IMI BR-08SSH User manual

BR - BOOSTER RELAY
INSTRUCTION MANUAL 2074

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 –BR i
01/02/2019
00
Issue
I. Zucchi
F. Tondolo
Date
Revision
Description
Compiled
Approved
STI S.r.l has taken every care in collecting and verifying the documentation contained in this Instruction
Manual. The information herein contained are reserved property of STI S.r.l

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 –BR ii
INDEX
1GENERAL INFORMATION .................................................................................................................. 1
1.1 GENERAL WARNINGS........................................................................................................................ 1
1.2 GENERALITIES.................................................................................................................................. 1
1.3 MANUFACTURER............................................................................................................................... 1
1.4 TERMS AND CONDITIONS................................................................................................................... 1
1.5 MANUFACTURER’S LIABILITY ............................................................................................................. 1
1.6 APPLICABLE STANDARDS AND DIRECTIVES ........................................................................................ 2
1.7 SYMBOLOGY USED........................................................................................................................... 2
2DEVICE DESCRIPTION ....................................................................................................................... 3
2.1 GENERAL DESCRIPTION.................................................................................................................... 3
2.2 BOOSTER CODING DESCRIPTION....................................................................................................... 4
3TECHNICAL DATA............................................................................................................................... 5
4LABEL................................................................................................................................................... 6
5INSTALLATION .................................................................................................................................... 7
5.1 TRANSPORT ..................................................................................................................................... 7
5.2 RECEPTION...................................................................................................................................... 7
5.3 STORAGE......................................................................................................................................... 7
5.4 REQUIREMENTS OF STABILITY........................................................................................................... 7
5.5 DOCUMENTS AND DIMENSIONAL DRAWINGS........................................................................................ 7
5.6 INSTALLATION................................................................................................................................... 8
5.7 DISASSEMBLING ............................................................................................................................. 12
6OPERATION AND USE...................................................................................................................... 13
6.1 OPERATION DESCRIPTION ............................................................................................................... 13
6.2 INTENDED USE................................................................................................................................ 20
6.3 REASONABLY FORESEEABLE MISUSE ............................................................................................... 20
6.4 OPERATING LIMITS.......................................................................................................................... 20
6.5 RESIDUAL RISKS ............................................................................................................................ 21
7INSTRUCTIONS FOR THE OPERATOR ........................................................................................... 21
8MAINTENANCE.................................................................................................................................. 22
8.1 PERIODIC INSPECTIONS .................................................................................................................. 22
8.2 SPECIAL MAINTENANCE................................................................................................................... 22
8.3 REPAIRS ........................................................................................................................................ 22
8.4 REASSEMBLING.............................................................................................................................. 22
8.5 MECHANISM LUBRICATION............................................................................................................... 22
9PARTS LIST GENERAL ASSEMBLY................................................................................................ 23
9.1 BR ASSEMBLY –BR-08SSH00 /BR-08SSS00 /BR-08SSL00....................................................... 23
9.2 BR ASSEMBLY –BR-08SSH01 /BR-08SSS01 /BR-08SSL01....................................................... 24
10 TROUBLESHOOTING .................................................................................................................... 25
11 SPARE PARTS ............................................................................................................................... 25
12 DECOMMISSIONING...................................................................................................................... 26

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 –BR iii

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 1
1 GENERAL INFORMATION
1.1 General Warnings
Important
This Instruction Manual is an integral part of the machine, it should be carefully
read before carrying out any operation and it should be kept for future references.
The operators shall adopt the safety precautions required by the country where
the product is installed.
This Instruction Manual is realized in accordance with the Directive 2006/42/CE.
1.2 Generalities
STI S.r.l. accessories are conceived, manufactured and controlled according to the Quality Control System
in compliance with EN ISO 9001 International Standard.
1.3 Manufacturer
With respect to Machinery Directive 2006/42/EC, the Manufacturer of the described BR Booster is STI S.r.l.
as specified on the label.
STI S.r.l. Via Dei Caravaggi 15
24040 Levate (BG) Italy
Tel. [phone]
Fax [phone]
[e-mail]
1.4 Terms and conditions
STI S.r.l. guarantees each single product to be free from defects and to conform to current goods
specifications. The warranty period is one year from the date of installation by the first user, or eighteen
months from the date of shipment to the first user, whichever occurs first.
The warranty does not cover special products or components not covered by warranty in their turn by
subcontractors. No warranty is given for products which have been subject to improper storage, improper
installation, misuse, corrosion, or which have been modified or repaired by unauthorised personnel: it is not
advisable that customer or end users modify the device characteristics.
1.5 Manufacturer’s Liability
STI S.r.l. declines all liability in the event of:
- use of the BR in contravention of local safety at work legislation;
- incorrect installation, disregard or incorrect application of the instructions provided on the BR label and
in this manual;
- modifications without STI’s authorisation;
- work done on the unit by unqualified or unsuitable persons.

