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XLW Series Water Operated
Valve Actuator |
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Installation, Operating and Maintenance
Instructions
Types: EDNW EIAW EDFW
| TABLE OF
CONTENTS |
| 1 |
Important Safety
Procedures |
| 2 |
Introduction
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| 3 |
Corrosion Protection
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| 4 |
DURASTRIP 'W' Bearings
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| 5 |
Operating Media
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| 6 |
Piping Instructions
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| 7 |
Mounting and Operating
Instructions |
| 8 |
Speed of Operation
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| 9 |
Maintenance
Requirements |
| 10 |
Testing and Cycling of
Infrequently Used or Stored Actuators |
| 11 |
Spares Kits
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| 12 |
Service |
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1. Important Safety Procedures |
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When carrying out maintenance on XLW Actuators follow the specific XLW
instructions given in this Dossier and the general XL instructions given
in Hytork® Dossier Installation, operating and maintenance instructions.
Qualified maintenance personnel should read and
follow these straightforward instructions.
- Always disconnect the Air or alternative
Operating Pressure and Electrical Supplies before carrying out any
form of maintenance on an Actuator.
- On Spring Return models always contain the
Spring Tension with HYTORK® Retractor Rods as explained in HYTORK®
Dossier. Follow instructions for using the Retractor Rod carefully.
- Never attempt to remove the pistons from the
Actuator body by using air or other pressure mediums when the End Caps
have been removed.
- Do not shorten or distort the
SafeKeys; correct length
SafeKeys are supplied with the Spares kit.
- When replacing items use only HYTORK® authorised
components.
Numbers in brackets (#) refer to parts on the
exploded XLW diagram (Fig.1)
- Read the relevant sections carefully before
continuing.
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2. Introduction |
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There are many applications where it can
be a benefit to operate the Actuators using pressurised water instead of
compressed air. This can be particularly useful in remote areas where
compressed air is not available.
The most common situation is when using mains water supply which is
normally in the pressure range from 4 - 7 bar (60-100psi).
Standard XL Actuators have been used successfully in many water
applications but Hytork® recommends that XLW Actuators are used in this
application to assure smooth and reliable operation.
Hytork® XLW Actuators are specifically prepared for operating by water.
This preparation is concerned with corrosion protection, bearings and
the preventing the ingress of particles with the water. Contaminated
water can cause damage to the Actuator Seals and bearing areas and
reduce the operating efficiency and Actuator life.
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3. Corrosion Protection |
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Aluminium Components:
- Aluminium body components on
Hytork®'s standard XL Actuators are treated with
CERAMIGARD,
a unique Di-Aluminium Tri-Oxide (AL203)
surface treatment, which provides a hard, corrosion resistant,
ceramic-like coating protecting all body parts against wear and
corrosion.
This CERAMIGARD finish is particularly efficient in water applications
and many years of site experience with water operation and water in
air lines has shown excellent protection against corrosion.
Pinion: (4)
- The finish on the Pinion will,
in most cases, be the standard XL treatment. There are certain
applications (as with high chlorine concentrations, for example) where
one of the HYTORK® CORROGARD Fluropolymer treatments may be more
suitable. HYTORK® will be pleased to give exact details of the finish
required once the specification of the water is known.
Spring Return Actuators:
- The Springs are protected by an
Electro Phoretic finish as standard.
External Surface Finish:
- The externals of all XLW Actuators are
treated with a long cure, two part epoxy coating to provide extra
protection against aggressive environments.
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Differences Between Standard XL and XLW Actuators |
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Part No.
|
Component |
Quantity
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Differences between
the Standard XL and XLW Models |
|
1
|
Travel stops
& Seals |
2
|
Standard XL |
|
2
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End Caps |
2
|
Standard XL |
|
3
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Pistons |
2
|
Standard XL |
|
4
|
Pinion |
1
|
Standard XL or CORROGARD
finish |
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5
|
Body |
1
|
Standard XL |
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6
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SAFEKEY & 'O' Rings |
2
|
Standard XL |
|
7
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Springs* |
2, 3 or 4
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Standard XL |
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8
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Retractor Caps* |
2
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Standard XL |
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9
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Pinion Radial Bearings |
2
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DURASTRIP 'W' |
|
10
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Piston Bearings |
2
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DURASTRIP 'W' |
|
11
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Piston 'O' Rings |
2
|
Standard XL |
|
12
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End Cap 'O' Rings |
2
|
Standard XL |
|
13
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Pinion 'O' Rings |
2
|
Standard XL |
|
14
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Thrust Bearings |
2
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DURASTRIP 'W' |
|
15
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Steel Thrust Washers |
2
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Standard XL |
|
16
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Snap Ring (Circlip) |
1
|
Standard XL |
|
17
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Position Indicator |
1
|
Standard XL |
|
18
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Sealing 'O' Ring* |
2
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Standard XL |
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19
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Sealing Bolts* |
2
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Standard XL |
*Spring Return models only
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4. Durastrip Bearings |
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DURASTRIP 'W' Bearings
- Continuous immersion in water
will cause the standard XL Bearing to wear prematurely. To maximise
Actuator Bearing life DURASTRIP 'W' Bearings are used.
