Purge Valves Maybe 91 463389 Hytork Xl Series 01 02 4m1s2w

91-463389 Hytork XL Series 01

Installation, Operating and Maintenance Instructions

MXL079703

XL 1 Important Safety Series Procedures Actuators Qualified maintenance personnel 1 2 3 4 5 6

ALWAYS disconnect the Air and Electrical Supplies before carrying out any form of maintenance on an Actuator. Always contain the Spring tension with HYTORK Retractor Rods as explained in Section 7.2. Follow instructions for using the Retractor Rods carefully.

Ensure that the square coupling shaft to be operated is a close, but free sliding fit into the female drive in the Actuator shaft (4). 2.2 Maximum Operating Pressure. XL models 45 to 2585 Do not exceed 8.2 bar (120 psi). XL model 4580 Do not exceed 7 bar (100 psi).

7 8 9

Never attempt to remove the Pistons from the Actuator body by using air pressure when the End Caps have been removed.

10 11

Do not shorten or distort the SAFEKEYS; correct length SAFEKEYS are supplied with the Maintenance Kit.

12 13 14

When replacing items use only those supplied by HYTORK or its Stocking Distributors.

2.3 Operating media. Use clean, dry or lubricated air. Other medias may be used, but consult your local HYTORK VALVE AUTOMATION CENTER for confirmation as to suitability.

Numbers in brackets (#) refer to parts on the exploded XL diagram (Fig. 1).

XL Series Actuators

Contents Important Safety Procedures Mounting and Operating Instructions Piping Instructions Solenoid Valves on Spring Return Actuators Spares Recommendations Complete DisassemblyDouble Acting Actuator Complete DisassemblySpring Return Actuator Assembly InstructionsDouble Acting Actuator Assembly InstructionsSpring Return Actuators Spring Adjustments Testing and Cycling of Infrequently Used or Stored Actuators Spares Kits Retractor Rods Service

should read and follow these straightforward instructions.

the Pinion drive, coupling device and Valve Stem should be centred and concentric to prevent any side loading to the bottom Pinion Radial Bearing and Valve Stem Seal area.

Installation, Operating and Maintenance Instructions

Hytork Dossier

Read the relevant sections carefully before continuing.

1

Fig. 2b

USA

2.1 Actuator to Valve Installation. The mounting hole sizes and bolt hole circle are to ISO 5211. These holes are ISO METRIC COARSE on metric models (UNC COARSE on imperial models for the USA) as standard. When mounting the Actuator to a Valve using a Mounting Kit,

Fig. 2a

MXL079703

Quality Assured ed management systems to ISO 9001

2 Mounting and Operating Instructions (Refer to Fig. 1)

91-463389 Hytork XL Series 01

2

bm

bsbt

Part No. Component

Quantity

1 2 3 4 5 6 7 8 9 bk

2 2 2 1 1 2 2, 3 or 4 2 2 2

Travel Stops & Seals End Caps Pistons Pinion Body SAFEKEYS & ‘O’ Rings Springs* Retractor Caps* DURASTRIP Pinion Radial Bearings DURASTRIP Piston Bearing Strips

br bobpbq

Part No. Component

Quantity

bl bm bn bo bp bq br bs bt

2 2 2 2 2 1 1 2 2

Piston ‘O’ Rings End Cap ‘O’ Rings Pinion ‘O’ Rings DURASTRIP Thrust Bearings Steel Thrust Washers Snap Ring (Circlip) Position Indicator Sealing ‘O’ Rings* Sealing Bolts* *Spring Return Models only

bn 9 bm 1

2 7

2 Double Acting

bl 8

bobp 5

Fig. 1

4

bk

3 Piping Instructions (Fig. 2a & 2b) All Actuators can be either piped with solid or flexible tubing with the Solenoid Valve mounted remotely from the Actuator or by mounting a NAMUR designed Solenoid Valve DIRECTLY onto the NAMUR Mounting Pad on the side of the Actuator. (ALL Solenoids made to the NAMUR standard can be mounted in this way.)

3 9

bm

2

bn

bs bt

67

specially designed to prevent contamination of the internals of the Actuator by dirt from the atmosphere. This increases the working life of the Actuator which reduces down time and maintenance periods. (See Dossier DSL019601)

Fig. 3a

4 Solenoid Valves on Spring Return Actuators (Fig. 3a & 3b) It is recommended that on Spring Return Actuators, the HYTORK “CATS” Solenoid Valves are used. These Valves are

2

Spring Return

Fig. 3b

91-463389 Hytork XL Series 01

5 Spares Recommendations

Viewed from above Pinion Slot

Travel Stop (1) 2

1

Double Acting Fig. 4

Body (5)

When disassembling and carrying out maintenance work on the XL Actuator, a HYTORK XL Spares Kit must be used to replace all ‘O’ Rings, DURASTRIP Bearing Strips, Washers etc. This Kit is available from HYTORK or its Stocking Distributors.

End Caps (2)

Important: Read Safety Instructions before starting (see Section 1).

