The High Performance Company

Series 92/93
Pneumatic Actuator
Installation, Operation and Maintenance Manual
 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

TABLE OF CONTENTS
Safety Information - Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hazard-free use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Open Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Open Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Open Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Open Method 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fail Closed Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting the Actuator to the Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting the Travel Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Final Assembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adding Spring Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Pneumatic System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Series 92/93 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

For information on this product and other Bray products please visit us at our web page - www.bray.com

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

Read and Follow These Instructions Save These Instructions

SAFETY INFORMATION - 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.

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

HAZARD-FREE USE of the device and who has appropriate qualifications, such as:
This device left the factory in proper condition to be safely • Is trained in the operation and maintenance of
installed and operated in a hazard-free manner. The notes pneumatic equipment and systems in accordance with
and warnings in this document must be observed by the established safety practices
user if this safe condition is to be maintained and hazard- • Is trained or authorized to energize, de-energize,
free operation of the device assured. ground, tag and lock electrical and pneumatic circuits
Take all necessary precautions to prevent damage to the and equipment in accordance with established safety
actuator due to rough handling, impact, or improper practices
storage. Do not use abrasive compounds to clean the • Is trained in the proper use and care of personal
actuator, or scrape metal surfaces with any objects. protective equipment (PPE) in accordance with
The control systems in which the actuator is installed must established safety practices
have proper safeguards to prevent injury to personnel, • Is trained in first aid
or damage to equipment, should failure of system • In cases where the device is installed in a potentially
components occur. explosive (hazardous) location – is trained in the
STORAGE operation, commissioning, operation and maintenance
Bray Series X is not weatherproof until the unit is properly of equipment in hazardous locations
installed, or all conduits and applicable port connections
are sealed off and prepared for storage. The units may be
shipped with temporary covers to prevent foreign matter
from entering through the conduit openings; however, the
user is responsible for replacing with the proper sealing The actuator must only be installed, commissioned,
plugs to support its NEMA/IP ratings. operated and repaired by qualified personnel.
To prevent condensation from forming inside the unit, The device generates large mechanical force when
maintain a near constant external temperature and pressurized with air, and/or powered by springs.
store indoors in a well ventilated, clean, dry room. The The actuator stores a large amount of energy when
temperature shall be between 40 F (4 C) and 85 F (29 C), pressurized with air, and/or when the springs are
with a relative humidity less than 70%. Store units away compressed.
from vibration and direct sunlight exposure, and place units To prevent injury, installation, commissioning, operation
on a shelf or wooden pallet in order to protect against and maintenance must be carried out under strict
dampness. Keep units covered to protect against dust and observation of the safety regulations.
dirt; if storing for long term, placing the unit inside a plastic
Reference is specifically made here to observe the
sealed bag may be preferred.
applicable safety regulations for actuators installed in
Bray cannot accept responsibility for deterioration caused on- potentially explosive (hazardous) locations.
site once the cover is removed or due to improper storage.
QUALIFIED PERSONNEL Correct and safe operation of this actuator is dependent
A qualified person in terms of this document is one who is upon proper transport, storage and installation in addition
familiar with the installation, commissioning and operation to proper operation and maintenance.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

