ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 1 / 18 Valve Automation Leader, HKC
ETS/C Series Heavy-duty Pneumatic Actuators
Installation , Operation & Maintenance Manual
Address :Seonggok-dong, 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do, South Korea (15417)
Tel : +82-31-488-8266, Fax : +82-31-488-8269, Home page : www.hkcon.co.kr, email : [email protected]
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 2 / 18 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 ............................................................................................................ 5
1.5. Storage ........................................................................................................................... 5
1.6. Installation ..................................................................................................................... 5
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 ............................................................................................................. 7
3. Mounting and Operating .............................................................................................. 8
3.1. Actuator Mounting ....................................................................................................... 8
3.2. Operating Pressure and Method ............................................................................... 8
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 ...................................................................................................... 12
5.1. General Information ................................................................................................... 12
5.2. Double Acting & Spring Return Actuator Reassembly ........................................ 12
5.3. Pneumatic Power Module Removal ........................................................................ 14
5.4. Actuator Testing ......................................................................................................... 14
6. Trouble Shooting Guide .............................................................................................. 15
7. Actuator Module Weights ........................................................................................... 16
8. Actuator O-ring Parts ................................................................................................. 17
9. Bolt & Nut Torque Table............................................................................................. 18
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 3 / 18 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.
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 4 / 18 Valve Automation Leader, HKC
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
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/temp.,
Operating air pressure,
Hydrostatic test pressure,
Manufacturer address &
telephone number
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)
1.3.3. Certification range
① ETS/C085-DA/SR200 ~ ETS/C200- DA/SR735
HP 180 DA/SR ~ HP 212 DA/SR
② Applicable temperature
-20 ~ 80℃ (Standard with NBR sealing),
-40~100℃ (Optional with HNBR sealing and with adjustable materials for low temp.)
③ Design Pressure : 12 bar,
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 (040, 050, 058, 065, 085, 100, 130, 160, 200, 270)
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)
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 5 / 18 Valve Automation Leader, HKC
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).
1.6.2. When connecting air pipe to NPT tap, be careful so that excessive power cannot be given
to the PT tap in the starting point of the screws because the PT 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.
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
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.
Tel.
+82 31 488 8266
Fax.
+82 31 488 8269 / 8696
Homepage
www.hkcon.co.kr
Email
Address
Sunggokdong,155, Byeolmang-ro, Danwon-gu,
Ansan-si, Gyeonggi-do Republic of Korea (15417)
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 6 / 18 Valve Automation Leader, HKC
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. 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 the
prior 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 100℃ ambient temperature
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: Hexagons are metric standard tools
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.
Table 1-2. Spare Parts
1. All Seals
2. Washer
3. Back up Ring
4. Piston Guide Plate
5. Painting Specification
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 7 / 18 Valve Automation Leader, HKC
#No
Description
Material
1
Housing
Ductile Iron
2
Housing Cover
Alloy Steel
3
Position Needle
Alloy Steel
4
Position Indicator
SUS
5
Upper Bushing O-ring
NBR
6
Upper Bushing
BSC
7
Yoke
Alloy Steel
8
Low Bushing O-ring
NBR
9
Low Bushing
BSC
10
Snap-ring
Alloy Steel
11
Slide Bearing
Alloy Steel
12
Slide Pin
Alloy Steel
13
Cover Fixed Pin
Alloy Steel
14
Cover Bolt
Alloy Steel
15
Slide Block
Alloy Steel
16
Piston Rod Lock Bolt
Alloy Steel
17
Guide Bar
Alloy Steel
18
Guide Bushing
DU Dry Bushing
19
Travel Stopper Bolt
Alloy Steel
20
Travel Stopper Nut
Alloy Steel
21
Travel Stopper Washer
Alloy Steel
22
Cylinder Front Cover
Alloy Steel
23
Cover O-ring
NBR
24
Center-ring
Alloy Steel
25
Piston Rod Bushing
DU Dry Bushing
26
Rod Seals
PTFE
27
Road Seals O-ring
NBR
28
Piston Rod O-ring Retainer
Alloy Steel
29
Seals Retainer Bolt
Alloy Steel
30
Piston Rod
Alloy Steel
31
Piston Guide Bar
Alloy Steel
#No
Description
Material
32
Piston Guide Bar O-ring
NBR
33
Tie Rod
Alloy Steel
34
Piston
Alloy Steel
35
Piston O-ring
NBR
36
Piston Guide Bushing
Phosphor Bronze
37
Piston Guide Bar Bushing
O-ring
NBR
38
Rod Washer
Alloy Steel
39
Rod Lock Nut
Alloy Steel
40
Back-up-ring
PTFE
41
Cylinder End Cover
Alloy Steel
42
Lifting Lug Plate
Alloy Steel
43
Tie Rod Washer
Alloy Steel
44
Tie Rod Nut
Alloy Steel
45
Piston Guide Bar Nut
Alloy Steel
46
Piston Guide Bar Bolt
Alloy Steel
47
End Air Plate
ALIM
48
Front Air Plate
ALIM
49
Air Plate O-ring
NBR
50
Air Plate Bolt
Alloy Steel
51
Air Pipe
SUS
52
Spring Case Front Cover
Alloy Steel
53
Spring Rod Guide Bushing
Phosphor Bronze
54
Spring Case
Carbon Steel
55
Spring
Alloy Steel
56
Spring Rod
Alloy Steel
57
Spring Retainer
Alloy Steel
58
Rod Adjust Nut
Alloy Steel
59
Spring Case End Cover
Alloy Steel
60
Cap
Alloy Steel
61
Cap Bolt
Alloy Steel
62
Cylinder
Alloy Steel
2. Bill of Materials
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 8 / 18 Valve Automation Leader, HKC
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.
