Emerson Hytork XL Series Installation and operating manual

Hytork XL-Series
Rack and Pinion Pneumatic Actuators
Safety Guide
DOC.SG.HX.1 Rev. 1
November 2022

Safety Guide
DOC.SG.HX.1 Rev. 1
Notes
November 2022
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Safety Guide
DOC.SG.HX.1 Rev. 1
Table of Contents
November 2022
Table of Contents
Section 1: Safety Instructions
1.1 ANSI 534.6 Safety Messages ..................................................1
Section 2: General Information
2.1 General Application ...............................................................2
2.2 Inspection and Maintenance Schedules .................................2
2.3 Parts Ordering .......................................................................3
Section 3: Hytork XL-Series Actuators
3.1 Installation ............................................................................4
3.2 Operation .............................................................................5
3.2.1 Operating Media ......................................................5
3.2.2 Operating Temperature Range .................................6
3.3 Maintenance .........................................................................7
Section 4: Actuator Accessories
Actuator Accessories .....................................................................8
Section 5: Instructions for Use in Explosive Areas
5.1 Intended Use .........................................................................9
5.2 Safety Instructions ................................................................9
5.3 Maximum Temperatures .....................................................11
Appendix A: EU Declaration of Conformity
EU Declaration of Conformity ......................................................12
Appendix B: UKCA Declaration of Conformity
UKCA Declaration of Conformity .................................................13

Safety Guide
DOC.SG.HX.1 Rev. 1
Notes
November 2022
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1
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Section 1: Safety Instructions
Section 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 personal injury or property damage, it is important to carefully
read, understand, and follow all of the contents of the associated Installation,
Operation and Maintenance 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
Indicates information considered important, but not hazard-related.
Safety Instructions

2
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Section 2: General Information
2.1 General Application
The Hytork XL-Series 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.
2.2 Inspection and
Maintenance Schedules
The Hytork XL-Series Rack and Pinion actuators must be inspected periodically
and maintained as needed. Refer to Installation, Operation and Maintenance
Manual, MAC050515 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 location (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.
Section 2: General Information
General Information

3
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
2.3 Parts Ordering
Whenever 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 only genuine replacement parts. Components that are not supplied by
Emerson should not be used under any circumstances in any Hytork 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.
Section 2: General Information
General Information

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Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Section 3: Hytork XL-Series Actuators
These safety instructions are limited to Hytork XL-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
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
eyewear when performing any installation operations.
• 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 might slip. 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.
Section 3: Hytork XL-Series Actuators
Hytork XL-Series Actuators

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Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
! WARNING
Stay away from moving parts to prevent serious injuries. When test cycling
the actuator and valve assembly by applying pressure to the A or B port
(2 or 4 port), be aware that there are moving parts like pinion top, actuator
to valve coupling and the valve blade, ball or plug, etc. Isolate the piping
system on which an actuator-valve assembly is installed, when removing this
assembly, relieve any media pressure that may be trapped in the valve cavities
before removing the actuator for maintenance.
3.2 Operation
! WARNING
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
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cant negative effect on the life expectancy of the actuator.
Section 3: Hytork XL-Series Actuators
Hytork XL-Series Actuators

6
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
3. Refer to Table 1 on applications where the spring stroke of
spring-return actuators is pneumatically operated.
Table 1. Maximum pressure on spring stroke of spring-return actuators
4. Dew point should be 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.
3.2.2 Operating Temperature Range
1. Using standard seals and grease the operating temperature
range is -20 °C to + 80 °C (-4 °F to +176 °F) as 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.
Section 3: Hytork XL-Series Actuators
Spring set Maximum pressure on spring stroke of
spring-return actuators
S20 6.9 barg / 100 psig
S30 6.2 barg / 90 psig
S40 5.5 barg / 80 psig
S50 4.8 barg / 70 psig
S60 4.1 barg / 60 psig
S70 3.4 barg / 50 psig
S80 2.8 barg / 40 psig
S90 2.1 barg / 30 psig
S1C 1.4 barg / 20 psig
Hytork XL-Series Actuators

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Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
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 personal 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 eyewear.
• 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
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 be “shot” away when completely turned out.
! CAUTION
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 damage to material. Hytork actuators are
equipped with the SAFEKEY design that allow in-eld removal of the end caps.
Refer to Section 9 of Manual MAC050515 EN for instructions to safely remove
the spring load using retractor rods, before disassembling the actuator from a
valve, which is stuck in mid stroke.
Section 3: Hytork XL-Series Actuators
Hytork XL-Series Actuators

