61

50

42

10.3

8.6

6.8

5.5

4.5

3.8

5.6

4.3

3.4

2.8

10.3

8.7

6.7

5.3

4.3

6.0

4.4

3.4

bar

10.3

9.9

8.0

5.6

4.1

6.3

5.0

4.0

2.8

10.3

7.4

5.4

4.1

5.3

3.7

10.3

10.3

7.8

5.9

4.7

6.3

5.3

3.9

3.0

10.3

8.4

6.9

5.8

4.3

5.2

4.2

3.5

2.9

150

126

93

71

56

76

64

47

123

100

83

69

51

62

50

41 psi

150

119

96

67

49

76

60

48

8.5

6.9

5.7

4.8

3.5

4.3

3.5

2.9

bar

10.3

8.2

6.6

4.6

3.4

5.2

4.1

3.3

142

104

80

63

51

72

52

40

127

88

65

49

64

44

134

102

81

66

54

46

67

52

10.3

8.7

6.4

4.9

3.9

5.2

4.4

3.2

9.8

7.2

5.5

4.3

3.5

4.9

3.6

2.8

8.7

6.1

4.4

3.4

4.4

3.0

9.2

7.1

5.6

4.5

3.7

3.1

4.6

3.5

Volume

Cu.in

Lts

1831

2387

3059

3750

4561

5452

3785

4948

6314

7834

1071

1458

1890

2421

2978

2223

3032

3951

6875

8173

11049

14589

18327

14080

16676

22763

30497

3722

4584

5591

6676

9074

7617

9462

11564

13745

Rod End Cap End Rod End Cap End

322 346 5.3

5.7

417

519

750

1020

442

560

831

1135

6.8

8.5

12.3

16.7

7.2

9.2

13.6

18.6

669

858

1079

1581

669

858

1079

1581

11.0

14.1

17.7

25.9

11.0

14.1

17.7

25.9

621

902

1227

1588

1289

1887

668

985

1347

1766

1289

1887

10.2

14.8

20.1

26.0

21.1

30.9

11.0

16.2

22.1

29.0

21.1

30.9

1152

1574

2061

2626

3300

2223

3032

3951

1954

2560

3255

4084

5012

5917

3785

4948

6314

7834

3895

4878

5973

7068

9699

7617

9462

11564

13745

7205

8504

11713

15908

19859

14080

16676

22763

30497

17.6

23.9

31.0

39.7

48.8

36.5

49.7

64.8

30.0

39.2

50.2

61.5

74.8

89.4

62.1

81.1

103.5

128.5

61.0

75.2

91.7

109.5

148.8

124.9

155.2

189.7

225.4

112.8

134.0

181.2

239.3

300.6

230.9

273.5

373.3

500.2

118.2

139.5

192.1

260.9

325.7

230.9

273.5

373.3

500.2

63.9

80.0

98.0

115.9

159.1

124.9

155.2

189.7

225.4

32.0

42.0

53.4

67.0

82.2

97.0

62.1

81.1

103.5

128.5

18.9

25.8

33.8

43.1

54.1

36.5

49.7

64.8

Actuator Weight

657

721

800

941

1041

1208

886

1014

1173

1455

386

437

507

591

721

536

637

778

Lbs

143

152

172

209

267

203

220

260

335

245

280

331

399

344

414

2092

2269

2754

3309

4017

2873

3225

4195

5306

1105

1241

1345

1515

1942

1543

1817

2024

2363

298

327

363

427

472

548

402

460

532

660

175

198

230

268

327

243

289

353

Kg

65

69

78

95

121

92

100

118

152

111

127

150

181

156

188

949

1029

1249

1501

1822

1303

1463

1903

2407

501

563

610

687

881

700

824

918

1072

331

366

417

485

873

937

1016

1157

1257

1424

534

584

655

739

869

Assembly Weight (approx)