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 10bar (145psi). 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 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.
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.
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 9 / 18 Valve Automation Leader, HKC
Figure 3-1. Operating Principle and Adjustment of the Common Assembly
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 Close
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 10 / 18 Valve Automation Leader, HKC
Figure 3-3b. Open Mode Operating Principle / Fail Close
4. Actuator Disassembly
4.1. General Information
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.
DANGER:
n
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.
n
Do not remove the Spring Module while the spring is compressed. Follow all instructions written
on the warning tag (wired to the actuator cover)
n
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:
n
Review the instructions and dangers in section 4.1
n
For details regarding the '#No' keys, refer to the Bill of Materials in section 2
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 11 / 18 Valve Automation Leader, HKC
WARNING:
Ensure that the air supply is isolated and any remaining pressure is vented before disassembly
of the actuator
① Disconnect pneumatic and electric supplies.
② Remove the air supply block sets from the cylinder body
③ Remove the end tie rod & nut from the cylinder body (No 33,43,44)
④ Remove the end cover from the cylinder body. (No 41)
⑤ Remove the cylinder from the body. (No 62)
⑥ Remove the three piston guide from the cylinder. (No 31,45,46)
⑦ Remove the piston guide bushing and o-ring from the piston. (No 35,36)
⑧ Remove the rod lock nut and washer from the piston. (No 38,39)
⑨ Remove the snap ring fixed shaft pin from the drive shaft. (No 10,)
⑩ Remove the yoke shaft slide pin from the yoke. (No 12)
DANGER:
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.
⑪ Remove the position indicator from the drive shaft. (No 4)
⑫ Remove the upper bushing & o-ring from the drive shaft. (No 5,6)
⑬ Remove the drive shaft & slide block from the housing. (No 15)
⑭ Remove the yoke from the cylinder. (No 7)
⑮ Remove the washers from the cylinder.
○
16 Remove the lower bushing from the drive shaft. (No 9)
○
17 Remove the lower bearing and o-ring from the drive shaft.(No 8)
○
18 Remove the top seal from the drive shaft.
○
19 Remove the two travel stop bolts and nuts from the housing. (No 19,20,21)
○
20 Remove the seal and plain washers from the travel stop bolts.
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 supplies.
② Remove the air supply block sets from the cylinder body
③ Remove the spring module from the cylinder body.(No 52~No 61)
④ Refer to section ‘Double acting actuator disassembly’ for disassembly of all Spring Return
Actuator components except the spring module.
⑤ Spring Module disassembly should only be performed by a competently trained
technician, using the correct tools and equipment in a “clean air” environment on a
workbench.
DANGER:
n
It is possible, that the actuator may contain dangerous gas and/or liquids. Ensure that all
proper measures have been taken to prevent exposure/release of harmful contaminants
before commencing any work. The Spring Module should not be disassembled using incorrect
tools or equipment. Failure to use the correct tools and equipment can cause severe
equipment damage or fatal injury to personnel. For Spring Module disassembly, consult HKC
Co., Ltd.
n
DO NOT REMOVE SPRING MODULE WHILE THE SPRING IS COMPRESSED
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 12 / 18 Valve Automation Leader, HKC
5. Actuator Assembly
5.1. General Information
DANGER:
Only new seals, which are still within the seal’s expectant shelf life, should be installed
into the actuator being refurbished.