6 Complete Disassembly Double Acting Actuator 6.1 Removal of Travel Stops. (Fig. 4) Release the lock nut and remove both Travel Stops and Seals (1) (cast Identity numbers 1 & 2), which are located at the top of the Actuator body (5) on the side opposite the Actuator air connections. 6.2 Removal of End Caps. Unscrew the two slotted SAFEKEY screws (6) (cast Identity letters C & D) located in the body next to each End Cap (2), and gently pull them from the body, removing each SAFEKEY. If the SAFEKEY screw tends to spring, then rotate the End Cap slightly to assist release. For larger models (1125 to 4585) use a wrench (spanner) on the End Cap to turn it to assist the release of the SAFEKEY (ensuring the End Cap is always flush to the body). When both SAFEKEYS have been removed, detach the Position Indicator (17) from the top of the Pinion and use a wrench (spanner) to rotate the Pinion (4), driving the Pistons (3) apart until they partially push the End Caps from the body. Remove the End Caps by pulling them free from the body, keeping them square to the end face of the body.

SAFEKEY C (6) Actuators, the Pistons are provided with cast extraction holes in the face of the Piston. By screwing the Travel Stop Bolt into this hole it can be used to pull the Pistons from the Actuator body using pliers or vice grips. 6.4 Removal of Pinion. On XL models 680, 1125 & 1370 with Location Rings to ISO 5211 (metric versions only), the Location Ring is a loose item and must be removed before the removal of the Pinion. Remove the Snap Ring (Circlip) (16), Steel Thrust Washer (15) and Thrust Bearing (14) from the top of the Pinion and CAREFULLY remove the Pinion from the cylinder body through the bottom. (If the Actuator is a 680, 1125 or 1370 gently tap the top of the Pinion with a rubber hammer to remove the Location Ring first.) Care MUST be taken to ensure that the Pinion Radial Bearing Strips (9) on the top and bottom of the Pinion do not become trapped in the bores during this operation. Take care that the Pinion does not damage the Pinion bores on removal. If necessary, remove any burrs, etc. from the top of the Pinion before removing it. 6.5 Inspection. Clean and examine all parts for damage and wear. Check SAFEKEYS for damage and length (Fig. 10). HYTORK recommends that ALL ‘O’ Rings, Bearing Strips, Washers etc. are replaced using a HYTORK XL Spares Kit.

6.3 Removal of Pistons. Rotate the Pinion using a wrench (spanner) to drive the Pistons apart until the Pinion rotates freely. Rotate the Pistons in the Actuator approximately 10 degrees. Rotate the Pinion carefully with a little force and the Pistons will push free of the Actuator body. On later models of XL

3

SAFEKEY D (6)

7 Complete Disassembly Spring Return Actuator 7.1 Removal of Travel Stops. (Fig. 4) Release the lock nut and unscrew both Travel Stops and Seals (1) (cast Identity numbers 1 & 2), which are located at the top of the Actuator body (5) on the side opposite the Actuator air connections. 7.2 Removal of Spring Pack Modules. (Fig. 5) Remove Sealing Bolts (19) and ‘O’ Rings (18) from each End Cap (2). Place the HYTORK Retractor Rod (see Section 13.10) through the hole in the End Caps and screw the Rod into the Spring Retractor Caps (8) until travel is stopped, the nut and washer being free of the End Cap face. Screw the nut and washer clockwise down the Retractor Rod until they come up against the face of the End Cap. Using a wrench (spanner), continue to screw the nut clockwise down the Rod exactly two turns, to draw the Spring Retractor Cap away from the Piston head (3). This compression of the Springs releases the Spring force and unlocks the SAFEKEY for removal. Repeat for the other End Cap. Rotate the Caps to ensure that the Springs are retracted; if the Cap will not turn easily, screw the nut further. Once the Retractor Rods have compressed the Spring and the Caps can be rotated freely, unscrew the two SAFEKEY slotted screws (6) located in the body (5) next to each End Cap to which the SAFEKEYS (cast Identity letters C & D)

91-463389 Hytork XL Series 01

Washers, etc. are replaced using only a HYTORK XL Series Spares Kit.

Retractor Rod

End Cap (2)

Nut

Insert Retractor Rod screw down nut SAFEKEY

Piston (3) Retraction Plate (8)

Remove SAFEKEY and then remove Spring End Cap assembly

Relax Springs if required to change Spring rating are connected. Gently pull the slotted screws from the body removing the SAFEKEY. If the SAFEKEY slotted screw tends to spring, rotate the End Cap slightly to assist release. For larger models (1125 to 4580) use a strap wrench to turn the End Cap to assist the release of the SAFEKEY (ensuring the End Cap is always flush to the body). When both SAFEKEYS have been removed, detach the Position Indicator (17) from the Pinion top and use a wrench (spanner) to rotate the Pinion (4), driving the Pistons (3) apart until they partially push the End Caps from the body. Remove the End Caps by pulling them free from the body, keeping them square to the end face of the body.

Fig. 5 Hytork’s “Safety Spring Removal System” 7.3 Disassembly of the center module. These operations are as described for Double Acting Actuators, Sections 6.3, 6.4 and 6.5.

8 Assembly Instructions IMPORTANT: All HYTORK XL Spares Kits are supplied with SAFEKEY (6) assemblies cut to an exact length which will fit the circumference of the End Cap (2) when fully assembled into the Actuator. Any shortened SAFEKEYS must not be used. If in doubt HYTORK or your local Stocking Distributor.

