Instruction & Maintenance Manual - Challenger Valves · 2015. 5. 20. · HK PNEUMATI A TUATORS ‘HP’ SERIES 3 QAD#IM6030, REVA, 20.05.15 INTRODU TION This instruction manual contains

HKC PNEUMATIC ACTUATORS ‘HP’ SERIES

1 QAD#IM6030, REVA, 20.05.15

www.challengervalves.com.au

Instruction &

Maintenance

Manual

Thank you for purchasing our HP Series Actuator. Before installing or operating actuator, please carefully read this manual. The

contents in this manual is subject to change due to quality improvement without individual notice.


2 QAD#IM6030, REVA, 20.05.15

1. INTRODUCTION 3

2. WARNING 4

3. SPECIFICATION

3.1 Supply Pressure 5

3.2 Operating Temperature 5

3.3 Operating Media 5

3.4 Supply Air Volume 5

3.5 Operating Time 5

3.6 Weight 5

4. CONSTRUCTION 6

5. MATERIALS 6

6. PRINCIPLES OF OPERATION

6.1 Air connections - Double acting 7

6.2 Air connections - Spring return 8

7. ASSEMBLY

7.1 Assembly of accessories and valve

7.1.1 Assembly of valve 9

7.1.2 Assembly of accessories 9

7.1.3 Open/close adjustment 11

8. DISASSEMBLY 13

9. DIMENSIONAL DRAWING 15

Index


3 QAD#IM6030, REVA, 20.05.15

INTRODUCTION 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 and high quality. The pneumatic double rack & pinion actuator is 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 product quality and high quality performance on every HP actuator produced.

Top Mounting Connection

Model G H O

HP035 25 50 20

HP050 30 80 20

HP063 30 80 20

HP066 30 80 20

HP075 30 80 20

HP088 30 80 20

HP100 30 80 20

HP115 30 80 20

HP125 30 80 20

HP145 30 80 30

HP160 30 130 30

HP180 30 130 30

HP200 30 130 30

HP211 30 130 30

HP212 30 130 30

Bottom Mounting Connection

Model FLANGE L

(ISO5211) Q

BASE Tap DP

(mm) R

STEM (mm)

M(DP)/N(□)

HP035 F03/F05 M5/M6

10/9 Ø36/Ø50 9/10

HP050 F03/F05 M5/M6

12/11 Ø36/Ø50 9/10

HP063 F05/F07 M6/M8

17/14 Ø50/Ø70 11/14

HP066 F05/F07 M6/M8

17/14 Ø50/Ø70 11/14

HP075 F05/F07 M6/M8

19/17 Ø50/Ø70 12/14

HP088 F05/F07/F10 M6/M8/M10

22/17 Ø50/Ø70/Ø102 12/14/18

HP100 F07/F10 M8/M10

22/17 Ø70/Ø102 14/18

HP115 F07/F10 M8/M10 25/22 Ø70/Ø102 14/18

HP125 F07/F10 M10/M12 25/22 Ø70/Ø102 14/18

HP145 F10/F12 M10/M12

30/27 Ø102/Ø125 18/23

HP160 F10/F12 M10/M12

30/27 Ø102/Ø125 18/23

HP180 F14 M16

38/36 Ø140 18/23

HP200 F14 M16

38/36 Ø140 26

HP211 F14 M16

43/36 Ø140 26

HP212 F14 M16

53/46 Ø140 26


4 QAD#IM6030, REVA, 20.05.15

WARNING Actuator must be isolated both pneumatically and electrically before disassembly. Before mounting or disassembling the

actuator, consult the relevant sections of this manual. Do not operate the actuator using inflammable, oxidising, corrosive,

explosive or 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 (disassembly of spring return actuator may become dangerous). Operating the actuator in corrosive

environments with incorrect protection may damage the internal and external parts. Do not disassemble individual spring

cartridges. Disassembly 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

pressurised. Before installing to a valve, make sure that the rotation of the actuator are the same and that the position

indicator orientation is also correct.


