GE Baker Hughes Masonelian BR200 User manual

Masoneilan*
BR200/BR400
High Capacity Volume Booster Relays
Instruction Manual (Rev. B)
BHGE Data Classication : Public

2 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 3
© 2019 Baker Hughes, a GE company. All Rights Reserved.
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC
REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND
MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE (BAKER
HUGHES, A GE COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE
SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE
OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND
APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND
THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR
TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION,
OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR
PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES
THE MATTER SHOULD BE REFERRED TO BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE AND THE CUSTOMER/OPERATOR ARE STRICTLY
LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT.
NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BHGE REGARDING THE EQUIPMENT OR ITS USE
ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS CONTAIN PROPRIETARY INFORMATION OF BHGE, AND ARE FURNISHED TO
THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR
MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE
OR IN PART NOR SHALL ITS CONTENTS BE DISCLOSED TO ANY THIRD PARTY WITHOUT THE WRITTEN
APPROVAL OF BHGE.

4 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.
Product Description
BHGE’s Masoneilan BR400 and BR200 are high capacity volume boosters for applications that require fast
stroking speeds using pneumatic actuators. Stable operation over a wide range of actuator sizes can be obtained
by adjusting the bypass valve on the booster to modify the dynamic response. The models BR200 and BR400 are
equally suitable for use on diaphragm or piston actuators.
Features and Benefits
• Flow characteristics suitable for control valves
• Short stroking times with consistently stable operation for use on high-volume actuators or on very
demanding stroking time control valve applications
• Built-in bypass valve with locking screw to adjust sensitivity and dynamic response
• Filter on the supply port to protect instrument from particles in air supply
• Corrosion resistant finish and stainless assembly hardware to permit use in corrosive atmosphere
Principle of Operation
The input signal pressure is applied to the upper diaphragm to produce a force that is opposed in a 1:1 ratio by
the output pressure acting on the lower diaphragm through the seal plate orifice. An increase in the input signal
pressure will depress the top diaphragm and open the pilot valve, allowing supply pressure to the output until the
output pressure action on the lower diaphragm re-balances the forces. Conversely, a decrease in the input signal
pressure allows the exhaust valve to open until the output pressure falls to the same value as the input signal
pressure.
A bypass valve allows a controlled flow of input signal direct to the output to obtain stable control for small or
slow changing input signals.
Figure 1 - Cut-away View of BR400 Booster Relay

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 5
© 2019 Baker Hughes, a GE company. All Rights Reserved.
Maximum Supply Pressure 150 psi (10.3 bar)
Dew Point At least 18°F (10°C) below minimum anticipated ambient temperature.
Particulate Matter Filtered to below 5 microns.
Oil Content: Less than 1 ppm w/w or v/v.
Contaminants Free of all corrosive contaminants and hazardous gasses, flammable or
toxic.
Pneumatic Supply
The BR400 and BR200 Booster Relays require a source of clean, dry, oil-free, instrument grade air to ANSI/
ASA-57.3 1975 (R1981) or ISA-S7.3-1075 (R1981).
Pneumatic Connections
The pneumatic connection locations are shown on Figure 1 and are also stamped on relay body. The supply and
output connections are 1/4" NPT and the signal connection is 1/4" NPT. The supply and output tubing should be a
minimum of 1/2". Blow out all piping prior to connecting to booster. Use of a soft setting anaerobic hydraulic seal,
such as Loctite Hydraulic Seal 542 is recommended on the male threads of all connections.
Do not use an excessive amount of hydraulic sealant as it will
not set and may migrate into the pneumatic passages.
Do not use pipe thread sealant tape on pneumatic fittings, as
it tends to shred small particles which can cause instrument
malfunction.
The booster relay should be close coupled to the actuator. Use of a short ½" pipe nipple between the relay output
and the actuator provides both the pneumatic connection and mounting means. The preferred orientation is with
the exhaust openings pointing down; however horizontal mounting is acceptable.
Installation

6 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.
Features Specifications
Maximum Cv (supply) 1.2 (BR200) and 2.6 (BR400)
Maximum Cv (exhaust) 1.2 (BR200) and 2.4 (BR400)
Maximum Signal Pressure 150 psi (10.3 bar)
Operating Temperature Limits
-30ºC to +83ºC (-22ºF to +181ºF)
Low Temperature: -55ºC to +60ºC (-67ºF to +140ºF)
High Temperature: 0ºC to +100ºC (32ºF to +212ºF)
Input / Output Ratio 1:1
Supply and Output Connections 1/4” NPT or Rc (BR200) and 1/2" NPT or Rc (BR400)
Signal Connection 1/4" NPT or Rc
Approximate Weight 0.7 kg (1.5 lbs) for BR200 and 1.4 kg (3 lbs) for BR400
Specifications
Flow Characteristics
Table 1 - Specifications
Figure 2 - Flow Characteristics

