HKC ET Series Instruction manual

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 1 / 17 Valve Automation Leader, HKC
ETS/C Series Heavy-duty Pneumatic Actuators
Installation, Operation & Maintenance Manual
Address : 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, (15119), Republic of Korea
Tel : [phone], Fax : [phone], Home page : www.hkcon.co.kr, email : [email protected]
0045

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 2 / 17 Valve Automation Leader, HKC
Contents
1. Introduction .......................................................................................................................... 3
1.1. Purpose ................................................................................................................................ 3
1.2. Safety Notices ..................................................................................................................... 3
1.3. Product Identification ....................................................................................................... 4
1.4. Initial Inspection ................................................................................................................. 4
1.5. Storage ................................................................................................................................. 4
1.6. Installation ........................................................................................................................... 4
1.7. Maintenance ........................................................................................................................ 5
1.8. Service Support Items ....................................................................................................... 6
1.9. Lubrication Requirements ................................................................................................ 6
1.10. Tool Information ................................................................................................................ 6
1.11. Conveyance ......................................................................................................................... 6
2. Bill of Materials.................................................................................................................... 6
3. Mounting and Operating ................................................................................................... 7
3.1. Actuator Mounting ............................................................................................................ 7
3.2. Operating Pressure and Method .................................................................................... 7
3.3. Working Principle .............................................................................................................. 8
3.4. Working Principle with Add-on ...................................................................................... 9
4. Actuator Disassembly .......................................................................................................10
4.1. General Information ........................................................................................................ 10
4.2. Double Acting & Spring Return Actuator Disassembly ........................................... 10
5. Actuator Assembly ............................................................................................................11
5.1. General Information ........................................................................................................ 11
5.2. Double Acting & Spring Return Actuator Reassembly ............................................ 11
5.3. Actuator Testing ............................................................................................................... 13
6. Trouble Shooting Guide ...................................................................................................13
7. Actuator Module Weights ...............................................................................................14
8. Actuator O-ring Parts .......................................................................................................15
9. [Bolt & Nut Torque Table ...............................................................................................16
10. [Safe disposal of the end-of-life products ..................................................................16

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 3 / 17 Valve Automation Leader, HKC
1. Introduction
This manual is offered as a guide to performance, installation, operation, disassembly and after-service of the ET- series Double
Acting and Spring Return Module type models which are manufactured by HKC Co., Ltd. The enterprise and the maintenance team
responsible for the ET - series must read this manual and use other relevant instruction manuals for respective accessories such as
the Positioner, Limit Switch and Solenoid Valve.
The scotch yoke type, having no load under a poor air pressure, is designed of 3 point piston guide bars in order to maintain smooth
operations and to prevent the deformation of piston, hence optimizing the lifecycle of the product. Also, by using a semi-permanent,
pin-on-disk phosphor bronze and plastic TP 601 bushing material, any problems caused by leakage and wear may be prevented. In
addition, by applying special plastic bearings, which are specially lubricated, the frictional abrasion between cylinder and piston is
minimized therefore increasing durability. This allows for the compact design to produce high torque. Various sizes of actuators are
manufactured so that a wide range of torque outputs can be obtained (from 495Nm to 250,000 Nm in 8bar of air pressure). In order
to adhere accessories and valves easily, both the NAMUR and ISO Standards are applied in every adhering part.
1.1. Purpose
This installation, operation and maintenance manual explain how to install, operate and maintain the ET-series pneumatic
actuators.
1.1.1. The normal recommended service interval for the ET-series actuators is three years.
1.1.2. This procedure is applicable when all electrical power and pneumatic pressure has been removed from the actuator.
1.1.3. Remove all piping and mounted accessories that may interfere with the module(s) that are to be worked on.
1.1.4. This procedure should only be implemented by a technically competent technician who takes care to observe good
workmanship practices.
1.1.5. Products supplied by HKC, in its "as shipped" condition, are intrinsically safe if the instructions contained within this
Service Instruction are strictly adhered to and executed by well-trained, equipped, prepared and competent
personnel.
1.1.6. When removing seals from seal grooves, use a commercial seal removing tool or a small screwdriver with sharp
corners rounded off.
1.1.7. Use a non-hardening thread sealant on all pipe threads.
1.1.8. WARNING: Apply the thread sealant per the manufacturer’s instructions.
1.1.9. HKC CO., LTD. recommends that actuator disassembly should be performed in a clean area on a workbench where
possible.
1.2. Safety Notices
Safety notices in this manual outline precaution the user must take to reduce the risk of personal injury and damage to the
equipment. The user(s) must read these instructions before the installation, operation or maintenance of ET-series
pneumatic actuators.
Danger: Refers to personal safety and alerts the user to danger or harm.
The hazard or unsafe practice will result in severe injury or death.
Warning: Refers to personal safety. Alerts the user to potential danger.
Failure to follow warning notices could result in personal injury or death.
Caution: Directs the user’s attention to general precautions that, if not followed, could result in personal injury
and/or equipment damage .
Notes: Highlighted information is critical to the user’s understanding of the actuator’s installation and operation.
DANGER:
 For the protection of personnel working on HKC actuators, this procedure should be reviewed and implemented for
safe disassembly and reassembly. Close attention should be noted to the WARNINGS, CAUTIONS and NOTES
contained in this procedure.
 This procedure should not supersede or replace any customer's plant safety or work procedures. If a conflict
arises between this procedure and the customer's procedures, then the differences should be resolved in writing
between an authorized customer representative and an authorized HKC representative.
 Do not attempt to remove the pistons from the actuator body by using air pressure when the end caps have been
removed

