HKC HP Series Instruction manual

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 1 / 18 Valve Automation Leader HKC
HP Series Pneumatic Actuator
Installation, Operation & Maintenance Manual

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 2 / 18
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. LUBRICATION REQUIREMENTS ............................................................................................................................................... 5
1.9. TOOL INFORMATION ................................................................................................................................................................ 6
1.10. CONVEYANCE............................................................................................................................................................................ 6
1.11. SUPPLY AIR VOLUME ................................................................................................................................................................ 6
1.12. OPERATING TIME ...................................................................................................................................................................... 7
1.13. WEIGHT ..................................................................................................................................................................................... 7
2. BILL OF MATERIALS ......................................................................................................................... 7
3. MOUNTING AND OPERATING........................................................................................................... 8
3.1. ACTUATOR MOUNTING ........................................................................................................................................................... 8
3.2. OPERATING PRESSURE AND METHOD .................................................................................................................................. 9
3.3. PRINCIPLES OF OPERATION .................................................................................................................................................... 9
4. ASSEMBLY .................................................................................................................................... 10
4.1. ASSEMBLY OF ACCESSORIES & VALVE ...............................................................................................................................10
4.2. OPEN/CLOSE ADJUSTMENT .................................................................................................................................................12
4.3. HP SERIES SPRING SETS ......................................................................................................................................................13
5. DISASSEMBLY ............................................................................................................................... 14
5.1. ACTUATOR TESTING ..............................................................................................................................................................15
6. TROUBLE SHOOTING GUIDE .......................................................................................................... 15
7. DIMENSION ................................................................................................................................... 16
7.1. TOP MOUNTING CONNECTION ............................................................................................................................................17
7.2. BOTTOM MOUNTING CONNECTION....................................................................................................................................17

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 3 / 18
1. Introduction
The manufacturer owns the present publication.
This instruction manual contains important information regarding the installation, operation,
maintenance and storage for HP Series rack and pinion pneumatic actuator.
HP series actuators are compact, high cycle, high quality pneumatic double rack & pinion pneumatic
actuator specifically designed to meet the demanding needs of the quarter turn valve automation
market.
HP actuators provide a wide range of torque outputs to suit quarter turn ball, butterfly, plug and
damper valves, together with the APL range of valve position monitors for complete valve automation
solutions.
Quality has been our primary concept in actuator development, the latest manufacturing technologies
have been employed to provide both quality and performance on every HP actuator produced.
1.1. Purpose
This installation, operation and maintenance manual explain how to install, operate and
maintain the HP-series pneumatic actuators.
1.1.1. The normal recommended service interval for the HP-series actuators is one 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
1.2.1. Safety notices in this manual outline precautions 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 HP-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:
n
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.
n
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

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 4 / 18
resolved in writing between an authorized customer representative and an authorized HKC
representative.
n
Do not attempt to remove the pistons from the actuator body by using air pressure when the end caps
have been removed
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 & temperature, Operating air pressure, Hydrostatic test pressure, Manufacturer
address & telephone number. If the markings are not applicable on the label, the marking
can be substituted to indicate on the test report.
② CE/PED certified body code (TUV SUD CE0036)
1.3.2. Applied directive and Standard
① 2014/68/EU Annex III, Module H (reference : 97/23/EC), DGR-0036-QS-1060-14,
1.3.3. Certification range
① HP-180DA/SR~HP-212DA/SR (Up to HP-160 models were self-declared)
Non-electric explosion proof protective system by 94/9/EC, 09TH0074
② Applicable ambient temperature
Standard product with NBR is applicable from -20℃ to +80℃ (-4℉ ~ +176℉)
Optionally, FKM O-ring : from -20℃ to +180℃, VMQ O-ring : from -40℃ to +176℃
However the O-ring was used as optional materials, if users have to operate at extremely
hot or cold condition such as under -20℃ or over +80℃, it shall be confirmed HKC Co.,
Ltd.
③ Design Pressure : 12 bar, Operation pressure : 8 bar max
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.
1.6.2. When connecting air pipe to NPT tap, be careful so that excessive power cannot be given
to the PF tap in the starting point of the screws because the PF tap can be worn easily.
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.

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 5 / 18
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 can be damaged. So,
in case of air leakage, replace or repair immediately on discovery.
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
Tel.
[phone]
Fax.
[phone] / 8696
Homepage
www.hkcon.co.kr
Email
[email protected].kr
Address
Sunggokdong,155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-
do, Republic of Korea (15417)
CAUTION:
n
Turn off all power services before attempting to perform any service on the actuator.
n 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
1.8. Lubrication Requirements
CAUTION:
Due to safety measures, alternative lubricants should not be used without the
prior written recommended of HKC Co., Ltd.
The HP-series are a totally enclosed unit with permanent lubrication in the actuator. Once
installed, lubrication should not be required. However, periodic preventative maintenance will
extend the operating life of the actuator.
1.8.1. Lubrication Points
① Cylinder Body
② Piston Seals
③ End Cover Seals

