Emerson EL-O-Matic F-Series Installations- und Betriebsanleitung

Safety Guide

DOC.SG.EF.EN Rev. 2

April 2018

EL MaticTM

EL-O-Matic F-Series

Rack and Pinion Pneumatic Actuators EN

Table of Contents

1: Safety Instructions........................................................ 1

1.1 ANSI 534.6 Safety Messages...............................1

2: General Information...................................................... 1

2.1 General Application............................................1

2.2 Inspection and Maintenance Schedules..............2

2.3 Parts Ordering....................................................2

3: EL-O-Matic F-Series Actuators ....................................... 3

3.1 Installation.........................................................3

3.2 Operation ..........................................................4

3.3 Maintenance ......................................................5

4: Actuator Accessories..................................................... 6

5: Instructions For Use in (potential) Explosive Areas......... 6

5.1 Intended use ......................................................6

5.2 Safety instructions .............................................6

5.3 Maximum temperatures ....................................7

Appendix A: EU Declaration of Conformity .......................... 8

Table of Contents

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

1. Safety Instructions

Please read these safety warnings, cautions, and instructions carefully before using

the product.

These instructions cannot cover every installation and situation. Do not install,

operate, or maintain this product without being fully trained and qualied in valve,

actuator, and accessory installation, operation and maintenance.

To avoid personnel injury or property damage, it is important to carefully read,

understand, and follow all of the contents of the associated instruction manual,

including all safety cautions and warnings. If you have any questions concerning

installation, or use of this product, contact your Emerson sales ofce before

proceeding.

1.1 ANSI 534.6 Safety Messages

WARNING -

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION -

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Note/Important

Indicates information considered important, but not hazard-related

2. General Information

2.1 General Application

The EL-O-Matic F Rack and Pinion actuators are intended for the automation and

operation of quarter-turn valves like Buttery, Ball and Plug valves.

Rack and Pinion actuators can also be used to operate venting louvers or any other

quarter-turn applications.

This product was intended for a specic range of service conditions: pressure,

ambient temperature, operating media, and possibly other specications. Do not

expose the product to service conditions or variables other than those for which the

product was intended.

If you are not sure what these conditions or variables are, contact your Emerson

sales ofce for assistance. Provide the product type, size, serial number and all other

pertinent information that you have available.

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

2.2 Inspection and Maintenance Schedules

The EL-O-Matic F Rack and Pinion actuators must be inspected periodically and

maintained as needed. Refer to the maintenance section of manual DOC.IOM.EF.EN

for more detailed information.

The schedule for inspection can only be determined based on the severity of your

service conditions. Your installation might also be subject to inspection schedules

set by applicable governmental codes and regulations, industry standards, company

standards, or plant standards.

In order to avoid increasing dust explosion risk, periodically clean dust deposits from

all equipment.

When equipment is installed in a hazardous area (potentially explosive atmosphere),

prevent sparks by proper tool selection and avoiding other types of impact energy.

Proper care must be taken to avoid generation of static electricity on the non-

conductive external surfaces of the equipment (e.g. rubbing of surfaces, etc.). The

actuator's surface temperature is dependent upon process operating conditions.

2.3 Parts Ordering

When ordering parts for older products, always specify the type, size and serial

number of the product and provide all other pertinent information that you can,

such as part material, age of the product, and general service conditions. If you have

recongured the product since it was originally purchased, include that information

with your request.

WARNING - USE GENUINE PARTS

Use only genuine replacement parts. Components that are not supplied by Emerson should not,

under any circumstances, be used in any EL-O-Matic product. Use of components not supplied

by Emerson may void your warranty, might adversely affect the performance of the product,

and could cause personal injury and property damage.

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

3. EL-O-Matic F-Series Actuators

These safety instructions are limited to EL-O-Matic F-Series actuators which are

operating using air or inert gas. If the application requires use of a ammable or

hazardous gas, you must contact your Emerson sales ofce for assistance.

3.1 Installation

WARNING - DO NOT EXCEED SPECIFICATIONS

To avoid personal injury and property damage caused by bursting of parts and to avoid parts

damage, malfunction of control valve, or loss of control of the process caused by excessive

pressure, do not exceed the maximum pressures or temperatures for this actuator, as given

in the applicable product literature or on the nameplate. Use pressure-limiting or pressure-

relieving devices to prevent the actuator pressure from exceeding specied limits. If you cannot

determine the limits for this product, contact your Emerson sales ofce before proceeding.

To avoid personal injury, always wear protective gloves, clothing and eye wear when

performing any installation operation.