DESCRIPTION OF OPERATION INSTALLATION

The Bray Series 92/93 Pneumatic Actuators feature a Bray Series 92/93 Actuators are designed to mount directly
double piston, rack and pinion mechanism designed to on the top plate of Bray Valves. Before the actuator is
automate quarter-turn valves. In the Series 92 Double- mounted on a valve, it is a good practice to lubricate the
Acting Actuator, pressure introduced through Port A (the output bore of the actuator with thick grease. The grease
left port when facing the ports) forces the pistons away will make it easier to remove the actuator from the valve
from each other and causes the pinion to rotate in a stem, even after years of service.
counter-clockwise direction. Pressure introduced through
Port B (the right port when facing the ports) is directed Normally, the actuator is mounted with its long side parallel
through an internal passage to the opposite side of the to the pipeline. A double acting actuator will normally
pistons, which forces the pistons together and rotates the rotate the valve stem clockwise to close, and counter-
pinion in a clockwise direction. Normally, the clockwise clockwise to open. Spring return actuators will normally
rotation (pistons moving together) closes the attached rotate the valve stem clockwise to close with the spring
valve, and the counter-clockwise rotation (pistons moving stroke, and counter-clockwise to open with the air stroke.
apart) opens the attached valve. The normal operation of the spring cartridges is therefore
fail closed.
In the Series 93 Spring-Return Actuators, spring cartridges
have been added to push the pistons together by spring Direction of operation may be changed to fail open by any
force in the event the compressed air pressure being one of several different methods. Refer to the Assembly
lost. This spring force normally closes the attached valve. Instructions and Exploded View on page 12 for more
However, in the event that the valve is required to open details.
under spring force, refer to the fail open portion of the Fail Open Assemblies
Installation section.
If the actuator is attached to a valve, the butterfly valve disc
OPERATING MEDIUM is shipped in the full open position (as no air pressure is
present to compress the springs and close the valve disc.)
NOTICE The sealing surface, or disc edge, is therefore exposed.
Damage to that surface will cause premature seat failure.
The recommended operating medium is clean, dry NOTE: Consult a factory representative when a non-
industrial compressed air, 40 - 140 psig (3 - 10 bar.) An air standard actuator configuration is made in the field or is
line lubricator is suggested for fast cycling applications, being changed in the field. Example: Mounting an actuator
i.e. more than 10 cycles per minute. Other media such perpendicular to the pipe due to space restrictions on site.
as hydraulic oil, water, or certain other inert gases may
also be used in some instances, but the factory should be
consulted for specific applications.

OPERATING TEMPERATURE Use caution installing the valve being careful not to
damage the disc edge. It is recommended to:

NOTICE • Remove the actuator. Be sure to scribe the valve and

actuator to ensure the re-installed actuator is in the
The recommended operating temperature range is -20°F exact same quadrant as originally configured
to 200°F (-29°C to 95°C). Below 32°F (0°C) care must
be taken to prevent condensed moisture from freezing • Install the valve per the attached installation tag
in the air supply lines. Consider the use of an air dryer instructions
if the device is installed in a cold location. The air dryer • Re-install the actuator ensuring it is in the proper
must be capable of lowering the dew point of the air quadrant
to a temperature 36°F (20 °C) lower than that of the
surrounding environment. The air dryer must be properly
maintained and kept in operation.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

Fail Open Method 1

Mounting the Actuator Perpendicular to the Pipeline

NOTICE Some actuators may have spring cartridges installed.

Before disassembly, all spring cartridges must be placed
into the relaxed (fully extended) position. All compressed
Fail Open Method 1 – Mounting the Actuator air must be removed from inside the actuator (See previous
Perpendicular to the Pipeline – works only with concentric warning) and the actuator pinion must be allowed to
disc valves such as the Bray Series 20/21, 22/23 and 30/31 rotate so the springs may be relaxed. Care must be taken
or other valves that allow the disc to be swung through to verify that any device connected to the actuator, such
the seat. as a valve mounted underneath, is not preventing the
Turn the actuator so the long side is perpendicular to the movement of the springs to the relaxed position.
pipeline. This will allow the spring cartridges to rotate the Remove the end caps, spring cartridges and pistons from
valve stem clockwise to open, and the air stroke to rotate the actuator. Remove the pinion, rotate it 90°, and reinstall
the valve stem counter-clockwise to close. This is the easiest the pinion in the actuator. This will also allow the spring
method if there is sufficient room to mount the actuator. cartridges to rotate the valve stem clockwise to open, and
Fail Open Method 2 the air stroke to rotate the valve stem counter-clockwise
Rotating the Pinion to close. This is the second easiest method, and allows the
actuator to be mounted with its long side parallel to the
pipeline.
NOTICE
Fail Open Method 3
Fail Open Method 2 – Rotating the Pinion - works only Reversing the Pistons
with concentric disc valves such as the Bray Series 20/21,
22/23 and 30/31 or other valves that allow the disc to be
NOTICE
swung through the seat.