5 QAD#IM6030, REVA, 20.05.15

SPECIFICATION 3.1 Supply Pressure

The maximum supply pressure (Double Acting, Spring return) is 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 gas

3.4 Supply Air Volume

3.5 Operating Time

3.6 Weight

Part HP035 HP050 HP063 HP066 HP075 HP088 HP100 HP115 Inner size (mm) Ø 35 50 63 66 75 88 100 115

Air Volume DA SR DA SR DA SR DA SR DA SR DA SR DA SR DA SR

Open (L) 0.1 -

0.1 0.1

0.2 0.2

0.2 0.2

0.3 0.3

0.5 0.5

0.7 0.7

1.2 1.2

Close (L) 0.1 0.2 0.3 0.3 0.5 0.8 1.1 1.8

Part HP125 HP145 HP160 HP180 HP200 HP210 HP211 HP212 Inner size (mm) Ø 125 145 160 180 200 210 210 210

Air Volume DA SR DA SR DA SR DA SR DA SR DA SR DA SR DA SR

Open (L) 1.5 1.5

2.4 2.4

3.1 3.1

4.3 4.3

5.9 5.9

7.8 7.8

5.1 5.1

9.6 9.6

Close (L) 2.3 3.8 4.2 6.9 9.5 8.2 8.6 10.7

Part HP035 HP050 HP063 HP066 HP075 HP088 HP100 HP115 Operating time (sec) DA SR DA SR DA SR DA SR DA SR DA SR DA SR DA SR

Open (L) 0.15 - 0.2 0.25 0.25 0.3 0.3 0.35 0.3 0.35 0.4 0.5 0.5 0.6 0.7 0.8

Close (L) 0.15 0.25 0.3 0.35 0.4 0.5 0.7 0.9 - 0.3 0.35 0.4 0.5 0.6 0.9 1.1

Part HP125 HP145 HP160 HP180 HP200 HP210 HP211 HP212 Operating time (sec) DA SR DA SR DA SR DA SR DA SR DA SR DA SR DA SR

Open (L) 0.9 1.1 1.2 1.4 1.5 1.7 2 2.2 2.7 3.2 3.1 3.5 2.7 3.2 3.5 4

Close (L) 1.2 1.5 1.8 2.4 3.5 4 4.3 5 1.4 1.8 2.1 2.8 4 4.5 4.3 5.5

Part HP035 HP050 HP063 HP066 HP075 HP088 HP100 HP115 Type DA SR DA SR DA SR DA SR DA SR DA SR DA SR DA SR

Weight (kg) 0.54 - 1.16 1.28 1.68 1.82 2.4 2.6 3 3.4 4.3 5 6 7 9 10.5

Part HP125 HP145 HP160 HP180 HP200 HP210 HP211 HP212 Type DA SR DA SR DA SR DA SR DA SR DA SR DA SR DA SR

Weight (kg) 11.3 13.4 15.5 19 22 25.9 26.5 33 38.4 46 46 54.5 46 62 71 91


6 QAD#IM6030, REVA, 20.05.15

CONSTRUCTION

MATERIALS

PART NO UNIT QTY PART DESCRIPTION STANDARD MATERIAL CORROSION PROTECTION OPTIONAL MATERIAL

1 4 Position Indicator Polypropylene +GF - -

2 1 Position Indicator Holder Polypropylene +GF - -

3 1 Spring Clip (Pinion) Stainless Steel HP160, 200 Nickel Plated -

4 1 Thrust Washer (Pinion) Stainless Steel - -

5 1 Thrust Bearing (Pinion) Polyphthalamide - -

6 1 Body Extruded Aluminium Alloy Hard Anodised -

7 2 Bearing (Piston Back) Polyphthalamide - -

8 2 Piston Die Cast Aluminium Hard Anodised -

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 (Cartridge) High Alloy Spring Steel Epoxy Coated -

28 1 Spring Holder Polypropylene +GF - -


7 QAD#IM6030, REVA, 20.05.15

PRINCIPLES OF OPERATION 6.1 Air connections - Double acting

OPEN

Air to port 2: counter clockwise/open

CLOSE

Air to port 4: clockwise/close

*Pistons must be inverted to reverse actuator rotation


8 QAD#IM6030, REVA, 20.05.15

PRINCIPLES OF OPERATION 6.2 Air connections - Spring return

Spring to close

Spring to open

Air to port 2: counter clockwise/open

Spring return: clockwise/close

Air to port 2: clockwise/close

Spring return: counter clockwise/open


9 QAD#IM6030, REVA, 20.05.15

ASSEMBLY 7.1 Assembly of accessories and valve

7.1.1 Assembly of valve

7.1.2 Assembly of accessories

Caution! Never disassemble a valve that is

under pressure!


