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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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

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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

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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

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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