Page 1
CONTROLS
R
OPERATION AND MAINTENANCE MANUAL
SERIES 6P
Pneumatic Positioner
Page 2
Safety InStructIonS - DefInItIon of termS
!
!
!
!
!
reaD anD foLLoW tHeSe InStructIonS
SaVe tHeSe InStructIonS
WARNING
CAUTION
NOTICE
CAUTION
Beware of moving parts when positioner
is operated!
CAUTION
Do not dismantle a pressurized positioner!
Dismantling a pressurized positioner will result in uncontrolled pressure release. Always isolate the relevant part
of the pipeline. Release the pressure from the positioner
and the pipng.
indicates a potentially hazardous situation which, if not avoided, could
death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
used without the safety alert symbol indicates a potential situation which, if not
avoided, may result in an undesirable result or state, including
property damage.
result in
CAUTION
Do not exceed the positioner
operating limitations!
Exceeding the limitations marked on the positioner may
cause damage to the positioner, actuator and valve.
Page 3
CONTROLS
R
SERIES 6P
Pneumatic Positioner
tabLe of contentS
Page
IntroductIon ............................................................................................ 4
Product descrIPtIon ................................................................................ 4
Manufacturer Warranty ....................................................................... 4
oPeratIon LogIc ....................................................................................... 5
LabeL descrIPtIon .................................................................................... 6
sPecIfIcatIons ........................................................................................... 6
Parts and asseMbLy ................................................................................. 7
dIMensIons ............................................................................................... 8
InstaLLatIon ............................................................................................. 8
bracket InforMatIon ............................................................................... 9
PIPIng connectIon .................................................................................... 10
adjustMent & caLIbratIon ...................................................................... 11
troubLe shootIng .................................................................................... 12
Page 4
Bray Series 6P
Operation and Maintenance Manual
Introduction
Every Series 6P is fully inspected after production
to offer the highest quality products. However, we
strongly recommend users read this manual carefully
to ensure the product is utilized to its fullest potential.
• This manual should be given to the end-user.
• This manual may be changed or revised without
any prior notice. The most current version of this
O&M is available at www.bray.com.
Product Description
Main Features and Functions
• The product has been designed to operate normally in a typical industrial environment.
• The durability has been proven after testing for two
million cycles under typical operating conditions.
• Response time is very quick and accurate.
• Can be easily switched to a 2 way split range by
changing the Span Spring
• Highenergyefciencyduetoitslow
air-consumption.
• Simple Zero & Span adjustment procedures.
• Position Feedback and switch modules
are available.
• Convert Double Acting to Single Acting simply
by putting a pipe plug in OUT 2.
Manufacturer Warranty
Warranty - Bray provides the following warranty
regarding products manufactured by it.
THE WARRANTY STATED HEREIN IS
EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES AND REPRESENTATIONS,
EXPRESSED OR IMPLIED, OR STATUTORY,
INCLUDING, WITHOUT LIMITATION, THE
IMPLIED WARRANTY OF MERCHANTABILITY
OR THE IMPLIED WARRANTY OF FITNESS FOR
A PARTICULAR PURPOSE.
Bray warrants its products to be free from defects in
materials and workmanship when these products are
used for the purposes for which they were designed
and manufactured. Bray does not warrant its products
against chemical or stress corrosion or against any
other failure other than from defects in materials or
workmanship. The warranty period is for twelve
(12) months from installation date or eighteen (18)
months from shipment date, whichever date comes
rst.Anyclaimregardingthiswarrantymustbein
writing and received by Bray before the last effective
date of the warranty period. Upon Bray’s receipt of a
warranty claim, Bray reserves the right to inspect the
product(s)inquestionateithertheeldlocationor
at Bray’s Manufacturing Plant. If, after inspection of
the product(s) in question, Bray determines that the
purchaser’s claim is covered by this warranty, Bray’s
sole liability and the purchaser’s sole remedy under
this warranty is limited to the refunding of the purchase
price or repair or replacement thereof at Bray’s option.
Bray will not be liable for any costs of repairs, labor,
material,orotherexpensesthatarenotspecically
authorized in writing by Bray, and in no event shall
Bray be liable for any direct or consequential damages
arising out of any defect or from any cause whatsoever.
IfanyBrayproductismodiedoralteredatany
location other than Bray’s Houston Manufacturing
Plant without the express written authorization of
Bray, then this warranty is null and void. Any products
sold by Bray but manufactured by companies other
than Bray are not covered by this warranty. The
warranty for such products shall be subject only to the
warranty relief, if any, provided by the suppliers and/or
manufacturers of such products.