If hoisting the actuator, use a nylon sling to protect the surfaces. Carefully position the sling

to prevent damage to the actuator tubing and any accessories. Also, take care to prevent

people from being injured in case the hoist or rigging slips. Be sure to use adequately sized

hoists and chains or slings to handle the assembly. If an actuator/valve assembly should be

lifted, it is strongly recommended to connect the nylon lifting slings in such way that the

actuator and valve is supported.

Check with your process or safety engineer for any additional measures that must be taken

to protect against process media.

If installing into an existing application, also refer to the WARNING in the Maintenance

section.

Do not connect a pressure vessel, to the actuator, with unrestricted media.

Do not exceed the MAXIMUM stated operating pressures.

Applying pressure directly to the actuator can turn the actuator's shaft/Valve stem.

Applying a control signal to the actuator's solenoid can turn the Actuator/Valve assembly.

WARNING - MOVING PARTS

Stay away from moving parts to prevent serious injury. When test cycling the actuator and valve

assembly by applying pressure to the A or B port, be aware that there are moving parts like

pinion top, actuator to valve coupling and the valve blade, ball, plug, etc.

Isolate the piping system on which an actuator-valve assembly is installed, when removing

this assembly, and relieve any media pressure that may be trapped in the valve cavities before

removing the actuator for maintenance.

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

3.2 Operation

WARNING - MOVING PARTS

When rotating the actuator stem or shaft with loading pressure applied, use caution to keep

hands and tools out of the actuator travel path. Personal injury and property damage is possible

if something is caught between the actuator stem and other control valve assembly parts.

3.2.1 Operating media

1. Use clean, dry or lubricated air or inert gas.

2. Maximum Operating Pressure (MOP) = 8.3 barg/120 psig

MOP is the pressure required to produce the maximum rated torque at the break

position for all actuators.

Pressure should not exceed MOP during valve rotation.

MOP should be the maximum pressure regulator setting.

WARNING - DO NOT EXCEED SPECIFICATIONS

It can be assured that the housing will not rupture or burst when applying 10 bar of pressure

but the cycle function cannot be guaranteed as it totally depends on the time span to which

actuator is subjected at 10 bar and the frequency at which these pressure peaks occurs. Every

time this peak occurs will, for sure, have a signicantly negative effect on the life expectancy of

the actuator.

3. Refer to below table on applications where the spring stroke of spring-return

actuators is pneumatically operated.

Table 3.1 Maximum pressure on spring stroke of spring-return actuators

Spring set Maximum pressure on spring stroke of spring-return actuators

N=10 7 barg / 101.5 psig

N=20 6 barg / 87.0 psig

N=30 5 barg / 72.5 psig

N=40 4 barg / 58.0 psig

N=50 3 barg / 43.5 psig

N=60 2 barg / 29.0 psig

4. Dew point at least 10K below ambient temperature.

5. For subzero applications take appropriate measures.

6. Mentioned pressure levels are "gauge pressures". Gauge pressure is equal to

absolute pressure minus atmospheric pressure.

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

3.2.2 Operating Temperature range

1. Using standard seals and greases the operating temperature range is -20°C to

+ 80°C (-4°F to +176°F) as is indicated on the product label.

2. Other medias and temperatures may be used but consult your local Emerson

sales ofce for conrmation as to suitability.

3.3 Maintenance

Before mounting or (dis) assembling the Actuator consult the relevant sections of

the installation, operation and maintenance manual for more detailed maintenance

information.

WARNING

Avoid personnel injury or property damage from sudden release of process pressure or

uncontrolled movement of parts. Before performing any maintenance operations:

Always wear protective gloves, clothing, and eye wear.

Disconnect any operating lines providing air pressure, electric power, or a control signal to

the actuator. Be sure the actuator cannot suddenly open or close the valve.

Do not remove the actuator from the valve while the valve is still pressurized.

Vent any pneumatic pressure from the actuator and relieve any actuator spring

pre-compression.

Use lock-out procedures to be sure that the above measures stay in effect while you work

on the equipment.

Never apply pressure to a partially assembled actuator unless all pressure-retaining parts

have been installed properly.

Check with your process or safety engineer for any additional measures that must be taken

to protect against process media.

Do not remove the Pistons from the Actuator Body by using air pressure when the End Caps

have been removed.

CAUTION - PRESSURIZED ACTUATOR

Do not turn out the travel stops completely when the actuator is pressurized. When

adjusting the travel stops and the actuator is still pressurized, the travel stops can “shoot”

away when completely turned out.