For normal maintenance when Spring changes are not required, it is not necessary to relax the Springs. The Spring End Cap assembly can be left with the Retractor Rod holding the assembly together, ready for reassembly.

Double Acting Actuators

If it is necessary to change the Spring rating refer to Section 10.1.

8.1 Inspection. Check that all components are clean and free from damage. HYTORK recommend that ALL ‘O’ Rings, Bearing Strips,

4

8.2 Installing the Pinion. Lightly grease the Pinion, ‘O’ Ring grooves and Bearing Strip grooves of the Pinion (4) and Pinion ‘O’ Rings (13) with Lithium based grease. Install one Steel Thrust Washer (15) over the top of the Pinion and slide it down to the top of the gear form. Take the top Pinion Radial Bearing Strip (9) and fit it into the top Pinion location groove and slide one Thrust Bearing Washer (14) down over the DURASTRIP Bearing Strip, holding the strip in position around the Pinion shaft. Fit the top ‘O’ Ring into the top Pinion groove. Fit the bottom Radial Bearing Strip (9) into the bottom Pinion location groove and hold in position using the bottom ‘O’ Ring. Lightly grease the Pinion bores of the body before assembly. Carefully insert the Pinion into the body (5) until the top of the Pinion rests in the top bore but the bottom Radial Bearing Strip groove is still protruding from the bottom of the Actuator. Gently slide the Pinion up through the body making sure that the ends of the bottom Bearing Strip are not trapped and the ‘O’ Ring slides or rolls into the ‘O’ Ring groove as the Pinion is pushed home into the body. With the Pinion in this position, install the top Thrust Bearing Washer (14), then the Steel Thrust Washer (15) and lastly the Snap Ring (Circlip) (16) into the narrow groove at the top of the Pinion (making sure the Snap Ring fits properly in the groove).

Standard mode of operation (8.3, 8.4 & 8.5). THIS MODE IS USED FOR MOST FAIL CLOSED SITUATIONS. CLOCKWISE ROTATION OF THE PINION WITH PISTONS MOVING TOWARDS EACH OTHER. (Fig. 6) 8.3 Alignment of Pinion for correct Piston installation. (Fig. 6) Rotate the Pinion to the position shown in Fig. 6 (when viewed from above the slot at the top of the Pinion) ensuring that the machined Stop Flats are in the correct

91-463389 Hytork XL Series 01

orientation. On later XL Actuators the top of the Pinion is marked with an single identification dot to indicate the correct orientation. To install the Pistons for standard air Fail Close operation, proceed as follows. Rotate the Pinion so that the dot on the top of the Pinion is positioned close to the single dot on the top pad of the Actuator body. Accurate Pinion alignment can now take place by lining the center of the slot on the top of the Pinion with the single dot on the body. (As indicated by the arrow on Fig.6.) 8.4 Installing the Pistons. Ensure that the dovetail on the Bearing Strip is correctly aligned to the dovetail grooves machined into the Piston with the tang, in the center of the Strip, pointing away from the Piston head. Once in the correct orientation, the small tang in the middle of the Strip must be adjusted to point away from the dovetail groove so that the Strip can be pushed into the Piston dovetail grooves. When the Strip is fully in the dovetail groove, the tang must be pushed into the retaining slot on the Piston. Lightly grease the Piston ‘O’ Rings (11) with Lithium based grease. Liberally grease the Actuator body bore and the

Single dot for standard mode

Pistons (3) using Lithium based grease and fit the ‘O’ Rings into the ‘O’ Ring groove on the Pistons. Insert the Pistons into the bore, one Piston in each end with the teeth facing each other (see Fig. 6), to ensure that the Piston rack lines up with the Pinion gear. The alignment groove in the front face of the Piston must be lined up parallel to the Pinion and “gun sights” cast in the body. Push both Pistons together until they are both in with the Pinion, so that when the Pinion is rotated clockwise (see Fig. 6) the Pistons are drawn together. When the Pistons are together and the racks correctly engaged with the Pinion, the top Pinion drive flats should now be at right angles to the axis of the body. 8.5 Installing the Travel Stops. (Fig. 4) With the Pistons together, screw in the Travel CLOSING Stop assembly complete with lock nut and seal (cast Identity number 2) until it comes into with the Pinion. Rotate the Pinion 90 degrees only to drive the Pistons apart and screw in the Travel OPENING Stop (cast Identity number 1) until it comes into with the Pinion. Final adjustment is easily made

Pinion Stop Flats

Pinion (dot)

Standard Operation Fig. 6 Pinion Stop Flats Three dots for Reverse Action

Pinion (dot)

Reverse Operation Fig. 7

5

when the Actuator has been mounted to its Valve, damper or other device, to suit individual requirements. Ensure the lock nut is tightened. HYTORK Actuators have an over travel of 3 degrees at each end of the stroke. (See Dossier ACT030503 for benefits)

