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

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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.

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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

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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

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Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 11 / 18
4.1.2. Assembly of accessories
FIG 3 Connect eventual accessories, making sure of the real position of the valve.
Connect pneumatic/electric feeding and verify correct operation.
Tightening torque table
Metric
Screw
Tightening torque
table(Nm)
M5
5~6
M6
10~11
M8
23~25
M10
48~52
M12
82~86
M14
132~138
M16
200~210
M20
390~410
M24
675~705
M30
1340~1400
Solenoid valve
Before mounting a s/o valve ensure that the
actuator is in its normal position(close)
Valve position monitor or Positioner
Fit the valve position monitor or positioner and
bracket on the actuator using four screws provided.
Bracket
Pneumatic Actuator
Solenoid valve
Fit the solenoid valve on the actuator using the
screws provided.
Bracket
Coupling
Valve
(Direct mounting)
Valve
(Bracket mounting)

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 12 / 18
4.1.3. Valve mounting
Before proceeding with the assembly of a valve onto an actuator be sure that the actuator
operates in the desired direction of rotation and both actuator / valve are correctly
orientated.
Important : When using a spring return actuator for a fail safe operation, ensure that when
air or electricity failure occurs the direction of rotation is correct for your application.
There are two types of valve assembly onto the actuator:
①Bracket-mount : Mounting with a bracket and coupling the bracket is bolted to the
actuator / valve to join them together and the coupling is used to connect the actuator
output drive to the valve stem (max. tightening torque see table).
②Direct-mount : Fit the square of the valve directly into the square of the actuator and bolt
together through the valve ISO pad (max. tightening torque see table above).
4.2. Open/close adjustment
OPEN/CLOSE Adjustment of HP 050~212 series (Except with HP-035)
OPEN/CLOSE Adjustment of END STOPPER TYPE (Option or HP-035)
4.2.1. Adjustment CLOSE
After Valve and Actuator are assembled for Close condition, adjust stop bolt inside
actuator for correct closed condition as shown on picture on the right-hand.
Disassemble bolts both side like shown on the picture and, remove end-cap covers
and springs(single acting actuator)
Loosen nut for adjustment of
stop bolt like shown on the
picture on the left-hand.
Adjust stop bolt using hex-
wrench while actuator stem is
fixed by spanner at closed
position.
- Clockwise : CLOSE-
- Counterclockwise : CLOSE+
Tighten and fasten NUT while
STOP BOLT is being fixed by hex-
wrench like picture on the left-
hand.
And assemble end - cap covers and
springs in reversed order.
Open/close adjustment Max: ±4~5°
CLOSE
- Clockwise : CLOSE-
- Counterclockwise :CLOSE+
OPEN
- Clockwise : OPEN-
- Counterclockwise :OPEN+

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Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 13 / 18
4.2.2. Adjustment for OPEN
Loosen NUT a little to adjust OPEN STOP BOLT like picture on the
right-hand.
Make actuator OPEN position by air like picture on
the left-hand.
Adjust and fix STOP BOLT using hex-wrench.
- Clockwise : OPEN-
- Counterclockwise : OPEN+
Tighten and fasten NUT while STOP BOLT is
being fixed by hex-wrench.
4.3. HP Series Spring Sets
ASSEMBLY
SET #5
SET #6
SET #7
SET #8
SET #9
SET
#10
SET
#11
SET
#12
Caution! If the actuator is a
"spring return" model, uniformly loosen
all end caps screws, two to three turns
at a time, in sequence, to relieve pre-
load of the springs.
On all actuators with springs use
caution when removing end caps.

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 14 / 18
5. Disassembly
5-5. Pistons shaft disassembly
5-6. Drive shaft assembly
5-4. Pistons disassembly
Holding the body in vice,
rotate the drive shaft until
the piston.
5-9. Pistons assembly
5-8. Pistons assembly
5-7. Pistons shaft assembly
5-2. Remove both (open /
close) stop cap screws
together with nut and
washer and o-ring
5-3. Remove end
cap screws
5-1. Remove cap screws
5-12. Indicator assembly
5-11. End cap assembly
5-10. Spring assembly