4
Page 5
Operation Logic
Bray Series 6P
Operation and Maintenance Manual
• When signal input pressure increases, the bellows
(11)pushestheapper(13), the gap between the
nozzle (5) andtheapper(13) increases, which
causes pressure in the upper spool chamber (4) to
exhaust. This causes the spool (1) to shift right.
• As the spool (1) moves right, it pushes the poppet
(2) off its seat (3), and air pressure is supplied to
the center actuator chamber (9).
• At the same time, the spool (1) causes the left
poppet (14) to seat and vent the outer chambers
(10).
Bray Series 6P
1. Spool
2. Right Poppet
3. Seat
4. Spool Chamber
5. Nozzle
6. Span Adjustment
7. Cam
8. Actuator Stem
9. Inner Actuator Chamber
10. Outer Actuator Chamber
11. Bellows
12. Zero Adjustment
13. Flapper
14. Left Poppet
SUPPLY
14
12
11
INPUT SIGNAL
PRESSURE
• As the actuator’s inner pressure increases, the
actuator stem (8) rotates.
• When the signal input pressure decreases, the
spool (1) moves to the left reversing the action,
lifting the left poppet (14) and supplying pressure
to the outer actuator chambers (10) and venting
the inner actuator chamber (9).
OUT 2
1
OUT 1
2
6
13
5
3
4
7
15
9
10
8
15. Feedback Springs
Input Signal
Bellows
Mechanism
Feedback
Spring
Flapper & Nozzle
Mechanism
Stabilizer
Spring
Communication
Mechanism
Figure 1
Pilot
Relay
Feedback
Lever
Actuator
Stroke Output
5
Page 6
Bray Series 6P
!
Operation and Maintenance Manual
Label Description
NOTICE
All Series 6P positioners are supplied as Double Acting.
For Single Acting operation, OUT 2 should be plugged
with a 1/4” NPT plug.
Specifications
Category Double Acting / Single Acting Pneumatic
Input Signal 3-15 psig (0.2 - 1.0 barg)
Supply
Pressure
Stroke 0 to 90˚
Air
Connection
Gauge
Connection
Protection IP66
Cam Linear & Optional Reverse Acting
Ambient
Temperature
Ranges
Linearity ±2.0% Full Scale (F.S.)
Hysteresis ±1.0% Full Scale (F.S.)
Sensitivity ±0.5% Full Scale (F.S.)
20-100 psig (1.4 - 7.0 barg)
1/4” NPTF
1/8” NPTF
Std. = -4˚F to +158˚F (-20˚C to +70˚C)
High = -4˚F to +248˚F (-20˚C to +120˚C)
Low = -40˚F to +158˚F (-40˚C to +70˚C)
Repeatability ±0.5% Full Scale (F.S.)
Air
Consumption
Flow
Capacity
Housing
Material
Weight 3.7 lbs (1.7 kg)
.1 Acfm (1.4 LPM) @ 20 psia (1.4 barA)
.39 Acfm (11 LPM) @ 60 psia (4 barA)
2.8 Acfm (80 LPM) @ 20 psia (1.4 barA)
7.1 Acfm (200 LPM) @ 60 psia (4 barA)
Die-cast Aluminum, Powder-coated
6
Page 7
COVER
SPAN ADJUSTMENT
Operation and Maintenance Manual
Parts and Assembly - Figure 2
Bray Series 6P
*
Auto/Manual Adjustment
PILOT VALVE
CONNECTOR
INPUT BELLOWS
ZERO ADJUSTMENT
SIGNAL IN
DOME GEAR
CAM
FEEDBACK SHAFT
OUTPUT 1
OUTPUT 2
SUPPLY IN
*Auto / Manual Adjustment is Factory
set, and should not be adjusted.
7
Page 8
Bray Series 6P
!
Operation and Maintenance Manual
Dimensions in Inches (mm)
Figure 3
7.34 (186.5)
5.20 (132.1)
2.84 (72.2)
1/8 NPT Gauge
4 Places
1.8
1/4 NPT Air
4 Places
(45)
4.86 (123.5)
0.33(8.4)
1.06
(26.9)
6.5 (166)
4.8 (122)
Installation
CAUTION
When installing a positioner, please read and
follow all safety instructions:
• Series 6P should be used for quarter-turn valves
and actuators only.
• All input and supply pressure to valve, actuator,
and other related devices must be turned off.
• Use a bypass valve or other equipment
to avoid entire system shut down.
• Make sure there is no remaining
pressure in the actuator.