10 QAD#IM6030, REVA, 20.05.15

ASSEMBLY 7.1.2 Assembly of accessories (cont.)

Caution! Never disassemble a valve

that is under pressure!

Tightening Torque Table

Metric Screw Nm

M5 5~6

M6 10~11

M8 23~25

M10 48~52

M12 82~86

M14 132~138

M16 200~210

M20 390~410

M24 675~705

M30 1340~1400


11 QAD#IM6030, REVA, 20.05.15

ASSEMBLY 7.1.3 Open/close adjustment


12 QAD#IM6030, REVA, 20.05.15

ASSEMBLY 7.1.3 Open/close adjustment (cont.)


13 QAD#IM6030, REVA, 20.05.15

DISASSEMBLY


14 QAD#IM6030, REVA, 20.05.15

DISASSEMBLY (cont.)


15 QAD#IM6030, REVA, 20.05.15

DIMENSIONAL DRAWING Bottom Mounting Connection

Model

FLANGE L

(ISO5211) R

A B C D E F G H I J K O S T U X V W

Q M/N (min)

HP035 F03/F05 M5/M6

126 54 30 24 69 49 25 50 PF M6 1/8” 20 4 4 12 32 24 16 Ø36/Ø50 10/9

HP050 F03/F05 M5/M6

144 72 42 30 93 30 30 80 PF M6 1/8” 20 4 4 12 32 24 16 Ø36/Ø50 12/11

HP063 F05/F07 M6/M8

163 85 47 38 107 87 30 80 PF M6 1/8” 20 4 4 12 32 24 16 Ø50/Ø70 17/14

HP066 F05/F07 M6/M8

202 85 47 38 107 87 30 80 PF M6 1/8” 20 4 4 12 32 24 16 Ø50/Ø70 17/14

HP075 F05/F07 M6/M8

210 96 53.

5 42.5 124 104 30 80 PF M6 1/8” 20 4 4 12 32 24 16

Ø50/Ø70 19/17

HP088 F05/F07/F10 M6/M8/M10

247 108 58.

5 49.5 136 116 30 80 PF M6 1/8” 20 4 4 12 32 24 16

Ø50/Ø70/Ø102 22M17

HP100 F07/F10 M8/M10

268 123 67 56 148 128 30 80 PF M6 1/4” 20 4 4 12 32 24 16 Ø70/Ø102 22/17

HP115 F07/F10 M8/M10

316 141 77 64 166 146 30 80 PF M6 1/4” 20 4 4 12 32 24 16 Ø70/Ø102 25/22

HP125 F07/F10 M8/M10/M12

347 151 82 69 179 159 30 80 PF M6 1/4” 20 4 4 12 32 24 16 Ø70/Ø102 26/22

HP145 F10/F12 M10/M12

414 172 92 80 209 176 30 80 PF M6 1/4” 20 4 4 12 32 24 16 Ø102/Ø125 30/27

HP160 F10/F12 M10/M12

467 190 101 89 226 196 30 130 PF M6 1/4” 20 4 4 12 32 24 16 Ø102/Ø125 30/27

HP180 F14 M10/M12

497 20 107 99 251 221 30 130 PF M6 1/4” 20 4 4 12 32 24 16 Ø140 38/36

HP200 F14 M16

555 227 116 111 277 247 30 130 PF M6 1/4” 20 4 4 12 32 24 16 Ø140 38/36

HP210 F14 M16

628 236 120 116 286 256 30 130 PF M6 1/4” 20 4 4 12 32 24 16 Ø140 43/36

F14 M16 - HP211 236 120 116 286 256 30 130 PF M6 1/4” 20 4 4 12 32 24 16

Ø140 53/46

HP212 F14 M16

- 236 120 116 286 256 30 130 PF M6 1/4” 20 4 4 12 32 24 16 Ø140 53/46

Documents

Instruction & Maintenance Manual - Challenger Valves · 2015. 5. 20. · HK PNEUMATI A TUATORS ‘HP’ SERIES 3 QAD#IM6030, REVA, 20.05.15 INTRODU TION This instruction manual contains