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

CAUTION - SPRING FORCE

Spring-return actuators contain springs in a compressed state. Follow these instructions

to release the spring force safely. The end caps of spring-return actuators sizes 25 to 600

should be free of the spring load after 10 full turns (crosswise relaxing) of the end cap

screws. If there is still spring load on the end cap, this might indicate a broken spring

cartridge. Stop this disassembly procedure immediately. Continuing might cause the end

cap to be “shot” away causing serious injury. Spring return actuator size 950 to 4000 have

long end cap screws to release the spring load safely.

Refer to Appendix A of manual DOC.IOM.EF.EN for the instructions on how to safely remove

the spring load before disassembling the end cap from the spring-return actuator.

A spring-return actuator mounted on a valve, which is stuck in mid stroke, contains a high

spring load which will cause a sudden rotation during disassembly of the actuator versus the

valve or valve bracket. This can cause serious injury to personnel or equipment damage.

Refer to Appendix A of manual DOC.IOM.EF.EN for instructions to safely remove the spring

load before disassembling the actuator from a valve, which is stuck in mid stroke.

4. Actuator Accessories

The actuator may be equipped with components for control and/or feedback. Check

the instructions of these components for installation, operation and maintenance

instructions.

5. Instructions For Use in (potential) Explosive Areas

5.1 Intended use

The EL-O-Matic F-Series pneumatic actuators are intended for use in areas in which

explosive atmospheres caused by mixtures of air and gases, vapours, mists or by

air/dusts are likely to occur. Therefore it may be used in classied Zones 1, 2 (Gases)

and/or 21, 22 (Dust).

5.2 Safety instructions

1. Assembly, disassembly and maintenance, is only allowed at the actuator, when, at

the time of the activity, there are no explosive mixtures.

2. Prevent entry of explosive mixtures into the actuator. We suggest utilizing a

solenoid with a "breather" function on spring-return actuators when used in

potentially explosive atmospheres.

3. Provided plastic position indicator is approved for use in potentially explosive (Ex)

gas group IIB areas.

— In areas where Ex gas group IIC requirements apply, the plastic indicator for

actuator sizes 25 to 350 is approved for use.

— In areas where Ex gas group IIC requirements apply, do not use the plastic

position indicator (for actuator sizes 600 up to 4000).

EL-O-Matic F-Series

April 2018

Safety Guide

DOC.SG.EF.EN Rev. 2

4. In order to avoid increasing dust explosion risk, periodically clean dust deposits

from all equipment.

5. When equipment is installed in a hazardous area location (potentially explosive

atmosphere), prevent sparks by proper tool selection and avoiding other types of

impact energy.

6. Rack and pinion actuators do not have an inherent ignition source due to electro-

static discharge, but explosion hazards may be present due to the discharge of

static electricity from other valve assembly components.

— To avoid personal injury or property damage, make sure that the valve is

grounded to the pipeline before placing the valve assembly into service.

— Use and maintain alternate shaft-to-valve body bonding, such as a shaft-to-

body bonding strap assembly.

7. Proper care must be taken to avoid generation of static electricity on the non-

conductive external surfaces of the equipment (e.g. rubbing of surfaces, etc.).

8. The paint protection must not exceed 200 μm if the actuator is used in a group

IIC atmosphere. For group IIA or IIB atmospheres the paint protection must not

exceed a thickness of 2 mm (0.08").

5.3 Maximum temperatures

WARNING - SURFACE TEMPERATURE

The actuator's surface temperature is dependent upon process operating conditions. Personal

injury or property damage, caused by re or explosion, can result if the actuator's surface

temperature exceeds the acceptable temperature for the hazardous area classication. To avoid

an increase of instrumentation and/or accessory surface temperature due to process operating

conditions, ensure adequate ventilation, shielding, or insulation of these actuator components

installed in a potentially hazardous or explosive atmosphere.

Table 5.1 Temperature range for (potential) explosive areas

Temperature

Valid for actuator model

Ambient range Temperature

class

TX (surface

temperature)

-20°C(-4°F)…75°C(167°F) T6 T85°C (185°F) S = Standard Temperature

-20°C(-4°F)…80°C(176°F) T5 T90°C (194°F)

-10°C(14°F)…90°C(194°F) T5 T100°C (212°F) H = High Temperature

-10°C(14°F)…120°C(250°F) T4 T130°C (266°F)

-40°C(-40°F)…75°C(167°F) T6 T85°C (185°F) L = Low Temperature

-40°C(-40°F)…80°C(176°F) T5 T90°C (194°F)

The specied values are valid with the following conditions:

Maximum cycle frequency of the actuator is 1Hz at a maximum of 50 cycles per hour and at maximum load.

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