Tools for Installation
1. Allen wrenches
2. Phillips and Flathead Screwdrivers
1.67 (42.5)1.71 (43.5)
2.6 (65)
0.8
(20)
3.2 (80)
7.34 (186.5)
1.6 (40) 2.4 (60) 1.4 (34.5)
0.8 (20)
0.8 (20)
4-M8 x 1.25P
2.4 (60)
2.8 (70)
3. Wrench for hex-head bolts
Before installation, be sure to check for the following
installation components.
1. 1 Main Body
2. 1 bracket set (3 pcs)
3. 8 pcs of hex head bolt M8 x 1.25P w/ washers
4. 12 pcs of M7 allen screws, lock washers & nuts
5. ¼” NPT plug
Note: All Series 6P positioners are supplied as Double
Acting. For Single Acting (Spring Return) operation
OUT 2 should be plugged with a 1/4” NPT plug (See
Figure 2 - pg. 7)
Figure 4
8-M8 x 1.25P Dp.10
0.1 (3) 3.6 (91.5) 1.8 (45.8)
8
Page 9
Bray Series 6P
H
Operation and Maintenance Manual
Bracket Information
The Series 6P is supplied with a standard adjustable
bracket for NAMUR mounting.
20
30
50
H: 50
H: 20, 30
NAMUR TYPE 20
NAMUR TYPE 30
NAMUR TYPE 50
H: 50
H: 20, 30
Figure 5
3. Attach the Series 6P to the bracket as shown in
Figure 8. This sets the alignment of the main
shaft and the center of the actuator stem.
NOTICE
Misalignment of the main shaft and the actuator stem
lowers the Series 6P’s sensitivity, because too much
side force will be imposed on the feedback shaft.
4. Tighten the Series 6P base and the bracket
hex-headed bolts to the actuator after checking
the position using the supplied Hex Head Bolts,
Spring Washers, and Lock Washers. M5 or
#10-32 bracket to actuator mounting screws are
supplied depend-
ingonspecied
actuator drilling
NOTICE
Care must be taken when assembling the two top
brackets to the bottom brackets. Please refer to
Figure 5 for proper placement. Failure to do so will
cause the positioner to be misaligned to the actuator
shaft causing binding and poor performance.
1. Standard actuator stem height (H) is .79”
(20mm), 1.18” (30mm), or 1.96” (50mm).
After checking “H” (Figure 6), assemble with
the bracket as shown in Figure 5.
Figure 6
2. Set rotation position of the actuator stem at the
zero point. For a Spring Return Actuator, Zero
point is the position at which the actuator rests
with no supply pressure. If a Double Acting
actuator is used, check actuator stem’s rotation
direction (clockwise or counter-clockwise) by
supplying pressure.
Counter-Clockwise
Figure 7
Clockwise
Figure 8
9
Page 10
Bray Series 6P
Operation and Maintenance Manual
5. Piping Connections
NOTICE
To avoid introducing moisture or dust, both supply
andsignalairshouldbeclean,dry,andltered
instrument air.
Supply Pressure Condition
1. Dry air with dew point of at least 50°F (10°C)
lower than ambient temperature.
2. Avoid dirty or oily air. Filtered air is recommended in compliance with ANSI/ ISA-573
1975 (R1981) instrument grade.
3. Do not use beyond the range of
20-100 psig (1.4 - 7.0 barg) supply air.
4. Setairlterregulator’ssupplypressure10%
higher than the actuator’s spring range pressure.
Pipe Condition
1. Make sure the inside of tubing is clean and clear.
Piping connection with actuator
Series 93 Spring Return Actuator
When mounting on the Bray S93 Spring Return
Actuator, OUT 1 should be connected to port A (left
port when facing the ports) and OUT 2 should be
plugged. This generates increasing pressure, forcing
the pistons away from each other, causing a counterclockwise rotation compressing the springs with
increasing signal to the positioner. When mounting
to other manufacturers rack and pinion actuators or
other actuator types, check actuator documentation to
determine proper connection.
OUT 1
OUT 2
A
B
2. Do not use tubing that has been pinched or has
holes.
3. Tomaintainproperowrate,useatubesizethat
is at least ¼” (6mm) inner diameter.
4. Do not use extremely long tubing systems.
Itmayaffecttheowrateduetoexcessive
pressure drop.
Figure 9 - Single Acting
Series 92 Double Acting Actuator
When mounting on the Bray S92 Double Acting
Return Actuator, OUT 1 should be connected to port
A (left port when facing the ports). OUT 2 should be
connected to port B (right port when facing the ports).
These connections will cause the pistons to move
away from each other causing a counter-clockwise
rotation with increasing signal to the positioner, and
clockwise on decreasing signal. When mounting to
other manufacturers rack and pinion actuators or
other actuator types, check actuator documentation to
determine proper connection.
