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HHPP--SSeerriieess PPnneeuummaattiicc AAccttuuaattoorr

IInnssttaallllaattiioonn aanndd OOppeerraattiioonn MMaannuuaall DDooccuummeenntt NNoo.. HQOI-08-HPH

OPERATION AND INSTALLATION MANUAL

3

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.

(NAMUR)VDI / VDE 3845

Top mounting connection

(NAMUR)VDI / VDE 3845Solenoid interface

ISO 5211 / DIN 3337

(optional)

Botton mounting connection

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H

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OPERATION AND INSTALLA TION MANUAL

HKC 01 EDS 05.11 4

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 gasesor 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 technicalspecifications. 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 externalcomponents.(diassembly of spring return actuator may become dangerous).Operating the actuator over in corrosive environments with incorrect protection may damagethe 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 servicingof 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.

Do not operate the actuator using inflammable, oxidising, corrosive, explosive and unstable gases or liquids.

Operating temperature : standard -20 C(-4 F) ~ 80 C(176 F) Operating the actuator over temperature limits will damage internal and externalcomponents.

OPERATION AND INSTALLATION MANUAL

HKC 01 EDS 05.11 5

SPECIFICATION

3 SPECIFICATION

O O O O

3.1 Supply pressureThe maximum supply pressure( Double Acting, Spring return): 12 bar

3.2 Operating Temperature Standard product from -20 C ~ +80 C (-4 F ~ +176 F) 3.3 Operating media Dry or lubricated air or non explosive/non-corrosive gas3.4 Supply air volume

3.5 Operating time

3.6 Weight

C ons truc tion a nd M a te r ia lsIN T R O DU C T IO N

4 C ons truc tion1

2

345

6

7

89

1 01 1

1 2

1 3

1 4

1 5

1 61 71 81 9

2 0

2 1

2 2

2 32 42 5

2 6

2 72 8

PART NO

12345678910111213141516171819202122232425262728

41111122228222211111111222

min.5/max.12

1

POSITION INDICATORPOSITION INDICATOR HOLDER

SPRING CLIP (Pinion)THRUST WASHER (Pinion)THRUST BEARING (Pinion)

BODYBEARING (Piston back)

PISTONO RING (Piston)

BEARING (Piston head)CAP BOLT WASHERCAP BOLT(End cap)

RIGHT AND LEFT END CAPO RING (End cap)PISTON GUIDE

O RING (Pinion top)BEARING (Piston top)

THRUST BEARING (Pinion)OPEN.CLOSE CAM (Stop arrangement)

DRIVE SHAFTBEARING (Pinion bottom)O RING (Pinion bottom)

O RING (Stop screw)STOP BOLT WASHER

STOP NUTSTOP BOLT

SPRING (Catridge)SPRING HOLDER

Polypropylene +GFPolypropylene +GF

Stainless SteelStainless Steel

PolyphthalamideExtruded Aluminium alloy

PolyphthalamideDie Cast Aluminium

Nitrile (NBR70)PolyphthalamideStainless SteelStainless Steel

Die Cast AluminiumNitrile (NBR70)

Polypropylene +GFNitrile (NBR70)

Nylon 46PolyphthalamideStainless Steel

Steel alloyNylon 46

Nitrile (NBR70)Nitrile (NBR70)Stainless SteelStainless SteelStainless Steel

High alloy Spring SteelPolypropylene +GF

HP160,200 Nickel plated

HARD ANODIZED

HARD ANODIZED

Chromate + Polyester coated

Nickel planted

Epoxy coated

Viton SiliconViton

Viton SiliconViton

Viton SiliconViton

Viton SiliconVitonViton SiliconViton

UNIT Q'TY PART DESCRIPTION STANDARD MATERIAL CORROSION PROTECTION OPTIONALMATERIAL

5 M a te r ia ls

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OPERATION AND INSTALLATION MANUAL

42

42

6 PRINCIPLES OF OPERATION

6.1 Air connections double acting

Air to port 2: counter clockwise/open

Air to port 4: clockwise/close

PRINCIPLES OF OPERATION

2

4

2

4

* Pistons must be inverted to reverse actuator rotation

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OP E R ATION AND INS TALLATION MANUAL

8

2

6 . 2 Air c onne c tions s pr ing re turn

Air to port 2: counterclockwise/open

S pring return: clockwise/close

2

P R IN C IP L E S O F O P E R AT IO N

S pring to c los e

2

4

2

4

S pr ing to ope n

Air to port 2: clockwise/close

S pring return: counter clockwise/open

2

2

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OP E R ATION AND INS TALLATION M AN U AL

C aution! Never disassemble a valvethat is under pressure!