w/Jackscrew

Override w/Hydraulic

Override

Lbs

207

216

236

273

331

Kg

94

98

107

124

150

Lbs kg

150

166

189

220

396

425

461

525

570

646

242

265

297

335

394

359

395

445

514

910

974

1054

1195

1294

1462

1457

1594

1698

1867

2295

2698

2875

3360

3915

4623

558

608

679

763

893

163

179

202

233

661

723

770

847

1041

1224

1304

1524

1776

2097

413

442

478

542

587

663

253

276

308

346

405

20

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

73E2-10

73E2-12

73E2-14

73E2-16

73E2-10

73E2-12

73E2-14

73E2-16

73E2-10

73E2-12

73E2-14

73E2-16

73E2-10

73E2-12

73E2-14

73E2-16

45E2-08

45E2-09

45E2-10

45E2-12

45E2-14

45E2-08

45E2-09

45E2-10

45E2-08

45E2-09

45E2-12

45E2-14

45E2-10

45E2-12

45E2-14

45E2-09

45E2-10

45E2-12

45E2-14

11.2 - Spring Return Actuators

Model

Spring

#

1

2

3

4

79

150

150

150

150

150

150

108

117

86

150

150

121

89

150

146

101

74

Maximum Operating Pressure

Symmetrical Canted psi

150 bar

10.3

psi

150 bar

10.3

10.3

10.0

7.0

5.1

150

125

87

63

10.3

8.6

6.0

4.4

10.3

10.3

10.3

7.4

5.4

10.3

10.3

10.3

8.1

5.9

10.3

10.3

8.4

6.1

150

150

135

93

69

150

150

148

103

75

150

150

107

79

7.1

5.2

10.3

10.3

7.4

5.4

4.7

10.3

10.3

10.2

10.3

10.3

9.3

6.4

1

2

3

4

150

150

117

90

150

150

111

85

150

144

105

80

150

139

102

78

10.3

10.3

8.1

6.2

10.3

10.3

7.7

5.9

10.3

9.9

7.3

5.5

10.3

9.6

7.0

5.4

150

141

103

79

150

133

98

75

150

125

91

70

150

120

88

67

10.3

9.7

7.1

5.4

10.3

9.2

6.7

5.1

10.3

8.6

6.3

4.8

10.3

8.3

6.1

4.6

621

902

1227

1588

621

902

1227

1588

621

902

1227

1588

621

902

1227

1588

1020

322

417

519

322

417

519

750

750

1020

417

519

750

1020

Cu.In

322

Volume

Rod End

Lts

5.3

417

519

750

1020

6.8

8.5

12.3

16.7

12.3

16.7

6.8

8.5

12.3

16.7

16.7

5.3

6.8

8.5

5.3

6.8

8.5

12.3

10.2

14.8

20.1

26.0

10.2

14.8

20.1

26.0

10.2

14.8

20.1

26.0

10.2

14.8

20.1

26.0

538

573

624

692

483

518

569

637

461

496

547

615

459

494

545

613

244

260

283

314

219

235

258

289

209

225

248

279

208

224

247

278

304

324

362

419

317

355

412

295

324

344

381

439

344

401

289

298

Lbs

278

287

306

138

147

164

190

144

161

187

134

147

156

173

199

156

182

131

135

Kg

126

130

139

Actuator Weight

439

353

362

381

315

324

344

381

Assembly Weight (approx)

w/Jackscrew Override w/Hydraulic Override

Lbs

304

Kg

138

Lbs Kg

313

333

370

428

142

151

168

194

419

476

384

403

441

498

143

147

156

173

199

160

164

173

190

216

174

183

200

226

604

639

690

758

549

584

635

703

525

560

611

679

520

556

606

675

274

290

313

344

249

265

288

319

238

254

277

308

236

252

275

306

615

650

701

769

560

595

646

714

538

573

624

692

536

571

622

690

279

295

318

349

254

270

293

324

244

260

283

314

243

259

282

313

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.

21

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

11.2 - Spring Return Actuators - Cont.