OUT 1
OUT 2
10
A
B
Figure 10 - Double Acting
Page 11
Bray Series 6P
!
Operation and Maintenance Manual
Adjustment – Cam
1. If the valve actuator rotates counter-clockwise to
open the valve on increasing air signal, the face
of the cam must show “RA (CCW)” (Factory
Default). If used on a valve-actuator which rotates clockwise to open the face of the cam must
show “DA (CW)” on the face.
2. With the valve in the closed position, loosen the
cam locking allen key and adjust the cam so the
reference line on the cam points to the center of
the bearing.
Counter-clockwise - To Open
RA(CCW)
(Reverse acting) (Direct acting)
Cam reference line
0
Bearing
Clockwise - To Open
DA(CW)
0
Figure 11
Adjustment – Span
1. After setting the Zero Point, increase the signal
pressure to 15 psi. Loosen the locking screw
slightly, and rotate or turn the Span Adjustment
Screw clockwise or counter-clockwise until the
actuator achieves its 90° or full open position.
2. Changing the Span Adjustment affects the Zero
Point setting. Decrease signal to 3 psi and
re-check the Zero Point and adjust as needed.
3. Re-check the Span Adjustment Screw by
repeating step 1. Steps 1 & 2 may need to be
repeated several times to optimally calibrate the
positioner. Once the Span and Zero Point are
set, tighten the Zero and Span Locking Screws
shown below.
NOTICE
The Series 6P may be 2 way split range by
changing the Span Spring. Consult factory for
additional parts required.
Adjustment – Zero Point
1. Set the signal to 3 psi. Rotate or turn the Zero
Adjustment wheel clockwise or counter-clockwise
so the pressure at OUT 1 port just begins to change.
Zero Adjustment
Wheel
Lock Screw
Figure 12
CAUTION
Lock Screw
S P A N
Figure 13
(1) Span
Adjustment Screw
Be cautious of moving positioner, actuator, and
valve parts while operating.
11
Page 12
OUT 1
OUT 2
OUT 1
Bray Series 6P
JamiesonEquipmentCompany
www.jamiesonequipment.com
tollfree800.875.0280
Operation and Maintenance Manual
Adjustment – Poppet Seat
Balance Pressure A/M Adjustment
NOTICE
The Poppet Seat Adjuster is factory set and sealed
before the positioner is shipped. Do not adjust
Auto / Manual default setting (Automatic) as shown.
Poppet Seal
Adjuster
A/M
A/M
A/M
Automatic/ Manual
Figure 14
Troubleshooting
Positioner does not respond to the input signal
1. Check the supply pressure to the actuator. The
supply must be at least 40 psi / 2.7 Bar / 0.27 MPa
Hunting occurs
• Check if feedback springs (15) have been dis-
placed.
• Hunting may occur when the positioner is
attached to a very small capacity actuator (ex:
Bray Series 92/93 size 48). In such case, install
anoutputoriceforOUT1andOUT2perthe
following steps.
1. Remove Pilot Valve Assembly (Figure 2).
2. Remove the O-ring from OUT 1 and OUT 2
port,installoriceinandreinstalltheO-ring
to OUT 1 and OUT 2 again. When mounting
theoutputorice,payattentionnottoletdust
ordebrisentertheorice(Figure 16).
3. If hunting does not stop after installing the
outputorice,pleasecontactyourlocal
Orifice Diameter
Orifice
O-ring
2. Check if input signal is properly supplied to the
positioner. The signal range should be 3-15 psi.
3. Check if the positioner’s nozzle (5) has been
blocked. If the nozzle has been blocked by any
substances, please contact your local
Bray distributor for a replacement.
4. Check if feedback shaft has been adjusted
properly and engaged to actuator pinion.
The pressure of OUT 1 reaches exhausting
pressure level and does not come back down
1. Check Auto/Manual (A/M) switch. For proper
operation it must be in the “A” position.
2. Check for a gap or damage between the nozzle
(5)andtheapper(13). If damaged, please contact your local Bray distributor.
CONTROLS
R
OUT 2
Figure 15
Bray distributor.
Actuator only operates Open or Closed
1. Check tubing connection
2. Check cam direction
Linearity is too low
1. Check if Zero and Span has been properly adjusted.
2. Check if supply air pressure level is stable from
the regulator. If the level is unstable, replace the
regulator.
Bray® is a registered trademark of BRAY INTERNATIONAL, Inc.
© 2013 Bray International. All rights reserved.
OM-6P-001 11-2013
Loading...