HP-Series Pneumatic Actuator

Installation and Operation Manual Document No. HQOI-08-HP

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HP-Series Pneumatic Actuator
Installation and Operation Manual Document No. H
HQOI-08-HP








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OPERATION AND INSTALLATION MANUAL INTRODUCTION

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.

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Botton
mounting connection
ISO 5211 / DIN 3337
(optional)

HKC 01 EDS 05.11 3

OPERATION AND INSTALLA TION MANUAL Warning

2 Warning

Actuator must be isolated both pneumatically and electrically before any disassembly is begun.
Before mounting or disassembling the actuator consult the relevant sections of this manual.
Do not operate the actuator using inflammable, oxidising, corrosive, explosive and unstable gases
or liquids. For actuators installed in potentially explosive zones, make sure that the internal parts
of the actuator cannot come into contact with the external atmosphere.
It is important that the actuator should only be used within pressure limits indicated in our technical
specifications. Operating the actuator over pressure limits will damage internal parts as well as cause
damage to the housing. Operating the actuator over temperature limits will damage internal and external
components.(diassembly of spring return actuator may become dangerous).
Operating the actuator over in corrosive environments with incorrect protection may damage
the internal and external parts.
Do not disassemble individual spring cartridage. Disassemble may result in personal injury.
Isolate all air lines and make sure that actuator air connection is vented before installation or servicing
of the actuator.
Do not remove end caps or disassemble the actuator while the actuator is perssurised.
Before installing on to a valve make sure that the rotation of the actuator are the same and that
the postion indicator orientation is also correct.

v v v v

Operating temperature : standard -20 C(-4 F) ~ 80 C(176 F)

Operating the actuator over temperature limits will damage
internal and externalcomponents.

GGDo not operate the actuator using inflammable,

oxidising, corrosive, explosive and unstable gases
or liquids.

HKC 01 EDS 05.11 4

OPERATION AND INSTALLATION MANUAL SPECIFICATION

3 SPECIFICATION
3.1 Supply pressure
The maximum supply pressure( Double Acting, Spring return): 12 bar

3.2 Operating Temperature O

O O O
Standard product from -20 C ~ +80 C (-4 F ~ +176 F)
3.3 Operating media
Dry or lubricated air or non explosive/non-corrosive gas
3.4 Supply air volume
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3.5 Operating time

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HKC 01 EDS 05.11 5

 IN T R O D U C T IO N C ons truc tion a nd M a te ria ls

4 C ons truc tion

1
2
3
4
5 27
28
6

7
23
8 24
9
10 25
11 26
12 16
15 17
13 18
14 19
20

21
22
5 M a te ria ls
OPTIONAL
PART NO UNIT Q'TY PART DESCRIPTION STANDARD MATERIAL CORROSION PROTECTION
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) Viton SiliconViton
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) Viton SiliconViton
15 2 PISTON GUIDE Polypropylene +GF
16 1 O RING (Pinion top) Nitrile (NBR70) Viton SiliconViton
17 1 BEARING (Piston top) Nylon 46
18 1 THRUST BEARING (Pinion) Polyphthalamide
19 1 OPEN.CLOSE CAM (Stop arrangement) Stainless Steel
20 1 DRIVE SHAFT Steel alloy Nickel planted
21 1 BEARING (Pinion bottom) Nylon 46
22 1 O RING (Pinion bottom) Nitrile (NBR70) Viton SiliconViton
23 1 O RING (Stop screw) Nitrile (NBR70) Viton SiliconViton
24 2 STOP BOLT WASHER Stainless Steel
25 2 STOP NUT Stainless Steel
26 2 STOP BOLT Stainless Steel
27 min.5/max.12 SPRING (Catridge) High alloy Spring Steel Epoxy coated
28 1 SPRING HOLDER Polypropylene +GF

HK C 01 E DS 05.11
6
PRINCIPLES OF OPERATION OPERATION AND INSTALLATION MANUAL

6 PRINCIPLES OF OPERATION

6.1 Air connections double acting

vwlu
Air to port 2: counter clockwise/open

4
2 4
2

jsvzl
Air to port 4: clockwise/close

2 2 4

* Pistons must be inverted to reverse actuator rotation

HKC 01 EDS 05.11 7

OP E R ATION AND INS TAL L ATION MANUAL P R IN C IP L E S O F O P E R AT IO N

6.2 Air c onne c tions s pring re tur n

S pring to c los e
Air to port 2: counterclockwise/open

2
2

S pring return: clockwise/close

2 2

S pring to ope n

Air to port 2: clockwise/close

S pring return: counter clockwise/open

HK C 01 E DS 05.11
8
AS S E MB L Y OP E R ATION AND INS TAL L ATION M A N U A L

7 AS S E M B L Y
C aution! Never disassemble a valve
7.1 As s e mbly of a c c e s s orie s & va lve that is under pressure!

7 . 1 . 1 As s e mbly of va lve

valve:close.

actuator:close.

(direct mounting)
4
2

F IG 1 Make sure that both valve F IG 2 Insert actuator on top of adapter and
and actuator are close. assembly it through screws

7 . 1 . 2 As s e mbly of a c c e s s orie s

Valve pos ition monitor or P os itioner

B rac k et

P neumatic Ac tuator
S olenoid valve
B efore mounting a s/o valve ensure that
the actuator is in its normal position (close)

Valve

F IG 3 C onnect eventual accessories, making sure of the real position of the valve.
C onnect pneumatic/electric feeding and verify correct operation.

