Emerson Hytork XL Series User manual

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

i
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. 0
Table of Contents
November 2022
Table of Contents
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

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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
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

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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
T 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
4
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
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”