See Assembly (page 7) for detailed instructions on Fail Open Method 3 – Reversing the Pistons – works for
reinstalling the travel stop cam on the pinion. all valves, but must be used with offset disc valves such
as the Bray Series 40/41, 42/43 and 44/45, or other offset
disc valves where the disc may only turn clockwise to
close.

See Assembly (page 7) for detailed instructions on

Before disassembly of the actuator, the pneumatic
reinstalling the travel stop cam on the pinion.
air supply must be completely disconnected from the
actuator, and all compressed air stored within the Remove the end caps, spring cartridges and pistons from
actuator must be released. Auxiliary devices connected the actuator. Rotate the pistons so that the racks turn the
to the actuator, such as tubing, ball valves, solenoid air pinion counter-clockwise as the pistons move toward each
valves, valve positioners, etc. can block the release of air other. (With the air input ports of the actuator body facing
from within the actuator. Do not rely upon the features you, the left hand piston rack should be on the side with
or controls of any auxiliary device to release the air from the air ports.) This is the third easiest method, and allows
inside the actuator to render it safe for disassembly. the actuator to be mounted with its long side parallel to the
pipeline, and clockwise to close rotation to be maintained.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

Fail Closed Assemblies SETTING THE TRAVEL STOPS

If the actuator is attached to a valve, the butterfly valve The final step in the installation process is to check the
is shipped in the full closed position (as no air pressure is travel stop settings. The travel stops are set for 90° of travel
present to compress the springs and open the disc). at the factory; however, each installation is different so they
should be checked before putting the valve in service. The
actuators are designed with a nominal 5° over or under
travel at each end of rotation. A screwdriver, an open end
or box end wrench and a hex wrench, of the appropriate
Installing the valve with the disc in the full closed position size, are the only tools required to make the necessary
may create a compression set on the seat causing higher adjustments. Refer to Figure 1 below.
than expected torques or premature seat failure. It is
recommended to:
• Remove the actuator. Be sure to scribe the valve and
actuator to ensure the re-installed actuator is in the Before setting the travel stops, the pneumatic air supply
exact same quadrant as originally configured must be completely disconnected from the actuator,
• Install the valve per the attached installation tag and all compressed air stored within the actuator must
instructions be released. Auxiliary devices connected to the actuator,
such as tubing, ball valves, solenoid air valves, valve
• Re-install the actuator ensuring it is in the proper positioners, etc. can block the release of air from within
quadrant the actuator. Do not rely upon the features or controls
MOUNTING THE ACTUATOR TO THE VALVE of any auxiliary device to release the air from inside the
actuator to render it safe for disassembly.
The actuator is attached to the valve by means of the studs
and nuts furnished in the mounting kit. Thread the studs Remove the black Position Indicator Pointer (23) to expose
into the proper holes in the actuator, before installing the the wrench flats on the top of the Pinion (3).
actuator on the valve. The studs should be snug in the
Rotate the valve to the desired position by using a wrench
bottom of the tapped holes; there is no need to torque
on the wrench flats on the top of the Pinion (3).
them. Install the actuator on the valve making sure that
the base of the actuator fits flat against the valve mounting Loosen the Lock Nut (12) on the Travel Stop Screw (13). It
flange. Use the nuts and washers from the kit to complete is not necessary to remove the nut completely. Using the
the installation. Torque the nuts in a diagonal pattern to hex wrench, turn the screw in or out until the desired travel
assure equal loading of the studs. stop position is reached. While holding the screw with the