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 4 / 17 Valve Automation Leader, HKC
1.3. Product Identification
The actuator name plate is located on the up side of the
body. The name plate contains the following:
1.3.1. Marking
① General
Logo (trade mark), Model,
Type, Fail position,
Manufactured year-month,
Fluid,
Design pressure/temp.,
Operating air pressure,
Hydrostatic test pressure,
[Manufacturer address & telephone number --- 18 r0]
② CE/PED certified body code
(TUV NORD CE0045)
1.3.2. Applied directive and Standard
① 2014/68/EU Annex III, Module H (reference : 2014/68/EU)
1.3.3. Certification range
① ETS/C085-DA/SR200 ~ ETS/C200- DA/SR735
Applicable temperature
-20 ~ 80℃ (Standard with NBR sealing),
-40~100℃ (Optional with HNBR sealing and with adjustable materials for low temp.)
② [Design Pressure : 9.99 bar (≒10 bar), ---- 17 Rev0]
Operation pressure : 8 bar max
1.3.4. Ordering information (example)
ET C/S 085 - SR 200 5 0 JS
C/S : Yoke type (C: Canted, S:Symmetric)
085: Model [(050, 065, 085, 100, 130, 160, 200, 270) --- 18 r0]
SR: Acting type (DA: Double acting, SR: Single acting, Spring return)
200: Cylinder diameter (200, 250, 300, 350, … 685, 735)
5: Operating pressure (3~8 bar)
0: Fail position (0-Fail close, 1-Fail open)
JS: Manual override (NA-Not applied, HO-Hydraulic override, JS-Jack screw)
1.4. Initial Inspection
Upon on the receipt of the actuator, the user should inspect the condition of the product and ensure that product
specification stated in the name plate matches with the order sheet.
1.4.1. Remove the packing wrap or wooden box carefully. Inspect the product for any physical damage that may have
occurred during shipment.
1.4.2. Check the product specification with product ordered. If a wrong product has been shipped, immediately inform to
our coordinator.
1.5. Storage
Actuators must be stored in a clean, cool and dry area. The unit should be stored with the air port openings sealed. Storage
must be off the floor, covered with a sealed dust protector. When actuators are to be stored outdoor, they must be stored
off the ground, high enough to prevent from being immersed in water or buried in snow.
1.6. Installation
1.6.1. During the installation, be careful so that dust and metal pieces do not enter the actuator through Inlet / Outlet port
(NPT tap). [In case of Single Acting type actuator and its dust plug face will be put to upside, there may be
permeated rain water into cylinder inside. If the actuator will be use in outdoor operation, the dust plug face shall be
installed to sideway or bottom direction using elbow or U-shape air pipe in order to prevent from permeating
rainwater into cylinder. Suitable installation direction is responsible to user and/or installer. --- 18 r0]