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5. Operating Media |
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XLW Actuators can be operated by clean air or filtered water. The water
must be clean and free from any particles that could damage the Seals or
score the Actuator cylinders. Solenoid directional control Valves
require a clean operating media and any form of contamination may cause
the spool to stick.Water
Filtration.:
- It is recommended that a filter
of 10 microns be used on all water supplies. Failure to use clean
water will reduce Actuator life and may
cause malfunction of both the Actuator
and directional control Valve.
- 5.3 Maximum Operating Pressure
- XL models 45 to 2585
- Do not exceed 8.3 bar (120 psi)
- XL models 4580
- Do not exceed 7 bar (100 psi)
The normal XL operating pressures should
be adhered to unless HYTORK® has given specific authorisation in writing
that this may be increased. The fact that water is virtually
incompressible means that it may be possible to utilise higher pressures
in certain applications. If you have an application where higher
operating pressures are required please consult HYTORK® with full details
for an assessment to be made. |
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6. Piping Instructions |
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 All
Actuators can be either piped with solid or flexible tubing with the
Solenoid Valve mounted remotely from the Actuator or by mounting the
Solenoid DIRECTLY onto the NAMUR mounting pad on the side of the
Actuator. (ONLY Solenoids made to the NAMUR
standard can be mounted in this way.)
(Fig. 2a & 2b)
6.1
Solenoid Valves
- Care must be taken to ensure that Solenoid
directional control Valves used on water applications are designed for
this purpose. For the best possible performance it is recommended that
the internal porting of Solenoid Valves is as large as possible.
6.2 Direct Acting Low Cv Solenoid Valves
- Low Cv (direct acting) Solenoid Valves MUST NOT
BE used even on small Actuators as the
small port sizes and low spring forces used in this design of Valve
will cause problems.
6.3
Hytork®
CATS Solenoid valves
- The CATS Solenoid Valve MUST NOT BE used on
water applications with Spring Return Actuators. The Spring chamber
must be allowed to vent to atmosphere.
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7. Mounting and Operating Instructions |
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7.1
Actuator to Valve Installation (Refer to Figure 10
- The mounting hole sizes and bolt hole circle of
the holes are to ISO 5211. These holes are ISO METRIC COARSE on metric
models (UNC COARSE
on USA
models) as standard. When mounting the Actuator to
a Valve using a Mounting Kit, the Pinion drive, coupling device and
Valve stem should be centered and concentric to prevent any side
loading to the bottom Pinion Radial Bearing.
Ensure that the square shaft or drive adapter to be
operated is a close, but free sliding fit, to the female drive in the
Actuator shaft (4).
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8. Speed Of Operation |
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Water used as the operating
medium reduces the operating speed considerably. The actual time will
depend on the Cv of the Solenoid Valve used and the friction losses
along the pipe. Small diameter and/or long pipes will increase these
losses and reduce operating speeds significantly.
8.1
Speed control
- Water is virtually incompressible
which makes it ideal for accurate speed control. Always ensure that
any speed adjustment is of the exhaust water.
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9. Maintenance Requirements |
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It is recommended that XLW
Actuators that have been operated by water be overhauled after 250,000
cycles. Follow the instructions in HYTORK® DOSSIER MXL029501 and ask for
the XLW Spares Kit.
9.1 Spares Recommendations
- When disassembling and carrying out
maintenance work on an XLW Actuator, HYTORK® recommends that a HYTORK®
XLW Spares Kit is used replacing all 'O' Rings, DURASTRIP Bearings,
washers etc. This kit is only available from HYTORK® or its Stocking
Distributors.
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10. Testing and Cycling |
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Actuators not in current use (ie: 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.
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11. Spare Kits |
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XLW Actuators Contents List:
1 x I, O & M (XL) -lnstructions
1 x I, O & M (XLW) -Instructions
2 x SAFEKEY Assemblies (6)
2 x SAFEKEY Seal 'O' Rings (6)
2 x Piston DURASTRIP 'W' Bearing Strips (10)
2 x Steel Thrust Washers (15)
1 x Pinion top 'O' Ring (13)
1 x Pinion top DURASTRIP'W' Radial Bearing Strip (9)
2 x DURASTRIP 'W' Thrust Bearing (14)
1 x Pinion bottom 'O' Ring (13)
1 x Pinion bottom Radial DURASTRIP 'W' 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)
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12. Service |
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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 contact one of Hytork®'s
VALVE AUTOMATION CENTERS
or your local Hytork® Stocking Distributor.
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