Reverse action mode of operation (8.6, 8.7 & 8.8) THIS MODE IS USED FOR MOST FAIL OPEN SITUATIONS. ANTI-CLOCKWISE ROTATION OF THE PINION WITH PISTONS MOVING TOWARDS EACH OTHER. (Fig. 7) 8.6 Alignment of Pinion for correct Piston installation. (Fig. 7) Rotate the Pinion to the position shown in Fig. 7 (when viewed from above the slot at the top of the Pinion) ensuring that the machined Stop Flats are in the correct orientation. On later XL Actuators the top of the Pinion is marked with an single identification dot to indicate the correct orientation. To install the Pistons for standard air Fail Open operation, proceed as follows: rotate the Pinion so that the dot on the top of the Pinion is positioned close to the three dots on the top pad of the Actuator body. Accurate Pinion alignment can now take place by lining the centre of the slot on the top of the Pinion with the three dots on the body. (As indicated by the arrow on Fig. 7.) 8.7 Installing the Pistons. Assemble Bearing Strips and ‘O’ Rings and grease as described in Section 8.4. Insert the Pistons into the bore, one Piston in each end with the teeth facing each other as shown in Fig. 7. The alignment groove in the front face of the Piston must be lined up parallel to the Pinion and cast “gun sights” in the body. Push both Pistons together until they are both in with the Pinion, so that when the Pinion is rotated anti-clockwise (see Fig. 7) the Pistons are drawn together. When the Pistons are together and the racks correctly engaged with the Pinion, the top Pinion drive flats should now be approximately parallel to the axis of the body.

91-463389 Hytork XL Series 01

8.8 Installing the Travel Stops. (Fig. 4) With the Pistons together, screw in the Travel OPEN Stop (cast Identity number 1) until it comes into with the Pinion. Rotate the Pinion 90 degrees to drive the Pistons apart and screw in the Travel CLOSING Stop (cast Identity number 2) until it comes into with the Pinion. 8.9 Installing the End Caps. Install the SAFEKEY ‘O’ Ring Seals to the slotted screws on the SAFEKEY assemblies (6). Lightly grease the End Cap ‘O’ Rings (12) with Lithium based grease. Grease the ends of the body bore and the End Caps (2), making sure the grease goes into the grooves. Install the ‘O’ Ring into the square bottomed groove in the End Cap and insert the Cap into the body. Holding the SAFEKEY close to the entry hole to prevent kinking, insert the SAFEKEY into the hole and gently push into place. For larger models (1125 to 4580) use a wrench (spanner) on the End Cap, ensuring the End Cap is flush to the body, to turn the End Cap to assist the insertion of the SAFEKEY. With the slotted screw in with the body, tighten with a screw driver to create a pressure seal by compressing the ‘O’ Ring. Repeat the operation for the other End Cap. With the Pistons together, replace the Position Indicator (17) with the white and red pegs located as required to indicate the Valve position. 8.10 Location Ring. On XL models 680, 1125 and 1370 (metric versions only) press the loose Location Ring into the bottom of the Pinion bore in the body. 8.11 Testing the HYTORK Actuator. Using compressed air at 80 - 100 psi, check the seal areas with soapy water, ensuring no bubbles are produced and that the Pinion rotates smoothly over its full travel.

S P R I N G

R A T I N G

Fig. 8

C H A R T

For Actuator Models 45, 70, 185, 425, 680, 1370, 2585, 4580

Spring Rating S30 S40 S50 S55 S65 S80 Spring Rating S40 S60 S80

Left Spring Assembly Inner Outer 15 psi 25 psi 15 psi none none 25 psi none 25 psi 15 psi 25 psi 15 psi 25 psi 15 psi 25 psi

Right Spring Assembly Inner Outer 15 psi 25 psi 15 psi none 15 psi none none 25 psi 15 psi none none 25 psi 15 psi 25 psi

For Actuator models 130, 280, 1125 Inner Outer Inner 20 psi 20 psi 20 psi 30 psi none 20 psi none none 30 psi none 20 psi 20 psi 20 psi

9 Assembly Instructions Spring Return Actuators 9.1 Assembly of Main Body Module. Assemble in accordance with the instructions for Double Acting Actuators as described in Section 8.1 to 8.8. 9.2 Installing the Spring End Cap Module. If the Springs have been completely relaxed on disassembly refer to Section 10 before proceeding. Lightly grease the End Cap ‘O’ Rings (12) with Lithium based grease. Grease the ends of the body bore and the End Caps (2), making sure the grease goes into the grooves. Install the ‘O’ Ring into the square bottomed groove in the End Cap and insert the Cap into the body (5), (making sure that the Springs have been sufficiently compressed so that the Retractor Cap locates in the Piston recess). Install the ‘O’ Ring Seals to the slotted screws on the SAFEKEY assemblies (6). Holding the SAFEKEY close to the entry hole to prevent kinking, insert the SAFEKEY into the hole and gently push into place. For larger models (1125 to 4580) use a strap wrench on the End Cap, ensuring the End Cap is flush to the body, to turn the End Cap to assist the insertion of the SAFEKEY. With the slotted screw in with the body, tighten the screw with a screw driver to create a pressure seal. Repeat the operation for the other End Cap. Line up each End Cap

6

Outer 20 psi 30 psi 20 psi 30 psi 20 psi

so that the safety symbols are correctly aligned for easy reading. When the End Caps are in place and the SAFEKEY is fitted correctly, remove the HYTORK Retractor Rod completely. First place a wrench (spanner) onto the double lock nuts at the end of the Retractor Rod to stop it turning while releasing the single nut and washer that is against the End Cap. When this nut is free, unscrew the Rod by using the lock nuts at the end of the Retractor Rod and replace the Sealing Bolts (19) and ‘O’ Rings (18) in each End Cap. With the Pistons together, in the Fail position, replace the Position Indicator (17) with the white and red pegs located as required to indicate the valve position. 9.3 Testing the HYTORK Actuator. Using compressed air at 80 - 100 psi, check the seal areas with soapy water, ensuring no bubbles are produced and that the Pinion rotates smoothly over its full Travel.