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Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Section 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.
Section 4: Actuator Accessories
Actuator Accessories

9
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Section 5: Instructions for Use in (Potential)
Explosive Areas
5.1 Intended Use
The Hytork XL-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. Actuator assembly, disassembly, and maintenance is only allowed
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 can cause an ignition due to
electrostatic discharge. Therefore, the plastic position indicators
are only approved for use in certain potentially explosive (Ex)
gas group areas, without additional warning on the actuator of
Electrostatic hazard.
Each indicator is shipped with an “Electrostatic Hazard Warning
Sticker” which must be applied to the actuator according to the
below schedule, refer to Table 2.
Table 2.
Section 5: Instructions for Use in Explosive Areas
Actuator Sizes Ex Gas Group
IIA IIB IIC
Small indicator
(actuator sizes up
to size XL 681)
OK to
use without
warning sticker
OK to
use without
warning sticker
Apply the
Electrostatic
Hazard Warning
sticker
Larger indicator
(actuator sizes
XL 1127 up to
XL 4581)
Apply the
Electrostatic
Hazard Warning
sticker
Apply the
Electrostatic
Hazard Warning
sticker
Apply the
Electrostatic
Hazard Warning
sticker
Instructions for Use in Explosive Areas

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Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
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 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.
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 in.).
Section 5: Instructions for Use in Explosive Areas
Instructions for Use in Explosive Areas

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Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
5.3 Maximum Temperatures
! WARNING
The actuators 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.
Table 3. Temperature range for (potential) explosive areas
Note:
1. The actual maximum surface temperature depends not on the equipment itself,
but mainly on operating conditions like e.g. the temperature of the supply media.
2. 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.
Section 5: Instructions for Use in Explosive Areas
Instructions for Use in Explosive Areas
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

VCCAQ-15691-EN
Signed:
Name:
Position:
Date:
Place:
ROC no 9010
Rev. 0
_____________________________
Girish Dalbhanjan
Director, Global Engineering
Emerson Process Management
Actuation Technologies
2022-08-01
Houston TX, U.S.A.
We hereby declare, that the products specied below meet the basic health and safety requirements of the below
mentioned European Directives.
EU Declaration of Conformity
Issued in accordance with the:
Pressure Equipment Directive (PED)
2014/68/EU
• For Gas Group 2 (see DOC.SG.HX.1, Section 3.2.1,
Operating Media). Hytork pneumatic actuators are
excluded from the requirements of the Pressure
Equipment Directive 2014/68/EU based on article 1,
Section 2 (f) of the directive.
• For Gas Group 1 pressure media, rst consult
engineering to check compatibility of pressure media
with the actuator.
• The below listed limited range of Hytork actuator sizes
are rated “Sound-Engineering-Practice” or Module A
(Internal production control) and are available on
request for use with Gas Group 1 media.
• Double-acting and spring-return actuators
• Sizes: XL26, XL71, XL131, XL186, XL221, XL281,
XL426, XL681, XL1127, and XL1372
EU Declaration of Conformity
Issued in accordance with the:
ATEX Directive 2014/34/EU
ATEX Marking:
• II 2G Ex h IIC TX Gb
II 2D Ex h IIIC TX Db
• For maximum temperature limits and classications,
see Safety Guide: DOC.SG.HX.1, Section 5, Instructions
for Use in (Potential) Explosive Areas.
Applicable Standards:
• EN IEC 60079-0:2018 EN ISO 80079-36:2016
EN ISO 80079-37:2016 EN 1127-1:2019
Declaration of Incorporation of Partly
Completed Machinery
Issued in accordance with the:
Machinery Directive 2006/42/EC,
Appendix IIb
Essential requirements applied and complied with:
• 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4, 1.3.7, 1.5.2, 1.5.3,
1.5.4, 1.5.7, 1.6.1, 1.7.1, 1.7.3, and 1.7.4.
• Technical documentation is drafted in compliance with
Appendix VII, Section B.
• Before the actuator is put into operation, the machine
into or onto which the actuator will be installed, must
comply with the stipulations of the machinery directive.
• The relevant information concerning the machine
or part will be available in the event of a motivated
request from national authorities.
Applicable Standards:
• EN ISO 12100:2010
Product Description:
• Hytork XL Pneumatic actuator
• Double-acting and spring-return actuators
• Sizes: XL26, XL71, XL131, XL186, XL221, XL281, XL426,
XL681, XL1127, XL1372, XL2586, and XL4581
Product Variations:
• Product variations of the below mentioned types
are still covered by the listed directive and are
CE marked.
Serial Number:
• Each actuator has an identiable serial number.
Manufacturer:
• Emerson Process Management
Valve Automation (M) Sdn. Bhd.
Lot 13112, Mukim Labu,
Kawasan Perindustrian Nilai,
71807 Nilai, Negeri Sembilan
Malaysia
Legal representative entity for the European Union:
Emerson Automation Solutions, Actuation Technologies Limited
Patrijsweg 140, 2289 EZ Rijswijk, Netherlands
12
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Appendix
Appendix A: EU Declaration of Conformity
Appendix