Figure 1

23

5°
13

12
5°

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

hex wrench, tighten the Lock Nut (12) with the box end
wrench. NOTICE
Replace the Position Indicator Pointer (23) making certain
the pointer is aligned with the position of the valve, open To lengthen service life, it is strongly recommended
or closed. that an adequately sized filter with a 40 micron (or
finer) element be installed adjacent to the inlet of the
Some valves or operating conditions require that the directional control (solenoid air) valve. Air lubricators are
actuator have more than 5° of travel adjustment. For these recommended for rapid cycling applications (10 cycles or
conditions, the Series 92/93 actuator can be fitted with more per minute.)
extended travel stops in the end caps. (See page page 11
for instructions on finding dimensional data) Consult the Routine maintenance of Series 92/93 actuators consists
Bray distributor in your area for this option. primarily of maintaining the air supply system by changing
Spring return actuators may be operated with only one air filter elements before they start by-passing, adding oil to
supply connected to Port A, since the spring cartridges will lubricators before they run dry, and preventing water from
move the pistons when the air pressure in removed. This entering the air lines.
operation, however, will draw the surrounding atmosphere The second most common cause of shortened service life is
into the spring chambers through Port B. misalignment between the valve and the actuator. This can
cause premature failure due to excessive side loads on the
bearings and gear teeth.
NOTICE
To prevent contamination from entering the spring NOTICE
chamber, actuators configured to operate with only one
air supply connected to Port A should be equipped with a To lengthen service life, the mechanical connection
40 micron (or finer) filter element installed in Port B. between the actuator and the valve should be verified to
be properly aligned and free to rotate throughout the full
Even better service may be obtained on spring return range of valve travel.
actuators by installing a four-way solenoid, covering both
Port A and Port B. A four-way solenoid will fill the spring
chambers with compressed air from the plant air supply
with each stroke. The plant air supply is often cleaner than
the surrounding atmosphere, especially in heavy industrial
or chemical areas.
MAINTENANCE
The rugged components and factory lubrication combine
to ensure a long and trouble-free service life for Series
92/93 actuators. Dirt, rust and water are the most common
causes for shortened service life, and they typically enter
the actuator through the air supply line.
Remove any dirt, rust, water or other contaminants from
inside the actuator. Any damaged or corroded components
must be replaced.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

TROUBLESHOOTING
Table 1 shows several common symptoms and their remedies.

Table 1

Symptom Probable Cause Check Remedy

Loss of Power Low air supply pressure, or Air supply pressure at Boost air supply pressure, repair air
damaged O-rings actuator, leakage across supply line leaks, replace O-rings
O-rings
Binding between valve Misalignment of coupling Alignment Realign coupling
and actuator
Valve “pops” out of Valve torque too high, Valve torque, actuator Repair valve, use proper size
seat and slams open actuator sized too small, or sizing calculations, size actuator, use larger air supply lines
insufficient air supply flow of air supply lines and/or and/or solenoid valve with higher
solenoid valve flow
Air Leakage Loose fasteners or worn, Fasteners and travel stop Tighten fasteners, travel stop lock
damaged seals lock nuts nuts. Replace o-rings.