Model

Spring

#

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

14E3-20

14E3-20

14E3-12

14E3-14

14E3-16

14E3-18

14E3-20

14E3-12

14E3-14

14E3-16

14E3-18

1

2

3

4

5

88

150

150

143

150

150

138

109

113

91

150

130

103

83

126

99

80

150

96

78

150

150

Maximum Operating Pressure

Symmetrical Canted psi

150

150

122 bar

10.3

10.3

8.4

psi

150

137

105 bar

10.3

9.5

7.2

6.6

5.4

10.3

10.3

83

67

150

142

5.7

4.6

10.3

9.8

8.7

6.8

5.5

10.3

10.3

9.0

7.1

5.7

108

86

69

150

148

113

89

72

10.2

7.8

6.1

5.0

7.5

5.9

4.8

10.3

6.1

10.3

10.3

9.8

10.3

10.3

9.5

7.5

7.8

6.3

77

150

150

126

150

150

121

95

99

80

5.3

10.3

10.3

8.7

10.3

10.3

8.3

6.6

6.8

5.5

1071

1458

1890

2421

2978

1071

1458

1890

2421

2978

1890

2421

2978

1071

1458

1890

2421

2978

Cu.In

1071

1458

1890

Volume

Rod End

Lts

17.6

23.9

31.0

2421

2978

1071

1458

39.7

48.8

17.6

23.9

23.9

31.0

39.7

48.8

31.0

39.7

48.8

17.6

48.8

17.6

23.9

31.0

17.6

23.9

31.0

39.7

39.7

48.8

891

974

1105

789

840

910

994

1124

952

1082

769

820

Lbs

747

798

869

816

866

937

1021

1151

838

888

959

1043

1173

381

413

451

510

404

442

501

358

432

491

349

372

Kg

339

362

394

522

380

403

435

370

393

425

463

473

532

Actuator Weight

930

981

1052

1135

1265

952

1003

1074

1157

1287

990

1074

1204

888

939

1010

1093

1224

Assembly Weight (approx)

w/Jackscrew Override w/Hydraulic Override

Lbs

842

893

963

Kg

382

405

437

Lbs

855

906

977

Kg

388

411

443

1047

1177

869

919

475

534

394

417

1060

1190

877

928

481

540

398

421

449

487

546

403

426

458

496

555

999

1082

1213

897

948

1019

1102

1232

430

462

500

559

453

491

550

407

574

432

455

487

422

445

477

515

525

584

924

974

1045

1129

1259

946

996

1067

1151

1281

571

429

452

484

419

442

474

512

522

581

22

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

11.2 - Spring Return Actuators - Cont.

Model

Spring

#

24E3-20

24E3-22

24E3-24

24E3-14

24E3-16

24E3-18

24E3-20

24E3-22

24E3-24

24E3-16

24E3-18

24E3-20

24E3-22

24E3-24

24E3-14

24E3-16

24E3-18

24E3-20

24E3-22

24E3-24

24E3-14

24E3-16

24E3-18

24E3-20

24E3-22

24E3-24

24E3-14

24E3-16

24E3-18

1

2

3

4

5

5.6

10.3

10.3

8.4

6.9

5.8

10.3

10.0

8.1

6.7

7.8

6.4

5.4

10.3

81

150

150

122

101

84

150

145

117

97

113

93

78

150

74

150

150

139

150

132

106

88

102

84

71

150

Maximum Operating Pressure

Symmetrical Canted psi

150

150

126 bar

10.3

10.3

8.7

psi

150

138

109 bar

10.3

9.5

7.5

7.0

5.8

4.9

10.3

88

73

61

150

6.1

5.0

4.2

10.3

10.3

9.1

7.3

6.1

5.1

10.3

10.3

9.6

145

114

92

76

64

150

150

122

4.4

10.3

10.3

8.4

10.0

7.9

6.4

5.2

71

150

133

108

89

75

150

127

103

85

99

81

68

150

4.9

10.3

9.2

7.4

6.1

5.1

10.3

8.8

7.1

5.8

6.8

5.6

4.7

10.3

5452

2387

3059

3750

4561

5452

3750

4561

5452

1831

2387

3059

3750

4561

2387

3059

3750

4561

5452

1831

2387

3059

Cu.In

1831

2387

3059

Volume

Rod End

Lts

30.0

39.2

50.2

3750

4561

5452

1831

61.5

74.8

89.4

30.0

89.4

30.0

39.2

50.2

39.2

50.2

61.5

74.8

89.4

39.2

50.2

61.5

74.8

89.4

39.2

50.2

61.5

74.8

61.5

74.8

89.4

30.0

1885

1400

1479

1620

1720

1887

1561

1660

1828

1334

1398

1477

1618

1717

1314

1393

1534

1634

1801

1276

1340

1420

Lbs

1232

1296

1376

1517

1616

1784

1250

855

635

671

735

780

856

634

670

734

779

708

753

829

605

817

579

608

644

596

632

696

741

688

733

809

567

Kg

559

588

624

Actuator Weight

2079

1596

1675

1817

1916

2083

1753

1852

2019

1528

1592

1671

1812

1911

1470

1550

1691

1790

1958

1468

1532

1612

Assembly Weight (approx)

