Emerson EL-O-Matic F-Series Installation and operating manual

Safety Guide
DOC.SG.EF.EN Rev. 2
April 2018
EL MaticTM
EL MaticTM
EL-O-Matic F-Series
Rack and Pinion Pneumatic Actuators EN
CN
DA
CS
DE
EL
ES
FI
FR
HU
IT
NL
NO
PL
PT
SK
SV
TR

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
I

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
1
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.
EN

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
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.
EN

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
3
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.
EN

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
4
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.
EN

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
5
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.
EN

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
6
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).
EN

EL-O-Matic F-Series
April 2018
Safety Guide
DOC.SG.EF.EN Rev. 2
7
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.
EN