10 Spring Adjustments 10.1 Spring selection. (Fig. 8) Diverse types of quarter turn Valves have significantly different operating torque characteristics. Plants have requirements for both Fail Open and Fail Close Valves. The air supply pressure to the Actuator also effects the Actuator size. HYTORK Springs are designed to give the flexibility for whatever application is required. The actual selection of the correct Spring combination can be done by either referring to the torque charts

91-463389 Hytork XL Series 01

turn by using a spanner (wrench) on the lock nuts at the top of the Rod. Continue until the Spring is in its relaxed position. Once the Spring is fully relaxed the Retractor Rod can be unscrewed from the Retractor Cap and the Springs changed as required.

given in the literature on Spring Return Actuators or by consulting your local HYTORK VALVE AUTOMATION CENTER. 10.2 Normal Maintenance Requirements. For normal maintenance when Spring changes are not required it is not necessary to fully relax the Springs. The Spring End Cap assembly can be left with the Retractor Rod holding the assembly together ready for reassembly.

10.4 Spring Module Assembly. (Fig. 5) To compress the Springs reverse the process ensuring that the Retractor Rod is screwed fully into the Retractor Plate before compressing the Springs.

10.3 Spring Removal. (Fig. 5) If it is necessary to alter the Spring rating, the nut on the Retractor Rod next to the End Cap is gradually unscrewed ensuring that the Retractor Rod does not

0.059/1.5 0.0

Actuators not in current use (i.e. Actuators in stores or stock and/or not operated for at least a 3 month period), should be cycled a minimum of ten times and tested against the possible ‘pre-set’ of the Seals. This is a safety precaution recommended by the Seal manufacturers.

0.039/1.0 0.0

A ExB

11 Testing and Cycling of Infrequently Used or Stored Actuators

Full thread

0.059/1.5 Full thread 0.0

ExC

0.039/1 x 45° Cham typical

Model A B C D E

45 7.09/180 2.99/76 0.24/6 0.20/5 M5

Dia. D

70 8.07/205 3.45/90 0.51/13 0.31/8 M8

130 6.30/160 3.94/100 0.55/14 0.31/8 M8

185 9.05/230 3.94/100 0.51/13 0.31/8 M8

280 6.70/170 3.94/100 0.63/16 0.39/10 M10

425 11.22/285 5.31/135 0.51/13 0.31/8 M8

680 14.17/360 6.50/165 0.51/13 0.47/12 M12

1125 10.63/270 6.30/160 0.91/23 0.47/12 M12

1370 16.53/420 7.09/180 0.59/15 0.47/12 M12

Material Specification:

Retractor Rod: High Tensile Steel; tensile strength of 55 - 65 tonf/in2 (850 - 1000 N/mm2). Nuts: High Tensile Steel; tensile strength of 50.8 tonf/in2 (785 N/mm2).

Important:

Retractor Rods must be made to this design specification for safety reasons. HYTORK can not take any responsibility for any other design.

Dimensions are given in inches/mm

2585 19.68/500 8.66/220 0.79/20 0.47/12 M12

4580 21.26/540 9.92/252 0.79/20 0.79/20 M20

RETRACTOR ROD DIMENSIONS Fig. 9

‘W’ dia. ‘L’

Model L mm L inches W dia mm W dia inches

45 166 6.54 3.175 0.125

70 201 7.91 3.175 0.125

130 251 9.88 3.175 0.125

185 281 11.06 3.175 0.125

280 351 13.82 3.175 0.125

425 361 14.21 3.175 0.125

Length dimension L tolerance = +/- 1.0mm Length dimension L tolerance = +/- 0.040 inches

680 421 16.57 3.175 0.125

1125 501 19.72 3.175 0.125

1370 556 21.89 3.175 0.125

2585 691 27.20 3.175 0.125

4580 821 36.26 4.978 0.196

4580AFS 1141 44.92 4.978 0.196

SAFEKEY DIMENSIONS Fig. 10

7

91-463389 Hytork XL Series 01

12 Spares Kits

13 Retractor Rods 14 Service

Contents List:

13.1 Spring Removal System Board. HYTORK’S “SPRING REMOVAL SYSTEM BOARD” contains a full set of Retractor Rods so that any size of Actuator can be disassembled on site. Ask your local HYTORK VALVE AUTOMATION CENTER or your local Stocking Distributor of HYTORK Products for details.