5.1.1. Remove and discard all old seals and gaskets.
5.1.2. All parts should be carefully cleaned to remove dirt and other foreign material prior to
inspection.
5.1.3. All parts should be thoroughly inspected for excessive wear, stress cracking, galling and
pitting. Attention should be directed to threads and sealing surfaces subjected to sliding or
rotating motion. The sealing surface of the cylinder must be free of deep scratches, pitting,
corrosion, blistering, and flaking of the coating.
5.1.4. Before installation all moving parts and the internal cylinder body should be coated with a
film of lubricant.
DANGER:
n
Actuator parts that reflect any of the above characteristics should be replaced with new parts
n
The recommended lubricant for all parts and seals are detailed in section 1.9
5.2. Double Acting & Spring Return Actuator Reassembly
5.2.1. Double Acting Actuator Reassembly
CAUTION:
n
Review the instructions and warnings in section 5.1 before proceeding with actuator reassembly
n
For details regarding the 'No' keys, refer to the Bill of Materials in Section 2
n
Lubricate the guide bushing before installation
n
Ensure the seal groove is lubricated
① Install the guide bushing (2 - 3 ea) and guide o-ring into the piston.(No 32,36,37)
② Install the piston seal and back up ring into the piston (No 34,35,40)
③ Put bushing o-ring in piston guide bar.(No 37)
④ Assemble bushing to piston and fix snap-ring on it.(No 25,26,27,28)
⑤ Assemble piston guide bar with piston.(No 31,34)
⑥ Put Back-up-ring and O-ring to piston (No 35,40,34)
⑦ Assemble slide bearing to slide block (No 11,15)
⑧ Assemble slide block, bearing to yoke and cover snap ring on it (No 7)
⑨ Assemble center-ring, front cover o-ring and cover to Housing. (No 24,23,22,1)
⑩ Install the lower bushing into the drive shaft.(No 9)
⑪ Install the upper bushing o-ring into the drive shaft.(No 5)
⑫ Install the upper bushing into the drive shaft.(No 6)
⑬ Install the lower bushing into the drive shaft.(No 8)
⑭ Assemble lower bushing, yoke assembly to housing(No 7,9,1). Connect yoke assembly
with guide bar (#No 7,17)
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 13 / 18 Valve Automation Leader, HKC
Tip for Assembly and Disassembly
In this section, parts are numbered with respect to the order of assembly
HOUSING and CYLINCDER Assembly
1. Insert ② COVER BUSH into ① HOUSING then attach ③ FRONT COVER to the side of ①using bolts and nuts.
2. Insert ④ to ① and equip ⑤ YOKE, ⑥ SLIDE BLOCK, and ⑦ SLIDE BEARING SLIDE PIN.
3. Lock in ⑧ PISTON ROD with ⑥ then insert ⑨ GUIDE BAR into ①.
4. Lock ⑩ ROD SEAL and ⑪ SEAL RETAINER into ③ using nuts. Similarly, tighten ⑫ PISTON into ⑧ with nuts.
5. Insert ⑬PISTON GUIDE BAR into ③ and assemble ⑭ CYLINDER.
6. Close ⑮ END COVER and tighten with ○
31 .
7. Insert ○
32 HOUSING COVER into ① and lock ○
32 HOUSING COVER and ○
33 INDICATOR together.
SPRING Assembly
1. Insert ○
17 CENTER RING into ① then weld ○
19 SPRING FRONT COVER and ○
20 SPRING CASE together, insert ○
21
.
2. Insert ○
24 ROD BUSH into ○
19 with ○
25 C-STYLE RETAINING RING After assembling ○
22 SPRING RETAINER and ○
21 ,
close ○
23 SPRING END COVER then weld with ○
20 .
3. Finally, adjust ○
18
and ○
22
then tighten ○
22
with NUT to finish.