w/Jackscrew Override w/Hydraulic Override

Lbs

1387

1451

1530

Kg

629

658

694

Lbs

1389

1453

1532

Kg

630

659

695

1671

1770

1938

1407

758

803

879

638

1673

1772

1940

1407

759

804

880

638

667

703

767

812

888

666

695

731

1470

1550

1691

1790

1958

1433

1497

1576

888

650

679

715

667

703

767

812

795

840

916

693

722

758

822

867

943

724

760

824

869

945

1717

1817

1984

1490

1554

1634

1775

1874

2041

1556

1636

1777

1876

2044

926

706

742

806

851

927

705

741

805

850

779

824

900

676

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.

23

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

11.2 - Spring Return Actuators - Cont.

Model

Spring

#

45E3-18

45E3-20

45E3-22

45E3-24

45E3-28

45E3-18

45E3-20

45E3-22

45E3-18

45E3-20

45E3-24

45E3-28

45E3-22

45E3-24

45E3-28

45E3-18

45E3-20

45E3-22

45E3-24

45E3-28

45E3-18

45E3-20

45E3-22

45E3-24

45E3-28

10E4-22

10E4-24

10E4-28

10E4-32

10E4-36

10E4-22

10E4-24

10E4-28

10E4-32

10E4-36

10E4-22

10E4-24

10E4-28

10E4-32

10E4-36

10E4-22

10E4-24

10E4-28

10E4-32

10E4-36

1

2

3

4

5

1

2

3

4

94

150

150

150

123

97

88

150

150

150

119

150

150

143

109

86

150

150

147

112

6.5

10.3

10.3

10.3

8.5

6.7

6.1

10.3

10.3

10.3

8.2

10.3

10.3

9.8

7.5

5.9

10.3

10.3

10.1

7.7

88

150

150

149

125

91

150

150

144

120

111

81

150

150

79

150

150

132

139

117

86

Maximum Operating Pressure

Symmetrical Canted psi

150 bar

10.3

psi

150 bar

10.3

150

128

107

10.3

8.8

7.4

134

110

93

9.2

7.6

6.4

10.3

10.3

9.9

8.3

6.1

10.3

10.3

10.2

8.6

6.3

5.4

10.3

10.3

9.1

7.6

5.6

10.3

10.3

9.6

8.1

5.9

77

150

150

131

110

80

150

150

126

105

96

70

150

147

68

150

138

114

122

102

75

10.3

10.3

8.7

7.3

5.3

10.3

10.3

9.0

7.6

5.5

4.7

10.3

9.5

7.9

6.6

4.8

10.3

10.2

8.4

7.0

5.2

82

150

150

141

108

85

76

150

150

135

103

150

150

123

94

74

150

150

126

97

5.6

10.3

10.3

9.7

7.4

5.9

5.3

10.3

10.3

9.3

7.1

10.3

10.3

8.4

6.4

5.1

10.3

10.3

8.7

6.7

3722

4584

5591

6676

9074

3722

4584

5591

6676

9074

9074

3722

4584

5591

6676

9074

3722

4584

5591

6676

9074

Cu.In

3722

Volume

Rod End

Lts

61.0

4584

5591

6676

75.2

91.7

109.5

61.0

75.2

91.7

109.5

148.8

61.0

75.2

91.7

109.5

148.8

148.8

61.0

75.2

91.7

109.5

148.8

61.0

75.2

91.7

109.5

148.8

18327

6875

8173

11049

14589

18327

6875

8173

11049

14589

18327

6875

