Hytork MAC050515 Maintenance Manual
Installation, Operation and Maintenance Manual
Hytork XL Pneumatic Actuator
MAC050515 EN Rev. E
July 2019
Table of Contents
July 2019
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. E
Contents
1 Important Safety Procedures ........... 1
2 ATEX instructions for use in (potential)
explosive areas ....................................2
2.1 Intended use ...............................................2
2.2 Safety Instructions ......................................2
2.3 Temperature range for (potential) explosive
areas ...........................................................2
3 Operating Media, Pressures and
Temperatures .................................. 3
3.1 Operating media ........................................3
3.2 Operating Temperature range ...................3
4 Actuator to Valve Installation ........... 3
4.1 Bi-directional Travel Stops ..........................3
4.2 Travel Stop Adjustments .............................3
5 Piping Instructions ........................... 3
6 Solenoid Valves on Spring Return
Actuators ............................................. 4
10 Assembly Instructions ...................... 6
10.1 End Cap and Springs Disassembly on Spring
Return Actuators ........................................6
10.2 Pinion Assembly .........................................6
10.3 Alignment of pinion for correct piston
assembly ................................................ 6
10.4 Piston Assembly .........................................6
10.4.1 Clockwise rotation ........................................6
10.4.2 Counter-Clockwise rotation ..........................7
10.5 Travel stop assembly ...................................7
10.6 End cap assembly on double acting
actuators ....................................................7
10.7 Spring Return Actuators .............................7
10.7.1 Spring set adjustments ..................................7
10.7.2 Installing the Springs .....................................7
11 Testing the Hytork Actuator ............. 8
12 Retractor Rods ................................. 8
7 Position Feedback ............................ 4
8 Spares Recommendations ................ 4
9 Disassembly Procedure .................... 4
9.1 End cap and springs disassembly on Spring
Return actuators .........................................4
9.2 Changing spring sets on XL26 to XL681 .....5
9.3 End cap disassembly on Double Acting
actuators ....................................................5
9.4 Piston disassembly .....................................5
9.5 Pinion disassembly .....................................5
9.6 Inspection ...................................................5
12.1 Spring Removal System Board ....................8
13 Service ............................................. 8
14 Parts and Materials .......................... 9
I Table of Contents
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. E
1 Important Safety Procedures
Hytork XL
July 2019
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 qualied personnel.
Before installation, operation and maintenance, read
the relevant sections of:
- This manual
- Quick Reference Guide: DOC.QRG.XL
!
CAUTION - BEFORE YOU START
• 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 (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.
Numbers in brackets (#) refer to parts on the exploded
view drawing (Chapter 15). 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.
IMPORTANT - STORAGE
• 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 - LIFTING INSTRUCTIONS
• Use lifting equipement 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
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
Double Acting Spring Return with S80 Springs
Kg Lbs Kg Lbs
1
Hytork XL
July 2019
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. E
2 ATEX instructions for use in (potential) explosive areas
2.1 Intended use
The 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) classied Zones 1, 2 (Gasses) and/or 21, 22 (Dust).
2.2 Safety Instructions
a. Assembly, disassembly and maintenance, is only allowed at the actuator, when, at the time of the
activity, there is not an explosive mixture.
b. 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.
c. 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 of sizes XL426 up to XL4581, to avoid build up of static electricity.
d. In order to avoid increasing dust explosion risk, periodically clean dust deposits from all equipment.
e. 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.
f. 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.).
g. 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.
h. 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”).
!
WARNING - SURFACE TEMPERATURE
• The actuator’s surface temperature is dependent upon process operating conditions. Personal injury
or property damage, caused by fire or explosion, can result if the actuator’s surface temperature
exceeds the acceptable temperature for the hazardous area classification. 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.
2.3 Temperature range for (potential) explosive areas
Table 3.
Temperature
Ambient range
-20..75°C T6 T85°C (185°F)
-20..80°C T5 T90°C (194°F)
-20..80°C T1...T4 T90°C (194°F)
-20..75°C T6 T85°C (185°F)
-20..90°C T5 T100°C (212°F)
-20..120°C T1...T4 T130°C (266°F)
-40..75°C T6 T85°C (185°F)
-40..80°C T5 T90°C (194°F)
-40..80°C T1...T4 T90°C (194°F)
-20..250°C for
2 hours
ATEX
class
(ATEX surface temperature)
T2 T260°C 500°F)
TX
Valid for
actuator model
Standard Temperature
models
High Temperature
models
Low Temperature
models
Tunnel application
models
NOTE:
a. The specied values are
valid with the following
conditions:
- Maximum working
frequency of the actuator is
1Hz at a maximum of 50
cycles per hour and at
maximum load.
2
Loading...