2 IntroductionThere are many applications whereit can be a benefit to operate theActuators using pressurised waterinstead of compressed air. Thiscan be particularly useful in remoteareas where compressed air isnot available.

The most common situation is whenusing mains water supply which isnormally in the pressure range from60-100psi (4 - 7 bar).

Standard XL Actuators have beenused successfully in many waterapplications but HYTORKrecommends that XLW Actuators areused in this application to assuresmooth and reliable operation.

HYTORK XLW Actuators arespecifically prepared for operating bywater. This preparation is concernedwith corrosion protection, bearingsand the preventing the ingress ofparticles with the water.Contaminated water can causedamage to the Actuator Seals andbearing areas and reduce theoperating efficiency and Actuator life.

3 CorrosionProtection3.1 Aluminium Components.Aluminium body components onHYTORK’S standard XL Actuators aretreated with CERAMIGARD, a uniqueDi-Aluminium Tri-Oxide (AL2O3) surfacetreatment, which provides a hard,corrosion resistant, ceramic-likecoating protecting all body partsagainst wear and corrosion.

This CERAMIGARD finish is particularlyefficient in water applications andmany years of site experience with

HytorkDossierInstallation,

Operating andMaintenanceInstructions

1

MAC099813

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89

10

1112

XLW SeriesWater Operated

Actuators

Types: EDNWEIAW

EDFW

ContentsImportant Safety Procedures

IntroductionCorrosion Protection

DURASTRIP ‘W’ BearingsOperating Media

Piping InstructionsMounting and

Operating InstructionsSpeed of Operation

Maintenance RequirementsTesting and Cycling of

Infrequently Used orStored Actuators

Spares KitsService

1 Important SafetyProceduresWhen carrying out maintenanceon XLW Actuators follow thespecific XLW instructions given inthis Dossier (MACxxxxx1) and thegeneral XL instructions given inHytork I, O & M DossierMACxxxxx1.

Qualified maintenance personnelshould read and follow thesestraightforward instructions.

Always disconnect the Air oralternative Operating Pressure andElectrical Supplies before carrying out any form of maintenance on an Actuator.

On Spring Return models alwayscontain the Spring Tension withHYTORK Retractor Rods as explainedin HYTORK Dossier MACxxxxx1.Follow instructions for using theRetractor Rod carefully.

Never attempt to remove the pistonsfrom the Actuator body by using airor other pressure mediums when theEnd Caps have been removed.

Do not shorten or distort theSAFEKEYS; correct length SAFEKEYSare supplied with the Spares Kit.

When replacing items use onlyHYTORK authorised components.

Numbers in brackets (#) refer to partson the exploded XLW diagram (Fig. 1).

Read the relevant sectionscarefully before continuing.

Installation, Operating and M

aintenance Instructions XLW

Series Water O

perated Actuators M

AC099813

QualityAssured

registeredmanagement

systemsto ISO 9001

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2

bm

bm

bm

bobpbq

bobp

br

bsbt

bt

bk9

9

7

8

76

34

2

2

2

bl

bn

bn

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Fig. 1

DoubleActing

SpringReturn

water operation and water in air lineshas shown excellent protectionagainst corrosion.

3.2 Pinion. (4)The finish on the Pinion will, in mostcases, be the standard XL treatment.There are certain applications (as withhigh chlorine concentrations, forexample) where one of the HYTORK

CORROGARD Fluropolymertreatments may be more suitable.HYTORK will be pleased to give exactdetails of the finish required once thespecification of the water is known.

3.3 Spring Return Actuators.The Springs are protected by anElectro Phoretic finish as standard.

3.4 External Surface Finish.The externals of all XLW Actuatorsare treated with a long cure, two partepoxy coating to provide extraprotection against aggressiveenvironments.

Differences betweenPart the Standard XL No. Component Quantity and XLW Models

1 Travel stops & Seals 2 Standard XL2 End Caps 2 Standard XL3 Pistons 2 Standard XL4 Pinion 1 Standard XL or

CORROGARD Finish5 Body 1 Standard XL6 SAFEKEY & ‘O’ Rings 2 Standard XL

Differences between Standard XL and XLW ActuatorsDifferences between

Part the Standard XL No. Component Quantity and XLW Models

7 Springs* 2, 3 or 4 Standard XL8 Retractor Caps* 2 Standard XL9 Pinion Radial Bearings 2 DURASTRIP ‘W’ bk Piston Bearings 2 DURASTRIP ‘W’ bl Piston ‘O’ Rings 2 Standard XLbm End Cap ‘O’ Rings 2 Standard XLbn Pinion ‘O’ Rings 2 Standard XLbo Thrust Bearings 2 DURASTRIP ‘W’ bp Steel Thrust Washers 2 Standard XLbq Snap Ring (Circlip) 1 Standard XLbr Position Indicator 1 Standard XLbs Sealing ‘O’ Ring* 2 Standard XLbt Sealing Bolts* 2 Standard XL

*Spring Return models only

2

4 DURASTRIP‘W’ BearingsContinuous immersion in water willcause the standard XL Bearing towear prematurely. To maximiseActuator Bearing life DURASTRIP ‘W’ Bearings are used.

5 Operating Media5.1 Operating Media.XLW Actuators can be operated byclean air or filtered water. The watermust be clean and free from anyparticles that could damage the Sealsor score the Actuator cylinders.Solenoid directional control Valvesrequire a clean operating media andany form of contamination may causethe spool to stick.