8173

11049

14589

18327

6875

8173

11049

14589

300.6

112.8

134.0

181.2

239.3

300.6

112.8

134.0

181.2

239.3

300.6

112.8

134.0

181.2

239.3

300.6

112.8

134.0

181.2

239.3

Lbs

2169

2306

2410

2579

2474

2610

2714

2884

3311

2535

2672

2776

2945

3373

3007

2220

2357

2460

2630

3058

2363

2500

2604

2773

3201

6519

4793

4969

5454

6010

6717

6221

4594

4771

5256

5811

4153

4330

4815

5370

6078

4297

4473

4958

5514

Kg

984

1046

1093

1170

1122

1184

1231

1308

1502

1150

1212

1259

1336

1530

1364

1007

1069

1116

1193

1387

1072

1134

1181

1258

1452

2957

2174

2254

2474

2726

3047

2822

2084

2164

2384

2636

1884

1964

2184

2436

2757

1949

2029

2249

2501

Actuator Weight Assembly Weight (approx)

w/Jackscrew Override w/Hydraulic Override

Lbs Kg Lbs Kg

2418

2555

2659

1097

1159

1206

2829

2723

2859

2963

3133

3560

2784

2921

3025

3194

3622

3256

2469

2606

2709

2879

3307

2612

2749

2853

3023

3450

1283

1235

1297

1344

1421

1615

1263

1325

1372

1449

1643

1477

1120

1182

1229

1306

1500

1185

1247

1294

1371

1565

6795

5068

5245

5730

6285

6993

6497

4870

5046

5531

6087

4429

4605

5090

5646

6354

4572

4749

5234

5789

3082

2299

2379

2599

2851

3172

2947

2209

2289

2509

2761

2009

2089

2309

2561

2882

2074

2154

2374

2626

24

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

12.0 MODULE WEIGHTS

Model

45 E2

73 E2

14 E3

24 E3

Rated

Torq.

Nm

4,500

7,300

14,000

24,000

45 E3 45,000

10 E4 100,000

Torque

Module

84

146

236

428

666

1312

8

60

9

68

10

88

99

MODULE WEIGHTS (APPROX), Lbs

12 14

Pressure Modules Size, Inch

16 18 20 22 24 28 32 36 1

Spring Modules

2 3 4 5

126 183

134 185 254

150 201 271 355 485

229 293 373 514 613 780

134

214

362

575

146

216

384

593

152

238

403

619

172

293

430

677

452

679

439 575 679 849 1276 1065 1116 1259 1369 1431

780 957 1442 1997 2705 2061 2205 2502 2701

45 E2

73 E2

14 E3

24 E3

45 E3

10 E4

Model

Rated

Torq.

Nm

4,500

7,300

14,000

24,000

45,000

100,000

Torque

Module

38

66

107

194

302

595

8

27

9

31

10

40

45

12

57

61

68

MODULE WEIGHTS (APPROX), Kg

14 16 18 20 22 24 28 32 36 1

Spring Modules

2 3 4 5

83

84 115

91 123 161 220

104 133 169 233 278 354

61

97

164

261

66

98

174

269

69

108

183

281

78

133

195

307

205

308

199 261 308 385 579 483 506 571 621 649

354 434 654 906 1227 935 1000 1135 1225

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.