1 x I, O and M Instructions 2 x SAFEKEY Assemblies (6) 2 x SAFEKEY Seal ‘O’ Rings (6) 2 x Piston DURASTRIP Bearing 2 x Strips (10) 2 x Steel Thrust Washers (15) 1 x Pinion top ‘O’ Ring (13) 1 x Pinion top DURASTRIP Radial 2 x Bearing (9) 2 x DURASTRIP Thrust Bearing (14) 1 x Pinion bottom ‘O’ Ring (13)

It is the policy of HYTORK to give the best possible service to our customers. We are happy to assist you in any way we can and if you have any questions about HYTORK Actuators or other HYTORK Products please do not hesitate to one of HYTORK’S VALVE AUTOMATION CENTERS or your local HYTORK Stocking Distributor.

The HYTORK Retractor Rod tools are specially designed for the safe removal of the Spring Return End Cap modules. Only HYTORK manufactured or approved rods are to be used for Spring End Cap removal.

1 x Pinion bottom DURASTRIP Radial 2 x Bearing (9) 2 x Stop Seals (1) 2 x Piston ‘O’ Rings (11) 2 x End Cap ‘O’ Rings (12) 1 x Pinion Snap Ring (Circlip) (16)

Important: As with any threaded tool that is used frequently 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. 13.2 Retractor Rod dimensions. (Fig. 9) Important: Retractor Rods must be made to this design specification for safety reasons. HYTORK can not take any responsibility for any other design.

Quality Assured ed management systems to ISO 9001 MXL079703

Hytork Controls Europe Valve Automation Center 6 Bracken Hill Southwest Industrial Estate Peterlee County Durham SR8 2LS UK

Hytork Controls Europe Ryeford Road South Kings Stanley Stonehouse Gloucestershire GL10 3HG UK

Tel: [+44] (0191) 5180020 Fax: [+44] (0191) 5180032 Email: [email protected] http://www.hytork.com

Hytork Controls Inc. Valve Automation Center 9009 King Palm Drive Tampa, Florida 33619 USA

Tel: [+1] (813) 630 2255 Fax: [+1] (813) 630 9449 Email: [email protected] http://www.hytork.com

Hytork Controls Australian Operations Tel: [+61] (2) 9841 2414 25 South Street Rydalmere Fax: [+61] (2) 9684 6439 NSW 2116 Email: [email protected] Austalia http://www.hytork.com

Tel: [+44] (01453) 827710 Fax: [+44] (01453) 827714 Email: [email protected] http://www.hytork.com

Hytork Controls Indian Operations Tel: [+91] (12) 9251618 311 Mayfair Tower Charmwood Village Fax: [+91] (12) 9251618 New Delhi 110044 Email: [email protected] India http://www.hytork.com

Part of the Hytork International plc Group

8

UK Patents: GB 2 102 887 B; GB 2 123 517 B; GB 2 138 505 B; GB 2 216 229 B; GB 2 225 079 B; GB 2 229 254 B; GB 2 253 459 B; GB 2 268 574 B. US Patents: 4,496,071; 4,651,627; 4,716,815. Warranties: Unauthorised modification to any Hytork Product totally invalidates all warranties.

Important: We have endeavoured in this publication to make the contents as accurate as possible, but being given as general information, it is not to be taken as binding unless specifically confirmed in writing. Due to Hytork's continuing commitment to engineered product advancement, the product specifications and data presented in this publication are subject to change without notice.

91-463389 Hytork XL Series 02

P

Installation, Operating and Maintenance Instructions. XL 26, XL 71, XL 131, XL 186, XL 221. Sheet No. D52A

June 22, 1999

Sheet 1 of 4

2. Spares Recommendations. Installation, 1. Important Safety Operating and Procedures. When disassembling and carrying out work on the XL Actuator, a Maintenance Qualified maintenance personnel should read maintenance HYTORK Spares Kit must be used to replace Instructions. and follow these straightforward instructions. all 'O' rings, DURASTRIP Bearings, Washers

XL Series Actuators Contents 1. Important Safety Procedures. 2. Spares Recommendations. 3. Actuator to Valve Installation. 4. Operating Media, Pressures and Temperatures. 5. Complete Disassembly and Safe Compression of Springs.

ALWAYS disconnect the Air and Electrical supplies before carrying out any form of maintenance on an Actuator. Caution ; 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. Caution ; Always contain the Spring tension with HYTORK Retractor Bolts as explained in Section 6 (Spring Return Actuators). Follow the instructions for using the Retractor Bolts carefully. Only HYTORK manufactured or approved Retractor Bolts are to be used for Spring removal. As with any threaded tool that is frequently used, Retractor Bolts should be checked to ensure that the threads are not worn or damaged in any way and are greased regularly. Any worn or damaged Retractor Bolts must not be used and must be destroyed.

6. Assembly Instructions. 7. Testing the HYTORK Actuator.

Never attempt to 'BLOW OUT' the Pistons from the Actuator Body by using air pressure when the End Caps have been removed.

8. Testing and Cycling of Infrequently Used or Stored Actuators.

Numbers in brackets (#) refer to parts shown in the sectioned drawing (Fig. 1).

9. Service.

Quality Assured ed management systems to ISO 9001

All HYTORK XL Spares Kits are supplied with SAFEKEY assemblies (13 / 14) cut to an exact length which will fit the circumference of the End Cap (21) when fully assembled into the Actuator. Any shortened SAFEKEY must not be used. If in doubt HYTORK.

etc. This Kit is available from HYTORK or its Stocking Distributors.