AS S E M B L Y

7 AS S E M B L Y

7 . 1 As s e mbly of a c c e s s or ie s & va lve

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

FIG 1 Make sure that both valveand actuator are close.

24

F IG 2 Insert actuator on top of adapter andassembly it through screws

valve:close.

actuator:close.

(direct mounting)

9HKC 01 EDS 05.11

7 . 1 . 2 As s e mbly of a c c e s s or ie s

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.

Valve pos ition monitor or P os itioner

B rac ket

P neumatic Ac tuator

S olenoid valve

Valve

B efore mounting a s/o valve ensure thatthe actuator is in its normal position (close)

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OP E R ATION AND INS TALLATION M AN U ALAS S E M B L Y

Valve pos ition monitor or P os itioner

B rac ket

P neumatic Ac tuator

S olenoid valve

Valve

C aution! Never disassemble a valvethat is under pressure!

Fit the valve position monitor or positioner and bracketon to the actuator using four screws provided.

Fit the solenoid valve on to the actuator usingthe screws provided.

B rac ket

C oupling

Valve(Direc t mounting)

(B rac ket mounting)

B efore proceeding with the assembly of a valveonto an actuator be sure that the actuator operates inthe desired direction of rotation and both actuator/ valve are correctly orientated.

Important : When using a spring return actuator for a failsafe operation, ensure that when air or electricity failureoccurs the direction of rotation is corredt for your application.

There are two types of valve assembly onto the actuator:

*B racket-mount : Mounting with a bracket and couplingthe bracket is bolted to the actuator / valve to join themtogether and the coupling is used to connect theactuator output drive to the valve stem

(max. tightening torque see table).

*Diredt-mount : Fit the square of the valve directly into thesquare of the actuator and bolt togetherthrough the valve IS O pad

(max. tightening torque see table above).

Valve mounting

OPERA TION AND INST ALLA TION MANUALASSEMBLY

7.1.3 Open/close adjustment

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

CLOSE

OPEN

4

2

Adjustment OPEN or CLOSE

Open/close adjustment Max: +4~5o

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

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OP E R ATION AND INS TALLATION M AN U ALAS S E M B L Y

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Adjustment for OPEN

Loosen NUT a little to adjust OPEN STOP BOLT like picture onthe right-hand.

Make actuator OPEN position by air like picture on theleft-hand.

Adjust and fix STOP BOLT using hex-lench.- Clockwise : OPEN-- Counterclockwise : OPEN+

Tighten and fasten NUT while STOP BOLT is beingfixed by hex-lench.

air

air

set #5

set #6

set #7

set #8

set #9

set #10

set #11

set #12

C aution! If the actuator is a "springreturn" model, uniformly loosen allendcaps screws, two to three turns at atime, in sequence, to relieve pre-load ofthe springs.On all actuators with springs use cautionwhen removing endcaps.

OP E R ATION AND INS TALLATION MANUAL

HK C 01 EDS 05.11 13

8 .

DIS AS S E MB LY

DIS AS S E MB LY

8-1. R emove cap screw.

8-2. R emove both (open/close)stop cap screwstogether with nut and washer and o-ring

8-3. R emove end cap screws

8-4. Pistons disassemblyHoding the body in vice , rotate the drive shaft

until the piston.

8-5. Pistons shaft disassembly

8-6. Drive shaft assembly

0-ringtop bearing

0-ringbottom bearing

OP E R ATION AND INS TALLATION MANUAL

14

AS S E MB LY

HK C 01 EDS 05.11

S tart: 40 ~ 45

o

o

45

8-7. Pistons shaft assembly

8-8. Pistons assembly

8-9. Pistons assembly

8-10. spring assembly

8-11. End cap assembly

8-12. Indicator assembly

28

Dimension unit: mm

Pneumatic Actuator HP-Series