25

A

D

E

F G

B

13.0 SERIES 98 DIMENSIONS

LEFT VIEW

S

ØQ

20

4.0

ØN

12.70

6.0

30

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

T

FRONT VIEW

L

J P

STEM BORE DETAIL

R

ACCESSORY DRIVE

DETAILS

D F

80.0

M

TOP VIEW

A

M5 7.00

G

U

K

RIGHT VIEW

E

B ØH

T

FRONT VIEW

C

LEFT VIEW

Model

45E2

73E2

14E3

24E3

45E3

10E4

ISO Base

S

F16/F12

F16/F12

F25/16

A B C

4.0

D

52.8

14.8

14.8

14.2

60.1

ØQ

16.8

20

16.8

15.8

72.6

21.3

21.3

ØN

18.8

12.70

E

6.3

12.5

26.2

30

9.3

F

18.5

G

35.3

H

9.4

13.5

J

9.7

12.1

K

9.4

15.4

L

13.1

7.9

15.8

28.5

12.8

11.8

11.3

16.5

19.6

F30/25

F35/30

90.0

113.3

STEM BORE DETAIL

R

25.1

33.3

25.1

33.3

21.9

25.8

F40/F35 138.1

41.7

38.0

32.8

11.5

14.3

17.8

22.9

28.6

35.5

45.2

58.9

69.8

15.6

18.7

21.9

M

14.3

15.3

18.9

19.3

22.8

28.3

23.8

29.5

37.6

TOP VIEW

M

5.1

5.1

--

--

5.1

5.1

N P Q R

0.7

8.5

9.8

0.7

10.9

1.0

13.1

2.0

2.5 0.625

3.0

4.5

0.5

0.75

1.0

1.0

14.1

1.0

17.8

6.0

U

1.5

K

7.0

1.75

RIGHT VIEW

S T

2.3

3.1

7.7

7.8

3.7

11.8

5.2

13.8

6.8

16.3

8.3

18.7

Model ISO Base A B C D

45E2

73E2

14E3

24E3

45E3

10E4

F16/F12

F16/F12

F25/16

F30/25

F35/30

F40/F35

1342 376

1526 427

1843 542

2287 638

376

427

542

638

2877 845 845

3507 1060 964

Refer ES drawings for dimensions of specific models

360

400

477

556

656

832

E

SERIES 98 MAX DIMENSIONS, mm

F G H J K L M

159

201

235

291

363

451

318

402

664

723

240

326

470 896 342

582 1148 397

726 1495 476

902 1773 556

246

300

307

364

388

481

240

288

390

491

580

720

333

420

498

605

750

955

--

--

130

130

130

130

N

18

18

18

25

25

25

P Q R S T

216 50.0

12.0

59

249 63.5

15.88

78

276 76.2

19.05

93

334 114.3

25.4

131

195

197

300

350

357 152.4

38.1

173 415

451 177.8 44.50 210.8

475

U

96

129

145

186

212

286

U

3.8

5.1

5.7

7.3

8.3

11.3

Cylinder Size

Ports, NPT

2.5" - 5"

1/4"

CYLINDER PORT SIZE

6" - 9" 10"

3/8" 1/2"

12" - 16"

3/4"

18" - 24"

1"

28" - 36"

1.5"

26

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

14.0 SERIES 98 GENERAL SPECIFICATIONS AND FEATURES

Model

DA

DD

SC

SO

45 E2

73 E2

14 E3

24 E3

45 E3

10 E4

Torque Base

Accessories

Testing

Ingress Protection

Safety

ISO

Mounting

Base

F12/F16

F12/F16

F16/F25

F25/F30

F30/F35

F35/F40

Pressure Range

Media

Temperature Range -

Standard Options

GENERAL SPECIFICATIONS

RANGE

Rated Torque

Nm

4,500

7,300

14,000

24,000

45,000

100,000

Lb-in

39,830

64,612

123,914

212,424

398,295

885,100

Double Acting- Single Cylinder

Double Acting- Dual Cylinders

Spring Return- Fail CW

Spring Return- Fail CCW

Spring End Torque

Nm

Min

1,070

2,130

Max

2,675

4,280

3,485

6,555

11,950

25,226

7,845

15,150

25,595

Spring End Torque

Lb-in

Min

9,471

18,853

Max

23,676

37,882

30,846

58,018

105,769

69,436

134,093

226,541

50,306 223,275 445,261

CONFIGURATIONS

OPERATING CONDITIONS

40 - 150 psi

Dry Compressed Air / Inert / Natural Gas

Standard : -20°F to 200°F (-29°C to 93°C)

High Temp : Up to 300°F (149°C)

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

ATEX, SIL 3, PED

Maximum

Stem Acceptance

Diameter mm inch

50.0

1.97

63.5

2.50

76.2

114.3

152.4

177.8

3.00

4.50

6.00

7.00

Contact factory for other media

Contact factory for extended ranges

Maximum

Stem Height mm

183

216

240

295

318

350

Over Travel

(on either side)

± degrees

5

5

3

3

5

3

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.

27

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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 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 builtin 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.

4. Secure the cylinder flange on the thrust base of the

Spring Module with the spring washers and nuts from the override mounting kit.

5. Thread in the hydraulic connector into the cylinder port (if not already fitted into the cylinder). Use a commercial hydraulic fitting thread sealant (Loctite 542 or equivalent).

6. 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.