ASSEMBLY Travel Stop Screws (13) - Slip the o-ring (14) over the flat
end of the screw until it is 5-7 threads from the end. Thread
To identify component names and shapes and for the the screw into the hole in the body, flat end first. Repeat
numbers in parentheses ( ) below, refer to the exploded these steps for the second screw. Thread the lock nuts (12)
view of the actuator shown on Figure 3, page 12. onto the screws and tighten the nuts against the body. This
Easiest assembly will result from lubricating all bearings will seal the threads for testing. It is not necessary to set the
and seals as they are installed. The lubricant should be a travel stops at this time, as they may have to be reset when
high pressure or extreme pressure petroleum grease with the actuator is installed on the valve.
a lithium based thickener which meets the NLGI grade 2.
Grease which meets this specification should be available Pistons (2) - Install the bearing pad (10) on the back of
from any automotive supply store. the rack and the o-ring (19) and guide ring (11) in their
appropriate piston grooves. The o-ring goes in the groove
Pinion (3) - Install bearing rings (6 & 7) and o-rings (21 & nearest the rack. With the ports on the actuator body
22) in their appropriate grooves. Insert the pinion through toward you, turn the pinion so that the slot is approximately
the large hole in the center bottom of the body (1). With 45° to the right of perpendicular with the long side of the
the pinion part of the way into the body, slide the cam body. Grasp the pistons in the spring pockets so that the
(16) over the pinion being careful to align the punch mark piston in the right hand has the bearing pad toward you
on the cam with the punch mark(s) on the pinion. For and the piston in the left hand has the bearing pad away
normal installation and rotation (Fail Close), align the single from you. Slide the pistons into the body so that they both
marks. For Fail Open operation described in Method 2 on engage the teeth on the pinion at the same time. Apply
page 4, align the single mark on the cam with the two enough steady force to compress the o-ring into the body
marks on the pinion. For Fail Open operation described bore. At this point, you may continue pushing or use a
in Method 3 on page 4, align the single marks. Next, wrench on the top of the pinion to pull the pistons into the
install the spacer (15) above the cam. Then insert the pinion body.
through the hole at the top of the body and secure it with
the washer (9) and retaining ring (8).

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

FINAL ASSEMBLY AND TESTING

NOTICE

Three important parameters must be verified before

assembly may be continued.
Do not connect a compressed air supply to the actuator
The pinion must turn clockwise as the pistons moved
that exceeds the pressure rating of the actuator (140 psig
toward the center of the body.
/ 10 barg)
The 4 mm slot in the top of the pinion must be within
a few degrees of perpendicular to the long side of the Connect the compressed air supply to the actuator input
body. ports and cycle the actuator fully open and fully closed to
check for proper travel and absence of air leaks. Air supply
The piston faces must both be the same distance from lines should have a minimum inside diameter of 0.250” (6
the end of the body. mm). Restricted air supply lines, or any portion of the air
supply system powering the actuator (such as solenoid air
If all three parameters above have been verified, the end
valves or valve manifolds) can reduce actuation time, cause
caps may be installed.
unexpected popping of the valve, or even malfunction.
If any parameter above is not verified, use a wrench on the
If compressed air is applied to Port A and the actuator
pinion to drive the pistons out of the body and repeat the
reaches the end of travel, there should be no air flow out of
insertion process. It is not necessary to remove the pistons
Port B, and vice versa. There should be no air flow between
from the body unless the answer to the first question is no.
the end caps and the body, through the travel stops, or out
It is only necessary to disengage the piston rack from the
the top or the bottom of the pinion. A solution of soap and
pinion.
water applied to the sealing points can indicate leaks that
are too small to be audible.
NOTICE
DISASSEMBLY
The assembly procedure described here is the standard
Fail Close method. For Fail Open actuators, refer to
Method 2 or Method 3 on page 4.

End Caps (4) - Install the o-ring (20) in the groove. Attach
Before disassembly of the actuator, the pneumatic
the end cap to the body with the 4 bolts (17) and washers
air supply must be completely disconnected from the
(18) making certain that the straight part of the o-ring
actuator, and all compressed air stored within the
groove is toward the bottom of the body. The air pressure
actuator must be released. Auxiliary devices connected
will not flow to the outboard side of the pistons if the
to the actuator, such as tubing, ball valves, solenoid air
straight part of the o-ring groove is at the top.
valves, valve positioners, etc. can block the release of air
Position Indicator (23) - Install the position indicator from within the actuator. Do not rely upon the features
pointer on the top of the pinion and secure it with the flat or controls of any auxiliary device to release the air from
head screw (24). Normally, the long axis of the pointer will inside the actuator to render it safe for disassembly.
be parallel to the groove in the pinion. If the actuator is
installed across the pipe line, as described in Method 1 on
page 4, the indicator should be turned so that it is in
line with the butterfly valve disc or port in the ball or plug
valve.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

ADDING SPRING CARTRIDGES

Some actuators may have spring cartridges installed.