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Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 15 / 18
5.1. Actuator Testing
DANGER:
n
Pressure applied to the actuator is not to exceed the maximum operating pressure
rating listed on the actuator name tag. Test the actuator using a properly adjusted self
relieving regulator, with gauge.
CAUTION:
n
If excessive leakage across the piston remains, the actuator must be disassembled
and the cause of leakage must be determined and corrected.
5.1.1. Leakage Testing: All areas where leakage to the atmosphere may occur are to be checked
using a commercial leak testing solution.
5.1.2. Cycle the actuator 5 times at the nominal operating pressure (NOP) as listed on the
actuator name tag or the user default actuator supply pressure. If excessive leakage
across the pistons is noted, generally a bubble which breaks three seconds or less after
starting to form, cycle the actuator five times as this will allow the seals to seek their
proper service condition.
5.1.3. Check the piston for leaks.
5.1.4. The cover, drive shaft and air ports should be tested by pressurizing each port in turn and
applying the test procedure.
5.1.5. Remove pressure from the pressure inlet port
5.1.6. If an actuator was disassembled and repaired, the above leakage test must be performed
again.
6. Trouble Shooting Guide
Table 6-1 provides solutions for the most commonly encountered issues during installation and start-up.
Issue
Reason
Solution
Valve open/close does
not operate smoothly
Air pressure is low
Raise the air supply
Pipe is obstructed by foreign
substance
Remove the substance in pipe
Locked speed controller
Open speed controller
Air is escaping from cylinder /
piston
Replace piston O-ring
Working torque of valve is too big
a) Raise the air supply
b) Replace valve
Valve does not open or
close correctly
Stopper setting is incorrect
Perform stopper settings again
Working torque of valve is too big
a) Raise the air supply
b) Replace valve
The open/close valve
operates too quickly or
slowly
The setting of speed controller is
not calibrated correctly
Reconfigure the speed controller
Air is escaping
O-ring of piston or cover bushing
is worn out
Replace O-ring

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 16 / 18
7. Dimension
MODEL
A
B
C
D
E
F
G
H
I
J
K
O
S
T
U
V
W
X
HP35
126
54
30
24
69
49
25
50
PF
M6
1/8”
20
4
4
12
24
16
32
HP50
144
72
42
30
93
73
30
80
PF
M6
1/8”
20
4
4
12
24
16
32
HP63
163
85
47
38
107
87
30
80
PF
M6
1/8”
20
4
4
12
24
16
32
HP66
202
85
47
38
107
87
30
80
PF
M6
1/8”
20
4
4
12
24
16
32
HP75
210
96
53.5
42.5
124
104
30
80
PF
M6
1/8”
20
4
4
12
24
16
32
HP88
247
108
58.5
49.5
136
116
30
80
PF
M6
1/8”
20
4
4
12
24
16
32
HP100
268
123
67
56
148
128
30
80
PF
M6
1/4”
20
4
4
12
24
16
32
HP115
316
141
77
64
166
146
30
80
PF
M6
1/4”
20
4
4
12
24
16
32
HP125
347
151
82
69
179
159
30
80
PF
M6
1/4”
20
4
4
12
24
16
32
HP145
414
172
92
80
209
179
30
80
PF
M6
1/4”
30
4
4
12
24
16
32
HP160
467
190
101
89
226
196
30
130
PF
M6
1/4”
30
4
4
12
24
16
32
HP180
497
206
107
99
251
221
30
130
PF
M6
1/4”
30
4
4
12
24
16
32
HP200
555
227
116
111
277
247
30
130
PF
M6
1/4”
30
4
4
12
24
16
32
HP210
628
236
120
116
286
256
30
130
PF
M6
1/4”
30
4
4
12
24
16
32
HP211
-
236
120
116
286
256
30
130
PF
M6
1/4”
30
4
4
12
24
16
32
HP212
-
236
120
116
286
256
30
130
PF
M6
1/4”
30
4
4
12
24
16
32

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 17 / 18
7.1. Top Mounting Connection
Top mounting connection
Model
G
H
O
HP035
25
50
20
HP050
30
80
20
HP063
30
80
20
HP066
30
80
20
HP075
30
80
20
HP088
30
80
20
HP100
30
80
20
HP115
30
80
20
HP125
30
80
20
HP145
30
80
30
HP160
30
130
30
HP180
30
130
30
HP200
30
130
30
HP210
30
130
30
HP211
30
130
30
HP212
30
130
30
7.2. Bottom Mounting Connection
Bottom mounting connection
Model
Flange L
(ISO5211) Q
Base Tap
DP(mm) R
Stem (mm)
M(DP)/N(□)
HP035
F03/F05
M5/M6
10/9
Ø36/Ø50
9/10
HP050
F03/F05
M5/M6
12/11
Ø36/Ø50
9/10
HP063
F05/F07
M6/M8
17/14
Ø50/Ø70
11/14
HP066
F05/F07
M6/M8
17/14
Ø50/Ø70
11/14
HP075
F05/F07
M6/M8
19/17
Ø50/Ø70
12/14
HP088
F05/F07/F10
M6/M8/M10
22/17
Ø50/Ø70/Ø102
12/14/18
HP100
F07/F10
M8/M10
22/17
Ø70/Ø102
14/18
HP115
F07/F10
M8/M10
25/22
Ø70/Ø102
Ø70/Ø102 14/18
HP125
F07/F10
M8/M10
25/22
Ø70/Ø102
14/18
HP145
F10/F12
M10/M12
30/27
Ø102/Ø125
18/23
HP160
F10/F12
M10/M12
30/27
Ø102/Ø125
18/23
HP180
F10/F12
M10/M12
38/36
Ø102/Ø125
18/23
HP200
F14
M16
38/36
Ø140
26
HP210
F14
M16
43/36
Ø140
26
HP211
F14
M16
53/46
Ø140
26
HP212
F14
M16
53/46
Ø140
26

HP Series Pneumatic Actuator
Installation Operation & Maintenance Manual
Document No. HUMG-HP-16 Rev0 Page 18 / 18