3. 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 fit into the female drive in the Actuator Pinion (19).

4. Operating Media, Pressures and Temperatures. Operating media : Use clean and dry or lubricated air. Operating pressures : not to exceed 10 bar ( 150 psi ). Operating temperature range : Using standard seals and grease the operating temperature range is -20°C to +100°C ( -4°F to +212°F ). For operating media's, pressures and temperatures outside these ranges please consult HYTORK.

Read the relevent sections carefully before continuing.

The information contained within this document is copyright © Hytork International Plc. And subject to change without notice. Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center. USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).

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Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Component Description Ball Bearing 'O' ring (End Cap) Wear Ring (Piston) 'O' ring (Piston) Thrust Bearing (Circlip) Circlip Indicator 'O' ring (Pinion top) Bearing (Pinion top) Bearing Block (Piston) Body 'O' ring (SAFEKEY) SAFEKEY Head SAFEKEY Wire Thread Insert

Installation, Operating and Maintenance Instructions. XL 26, XL 71, XL 131, XL 186, XL 221 Sheet No. D52A

Material Chromium Steel Nitrile DURASTRIP Nitrile DURASTRIP Spring Steel Nylon Nitrile DURASTRIP DURASTRIP Aluminium Alloy Nitrile Grivory Stainless Steel Steel

5. Complete Disassembly and Safe Compression of Springs. Release Locking Nuts (24) and remove both Travel Stops and Thread Seals (22 / 23) which are located at the top of the Actuator Body (cast identity numbers 1 & 2), on the side opposite the Actuator air connections. Remove both Sealing Bolts (28) and seals (29) from the End Caps (21). Place the HYTORK Retractor Bolt complete with Washer (see Fig. 3a) through the hole in the End Caps and screw the Bolt into the Piston (20) until the Bolt Head touches the End Cap. Now screw in a further 1/2 to 1 turn to compress the Springs (26 / 27). DO NOT OVERTIGHTEN. Repeat for the other End Cap. Unscrew the two slotted SAFEKEYS (13 / 14) located on the Body (11) next to each End Cap (cast identity letters C & D),

Quantity 2 2 2 2 1 1 1 1 1 2 1 2 2 2 2

June 22, 1999 Item 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Component Description Location Ring 'O' ring (Pinion bottom) Bearing (Pinion bottom) Pinion Piston End Cap Travel Stop Thread Seal Locking Nut Thrust Washer (Circlip) Spring Outer Spring Inner Sealing Bolt (End Cap) 'O' ring (Sealing Bolt)

and gently pull each SAFEKEY from the Body. If the SAFEKEY resists removal, gently tap the End Cap with a soft mallet (hammer) to assist release. When both SAFEKEYS have been removed, detach the Indicator (7) from the top of the Pinion (19) and use a wrench (spanner) to rotate the Pinion, driving the pistons (20) apart until they partially push the End Caps from the Body. Spring Return Actuators : To keep the Spring Pack Assembly intact (Fig. 3b), leave the Retractor Bolt in place. To disassemble the Spring Pack, unscrew the Retractor Bolt relieving the Spring force. Double Acting Actuators : Remove the SAFEKEY as described previously. The Retractor Bolt is not required for Double Acting Actuators. Remove the End Caps by pulling them free from the Body keeping them square to the end face of the Body.

Sheet 2 of 4 Material Acetal Nitrile DURASTRIP Steel Aluminium alloy Aluminium alloy Stainless Steel Steel / Rubber Stainless Steel Stainless Steel Spring Steel Spring Steel Steel Nitrile

Quantity 1 1 1 1 2 2 2 2 2 1 2 2 2 2

Removal of Pistons : Rotate the Pinion using a wrench (spanner) to drive the Pistons apart and remove from the Body by pulling the Pistons. Removal of the Pinion : Remove the snap ring (Circlip)(6), Thrust Washer (25) and DURASTRIP Thrust Bearing (5) from the top of the Pinion and CAREFULLY push the Pinion from the Body through the bottom. Take care that the Pinion does not damage the pinion bores on removal. If necessary, remove any burrs, etc. from the top of the Pinion before removal. Carefully remove Pinion Top Bearing (9) from the Body. Inspection : Clean and examine all parts for damage and wear. HYTORK recommends 'O' rings, DURASTRIP Bearings, SAFEKEYS, Washers, etc. are replaced using a HYTORK XL Spares Kit.

The information contained within this document is copyright © Hytork International Plc. And subject to change without notice. Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center. USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).

91-463389 Hytork XL Series 02

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6. Assembly Instructions. Note : The grease used in ALL HYTORK Standard Model Actuators is a Lithium Based Grease. Check with HYTORK for high and low temperature applications.

Double Acting Actuators. Installing the Pinion. Lightly grease all 'O' rings, 'O' ring grooves, bearing grooves and Pinion. Assemble the Top Pinion Bearing (9) to the Pinion, ensuring that the recess openings are facing away from the gear form, then assemble items (8), (17) and (18). Lightly grease the pinion bores in the Body (11) and insert the Pinion being careful not to damage the 'O' rings.When the Pinion is in place, install the DURASTRIP Thrust Bearing (5), Thrust Washer (25) and the snap ring (Circlip)(6) into the narrow groove at the top of the Pinion (ensuring the snap ring fits properly into the groove). .

