Emerson Hytork XL Series Bedienungsanleitung

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

November 2022

Hytork XL Pneumatic Actuator

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Notes

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

Table of Contents

November 2022

Table of Contents

Section 1: Important Safety Procedures

Important Safety Procedures...................................................................................1

Section 2: ATEX Instructions for Use in (Potential)

Explosive Areas

2.1 Intended Use................................................................................................. 3

2.2 Safety Instructions ........................................................................................ 3

2.3 Temperature Range for (Potential) Explosive Areas........................................ 4

Section 3: Operating Media, Pressures and Temperatures

3.1 Operating Media ........................................................................................... 5

3.2 Operating Temperature Range...................................................................... 5

Section 4: Actuator to Valve Installation

4.1 Bi-directional Travel Stops ............................................................................. 6

4.2 Travel Stop Adjustment Procedure ................................................................ 7

Section 5: Piping Instructions

Piping Instructions...................................................................................................8

Section 6: Solenoid Valves on Spring-Return Actuators

Solenoid Valves on Spring-Return Actuators.............................................................9

Section 7: Position Feedback

Position Feedback..................................................................................................10

Section 8: Spares Recommendations

Spares Recommendations......................................................................................11

Section 9: Disassembly Procedure

9.1 End Cap and Springs Disassembly on Spring-Return Actuators .................... 12

9.2 Changing Spring Sets on XL26 to XL681...................................................... 13

9.3 End Cap Disassembly on Double-Acting Actuators...................................... 13

9.4 Piston Disassembly...................................................................................... 13

9.5 Pinion Disassembly ..................................................................................... 13

9.6 Inspection................................................................................................... 13

Table of Contents

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

Table of Contents

Section 10: Assembly Instructions

10.1 Grease Instructions ..................................................................................... 14

10.2 Pinion Assembly.......................................................................................... 15

10.3 Alignment of Pinion for Correct Piston Assembly......................................... 15

10.4 Piston Assembly.......................................................................................... 16

10.4.1 Clockwise Rotation........................................................................... 16

10.4.2 Counterclockwise Rotation .............................................................. 16

10.5 Travel Stop Assembly .................................................................................. 16

10.6 End Cap Assembly on Double-Acting Actuators .......................................... 17

10.7 Spring-Return Actuators ............................................................................. 17

10.7.1 Spring Set Adjustments .................................................................... 17

10.7.2 Installing the Spring and End Cap ..................................................... 18

Section 11: Bottom Mounted Stop Block

11.1 The Hytork Solution.................................................................................... 20

11.2 Basic Stop Block Assembly........................................................................... 20

11.3 General Notes when Fitting to Valves .......................................................... 21

11.3.1 Double-Acting.................................................................................. 21

11.3.2 Standard Conguration Fail-Safe Clockwise ...................................... 21

11.3.3 Reverse Action Fail-Safe Counterclockwise ....................................... 22

11.4 Actuator Conventions for the Normal Position............................................. 22

11.4.1 Double-Acting.................................................................................. 22

11.4.2 Spring-Return................................................................................... 22

11.5 Assembly to Valves for Standard Rotation Conguration ............................. 22

11.5.1 Double-Acting and Fail-Safe Clockwise............................................. 22

11.5.2 Stop Adjustment (Fail Closed)........................................................... 23

11.6 Assembly to Valves for Reverse Action Conguration .................................. 24

11.7 Long Shaft Adaptor Dimensions and Materials............................................. 24

11.8 Adjustment of the Bottom Mounted Stop Block .......................................... 25

Section 12: Testing the Hytork Actuator

Testing the Hytork Actuator...................................................................................26

Section 13: Retractor Rods

13.1 Spring Removal System Board..................................................................... 27

Section 14: Service

Service...................................................................................................................28

Section 15: Parts and Materials

Parts and Materials.................................................................................................29

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

Important Safety Procedures 1

Section 1: Important Safety Procedures

Table 1. Applicable Models

XL 26 XL 281 XL 2586

XL 71 XL 426 XL 4581

XL 131 XL 681 -

XL 186 XL 1127 -

XL 221 XL 1372 -

Hytork XL actuators are only intended for use in large-scale xed installations excluded

from the scope of Directive 2011/65/EU on the restriction of the use of certain hazardous

substances in electrical and electronic equipment (RoHS 2).

Installation, adjustment, putting into service, use, assembly, disassembly, and maintenance

of the actuator is strictly reserved to qualied personnel.

Before installation, operation and maintenance, read the relevant sections of:

• This manual

• Quick Reference Guide: DOC.QRG.XL

! CAUTION

• Always disconnect the air and electrical supplies before carrying out any form of

maintenance on an actuator.

• When removing any ball valve or plug valve assemblies from a pipe system,

isolate the piping system on which the actuator is installed and relieve any media

pressure that may be trapped in the valve cavities before removing the actuator

for maintenance.

• Always contain the spring tension with Hytork retractor rods as explained in

Section 9.1 (Disassembly Procedure). Follow instructions for using the retractor

rod carefully. Only Hytork manufactured or approved retractor rods are to be

used for spring removal. As with any threaded tool that is frequently used retractor

rods should be checked to ensure that the threads are not worn or damaged in any

way and greased regularly. Any damaged or worn rods must not be used and must

be destroyed.

• Never attempt to “BLOW OUT” the pistons or the end caps from the actuator body

by using air pressure.

• Never turn the stop screws completely out when the actuator is under pressure.

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

Important Safety Procedures2

Section 1: Important Safety Procedures

Numbers in brackets (#) refer to parts on the exploded view drawing (refer to Section 15,

Figure 13). All Hytork XL spares kits are supplied with SAFEKEY assemblies (13/14) cut to an

exact length which will t the circumference of the end cap (21) when fully assembled into

the actuator.