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 5 / 17 Valve Automation Leader, HKC
1.6.2. [When connecting air pipe to NPT tap, pitting with a kind of PT taps shall not be use, as a results of a cause of
damage and/or leakage because there are difference of thread angle. Therefore pitting shall be only use NPT thread
ones. ---- 18 r0]
1.6.3. Speed controllers have to be used only for controlling speed in opening / closing. Regulator cannot be used for the
same purpose.
1.6.4. In case of air supply in the product, it is a general rule to use dry air without any dust.
1.6.5. The temperature around the actuators must be below 80°C. If the temperature is over 80°C, smooth operation
cannot be guaranteed. For use in low temperatures, consult the manufacturer prior to order.
1.6.6. Shock and overpower from external forces should not be applied to the actuators.
1.6.7. It is a general rule to use separate lubricate oil in the actuators but not excessively. To protect the actuators, the ISO
VG32 is recommended as the lubricate oil.
1.6.8. Check all the bolts and correctly tighten them if necessary.
1.6.9. Close checking and cleaning should be carried out over once a year periodically, not only during operation but also
during shutdown.
1.6.10. If air is let out inside/ outside for a long time, the o-ring sliding parts may be worn out. So, in case of air leakage,
replace or repair immediately when detected.
1.7. Maintenance
For the maintenance of the actuators, there should not be any air or electrical leaks. Periodical checking should be carried
out regardless of whether joints always seemed fastened. For optimal working life of the actuators, it is necessary to use
enough lubrication oil. The inner seal should be replaced periodically. When there is a need for repairing tools (including
seals), they can be purchased through agreed representative(s). In the case of spring return actuators, as repeated
condensed power is added on the spring, output torque is reduced due to change of spring length in long term operation.
The spring set can be purchased at any time via the head office:
Table 1-1. HKC Co., Ltd. Contact Information
CAUTION:
 Turn off all power services before attempting to perform any service on the actuator.
 POTENTIAL HIGH PRESSURE VESSEL. Before removing or disassembling your actuator, ensure that the valve or
other actuated devices are isolated and not under pressure.
Perform maintenance procedures, under normal conditions, in six month intervals. But when conditions are more severe,
more frequent inspections is advised.
1.7.1. Ensure that the actuator is properly aligned with the valve or other actuated device
1.7.2. Ensure that all screws are present and tight
1.7.3. Ensure that air supply connections are installed properly
1.7.4. Check that the supply pressure of the operating media is in the required range
1.7.5. Check the enclosure of O-ring seals and verify that the O-rings are not pinched between flanges
1.7.6. Visually inspect the open/close cycle
1.7.7. Inspect the identification labels for wear and replace it if necessary
Tel. [phone]
Fax. [phone] / 8696
Homepage www.hkcon.co.kr
Email [e-mail]
Address 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, (15119), Republic of Korea
< Direction of Dust Plug Installation >
Make sure to avoid
upside direction
Install to sideway or
bottom direction