5.2 Water Filtration.It is recommended that a filter of 10 microns be used on all watersupplies. Failure to use clean waterwill reduce Actuator life and maycause malfunction of both theActuator 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 pressuresshould be adhered to unless HYTORKhas given specific authorisation inwriting that this may be increased.The fact that water is virtuallyincompressible means that it may bepossible to utilise higher pressures incertain applications. If you have anapplication where higher operatingpressures are required please consultHYTORK with full details for anassessment to be made.

Fig. 2a

Fig. 2b

6 PipingInstructions (Fig. 2a & 2b)

All Actuators can be either piped withsolid or flexible tubing with theSolenoid Valve mounted remotelyfrom the Actuator or by mounting theSolenoid DIRECTLY onto the NAMURmounting pad on the side of theActuator. (ONLY Solenoids made tothe NAMUR standard can be mountedin this way.)

6.1 Solenoid Valves.Care must be taken to ensure thatSolenoid directional control Valvesused on water applications aredesigned for this purpose. For thebest possible performance it isrecommended that the internalporting of Solenoid Valves is as large as possible.

6.2 Direct Acting Low Cv Solenoid Valves.Low Cv (direct acting) Solenoid Valvesmust not be used even on smallActuators as the small port sizes andlow spring forces used in this designof Valve will cause problems.

6.3 HYTORK CATS Solenoid valves.The CATS Solenoid Valve MUST NOTBE used on water applications withSpring Return Actuators. The Springchamber must be allowed to vent toatmosphere.

7 Mountingand OperatingInstructions (Refer to Fig. 1)

7.1 Actuator to Valve Installation.The mounting hole sizes and bolt holecircle of the holes are to ISO 5211.These holes are ISO METRIC COARSEon metric models (UNC COARSE onUSA models) as standard. Whenmounting the Actuator to a Valveusing a Mounting Kit, the Pinion drive,coupling device and Valve stemshould be centred and concentric to prevent any side loading to thebottom Pinion Radial Bearing.

Ensure that the square shaft or driveadaptor to be operated is a close, butfree sliding fit, to the female drive inthe Actuator shaft (4).

8 Speedof OperationWater used as the operating mediumreduces the operating speedconsiderably. The actual time willdepend on the Cv of the SolenoidValve used and the friction lossesalong the pipe. Small diameter and/orlong pipes will increase these lossesand reduce operating speedssignificantly.

8.1 Speed control.Water is virtually incompressiblewhich makes it ideal for accuratespeed control. Always ensure thatany speed adjustment is of theexhaust water.

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MAC099813

9 MaintenanceRequirementsIt is recommended that XLWActuators that have been operated bywater be overhauled after 250,000cycles. Follow the instructions inHYTORK DOSSIER MACxxxxx1 andask for the XLW Spares Kit.

9.1 Spares Recommendations.When disassembling and carrying outmaintenance work on an XLWActuator, HYTORK recommends thata HYTORK XLW Spares Kit is usedreplacing all ‘O’ Rings, DURASTRIPBearings, washers etc. This kit is onlyavailable from HYTORK or itsStocking Distributors.

10 Testing andCycling ofInfrequentlyUsed or StoredActuators Actuators not in current use (ie:Actuators in stores or stock and/ornot operated for at least a 3 monthperiod), should be cycled a minimumof ten times and tested against thepossible ‘pre-set’ of the seals.

11 Spares KitsXLW Actuators Contents List:1 x I, O & M (XL) Instructions1 x I, O & M (XLW) Instructions2 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)

12 ServiceIt is the policy of HYTORK to give the best possible service to ourcustomers. We are happy to assistyou in any way we can and if you have any questions about HYTORKActuators or other HYTORK Productsplease do not hesitate to contact oneof HYTORK’S VALVE AUTOMATIONCENTERS or your local HYTORKStocking Distributor.

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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 totallyinvalidates all

warranties.

Important:We have endeavoured

in this publication tomake the contents asaccurate as possible,

but being given asgeneral information, it

is not to be taken asbinding unless

specifically confirmedin writing. Due to

Hytork's continuingcommitment to

engineered productadvancement, the

product specificationsand data presented in

this publication aresubject to change

without notice.

Hytork Controls Inc.Valve Automation Center Tel: [+1] (813) 630 22559009 King Palm Drive Fax: [+1] (813) 630 9449Tampa, Florida 33619 Email: hcisales@hytork.comUSA http://www.hytork.com

Hytork Controls Australian Operations25 South Street Tel: [+61] (2) 9841 2414Rydalmere Fax: [+61] (2) 9684 6439NSW 2116 Email: hcpsales@hytork.comAustalia http://www.hytork.com

Hytork Controls EuropeValve Automation Center 6 Bracken HillSouthwest Industrial Estate Tel: [+44] (0191) 5180020Peterlee Fax: [+44] (0191) 5180032County Durham Email: hcesales@hytork.comSR8 2LS UK http://www.hytork.com

Hytork Controls EuropeRyeford Road South Kings Stanley Tel: [+44] (01453) 827710Stonehouse Fax: [+44] (01453) 827714Gloucestershire Email: hcesales@hytork.comGL10 3HG UK http://www.hytork.com

Part of the Hytork International plc Group

QualityAssured

registeredmanagement

systemsto ISO 9001