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 2
1.6 Applicable Standards and Directives
-EN ISO 12100:2010
Safety of machinery - General principles for design;
-2006/42/EC
Machinery Directive;
-2014/68/UE
Pressure Equipment Directive (PED);
1.7 Symbology Used
1.7.1 Signs of warning
Be careful where these symbols are shown, they indicate a potentially hazardous situation and they
warn that if the steps are not properly performed, MAY RESULT CAUSING serious injury, death or
long-term risks to the health of exposed persons.
1.7.2 Sings of obligation
General
obligation (with
the possible
supplementary
signboard)
Obligation to
wear
protective
clothing.
Obligation to
wear
protective
footwear.
Obligation to
wear a helmet.
Obligation to
protect your
eyes.
Obligation to
protect your
hearing.
GENERAL DANGER
DANGER POWER SUPPLY
CRUSHING HAZARD

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Manual 2074, rev.00 02/2019 - BR 3
2 DEVICE DESCRIPTION
2.1 General Description
The Booster Relay BR is a flow amplifier that allows to increase the actuator stroking time by increasing the
fluid mass flow to the actuator or from the actuator. Designed to meet high control applications, the BR
booster contains an integral stabilizing bypass valve controlled by a screwdriver adjustment. The bypass
valve screwdriver creates a pressure drop between the pilot and the actuator connection depending on its
adjustment and the working fluid flow rate.
Figure 1 –Booster Relay BR
Bypass valve

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Manual 2074, rev.00 02/2019 - BR 4
2.2 Booster Coding Description
BR
-
Size
08
½”
Material
SS
Stainless Steel 316
Temperature range
H
-20°C / +85°C
S
-20°C / +70°C
L
-40°C / +70°C
Mounting Kit
00
Mounted on fittings
01
Mounted on plate

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 5
3 TECHNICAL DATA
Technical features (*)
BR Model
BR-08SSH
BR-08SSS
BR-08SSL
Body Material
Stainless steel 316
Stainless steel 316
Stainless steel 316
Booster Size
½ “
½ “
½ “
Media
Instrument air
Natural gas
Instrument air
Natural gas
Instrument air
Natural gas
Supply connection
(S)
½” NPT Female
½” NPT Female
½” NPT Female
User connection
(U)
½” NPT Female
½” NPT Female
½” NPT Female
Exhaust connection
(E)
¾”NPT Male
¾”NPT Male
¾”NPT Male
Pilot/Signal connection
(P)
¼” NPT Female
¼” NPT Female
¼” NPT Female
Cv max @6 bar
(S→U)
3,80
3,80
3,80
Cv max @6 bar
(U→E)
4
4
4
Testing temperature
range
-20/+85 °C
-20/+70 °C
-40/+70 °C
Operating pressure
range
3 bar / 7 bar
3 bar / 7 bar
3 bar / 7 bar
Max supply pressure
10,4 bar
10,4 bar
10,4 bar
Pressure containment
Up to 15 bar
Up to 15 bar
Up to 15 bar
Expected lifetime
@20°C
100000 cycles
100000 cycles
100000 cycles
(*) All the models are PED 2014/68/UE and ATEX 2014/34/UE (see label for ATEX details) certified.

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 6
4 LABEL
The label attached on the BR contains the info related to ATEX certification. This label must be attached on
the booster when the BR is sold alone. When the BR is sold mounted on the actuator or as spare part, the
label is not required.
It is forbidden to modify the information and the marks without previous written authorization by STI S.r.l.
Figure 2 –Booster Relay label

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 7
5 INSTALLATION
Important
Not performing the following procedures will invalidate the product guarantee.
5.1 Transport
Important
The lifting and handling should be made by qualified staff and in compliance with
the laws and provisions in force.
5.2 Reception
- Check that the model corresponds with that of order confirmation.
- Check that the BR was not damaged during transportation.
5.3 Storage
Booster Relay BR leaves the factory in perfect conditions. Performances of each unit are guaranteed by tests
and data reported on the specific. To maintain these conditions until the BR is installed on site, proper
attention must be observed for preservation during the storage period.
If the BR needs storage, before installation follow these steps:
- place it on a wood surface pallet or on metallic support, thus it is not in direct contact with the ground,
and packed with appropriate covering;
- make sure that plastic plugs are present on the pneumatic connections;
- keep the BR protected from direct weather conditions;
- if stored outdoor, replace plastic plugs on pneumatic connections with metal plugs that guarantee perfect
tightness.
5.4 Requirements of Stability
Concerning the requirement of stability during installation and disassembling, it is possible to refer to the next
chapters 5.6 and 5.7.
5.5 Documents and dimensional drawings
Pneumatic diagrams, wiring diagrams and dimensional drawings are furnished with document accompanying
the actuator.