7. 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.

8. On the Tee fitting at the pump outlet, remove the plug and install a suitable pressure gage (0-4000psi).

9. 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.

10. 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 rod advances to press against the Spring Rod’s end face and the thrust from the hydraulic pressure effects the override function.

11. 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.

28

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

Model MOP

MOP for SR Hydraulic Overrides

Spring Number

73 E2

14 E3

24 E3

45 E3

10 E4 psi bar psi bar psi bar bar psi bar psi

1

1585

109

1325

91

1290

89

1185

82

2465

170

2

1880

130

1520

105

1530

105

1415

98

3005

207

3

2425

167

1770

122

1950

134

1615

111

3630

250

4

2740

189

2260

156

2260

156

1855

128

4400

303

5

2705

187

2595

179

2155

149

15.1.2 Operation - Spring Return Hydraulic

Override

1. 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.

2. 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.

3. 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.

15.2 Installing Hydraulic Override on DA

Actuator

1. 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.

2. 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 flange.

3. 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

Model

Lb-ft

Torque

Nm

73 E2

14 E3

24 E3

45 E3

10 E4

148

184

184

258

332

200

250

250

350

450

4. Replace the end cap, taking care not to damage the cap seal, and tighten the tie rod nuts of the hydraulic cylinder.

5. 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.

6. Mount the hydraulic pump assembly on the Torque

Module’s rear accessories pad, as described in previous section.

7. 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 fillerbreather cap.

8. 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.

9. Check and ensure the Hydraulic pressure setting 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 detailed knowledge and experience with their application.

29

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

MOP for DA Hydraulic Overrides

Model MOP

73 E2 psi bar

1935

133

14 E3

24 E3

45 E3

10 E4 psi bar psi bar psi bar psi bar

2000

138

2090

144

2005

138

2130

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 adjusting 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.

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 cylinder 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.

3. 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.

30

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.

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.

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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.

31

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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.

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.

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.

Direct Drive J ackscrew -DA

32

Gear Drive J ackscrew -

DA

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

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 to atmosphere. The ports must be vented when operating the manual override

(Refer to Figure C).

2. Turn the hand wheel on the jackscrew assembly to move the screw forward, until it touches the extension rod’s end.

3. Push the T-handle into the jackscrew head to couple it with the extension rod.

4. Turn the hand wheel to turn the actuator in required direction (see direction markers on the hand wheel).

5. After completing the manual override stroke, disengage the coupler by pulling out the T-handle. Back off the jackscrew completely before restoring pneumatic operation.

Figure C

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.

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.

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 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.

33

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.

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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 module end cap.

Figure D

4. Back off the jackscrew fully in the assembly and mount the jackscrew assembly on the spring module end cap thrust base.

Direct Drive Jacksc rew -SR

5. Locate the Jackscrew assembly flange into the studs and fasten with the supplied nuts and lock washers.

16.2.1 Operating SR Jackscrew Override

1. To test / operate the override, shut off the main air supply and turn the 3 position valve on the cylinder port 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 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 turn the 3 position valve on cylinder port to connect to 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.

34

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

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 Guide 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.

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.

4

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 and lock washers from the mounting kit.

3. Clean threads on the Guide Block.

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.

35

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 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.

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

NOTICE

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 on it.

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.

2. Confirm position and tighten the seal-nut to lock the position.

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

This Extended Stopper module is installed on Spring Module's thrust base.

1. Disconnect air pressure and any electrical power from 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

(Loctite 242 or equivalent). Locate the end cover O-ring in the groove.

4. Back off the stopper bolt and mount the Extended

Stopper assembly on the Spring Module end cap.

NOTICE

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 on it.

WARNING

Never remove the assembly fasteners without first backing off the Extended Stopper fully to release any load on it.

36

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.

REFERENCE DRAWINGS

Description

Hydraulic Override Assembly DA

Hydraulic Override Assembly SR

Jackscrew Assembly, DA Direct Drive

Jackscrew Assembly, DA Gear Drive

Jackscrew Assembly, SR Direct

Jackscrew Assembly, SR Gear Drive

Sandwich Gearbox

Extended Stoppers, SR

Extended Stoppers, DA

Drg #

ES 00094

ES 00095

ES 00105

ES 00106

ES 00113

ES 00114

ES 00126

ES 00127

ES 00201

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

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.