HK C 01 E DS 05.11 9
AS S E MB L Y OP E R ATION AND INS TAL L ATION M A N U A L

Valve pos ition monitor or P os itioner

Fit the valve position monitor or positioner and bracket 7LJKWHQLQJWRUTXHWDEOH
on to the actuator using four screws provided.

B rac k et

P neumatic Ac tuator

S olenoid valve
Fit the solenoid valve on to the actuator using
the screws provided.

B rac k et
Valve mounting
B efore proceeding with the assembly of a valve
onto an actuator be sure that the actuator operates in
C oupling 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
Valve occurs the direction of rotation is corredt for your application.
(B rac k et mounting)
There are two types of valve assembly onto the actuator:

*B racket-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
Valve (max. tightening torque see table).
(Direc t mounting)
*Diredt-mount : Fit the square of the valve directly into the
square of the actuator and bolt together
through the valve IS O pad
(max. tightening torque see table above).

C aution! Never disassemble a valve

that is under pressure!

HK C 4.1 E DS 05.11 10
ASSEMBLY OPERA TION AND INST ALLA TION MANUAL

7.1.3 Open/close adjustment

OPEN/CLOSE Adjustment of HP 050~212 series (Except with HP-035)

o o
Open/close adjustment Max: +4~5

CLOSE TGj“–Š’žšŒGaGjsvzlT
TGj–œ•›Œ™Š“–Š’žšŒGajsvzlR

OPEN TGj“–Š’žšŒGaGvwluT
TGj–œ•›Œ™Š“–Š’žšŒGavwluR
4

OPEN/CLOSE Adjustment of END STOPPER TYPE (Option or HP-035)

Adjustment OPEN or CLOSE

h›Œ™G}ˆ“ŒGˆ•‹GhŠ›œˆ›–™Gˆ™ŒGˆššŒ”‰“Œ‹G–™Gj“–šŒGGGG
Š–•‹›–•SGˆ‹‘œš›Gš›–—G‰–“›G•š‹ŒGˆŠ›œˆ›Œ™G–™GŠ–™™ŒŠ›GŠ“–šŒ‹GGGG
Š–•‹›–•GˆšGš–ž•G–•G—Š›œ™ŒG–•G›ŒG™Ž›Tˆ•‹U

kšˆššŒ”‰“ŒG ‰–“›šG ‰–›G š‹ŒG “’ŒG š–ž•G –•G ›ŒG —Š›œ™ŒG ˆ•‹S
™Œ”–ŒGŒ•‹TŠˆ—GŠ–Œ™šGˆ•‹Gš—™•ŽšOš•Ž“ŒGˆŠ›•ŽGˆŠ›œˆ›–™P

s––šŒ•G•œ›G–™Gˆ‹‘œš›”Œ•›G–Gš›–—G‰–“›G
“’ŒGš–ž•G–•G›ŒG—Š›œ™ŒG–•G›ŒG“Œ›Tˆ•‹U

h‹‘œš›Gš›–—G‰–“›Gœš•ŽGŒŸT“Œ•ŠGž“ŒGG
ˆŠ›œˆ›–™G š›Œ”G šG ŸŒ‹G ‰ G š—ˆ••Œ™G ˆ›
Š“–šŒ‹G—–š›–•U
TGj“–Š’žšŒGaGjsvzlT
TGj–œ•›Œ™Š“–Š’žšŒGaGjsvzlR

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ŸŒ‹G‰ GŒŸT“Œ•ŠG“’ŒG—Š›œ™ŒG–•G›ŒG“Œ›Tˆ•‹U

h•‹G ˆššŒ”‰“ŒG Œ•‹TŠˆ—G Š–Œ™šG ˆ•‹G š—™•ŽšG •

™ŒŒ™šŒ‹G–™‹Œ™U

HKC 01 EDS 05.11 11

AS S E MB L Y OP E R ATION AND INS TAL L ATION M A N U A L

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-lench.

air - Clockwise : OPEN-
- Counterclockwise : OPEN+

Tighten and fasten NUT while STOP BOLT is being

fixed by hex-lench.
air

C aution! If the actuator is a "spring

return" model, uniformly loosen all
<DG9F=9GGDF=B;G9HG endcaps screws, two to three turns at a
5GG9A6@M time, in sequence, to relieve pre-load of
the springs.
On all actuators with springs use caution
when removing endcaps.

set #5 set #9

set #6 set #10

set #7 set #11

set #8 set #12

HK C 01 E DS 05.11 12
OP E R ATION AND INS TAL L ATION MANUAL DIS AS S E MB LY

8 . DIS AS S E MB L Y

8-1. R emove cap screw. 8-4. Pistons disassembly

Hoding the body in vice , rotate the drive shaft
until the piston.

8-2. R emove both (open/close)stop cap screws 8-5. Pistons shaft disassembly
together with nut and washer and o-ring

0-ring
top bearing

0-ring
bottom bearing

8-3. R emove end cap screws 8-6. Drive shaft assembly

HK C 01 E DS 05.11 13
OP E R ATION AND INS TAL L ATION MANUAL AS S E MB LY

8-7. Pistons shaft assembly 8-10. spring assembly

8-8. Pistons assembly 8-11. E nd cap assembly

o
S tart: 40 ~ 45

o
45

8-9. Pistons assembly 8-12. Indicator assembly

HK C 01 E DS 05.11 14
Pneumatic Actuator HP-Series

Dimension unit: mm

28