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 8
5.6 Installation
Warning
Before proceeding with any Installation, the following instructions must be
respected:
- Always wear protective clothing, gloves, and eyewear to prevent personal
injury;
- Check with your process or safety engineer for any additional measures that
must be taken to protect against process media.
5.6.1 Checks to be performed before installation
- Check that the coupling dimensions meet the specified coupling dimensions.
- Prepare the necessary tools for the assembly and setting of the unit.
- Check that the outer surface of the BR is free from dust and dirt.
- Clean the BR surfaces and remove anything that might prevent a correct installation.

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 9
5.6.2 BR mounting on actuator
Figure 3 - Dimensional drawing BR-08SSH00 / BR-08SSS00 / BR-08SSL00

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 10
Figure 4 - Dimensional drawing BR-08SSH01 / BR-08SSS01 / BR-08SSL01

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 11
5.6.3 Pneumatic connections
Warning
Check that the values of pneumatic supply available are compatible with
those reported on the BR body. Use pipes and connections appropriate as
for type, rating, material and dimensions. The connection should be made
by qualified staff.
-Properly deburr the ends of rigid pipes.
-Properly clean the interior of pipes sending through them plenty of the supply fluid used in the
system.
-Mould and fasten the connection pipes so that no irregular strains at entries or loosening of
threaded connections occur.
-Use pipe sealant sparingly and only on male threads. A non-hardening sealant is strongly
recommended.
-Make the connections according to the actuator pneumatic diagram.
-Check the absence of leakages from pneumatic connections. If necessary, tighten the nuts of the
pipe-fittings.
-8mm or 3/8” tubing are recommended as pilot from positioner.
Figure 5 –Pneumatic connections

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 12
5.6.4 Grounding connection
The earthing connection is guaranteed trough the fixing screws of the BR. If the earthing connection
of the system where BR is mounted is not guaranteed, it is necessary ensure a directly earthing
connection from the BR body.
5.7 Disassembling
Warning
Before starting the disassembly operations, it is mandatory to disconnect the
pneumatic power and exhaust the BR. Cylinder chambers, pipes, fittings and
accessories must not be under pressure. The staff must be qualified for the required
operation.

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 13
6 OPERATION AND USE
6.1 Operation description
Booster Relay BR has 2 main setups: charge and discharge. The by-pass stem may create a pressure drop
depending on its adjustment and the working fluid flow rate.
In the charge setup the working fluid from the pilot passes through the by-pass connection:
a) if the flow rate is lower than a threshold value depending on the by-pass stem adjustment, the by-pass
stem throttling can’t generate a pressure drop between the two side of the piston and the working fluid
goes to the actuator chamber. This case is called “stand-by mode” (figure 6);
b) if the flow rate is greater than a threshold value depending on the by-pass stem adjustment, the by-pass
stem throttling generates a pressure drop between the two side of the piston and the working fluid
pushes down the piston and the lower shutter, allowing the connection between the BR supply and the
actuator chamber. This case is called “modulating mode” (figure 7);
c) if the flow rate is much greater than a threshold value depending on the by-pass stem adjustment, the
by-pass stem throttling generates a pressure drop between the two side of the piston and the working
fluid pushes down the piston and the lower shutter, allowing the connection between the BR supply and
the actuator chamber. In this case the lower shutter generates the greatest flow section available
because the piston reaches its lower stroke limit. This case is called “on-off mode” (figure 8).
In the discharge setup the working fluid from the actuator passes through the valve shutter:
a) if the flow rate is lower than a threshold value depending on the by-pass stem adjustment, the by-pass
stem throttling can’t generate a pressure drop between the two side of the piston and the working fluid
goes to the pilot. This case is called “stand-by mode” (figure 9);
b) if the flow rate is greater than a threshold value depending on the by-pass stem adjustment, the valve
shutter throttling generates a pressure drop between the two side of the piston and the working fluid
pushes up the piston, allowing the connection between the actuator chamber and the exhaust. This
case is called “modulating mode” (figure 10);
c) if the flow rate is much greater than a threshold value depending on the by-pass stem adjustment, the
by-pass stem throttling generates a pressure drop between the two side of the piston and the working
fluid pushes up the piston, allowing the connection between the actuator chamber and the exhaust. In
this case the upper shutter generates the greatest flow section available because the piston reaches its
upper stroke limit. This case is called “on-off mode” (figure 11).

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 14
Figure 6 –Charge setup: stand-by model
PILOT
ACTUATOR
By-pass stem
Piston
Lower Shutter
SUPPLY LINE

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 15
Figure 7 –Charge setup: modulating model
PILOT
ACTUATOR
SUPPLY LINE
By-pass stem
Piston
Lower Shutter

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STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALIA www.imi-critical.com
Manual 2074, rev.00 02/2019 - BR 16
Figure 8 –Charge setup: on-off model
PILOT
ACTUATOR
SULLPY LINE
Piston
Lower Shutter
By-pass stem