37

Bray Series 98 Pneumatic Scotch Yoke Actuator

Operations and Maintenance Manual

TROUBLE SHOOTING POTENTIAL PROBLEMS

FAULT

Erratic Movement

Loss of power

No response to energizing

Fails to go to the failsafe position

POSSIBLE CAUSES

Inconsistent supply /dirty operating media/clogged filters

Inadequate lubrication

Worn/damaged parts

Seal set due to long periods of inactivity

Valve problem - bearing/seal friction, damaged parts

Incomplete Stroke Stoppers set incorrectly

Foreign object left inside during maintenance

Manual override in wrong position

RECOMMENDED ACTIONS

Check media supply pressure and line filters, correct as necessary.

Refer to Introduction section in this manual for operating media requirements.

Disassemble and lubricate. Refer to Maintenance section in this manual for lubricant specs.

Disassemble and inspect. Replace worn/damaged parts. Refer to

Disassembly, Service & Reassembly of Modules section in this manual.

Operate for 5-10 cycles and check. Replace seals if not resolved. Refer to the procedures under Pressure Module section in this manual, for replacement and testing procedures.

Refer to valve manufacturer’s IOM.

Check and adjust.

Disassemble, inspect for damages and correct.

Check and fully retract manual override devices for proper automatic operation.

Refer to valve manufacturer’s IOM.

Valve problem - Restriction, friction, incorrect valve stopper

Supply pressure inadequate

Inadequate flow

Tubing or exhaust vents blocked

Pressure Module seals leaking

Control component malfunction/failure

Choked exhaust silencer/foreign object blocking exhaust line

Check and correct supply pressure to operating pressure.

Check flow control devices and adjust for sufficient flow. Repair any kinked tubing.

Check and clean the vents, silencers and tubing.

Check leaks and replace seals. Refer to the procedures under

Pressure Module section in this manual, for replacement and testing procedures.

Refer to accessory manufacturer’s IOM manual and specs.

Refer to valve manufacturer’s IOM.

Defective Accessories/Inadequate capacity

Valve jammed or requires higher torque

Altered schematic Check if the control circuit is as per the supplied schematic. Correct the circuit, if altered.

Solenoid valve/positioner/control elements malfunction Check /Refer to accessory manufacturer’s IOM manual for troubleshooting.

Disengaged piston rod/ broken connection/ jammed mechanism

Valve problem - jammed

Refer to Maintenance section for module/actuator disassembly procedures to disassemble appropriate module for inspection.

Refer to valve manufacturer’s IOM.

Altered schematics Check if the control circuit is as per the supplied schematic. Correct the circuit, if altered.

Check and replace

Remove vent to confirm normal operation. Clean/replace exhaust silencer.

Spring rod disengaged/connection broken

Valve problem - jammed

Refer to Maintenance section for module/actuator disassembly procedures to disassemble appropriate module for inspection.

Refer to valve manufacturer’s IOM.

38

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

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 limits

Used with operating media that does not conform to specification

Lifting actuator-valve-accessories assembly using lifting lugs on actuator that are meant only for the actuator

Pressurizing cap end port on spring return actuators to overcome valve jamming or to compensate valve sealing problems

Maintenance by unauthorized personnel

Maintenance without de-energizing

Operating the actuator without end covers

Altering the design to increase spring end load for compensating valve seating problems

PREVENTION MEASURES

Refer to Introduction & 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 to actuator’s MOP is highly recommended and shall be ensured by the end user. Refer to the

Maximum 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 temperature of the supplied trim. Ensuring the environmental conditions do not cause over the 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 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 & 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.

End user shall devise and provide adequate protection against hazards such as:

External Fire

Impacts during installation/servicing

Hazardous emissions when Natural Gas is operating media

Contact with metal surfaces due to high/low ambient temperatures or conduction/ radiation

Static electricity.

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.

39

All statements, technical information, and recommendations in this bulletin are for general use only. Consult Bray representatives or factory for the specific requirements and material selection 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

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A Division of Bray International, Inc.

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Houston, Texas 77041

Tel: 281.894.5454 • www.bray.com