⑮ Install the piston rod into the housing. (No 1,30)
○
16 Assemble piston rod to slide block and fix them by set screw (No 30,15)
○
17 Install the piston & guide bar & piston rod into the body housing(No 34,31,30)
○
18 Install the cylinder into the body housing(No 62,1)
○
19 Install the end cover & tie bolt into the body (No 1, 42, 43, 44, 45, 46…)
○
20 Assemble cover assembly to body housing (No 2,1)
○
21 Ensure the piston moves clockwise when the actuator is closing.
CAUTION:
Before installing the piston, rotate the drive shaft to align the yoke and piston roller
bearing before installing the end cover, ensure the seal is lubricated
○
22 Install the travel stop into the body housing and rotate the yoke 90° to move the piston to
the open position (No 19,20,21, 1)
○
23 External coating
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 14 / 18 Valve Automation Leader, HKC
5.2.2. Single Acting Actuator Reassembly
CAUTION:
n
Review the instructions and warnings in section 5.1 before proceeding with actuator reassem
bly. The operating torque of the valve, failure position, and the air supply pressure effects the
spring selection. For correct spring selection, refer to the torque table, for spring return actu
ators, in the literature or consult with HKC CO., LTD.
n
For details regarding the 'No' keys, refer to the Bill of Materials in section 2
① If the failure position is to be altered, make sure that the spring return actuator
disassembly procedures have been thoroughly reviewed
② It is not necessary to fully extend the spring unless it is to be changed.
DANGER:
Do not disassemble the spring end cap sub-assembly
③ Install the spring rod into the slide block (No 1,56)
④ Install the spring & spring case into the housing (No 55,54,1)
⑤ Spring adjust setting (No 58)
⑥ Install the spring cap into the spring case (No 60,61)
⑦ Install the travel stop into the body housing and rotate the yoke 90° to move the piston to
the open position.
5.2.3. Spring Case
① Weld the spring case front cover to spring case and grind them to be polished (No 52,54)
② Put spring inside spring case and connect spring retainer then press them by spring case
end cover. Weld the case cover then grind afterwards for a safe and polished finish.(No
55,54,57,59)
③ Adjust yoke degree by spring rod adjust nut and fix them (No 58)
④ Assemble spring case cap on above part (No 60)
5.3. Pneumatic Power Module Removal
CAUTION:
n
Review instructions and warnings in section 5.1 before proceeding with actuator
reassembly.
n
Before work commences, ensure the actuator position meets the fail position correctly. If
not specified, the actuator position should be failed closed.
① Review Sections 5.1 to 5.2 for the cylinder body assembly.
② If not already removed piston rod from drive module.
③ Depending on the actuator fail position, work procedures should be altered. The standard
procedures are the failed close (review 3.3). Two pistons should move in the same
direction of the drive shaft to clockwise.
④ Install the SR type adjusting bolt, fixed to the spring guide pack, into the spring cover.
⑤ Adjust yoke degree by spring nut and fix them
⑥ Assemble spring module into the cylinder.
⑦ Install the travel stop into the cylinder.
⑧ Apply suitable air pressure to the cylinder and check the fail position.
⑨ Adjust the travel stop for correct operation.
5.4. 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.
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 15 / 18 Valve Automation Leader, HKC
CAUTION:
n
If excessive leakage across the piston remains, the actuator must be disassembled and
the cause of leakage must be determined and corrected.
5.4.1. Leakage Testing: All areas where leakage to the atmosphere may occur are to be checked
using a commercial leak testing solution.
5.4.2. 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.
5.4.3. Check the piston for leaks.
5.4.4. The cover, drive shaft and air ports should be tested by pressurizing each port in turn and
applying the test procedure.
5.4.5. Remove pressure from the pressure inlet port
5.4.6. 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