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 6 / 18
Table 1-2. 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 1-3).
Table 1-3. 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 80℃ ambient temperature
1.9. 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: Hexagons are metric standard tools
1.10. Conveyance
1.10.1. Ensure the actuator is fully vented and decontaminated before operation.
1.10.2. Pay attention in shock.
1.10.3. Ensure all power supplies are removed before operation.
1.11. Supply air volume
Model
Part
HP125
HP145
HP160
HP180
HP200
HP210
HP211
HP212
Inner size(mm)ø
125
145
160
180
200
210
210
210
Air Volume
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
Open(L)
1.5
1.5
2.4
2.4
3.1
3.1
4.3
4.3
5.9
5.9
7.8
7.8
5.1
5.1
9.6
19.6
Close(L)
2.3
3.8
4.2
6.9
9.5
8.2
8.6
10.7
Model
Part
HP035
HP050
HP063
HP066
HP075
HP088
HP100
HP115
Inner size(mm)ø
35
50
63
66
75
88
100
115
Air Volume
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
Open(L)
0.1
-
0.1
0.1
0.2
0.2
0.2
0.2
0.3
0.3
0.5
0.5
0.7
0.7
1.2
1.2
Close(L)
0.1
0.1
0.3
0.3
0.5
0.8
1.1
1.8

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Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 7 / 18
1.12. Operating time
Model
Part
HP035
HP050
HP063
HP066
HP075
HP088
HP100
HP115
Operating
time(sec)
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
Open
0.15
0.2
0.25
0.25
0.3
0.3
0.35
0.3
0.35
0.4
0.5
0.5
0.6
0.7
0.8
Close
0.15
0.25
0.3
0.3
0.35
0.35
0.4
0.4
0.5
0.5
0.6
0.7
0.9
0.9
1.1
Model
Part
HP125
HP145
HP160
HP180
HP200
HP210
HP211
HP212
Operating
time(sec)
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
Open
0.9
1.1
12
1.4
15
1.7
2
2.2
2.7
3.2
3.1
3.5
2.7
3.2
3.5
4
Close
1.2
1.4
1.5
1.8
1.8
2.1
2.4
2.8
3.5
4
4
4.5
4.3
4.3
5
5.5
1.13. Weight
Model
Part
HP035
HP050
HP063
HP066
HP075
HP088
HP100
HP115
Type
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
Close
0.54
-
1.16
1.28
1.68
1.82
2.4
2.6
3
3.4
4.3
5
6
7
9
10.5
Model
Part
HP125
HP145
HP160
HP180
HP200
HP210
HP211
HP212
Type
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
DA
SR
Close
11.3
13.4
15.5
19
22
25.9
26.5
33
38.4
46
46
54.5
46
62
71
91
2. Bill of Materials

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 8 / 18
Part
No
Unit
Q’ty
Part Description
Standard Material
Corrosion Protection
Optional Material
1
4
Position Indicator
Polypropylene +GF
2
1
Position Indicator Holder
Polypropylene +GF
3
1
Spring Clip (Pinion)
Stainless Steel
HP160,200 Nickel
plated
4
1
Thrust Washer (Pinion)
Stainless Steel
5
1
Thrust Bearing (Pinion)
Polyphthalamide
6
1
Body
Extruded Aluminium alloy
Hard Anodized
7
2
Bearing(Piston back)
Polyphthalamide
8
2
Piston
Die Cast Aluminium
Hard Anodized
9
2
O Ring (Piston)
Nitrile (NBR70)
NBR, FKM, VMQ
10
2
Bearing(Piston head)
Polyphthalamide
11
8
Cap Bolt Washer
Stainless Steel
12
2
Cap Bolt(End cap)
Stainless Steel
13
2
Right and Left End Cap
Die Cast Aluminium
Chromate +
Polyester coated
14
2
O Ring (End cap)
Nitrile (NBR70)
NBR, FKM, VMQ
15
2
Piston Guide
Polypropylene +GF
16
1
O Ring (Pinion top)
Nitrile (NBR70)
NBR, FKM, VMQ
17
1
Bearing (Pinion top)
Nylon 46
18
1
Thrust Bearing (Pinion)
Polyphthalamide
19
1
Open / Close Cam
(Stop arrangement)
Stainless Steel
Nickel plated
20
1
Drive Shaft
Steel alloy
21
1
Bearing(Pinion bottom)
Nylon 46
22
1
O Ring (Pinion bottom)
Nitrile (NBR70)
NBR, FKM, VMQ
23
1
O Ring (Stop screw)
Nitrile (NBR70)
NBR, FKM, VMQ
24
2
Stop Bolt Washer
Stainless Steel
25
2
Stop Nut
Stainless Steel
26
2
Stop Bolt
Stainless Steel
27
5~12
Spring (Cartridge)
High alloy Spring Steel
Epoxy coated
28
1
Spring Holder
Polypropylene +GF
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
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.

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 9 / 18
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.
3.2.2.
CAUTION:
Before using an alternative air supply that is not of instrument quality, please
consult with HKC Co., Ltd.
3.3. Principles of Operation
3.3.1. Air connections double acting
OPEN Air to port 2 : counter clockwise/open
CLOSE Air to port 4 : clockwise/close
* Pistons must be inverted to reverse actuator rotation
3.3.2. Air connections of spring return
Spring to Close
Air to port 2: counter clockwise / open
Spring return: clockwise / close

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 10 / 18
4. Assembly
4.1. Assembly of accessories & valve
4.1.1. Assembly of valve(Direct mounting)
Spring to Open
Air to port 2: clockwise / close
Spring return: counter clockwise / open
Valve: close
Actuator: close
Caution! Never disassemble a
valve that is under pressure!
FIG 1 Make sure that both valve
and actuator are close.
FIG 2 Insert actuator on top of adapter
and assembly it through screws