Before disassembly, all spring cartridges must be placed
into the relaxed (fully extended) position. All compressed Before disassembly of the actuator, the pneumatic
air must be removed from inside the actuator (See air supply must be completely disconnected from the
warning on previous page 8) and the actuator pinion actuator, and all compressed air stored within the
must be allowed to rotate so the springs may be relaxed. actuator must be released. Auxiliary devices connected
Care must be taken to verify that any device connected to to the actuator, such as tubing, ball valves, solenoid air
the actuator, such as a valve mounted underneath, is not valves, valve positioners, etc. can block the release of air
preventing the movement of the springs to the relaxed from within the actuator. Do not rely upon the features
position. or controls of any auxiliary device to release the air from
inside the actuator to render it safe for disassembly.

Move the pinion to the fully closed (0°) position. Remove

If the actuator is installed on a valve, remove the actuator the end caps and insert the desired number of spring
from the valve, and move the actuator to a clean work cartridges into the end cap pockets, up to a maximum of
area. Remove the indicator pointer. Remove both end caps six cartridges per end cap.
by loosening the hex head end cap bolts. Remove both
pistons by rotating the pinion counter-clockwise until the
piston heads are protruding from the body. Pull the pistons NOTICE
out. Using snap-ring pliers, remove the pinion retaining
ring and acetal washer, then remove the pinion from the For proper operation, actuators equipped with Spring
body. The pinion bearings, o-rings, cam and spacer may Cartridges should have the spring cartridges installed in
then be removed. accordance with the positions shown in Figure 2.

Align the end cap with the body so the spring cartridges
fit into the piston pockets. Attach the end caps to the
body with the hex head end cap bolts. Tighten the bolts
gradually in a diagonal sequence.
Proceed to Final Assembly and Testing.

Figure 2

XX

2 SPRINGS 3 SPRINGS
XX = SIZE CODE EACH PISTON EACH PISTON

XX XX

4 SPRINGS 5 SPRINGS 6 SPRINGS

EACH PISTON EACH PISTON EACH PISTON

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

REMOVING SPRING CARTRIDGES

When removing end caps from an actuator containing

spring cartridges, the end cap bolts must be loosened
Before disassembly of the actuator, the pneumatic gradually in a diagonal sequence until the spring
air supply must be completely disconnected from the cartridges are completely relaxed (fully extended.) The
actuator, and all compressed air stored within the spring cartridges should reach the completely relaxed
actuator must be released. Auxiliary devices connected (fully extended) position while all four end cap bolts still
to the actuator, such as tubing, ball valves, solenoid air have some thread engagement with the actuator body.
valves, valve positioners, etc. can block the release of air Do not remove three end cap bolts completely from the
from within the actuator. Do not rely upon the features body and expect the remaining single bolt to hold the
or controls of any auxiliary device to release the air from spring cartridges in a compressed position.
inside the actuator to render it safe for disassembly.
Remove the spring cartridges. Replace the end caps and
tighten the end cap bolts gradually in a diagonal sequence.

Before disassembly, all spring cartridges must be placed

into the relaxed (fully extended) position. All compressed
air must be removed from inside the actuator (See
warning above) and the actuator pinion must be allowed When replacing end caps onto an actuator containing
to rotate so the springs may be relaxed. Care must be spring cartridges, the end cap bolts must be tightened
taken to verify that any device connected to the actuator, gradually in a diagonal sequence until the spring
such as a valve mounted underneath, is not preventing cartridges are slightly compressed into their fail position.
the movement of the springs to the relaxed position. The spring cartridges should reach the slightly compressed
fail position while all four end cap bolts have some thread
An actuator with spring cartridges installed and no engagement with the actuator body. Do not attempt
compressed air connected will move to the spring fail to tighten a single end cap bolt fully and compress the
position if the pinion is free to rotate. This may be either spring cartridges while the other three bolts have not
fully closed (0°) or fully open (90°). In either case, when been installed.
the spring fail position is reached, remove the end caps
by gradually loosening the hex head end cap bolts in a Proceed to Final Assembly and Testing.
diagonal sequence.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