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 6 / 17 Valve Automation Leader, HKC
1.8. Service Support Items
Spare parts are used on all the models, repeated and single working equally. In the case
of returned spring models, added spare parts should be used as shown in Table 1-2. All
seals, bearings, and parts are not able to be re-used as spare parts.
1.9. Lubrication Requirements
CAUTION: Due to safety measures, alternative lubricants should not be used without written recommended of HKC Co.,
Ltd.
The ET-Series is a totally enclosed unit with permanent lubrication in the actuator. Once installed, lubrication should not be
required (an exception is Table 1-2). However, periodic preventative maintenance will extend the operating life of the actuator.
Lubrication Points
1. Cylinder Body 2. Piston Seals 3. End Cover Seals 4. Drive Shaft Seals
Table 1-3. Grease Specification
Manufacturer Shell
Product Bearing Grease (Low Temp)
Color Brown
Model No Shell DARINA GREASE R2
ISO NLGI2
Additional grease is required on the following conditions (see Table 1-4).
Table 1-4. Additional Grease
1. Humidity Moisture found inside pipeline (water ingress and/or condensation)
2. Cycle Frequency of operation is
- over 100,000 cycle times per year
- less than 3 cycle times per year
3. High Temp. [Over 60℃ ambient temperature ---- 18 r0]
1.10. Tool Information
1. Allen key set 6. L-screwdrivers
2. Oblate spanner set 7. Adjustable monkey wrench
3. Snap ring clip 8. Impact end wrench set
4. Rubber or leather mallet 9. Impact socket
5. Air impact wrench
Note: [All of the tools are specified in metric standards --- 18 r0]
1.11. Conveyance
1.11.1. Ensure the actuator is fully vented and decontaminated before conveyance.
1.11.2. Pay attention in shock.
1.11.3. Ensure all power supplies are removed before conveyance.
2. Bill of Materials
Table 1-2. Spare Parts
1. All Seals
2. Washer
3. Back up Ring

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 7 / 17 Valve Automation Leader, HKC
No
Part Name
Material
No
Part Name
Material
1 Housing Ductile Iron 26 Seals Retainer Bolt Alloy Steel
2 Housing Cover Alloy Steel 27 Piston Rod Alloy Steel
3 Position Indicator SUS 28 Piston Guide Bar Alloy Steel
4 Upper Bushing O-ring NBR 29 Tie Rod Alloy Steel
5 Upper Bushing BSC 30 Piston Alloy Steel
6 Yoke Alloy Steel 31 Piston O-ring NBR
7 Lower Bushing O-ring NBR 32 Piston Guide Bushing [TP 601 Oilon--18r0]
8 Lower Bushing BSC 33 Rod Washer Alloy Steel
9 Snap-ring Alloy Steel 34 Rod Lock Nut Alloy Steel
10 Slide Bearing Alloy Steel 35 Back-up-ring PTFE
11 Slide Pin Alloy Steel 36 Cylinder End Cover Alloy Steel
12 Cover Fixed Pin Alloy Steel 37 Lifting Lug Plate Alloy Steel
13 Cover Bolt Alloy Steel 38 Tie Rod Washer Alloy Steel
14 Slide Block Alloy Steel 39 Tie Rod Nut Alloy Steel
15 Guide Bar Alloy Steel 40 Spring Case Front Cover Alloy Steel
16 Guide Bushing DU Dry Bushing 41 Spring Rod Guide Bushing [TP 601 Oilon---18r0]
17 Travel Stopper Bolt Alloy Steel 42 Spring Case Carbon Steel
18 Travel Stopper Nut Alloy Steel 43 Spring Alloy Steel
19 Travel Stopper Washer Alloy Steel 44 Spring Rod Alloy Steel
20 Cylinder Front Cover Alloy Steel 45 Spring Retainer Alloy Steel
21 Cover O-ring NBR 46 Rod Adjust Nut Alloy Steel
22 Front Cover Bushing [TP 601 Oilon---18r0] 47 Spring Case End Cover Alloy Steel
23 Rod Seals PTFE 48 Cap Alloy Steel
24 Road Seals O-ring NBR 49 Cap Bolt Alloy Steel
25 Piston Rod O-ring Retainer Alloy Steel 50 Cylinder Alloy Steel
---- 18 rev0]
3. Mounting and Operating
3.1. Actuator Mounting
CAUTION: Do not attempt to work on your HKC actuator without first shutting off its incoming power, compressed air &
related internal piping fluid.
Note: Prior to mounting, the part-turn actuator must be checked for any damage. If something of damaged parts must be
replaced by original spare parts.
3.1.1. Mounting is most easily done with the valve shaft pointing vertically upward. But mounting is also possible in any
other position; the actuator may be mounted in any position.
3.1.2. The ET-series pneumatic actuators are supplied with a female drive output. The ISO5211 bolt patterns are provided
for actuator mounting. The actuator drive bush is removable for ease of machining.
3.1.3. It is mandatory for the actuator to be firmly secured to a sturdy mounting bracket or directly mounted to the valves’
ISO mounting pad. High tensile bolts or studs with spring locking washers must be used.
3.1.4. The valve output shaft must be in lined with the actuator output drive to avoid side-loading the shaft. To avoid any
backlash, flexibility in the mounting bracket or mounting should not be allowed.
3.2. Operating Pressure and Method
3.2.1. The maximum operating Air supply pressure should not exceed 8 bar (115psi). The air supply should be clean, dry
and lubricated. The following Table 3-1 contains information regarding appropriate tube size which will provide
enough air each actuator.
Table 3-1. Actuator Model and Tube Size
Cylinder Size Inside-diameter of Tube
Ø 130 - 180 3/8 NPT
Ø 200 - 300 1/2 NPT
Ø 335 - 485 3/4 NPT
Ø 535 - 785 1 NPT
Ø 835 - 1250 1