Installation, Operating and Maintenance Instructions. XL 26, XL 71, XL 131, XL 186, XL 221 Sheet No. D52A

June 22, 1999

Only open the snap ring (Circlip) enough to just clear the Pinion diameter as opening too far will damage the snap ring. If damage occurs replace with a new part. Note : The snap ring (Circlip) has one side with bevelled edges which must go down onto the Thrust Washer (25) ; the square edge side must face UPWARDS. Alignment of Pinion for correct Piston installation. (When viewed from above the slot at the top of the Pinion) (Fig. 2a & Fig. 2b). Standard rotation is clockwise with the Pistons moving towards each other. Installing the Pistons. Clockwise rotation with Pistons moving towards each other (Fig.2a). Align the Pinion by lining up the center of the NAMUR slot in the top of the Pinion with the single dimple on the Body. The top of the Pinion is marked with a single identification dot to indicate the correct orientation of the stop faces.

Sheet 3 of 4

Lightly grease all piston grooves, gear form and piston 'O' rings (4) and fit the 'O' ring (4) and Wear Ring (3) to the Piston. Fit the Bearing Block (10) to the back of the Piston. Grease the Actuator body bore. Insert the Pistons into the bore, ensuring the piston racks line up with the pinion gear. (the part number in the front face of the Piston must be lined up parallel to the Pinion). Push both Pistons together until they are both in with the Pinion, so that when the Pinion is rotated clockwise the Pistons are drawn together. When the Pistons are together and the racks are correctly engaged with the Pinion, the top pinion drive flats should be at right angles to the axis of the Body. Anti-Clockwise rotation with pistons moving towards each other (Fig. 2b). Align the NAMUR slot in the top of the Pinion with the multiple dimples on the Body and assemble Pistons so that the Pinion rotates anti-clockwise as the Pistons are drawn together.

The information contained within this document is copyright © Hytork International Plc. And subject to change without notice. Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center. USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).

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Installing the Travel Stops (Fig. 4). With the Pistons together, screw in the CLOSING (cast identity number 2) Travel Stop (22), complete with Locking Nut (24) and Thread Seal (23), until it comes into with the pinion stop face. Rotate the Pinion through 90° only, driving the Pistons apart and screw in the OPENING (cast identity number 1) Travel Stop (22), complete with Locking Nut and Thread Seal, until it comes into with the pinion stop face. For individual position requirements final adjustment is easily made when the Actuator has been mounted to its valve, damper or other device. Ensure the Locking Nuts are tightened. HYTORK Actuators provide an over travel of 3° at each end of the stroke.

Installation, Operating and Maintenance Instructions. XL 26, XL 71, XL 131, XL 186, XL 221 Sheet No. D52A

June 22, 1999

With the SAFEKEY Head in with the Body, tighten with a screw driver to gently compress the 'O' ring and create a pressure seal. Repeat the operation for the other End Cap. With the Pistons together, replace the position Indicator (7) to the top of the Pinion.

Spring Return Actuators.

Installing the Springs. (Other instructions are as Double Acting Actuators). Insert the springs (26 / 27) into the face of the Piston and then the End Cap onto the Springs. the correct HYTORK Retractor Bolt through the End Cap (Fig.3a) and screw it into the Piston. Line up the End Cap so that the safety symbol is correctly positioned for easy reading. Continue to screw the HYTORK Retractor Bolt in until the End Cap is completely engaged in the Body. Installing the End Caps. It will be necessary to push the End Cap into Install the SAFEKEY 'O' ring seals (12) to the Body to overcome the 'O' ring the SAFEKEY heads (13). Lightly grease compression. When the End Caps are in the End Cap 'O' rings (2), the End Cap place and the SAFEKEYS fitted correctly, grooves and the ends of the Body bore. remove the HYTORK Retractor Bolts and Taking one of the End Caps install its 'O' replace the Sealing Bolts (28) and seals (29). ring and insert it into the Body. Holding IMPORTANT : HYTORK Retractor Bolts the SAFEKEY close to the entry hole are made to a HYTORK design (cast identity letter C or D) to prevent specification for safety reasons. HYTORK kinking, insert the SAFEKEY into the can not take any responsibility for any hole and gently push into place. other design.

Sheet 4 of 4

7. Testing the HYTORK Actuator. Using compressed air at 80 - 100 psi (5.5 7 bar) check the seal areas with soapy water, ensuring there are no leaks and that the Pinion rotates smoothly over its full travel.

8. Testing and Cycling of Infrequently Used or Stored Actuators. Actuators not in current use (ie. Actuators in storage or stock and / or not operated for at least a 3 month period), should be cycled a minimum of ten times and tested against the possible 'pre-set' of the seals. This is a safety precaution recommended by the seal manufacturers.

9. Service. It is the policy of HYTORK to give the best possible service to our customers. We are happy to assist you in any way we can and if you have any questions about HYTORK Actuators and other HYTORK products please do not hesitate to any HYTORK VALVE AUTOMATION CENTER or your local HYTORK Stocking Distributor.

The information contained within this document is copyright © Hytork International Plc. And subject to change without notice. Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center. USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).