Installation, Operation & Maintenance Manual

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 : hkcon@hkcon.co.kr Doc No. : HUMG-ET-16 Rev0 Page 1 / 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 Doc No. : HUMG-ET-16 Rev0 Page 2 / 18 Valve Automation Leader, HKC

1. Introduction This manual is offered as a guide to performance, installation, operation, disassembly and afterservice 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. Doc No. : HUMG-ET-16 Rev0 Page 3 / 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) Doc No. : HUMG-ET-16 Rev0 Page 4 / 18 Valve Automation Leader, HKC

1.4. Initial Inspection ET Series Heavy-duty Pneumatic Actuators 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 Tel. +82 31 488 8266 Fax. +82 31 488 8269 / 8696 Homepage www.hkcon.co.kr Email hkcon@hkcon.co.kr Address Sunggok dong,155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do Republic of Korea (15417) n n CAUTION: Turn off all power services before attempting to perform any service on the actuator. POTENTIAL HIGH PRESSURE VESSEL. Before removing or disassembling your actuator, ensure that the valve or other actuated devices are isolated and not under pressure. Doc No. : HUMG-ET-16 Rev0 Page 5 / 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 Table 1-2. Spare Parts 1. All Seals 2. Washer 3. Back up Ring 4. Piston Guide Plate 5. Painting Specification 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. Doc No. : HUMG-ET-16 Rev0 Page 6 / 18 Valve Automation Leader, HKC

2. Bill of Materials #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 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 Doc No. : HUMG-ET-16 Rev0 Page 7 / 18 Valve Automation Leader, HKC

3. Mounting and Operating 3.1. Actuator Mounting ET Series Heavy-duty Pneumatic Actuators 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 sideloading 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 Ø 335-485 Ø 535-785 Ø 835-1250 1/2 NPT 3/4 NPT 1 NPT 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. Doc No. : HUMG-ET-16 Rev0 Page 8 / 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 Doc No. : HUMG-ET-16 Rev0 Page 9 / 18 Valve Automation Leader, HKC

Figure 3-3b. Open Mode Operating Principle / Fail Close 4. Actuator Disassembly 4.1. General Information CAUTION: n n Turn off all power services before attempting to perform any service on the actuator. POTENTIAL HIGH PRESSURE VESSEL. Before removing or disassembling your actuator, ensure that the valve or other actuated devices are isolated and not under pressure. n n n DANGER: 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. Do not remove the Spring Module while the spring is compressed. Follow all instructions written on the warning tag (wired to the actuator cover) 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 Doc No. : HUMG-ET-16 Rev0 Page 10 / 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 Doc No. : HUMG-ET-16 Rev0 Page 11 / 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) Doc No. : HUMG-ET-16 Rev0 Page 12 / 18 Valve Automation Leader, HKC

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 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 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 into 8 with nuts. 5. Insert 13 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. Doc No. : HUMG-ET-16 Rev0 Page 13 / 18 Valve Automation Leader, HKC

5.2.2. Single Acting Actuator Reassembly CAUTION: ET Series Heavy-duty Pneumatic Actuators 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 2 If the failure position is to be altered, make sure that the spring return actuator disassembly procedures have been thoroughly reviewed 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. Doc No. : HUMG-ET-16 Rev0 Page 14 / 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 Air pressure is low Raise the air supply Pipe is obstructed by foreign substance Remove the substance in pipe Valve open/close does not operate smoothly 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 The open/close valve operates too quickly or slowly Air is escaping Stopper setting is incorrect Working torque of valve is too big The setting of speed controller is not calibrated correctly O-ring of piston or cover bushing is worn out Perform stopper settings again a) Raise the air supply b) Replace valve Reconfigure the speed controller Replace O-ring Doc No. : HUMG-ET-16 Rev0 Page 15 / 18 Valve Automation Leader, HKC

7. Actuator Module Weights Table 7-1. Symmetric Type Actuator ET Series Heavy-duty Pneumatic Actuators 085 100 130 160 200 ET-S DA (Kg) SR 4.2 BAR (Kg) SR 5.6 BAR (Kg) 200 90 150 160 250 110 190 200 300 130 230 240 335 150 250 280 335 220 350 380 385 260 410 430 435 290 460 550 435 390 620 740 485 430 730 820 535 520 880 1,010 535 620 1,110 1,250 585 720 1,200 1,390 635 840 1,450 1,620 635 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) 200 110 170 180 085 250 130 210 230 300 150 250 270 335 170 280 310 335 240 370 440 100 385 270 460 510 435 310 520 570 435 430 750 800 130 485 480 850 970 535 560 980 1,080 535 760 1,250 1,450 160 585 820 1,410 1,650 635 900 1,580 1,780 635 1,180 1,980 2,210 200 685 1,260 2,250 2,390 735 1,410 2,460 2,790 Doc No. : HUMG-ET-16 Rev0 Page 16 / 18 Valve Automation Leader, HKC

8. Actuator O-ring Parts SERIES PART 065 085 100 130 160 200 270 NAME 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 GUIDE BAR - - - P15 P16 G25 P35 GUIDE BUSH - - - P20, P26 P20, P26 P30, P40 P42, P50 F/E COVER AN264 AN372 G325 G325 AN383 P470 P720 200 P180 235 P220 335 P320 335 P320 385 P370 485 P470 735 P720 F/E PORT PLATE P12,P24 P12,P24 P12,P29 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER AN270 AN375 AN383 AN383 AN385 P770 235 P220 250 P235 385 P370 385 P370 435 P420 535 785 P770 F/E PORT PLATE P12,P24 P12,P24 P12,P29 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER AN272 G290 AN469 AN385 AN466 P570 P820 250 P235 300 P285 435 435 P420 485 P470 585 P570 835 P820 F/E PORT PLATE P12,P24 P12,P24 P12,P29 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER AN275 G325 AN466 AN466 P620 P870 280 P265 335 P320 485 P470 485 P470 535 635 P620 885 P870 F/E PORT PLATE P12,P24 P12,P24 P12,P24 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER AN277 AN383 P570 P670 P920 300 P285 385 P370 535 535 585 P570 685 P670 935 P920 F/E PORT PLATE P12,P24 P12,P24 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER G325 AN385 P570 P570 P620 P720 P970 335 P320 435 P420 585 P570 585 P570 635 P620 735 P720 985 P970 F/E PORT PLATE P12,P24 P12,P24 P570 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER AN383 AN466 P620 P670 P770 P1035 385 P370 485 P470 635 P620 685 P670 785 P770 1050 P1035 F/E PORT PLATE P12,P24 P12,P24 P12,P29 P12,P29 P12,P29 P12,P29 F/E COVER P670 P720 P820 P1135 535 685 P670 735 P720 835 P820 1150 P1135 F/E PORT PLATE P12,P29 P12,P29 P12,P29 P12,P29 Doc No. : HUMG-ET-16 Rev0 Page 17 / 18 Valve Automation Leader, HKC

9. Bolt & Nut Torque Table ET Series Heavy-duty Pneumatic Actuators Cover Bolt Spring Rod Lock Nut Model Name Torque Thickness Torque Size Length (L) Size (Nm) (T) (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 Top Cover Bolt Piston Retaining Nut Tie Rod Lock Nut Model Name 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 Doc No. : HUMG-ET-16 Rev0 Page 18 / 18 Valve Automation Leader, HKC