NPT
CAUTION: Before using an alternative air supply that is not of instrument quality, please consult with HKC Co., Ltd.
Notes : Port size of air supply may be changed in order to meet with customer’s requirement such as operating time.

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 8 / 17 Valve Automation Leader, HKC
3.3. Working Principle
3.3.1. Adjustment of the angle of Double Acting Actuator
① Adjust the angle ± 5 degree with two bolts when the piston is operated back and forth at 90 degree
② If you want to adjust the travel stops, first unfasten cap nut slightly and operate with a spanner and then re-adjust.
3.3.2. Double Travel working principle and solenoid valve attachment
① When air is provided to center of the cylinder through port B of the actuator, piston moves forward due to the air
pressure. The rod, which is connected with piston, delivers power to the Yoke. During this time, as the Yoke turns
clockwise, the valve shaft is closed. Additional air is vented out from port A.
② Inversely to ①, air is provided to the center of the cylinder through port A of the actuator. Everything basically
operates in the opposite steps to ①
The operating principle and adjustment of the common assembly is as follows. Refer to Figure 3-1 below.
Figure 3-1a. Operating Principle and adjustment of the common assembly
Figure 3-1b. Operating Principle and adjustment of the common assembly
Option : Double Acting(Dual Cylinder).
Figure 3-1c. Open Mode Operating Principle Option : Double Acting(Dual Cylinder).
Supply air to port A : Actuator Open
Figure 3-1d. Close Mode Operating Principle Option : Double Acting(Dual Cylinder).
Supply air to port B : Actuator Close

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 9 / 17 Valve Automation Leader, HKC
3.4. Working Principle with Add-on
This section explains the working principle of the Spring Return Actuator and solenoid valve attachment. When air is
provided to the center of cylinder through port A of the actuator, piston moves “outwards” due to air pressure. The rod is
connected with the piston which delivers power to the Yoke and during this time the Yoke turns counter-clockwise. This
changes the valve shaft to the open position. The power is delivered to the Yoke and spring rod compresses the spring thus
opening valve shaft. When the air is sent out through port A, the piston moves due to the compressed spring, and then the
Yoke operates clockwise hence valve shaft closes. The Spring Return Open/Close operating diagrams (Figure 3-2a and
Figure 3-2b) is as shown below.
Figure 3-2a. Open Mode Operating Principle / Fail Close
Figure 3-2b. Close Mode Operating Principle / Fail Close
Figure 3-3a. Close Mode Operating Principle / [Fail Open ---- 17 Rev0]
Figure 3-3b. Open Mode Operating Principle / [Fail Open ---- 17 Rev0]

ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HumG-ET-21 E Rev0 Page 10 / 17 Valve Automation Leader, HKC
4. Actuator Disassembly
4.1. General Information
CAUTION:
 Turn off all power services before attempting to perform any service on the actuator.
 POTENTIAL HIGH PRESSURE VESSEL. Before removing or disassembling your actuator, ensure that the valve or other
actuated devices are isolated and not under pressure.
DANGER:
 Before work commences, ensure that explosive and/or noxious gases/liquids are fully vented from the actuator and confirm
the use of appropriate measuring equipment. It is possible that the actuator may contain dangerous gases and/or liquids.
Ensure that all safety measures have been taken to prevent exposure or release of these types of contaminants before
commencing any work. The Actuator Disassembly section has been written to guide through either complete disassembly of
the entire actuator or individual module disassembly as needed (Pneumatic Power Module or Drive module only). Consult
HKC before attempting any potentially dangerous procedures.
 Do not remove the Spring Module while the spring is compressed. Follow all instructions written on the warning tag (wired to
the actuator cover)
 Where actuators are equipped with a spring cartridge mounted manual override or stroke adjuster, ensure any air or
electrical equipment are moved or isolated and double check that the manual override is set to the auto position.
4.2. Double Acting & Spring Return Actuator Disassembly
4.2.1. Double Acting Actuator Disassembly
CAUTION:
 Review the instructions and dangers in section 4.1
 For details regarding the '#No' keys, refer to the Bill of Materials in section 2
WARNING:
Ensure that the air supply is isolated and any remaining pressure is vented before disassembly of the actuator.
While removing the yoke shaft pin, care should be taken to avoid dropping it into the cylinder. This may cause damage to
the internal bore coating, and air leakage.
① [Disconnect pneumatic and electric supplies.
② Remove air supply block sets from cylinder unit
③ Remove nuts and washers of the tie rod end from the cylinder unit (No 29,38,39)
④ Remove end cover from the cylinder unit. (No 36)
⑤ Remove cylinder from the body. (No 50)
⑥ Remove rod lock nut and rod washer from piston. (No 33,34)
In case of 635 and over, remove prior to piston guide bar from the piston. (No 28)
⑦ Remove piston from piston rod. (No 27,30)
⑧ Take off rod seal retainer and rod seal from front cover. (No 20,25,23)
⑨ Remove front cover from housing. (No 20, 1)
⑩ Remove position indicator from housing unit, and separate housing cover (No 1, 3, 2)
⑪ Loosen piston rod fixing bolt from slide block and separate piston rod. (No 14, 27)
⑫ Remove guide bar from housing. (No 1,15)
⑬ Pull off yoke and upper bushing from housing. (No 1,6,4,5)
⑭ Pull off lower bushing from housing. (No 1,7,8)
⑮ Remove protection cover from housing which located to opposite side of cylinder. (No 1)
The protection cover is only applied when doesn’t have anything of attachment in opposite side of cylinder.
○
16 Loosen stopper bolts and nuts about 60 mm from housing. (No 1,18,17)
○
17 Disassemble yoke unit
 Pull out snap rings (or fixing washers) from both side of slide pin.
 Remove slide bearing from the slide pin.
 Pull off the slide pin from slide block.
 Separate slide block from yoke.--- 18 r0]
4.2.2. Spring Return Actuator Disassembly
CAUTION: Review the instructions and warnings in section 4.1 before proceeding the disassembly of the Spring Return
type Actuator
DANGER: Ensure that the air supply is isolated and any remaining pressure is vented before disassembly of the actuator
① Disconnect pneumatic and electric power supplies.
② [Separate between cylinder unit and air supply block (if it were installed).
③ Vent completely remained air from the cylinder.