controlair T-6100, Type-6100 Installation, Operation And Maintenance Instructions

Installation, Operation and Maintenance

Instructions

TYPE-6100

The Type-6100 volume booster is a 1:1 signal to output relay that is utilized in applications that require high
forward flow and exhaust capacities. Typically used to increase throttling speed of large volume valve
actuators. Suitable for either diaphragm or piston actuators. A fixed deadband and adjustable bypass valve
combine to allow small incremental downstream adjustment without opening the main booster valve. The
bypass valve is used to adjust dynamic response to provide stable operation over a wide range of actuator
sizes.

1. SPECIFICATIONS

Functional Specifications

Signal / Output Ratio 1:1

Supply Pressure 250 psig (17.0 bar) maximum
Signal Pressure 150 psig (10 bar) maximum
Maximum Flow

Coefficients (Cv)

Exhaust Capacity

5 psig (0.35 bar) above 20 psig
(1.38 bar) setpoint

Output Accuracy 1.0% of a 100 psig (7.0 bar) output span
Sensitivity 1”H2O (2.54 cm)
Deadband Under 0.2 psig (0.01 bar)
Supply Pressure Effect
Temperature Limits

High Flow Capacity Volume Booster

Port Forward Exhaust

3/4" 5.0 3.5
1/2" 4.5 3.5
1/4" 2.0 2.5

3/4" 80 scfm (2,264 NL/min)
1/2” 75 scfm (2,123 NL/min)
1/4" 35 scfm (991 NL/min)

0.1 psig (0.007 bar) for a 25 psig (1.7 bar) change

-40 to 200

0

F (-40 to 930 C)

Physical Specifications

MATERIALS

Housing:
Bolting:
Other Trim:
Internal Components:
Elastomers:

Weight 2.5 lbs (1.13 kg)
Signal Port 1/4" NPT
Supply / Output Ports 1/4", 1/2", or 3/4” NPT

Exhaust Ports (2)
Gauge Ports (2) 1/4” NPT

Aluminum
Zinc Plated Steel
Aluminum
Aluminum
Nitrile

 7/16” or 1/4" NPT option

2. DIMENSIONAL DRAWING

3. INSTALLATION

WARNING: Only qualified personnel should install or service a volume booster. Volume Boosters should be installed, operated,
and maintained in accordance with international and applicable codes and regulations, and ControlAir instructions. If the booster
vents fluid or a leak develops in the system, it indicates that service is required. Failure to take the booster out of service
immediately may create a hazardous condition. Personal injury, equipment damage, or leakage due to escaping fluid or bursting
of pressure-containing parts may result if this booster is over pressured or is installed where service conditions could exceed the
limits given in the Specifications section, or where conditions exceed any rating of the adjacent piping or piping connections. To
avoid such injury or damage, provide pressure-relieving or pressure-limiting devices (as required by the appropriate code,
regulation, or standard) to prevent service conditions from exceeding limits. Additionally, physical damage to the booster could
result in personal injury and property damage due to escaping fluid. To avoid such injury and damage, install the booster in a safe
location.

(Drawing downloads available at http://www.controlair.com)

3.1 Pre-Installation Requirements

3.1.1 The Type-6100 requires a source of clean, oil-free dry instrument grade air filtered to 40 microns.

3.1.2 Air should be free of all contaminants and hazardous gases, flammable or toxic.

3.1.3 Clean all pipelines of dirt and scale prior to installation.

NOTE

CAUTION

Failures attributable to instrument air supply contamination are not covered by the
warranty.

This instrument vents to atmosphere. The use of supply g as other than air can create
a hazardous environment.

3.1.4 Apply a minimum amount of pipe compound to the male threads of the fitting only. Do not use
thread sealant tape on pipe fittings as it tends to contaminate the valve causing the booster to
malfunction.

2

3.2 Installation

3.2.1 Install the booster so that direction of flow is from Inlet to Outlet as labeled “IN” and “OUT” marked
on the body. Inlet and outlet porting is 1/4", 1/2" or 3/4" NPT. The signal port is 1/4" NPT. Tighten
all connections securely.

3.2.2 Booster can be mounted in any position and is typically nipple-mounted between the pneumatic
supply source and the actuator. See Figure 2 for typical installation illustrations.

CAUTION

3.2.3 Ensure that piping to and from the booster is of proper size to meet the capacity demands of the
booster and that the downstream actuator has properly sized input connections so as not to limit
flow.

CAUTION

Figure 2 – Typical Installations

Do not use separate pressure supplies for the volume booster and associated
positioner as this may prevent the booster from exhausting immedi ately w hen there is
loss of positioner supply pressure, but not loss of booster supply pressure.

Keep exhaust port free of any obstructions. Excessive exhaust rest riction can
damage the booster. High flow capacity exhaust silencers and full size exhaust piping
must be used to limit back pressure during the exhaust cycle in operatio n.

3

4. OPERATION

4.1 Prior to applying supply pressure to the booster, open the bypass valve approximately one turn by turning
counter clockwise. After applying supply pressure, note response of actuator to open and close
commands from the positioner. If excessive overshoot or hunting is seen, open bypass valve until stable
operation is obtained. If valve becomes too slow to react to signal change from the positioner, close
needle valve until more responsive.

Turning the bypass valve clockwise (closing) speeds response but can lead to instability. Turning the

bypass valve counter clockwise (opening) aids stability but will slow down the actuator’s response. Proper
setting provides stable operation and acceptable response time.

5. MAINTENANCE AND REPAIRS

NOTE

5.1 Repairs

5.1.1 In the event of unit failure, the Type-6100 can be

returned to the factory through point of purchase
for warranty repair if the warranty period has not
expired.

Under normal circumstances, no maintenance should be required.

5.1.2 All units returned for repair must be authorized

prior to receipt at the factory. Contact a
representative at the point of purchase to
receive a Return Authorization Number

5.1.3 Repair kit for the Type-6100 is available.

Repair Kit P/N: 449-871-138

Repair Kit includes: * Items

6. WARRANTY & DISCLAIMER

ControlAir, Inc. products are warranted to be free from
defects in materials and workmanship for a period of
eighteen months from the date of sale, provided said
products are used according to ControlAir, Inc.
recommended usages. ControlAir, Inc.’s liability is limited to
the repair, purchase price refund, or replacement in kind, at
ControlAir, Inc.’s sole option, of any products proved
defective. ControlAir, Inc. reserves the right to discontinue
manufacture of any products or change products materials,
designs or specifications without notice. Note: ControlAir
does not assume responsibility for the selection, use, or
maintenance of any product. Responsibility for the proper
selection, use, and maintenance of any ControlAir product
remains solely with the purchaser and end user.

WARNING

These products are intended for use in
industrial compressed-air systems only. Do

not use these products where pressures and
temperatures can exceed those listed under
Specification.

441-622-176 09/25/2018 4

8 Columbia Drive, Amherst, New Hampshire 03031 U.S.A.

Tel: [phone]  Fax: [phone]

www.controlair.com