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 16 / 18 Valve Automation Leader, HKC
7. Actuator Module Weights
Table 7-1. Symmetric Type Actuator
ET-S
DA (Kg)
SR 4.2 BAR (Kg)
SR 5.6 BAR (Kg)
085
200
90
150
160
250
110
190
200
300
130
230
240
335
150
250
280
100
335
220
350
380
385
260
410
430
435
290
460
550
130
435
390
620
740
485
430
730
820
535
520
880
1,010
160
535
620
1,110
1,250
585
720
1,200
1,390
635
840
1,450
1,620
200
635
1,090
1,810
2,030
685
1,160
1,990
2,320
735
1,320
2,280
2,650
Table 7-2. Canted Type Actuator
ET-C
DA (Kg)
SR 4.2 BAR (Kg)
SR 5.6 BAR (Kg)
085
200
110
170
180
250
130
210
230
300
150
250
270
335
170
280
310
100
335
240
370
440
385
270
460
510
435
310
520
570
130
435
430
750
800
485
480
850
970
535
560
980
1,080
160
535
760
1,250
1,450
585
820
1,410
1,650
635
900
1,580
1,780
200
635
1,180
1,980
2,210
685
1,260
2,250
2,390
735
1,410
2,460
2,790
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 17 / 18 Valve Automation Leader, HKC
8. Actuator O-ring Parts
SERIES
PART
NAME
065
085
100
130
160
200
270
UPPER
BUSH
AN42
AN239
AN244
AN259
AN264
AN269
G350
LOW BUSH
AN42
AN239
AN244
AN259
AN264
AN269
G350
YOKE
AN150
AN236
AN241
AN255
AN261
AN266
AN382
ROD SEAL
AN217
AN325
P50A
P55
P65
P65
P90
ROD
WASHER
AN119
AN123
AN130
AN132
AN139
AN139
AN150
PISTON
GUIDE BAR
-
-
-
P15
P16
G25
P35
PISTON
GUIDE BUSH
-
-
-
P20 , P26
P20 , P26
P30 , P40
P42 , P50
F/E COVER
200
AN264
235
AN372
335
G325
335
G325
385
AN383
485
P470
735
P720
PISTON
P180
P220
P320
P320
P370
P470
P720
F/E PORT
PLATE
P12,P24
P12,P24
P12,P29
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
235
AN270
250
AN375
385
AN383
385
AN383
435
AN385
535
P520
785
P770
PISTON
P220
P235
P370
P370
P420
P520
P770
F/E PORT
PLATE
P12,P24
P12,P24
P12,P29
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
250
AN272
300
G290
435
AN469
435
AN385
485
AN466
585
P570
835
P820
PISTON
P235
P285
P520
P420
P470
P570
P820
F/E PORT
PLATE
P12,P24
P12,P24
P12,P29
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
280
AN275
335
G325
485
AN466
485
AN466
535
P520
635
P620
885
P870
PISTON
P265
P320
P470
P470
P520
P620
P870
F/E PORT
PLATE
P12,P24
P12,P24
P12,P24
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
300
AN277
385
AN383
535
P520
535
P520
585
P570
685
P670
935
P920
PISTON
P285
P370
P520
P520
P570
P670
P920
F/E PORT
PLATE
P12,P24
P12,P24
P520
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
335
G325
435
AN385
585
P570
585
P570
635
P620
735
P720
985
P970
PISTON
P320
P420
P570
P570
P620
P720
P970
F/E PORT
PLATE
P12,P24
P12,P24
P570
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
385
AN383
485
AN466
635
P620
685
P670
785
P770
1050
P1035
PISTON
P370
P470
P620
P670
P770
P1035
F/E PORT
PLATE
P12,P24
P12,P24
P12,P29
P12,P29
P12,P29
P12,P29
F/E COVER
535
P520
685
P670
735
P720
835
P820
1150
P1135
PISTON
P520
P670
P720
P820
P1135
F/E PORT
PLATE
P520
P12,P29
P12,P29
P12,P29
P12,P29
ET Series Heavy-duty Pneumatic Actuators
Installation Operation& Maintenance Manual
Doc No. : HUMG-ET-16 Rev0 Page 18 / 18 Valve Automation Leader, HKC
9. Bolt & Nut Torque Table
Model Name
Cover Bolt
Spring Rod Lock Nut
Size
Length (L)
Torque
(Nm)
Size
Thickness
(T)
Torque
(Nm)
ET S/C 065
M8
25
29
M30
30
1,700
ET S/C 085
M8
25
29
M40
32
3,800
ET S/C 100
M10
30
59
M48
39
7,000
ET S/C 130
M14
40
166
M48
39
7,000
ET S/C 160
M16
50
255
M60
50
14,000
ET S/C 200
M18
50
350
M60
50
14,000
ER S/C 270
M24
50
860
M85
60
35,000
Model Name
Top Cover Bolt
Piston Retaining Nut
Tie Rod Lock Nut
Size
Strength
(T)
Torque
(Nm)
Size
Strength
(T)
Torque
(Nm)
Size
Strength
(T)
Torque
(Nm)
ET S/C 065
ET S/C 085
M16
10.9
385
M25
10.9
1100
M14
8.8
132
ET S/C 100
M20
10.9
550
M30
10.9
1900
M16
8.8
200
ET S/C 130
M22
10.9
730
M40
10.9
5000
M20
8.8
390
ET S/C 160
M24
10.9
950
M45
10.9
7000
M20
8.8
390
ET S/C 200
M27
10.9
1400
M50
10.9
9800
M22
8.8
530
ET S/C 270
HKC Co., Ltd.
Sales Office Tel: +82 2 2138 8266, Fax: +82 2 2138 8269
Head Office & Plant Tel: +82 31 488 8266, Fax: +82 31 488 8269
Address (Seonggok-dong) 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do,15417
South Korea
Website www.hkcon.co.kr
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