GENERAL PNEUMATIC SYSTEM DIMENSIONAL DATA

RECOMMENDATIONS For Dimensions see Bray ES Drawings:
To maintain maximum efficiency with the Series 92/93 • ES11A-0460
actuator, as well as many other pneumatic devices, the • ES11A-0533
following suggestions are offered: • ES11A-0534
• ES12A-0533
• Air supply lines should be run in accordance with • ES12A-0534
a Standard Piping Practice, and should not have on www.bray.com
exaggerated loops, which may trap condensate.
• All pipe ends should be thoroughly cleaned and
deburred after cutting to ensure that the pipeline is
clear of cuttings.
• Where air pipelines are subjected to extremes of
temperature, the system should be fitted with air
drying equipment.
• If pipelines are hydraulically tested, the lines should be
“blown down” with high pressure air to clear all water
prior to connecting the lines to the actuator.
• Where a system is dependent on air filter equipment,
the air filters should be in positions that allow easy
access for maintenance and/or draining.
• Where pneumatic valve positioners or pneumatic
controllers are installed in a valve actuator assembly,
oil mist lubricated air should not be used unless the
manufacturer states specifically that the positioner or
controller is compatible with lubricated air. In general,
lubricated air is not recommended for a positioner.
• Where pipe fitting sealants or tapes are used, they
should be applied to the male threads only, and limited
to the first three threads. When applied to female
threads, excess compound or tape can be transmitted
into the actuator control lines and cause malfunctions
in downstream equipment.
• Lubricators should be installed downstream of
regulators.
• Eliminate or minimize sharp bends in the air supply
lines.

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 Series 92/93 Pneumatic Actuator
Installation, Operation and Maintenance Manual

Figure 3:
Series 92/93 Exploded View

24
11
23 19
8
9
1

2
20
5 10

13 14 12 Item
Qty. Description
No
15 1 1 Body
2 2 Piston
3 1 Pinion
16 4 2 End Cap
12
21 5
max.
Spring Cartridge*

6 6 1 Upper Pinion Bearing*

7 1 Lower Pinion Bearing*
8 1 Retaining Ring
9 1 Washer, Acetal*
17 18 4 10 2 Bearing Pad, Acetal*
11 2 Guide Ring, Acetal*
3
12 2 Lock Nut
13 2 Travel Stop Screw
14 2 O-ring, Travel Stop
15 1 Spacer, Int. Travel Stop
7 16 1 Cam, Internal Travel Stop
17 8 Hex Head Cap Screw
22 18 8 Washer, Stainless Steel
19 2 O-ring, Piston
20 2 O-ring, End Cap
21 1 O-ring, Upper Pinion
22 1 O-ring, Lower Pinion
23 1 Position Indicator Pointer*
24 1 Flat Head Screw

*Extreme temperature trim actuator (-90U) uses proprietary components. Do not install other trim (Low, Standard, High) components.
Only install components designed for the designated actuator trim. Contact Bray for service requirements.

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All statements, technical information, and
recommendations in this bulletin are for general use Bray Controls
only. Consult Bray representatives or factory for the A Division of Bray International, Inc.
specific requirements and material selection for your
intended application. The right to change or modify
13333 Westland East Blvd.
product design or product without prior notice is reserved. Houston, Texas 77041
Patents issued and applied for worldwide. THE HIGH PERFORMANCE COMPANY Tel: 281.894.5454 • www.bray.com
Bray® is a registered trademark of Bray International, Inc.
© 2016 Bray International, Inc. All rights reserved.
OM_92/93_08_19_2020