Signed:
Name:
Position:
Date:
Place:
VCCAQ-17151-EN
Rev. 0
This declaration of conformity is issued under the sole responsibility of the manufacturer.
The products specied below meet the basic health and safety requirements of the below mentioned UK legislations.
Declaration of Incorporation of Partly
Completed Machinery
Issued in accordance with the:
UK Regulation 2008 – UK SI 2008 No. 1597
SCHEDULE 2, Annex II(B)
Essential requirements applied and complied with:
• 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4, 1.3.7, 1.5.2, 1.5.3,
1.5.4, 1.5.7, 1.6.1, 1.7.1, 1.7.3, and 1.7.4.
• Technical documentation is drafted in compliance with
Annex VII, Section B of the Regulation.
• Before the actuator is put into operation, the machine
into or onto which the actuator will be installed, must
comply with the stipulations of the machinery directive.
• The relevant information concerning the machine
or part will be available in the event of a motivated
request from national authorities.
Applicable Standards:
• BS EN ISO 12100:2010
Product Description:
• Hytork XL Pneumatic actuator
• Double-acting and spring-return actuators
• Sizes: XL26, XL71, XL131, XL186, XL221, XL281,
XL426, XL681, XL1127, XL1372, XL2586, and XL4581
Product Variations:
• Product variations of the above mentioned types
are still covered by the listed regulations and are
UKCA marked.
Serial Number:
• Each actuator has an identiable serial number.
Manufacturer:
• Emerson Process Management
Valve Automation (M) Sdn. Bhd.
Lot 13112, Mukim Labu,
Kawasan Perindustrian Nilai,
71807 Nilai, Negeri Sembilan
Malaysia
Legal representative entity for the GB Market:
Emerson Automation Solutions, Actuation Technologies Limited
6 Bracken Hill, Peterlee County Durham, SR8 2LS, United Kingdom
UK Declaration of Conformity
Issued in accordance with the:
UK Regulation 2016 – UK SI 2016 No. 1105
• For Gas Group 2, (see Safety Guide, DOC.SG.HX.1,
Section 3.2.1, Operating Media). Hytork pneumatic
actuators are excluded from the requirements of
the Pressure Equipment (Safety) Regulations 2016,
UK Statutory Instrument 2016 No. 1105, as amended
by the Product Safety and Metrology etc.
(Amendment etc.) (EU Exit) Regulations 2019,
UK Statutory Instrument 2019 No. 696 based on
SCHEDULE 1, Paragraph 1(f) of the regulation.
• For Gas Group 1 pressure media, rst consult
engineering to check compatibility of pressure media
with the actuator.
• The below listed limited range of Hytork actuator sizes
are rated “Sound-Engineering-Practice” or Module A
(Internal production control) and are available on
request for use with Gas Group 1 media.
• Double-acting and spring-return actuators
• Sizes: XL26, XL71, XL131, XL186, XL221, XL281,
XL426, XL681, XL1127, and XL1372
UK Declaration of Conformity
Issued in accordance with the:
UK Regulation 2016 – UK SI 2016 No. 1107
Marking of the Product:
• II 2G Ex h IIC TX Gb
II 2D Ex h IIIC TX Db
• For maximum temperature limits and classications,
see Safety Guide: DOC.SG.HX.1, Section 5, Instructions
for Use in (Potential) Explosive Areas.
Applicable Standards:
• BS EN IEC 60079-0:2018 BS EN ISO 80079-36:2016
BS EN ISO 80079-37:2016 BS EN 1127-1:2019
_____________________________
Girish Dalbhanjan
Director, Global Engineering
Emerson Process Management
Actuation Technologies
2022-08-01
Houston TX, U.S.A.
13
Safety Guide
DOC.SG.HX.1 Rev. 1 November 2022
Appendix
Appendix B: UKCA Declaration of Conformity
Appendix

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Emerson Electric Co. HytorkTM is a mark of one of the Emerson
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