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 7
© 2019 Baker Hughes, a GE company. All Rights Reserved.
Operation
Prior to applying supply pressure to the relay, open the bypass needle valve approximately one turn. After
applying pressure, note response of actuator to open and close commands from the positioner. If excessive
overshoot or hunting is seen, open needle valve until stable operation is obtained. If valve is sluggish, close needle
valve until unstable operation occurs, then back off until stable operation is obtained.
Turning valve clockwise (closing) speeds response but can lead to instability. Turning valve counterclockwise aids
stability but will slow down the actuator's response. Proper setting provides stable operation and acceptable
response time.
Bypass valve
Safety screw
Safety screw
Bypass valve
Figure 3
Bypass valve adjustment on BR200 model
Figure 4
Bypass valve adjustment on BR400 model
Break loose of bypass valve:
Completely loose small screw and turn bypass valve near the
fully opened position may cause bypass valve to break loose by
internal pressure
Adjustment of bypass valve during plant operation:
Adjusting bypass value when control valve is in service may
generate sudden valve opening change or oscillation.

8 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.
Maintenance
The BR400 Booster Relays do not require any routine maintenance. If a contaminated air supply has been used,
then there may be need to clean the filters or disassemble the relay to clean the supply and exhaust seats and
valves.
Troubleshooting
If the output pressure does not respond to changes in the input pressure, check that supply pressure is at proper
value and that signal and supply filters are not plugged with foreign matter. Check also that supply and exhaust
valve seats are clean.
If output pressure is not stable or is slow to respond, check setting of bypass needle valve. See bypass valve
setting procedure under "Operation".

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 9
© 2019 Baker Hughes, a GE company. All Rights Reserved.
Material of Construction and Dimensions
No. Part Standard Material
1Body Aluminium Alloy Die Casting
2 Case Aluminium Alloy Die Casting
3Upper Diaphragm Chloroprene / Polyester
4Lower Diaphragm Chloroprene / Polyester
5Lower Diaphragm Plate Aluminium Alloy Plate
6Exhaust Seat Copper Alloy
7 Seal Plate Austenitic Stainless Steel
8 Exhaust Seal Guide Copper Alloy
9 Seal Plate Gasket Inorganic Fiber/Oil Resistant
Synthetic Rubber
10 Plug Cap Copper Alloy
11 Coil Spring Austenitic Stainless Steel
12 Plug Austenitic Stainless Steel
13 Bypass Valve Plug Austenitic Stainless Steel
14 Piston Glass Fiber Reinforced
Thermoplastic Polyester
15 Supply Filter Austenitic Stainless Steel
16 Signal Filter Austenitic Stainless Steel
17 Bleed Ring Aluminium Alloy Die Casting
Note: model BR400 is available in stainless steel for marine
offshore applications.
Model BR400
Model BR200
14
ø86mm (3.4")
3
4
5
7
9
15
10
82mm (3.3")
2
13
1
6
8
12
11
57mm
(2.2")
79.5
mm
(3.1")
17
14
ø127mm (5")
3
4
5
7
9
15
10
87mm (3.4")
16 2
13
1
6
8
12
11
17
90mm
(3.5")
119mm
(4.7")
Figure 5 - BR200 Construction and Dimensions
Figure 6 - BR400 Construction and Dimensions

10 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.
Notes

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 11
© 2019 Baker Hughes, a GE company. All Rights Reserved.
Notes

GEA30642B 05/2019
*Denotes a trademark of Baker Hughes, a GE company, LLC.
Other company names and product names used in this document are the registered trademarks or
trademarks of their respective owners.
© 2019 Baker Hughes, a GE company LLC - All rights reserved.
Baker Hughes, a GE company, LLC and its aliates (“BHGE”) provides this information on an “as is”
basis for general information purposes and believes it to be accurate as of the date of publication.
BHGE does not make any representation as to the accuracy or completeness of the information and
makes no warranties of any kind, specic, implied or oral, to the fullest extent permissible by law,
including those of merchantability and tness for a particular purpose or use. BHGE hereby disclaims
any and all liability for any direct, indirect, consequential or special damages, claims for lost prots,
or third party claims arising from the use of the information, whether a claim is asserted in contract,
tort, or otherwise. The BHGE logo is a trademark of Baker Hughes, a GE company LLC. GE and the GE
monogram are trademarks of the General Electric Company used under trademark license.
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