Any shortened SAFEKEY must not be used.

If in doubt, contact Emerson or your local Hytork Stocking Distributor. Read the relevant

sections carefully before continuing.

NOTE:

• Failure to follow proper storage guidelines will void warranty.

• Warehouse storage: Hytork actuators should be stored in a clean, dry warehouse,

free from excessive vibration and rapid temperature changes. Actuators should

not be stored on any oor surface.

• On site storage: Hytork actuators should be stored in a clean, dry warehouse, free

from excessive vibration and rapid temperature changes. Prevent moisture or dirt

entering the actuator. Plug or seal both air connection ports.

! WARNING

• Use lifting equipment as required by national or local legislation.

• Use lifting straps to lift the assembly of actuator and valve.

•

Do not attach lifting straps to only the actuator, to lift the assembly of actuator

and valve.

Table 2. Weight of Actuators

Model Double-Acting Spring-Return with S80 Springs

kg lb kg lb

XL26 1.39 3.06 1.53 3.37

XL71 2.39 5.27 2.78 6.13

XL131 3.90 8.60 4.76 10.49

XL186 4.77 10.52 5.45 12.02

XL221 6.19 13.65 7.76 17.11

XL281 7.02 15.47 9.90 21.83

XL426 7.30 16.10 12.50 27.56

XL681 8.80 19.40 22.50 49.60

XL1127 22.00 48.50 36.00 79.37

XL1372 27.00 59.52 46.60 102.73

XL2586 46.00 101.41 79.00 174.16

XL4581 83.00 182.98 142.00 313.05

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

ATEX Instructions in Explosive Areas 3

Section 2: ATEX Instructions in Explosive Areas

Section 2: ATEX Instructions for Use in

(Potential) Explosive Areas

2.1 Intended Use

he Hytork XL series pneumatic actuators are a Group II category 2 equipment and

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 (ATEX)

classied Zones 1, 2 (Gases) and/or 21, 22 (Dust).

2.2 Safety Instructions

1. Actuator assembly, disassembly, and maintenance is allowed only in absence of

explosive mixture.

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. The plastic position indicator caps are approved for ATEX gas group IIB areas.

— In areas where ATEX gas group IIC requirements apply, the plastic

indicator for actuator sizes XL26 to 281 is approved for use.

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

plastic position indicator cap for actuator sizes XL426 up to XL4581, to

avoid build up of static electricity.

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. 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.).

7. Hytork XL actuators do not have an inherent ignition source due to electro-static

discharge, but explosion hazard 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.

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 inch).

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

ATEX Instructions in Explosive Areas

Section 2: ATEX Instructions in Explosive Areas

! WARNING

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

If the actuator's surface temperature exceeds the acceptable temperature for the

hazardous area classication, it can catch re or in worst case can explode causing personal

injury and property damage. 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.

NOTE:

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

— Maximum working frequency of the actuator is 1 Hz at a maximum of 50 cycles per hour and at

maximum load.

Temperature

Valid for actuator model

Ambient range ATEX class TX (ATEX surface

temperature)

-20 °C to +75 °C T6 T85 °C (185 °F)

Standard temperature models-20 °C to +80 °C T5 T90 °C (194 °F)

-20 °C to +80 °C T1 to T4 T90 °C (194 °F)

-20 °C to +75 °C T6 T85 °C (185 °F)

High temperature models-20 °C to +90 °C T5 T100 °C (212 °F)

-20 °C to +120 °C T1 to T4 T130 °C (266 °F)

-40 °C to +75 °C T6 T85 °C (185 °F)

Low temperature models-40 °C to +80 °C T5 T90 °C (194 °F)

-40 °C to +80 °C T1 to T4 T90 °C (194 °F)

-20 °C to +250 °C for

2 hours T2 T260 °C (500 °F) Tunnel application models

2.3 Temperature Range for (Potential)

Explosive Areas

Table 3. Actuator model classication according to maximum

surface temperature

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

Operating Media, Pressures and Temperatures 5

Section 3: Operating Media, Pressures and Temperatures

Section 3: Operating Media, Pressures

and Temperatures

3.1 Operating Media

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

2. Maximum pressure: 8 bar/116 psi.

NOTE:

On applications where the spring stroke of single acting actuators is pneumatically

operated, the maximum pressure is 6.5 bar/95 psi.

3. Dew point 10 K below operating temperature.

4. For subzero applications take appropriate measures.

3.2 Operating Temperature Range

Using standard seals and grease the operating temperature range is -20 °C to +100 °C

(-4 °F to +212 °F) as is indicated on the product label. Other medias and temperatures may

be used but consult your local Hytork supplier for conrmation as to suitability.

November 2022

Installation, Operation and Maintenance Manual

MAC050515 EN Rev. 0

6Actuator to Valve Installation

Section 4: Actuator to Valve Installation

The pinion drive, coupling device, and valve stem should be centered and concentric to

prevent any side loading to the pinion radial bearing and valve stem seat area. Ensure that

the coupling shaft to be operated is a tight but free sliding t into the female drive in the

actuator pinion (19).

4.1 Bi-directional Travel Stops

Hytork XL actuators have two travel stops (22, 23, and 24) for setting accurately the travel

and the open and closed positions. XL2586 and XL4581 can be tted with the optional

bottom stop block for setting the travel.

The actuator has a factory set stroke of 90°. The adjustable stroke range of the actuator is:

• at closed (0°) position: -3° to +7°

• at open (90°) position: -83° to +93°

NOTE:

If the actuator is assembled for reverse operation, instead of standard operation, Stop “1”

will adjust the “open” position and stop “2” the “closed” position (refer to Figure 1).

Figure 1 Travel Stops

“2” “1”

Stop marked Stop marked

View from top

“2”“1”

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