A-T Controls TRIAC APL-9 Series Instruction Manual


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
1
May 16, 2016
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Iom08074
APL-9 Series Valve Position Monitor
Installation, Operation & Maintenance Manual


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
2
May 16, 2016
www.atcontrols.com
Iom08074
Contents
1. General......................................................................................................................................... 3
2. Standard specification..................................................................................................................3
3. Standard Features ........................................................................................................................ 4
4. Installation ...................................................................................................................................5
4.1. Mounting bracket...............................................................................................................5
4.2. Mounting limit switch box ................................................................................................5
4.3. Cam setting ........................................................................................................................ 6
4.4. Wiring................................................................................................................................6
5. Maintenance................................................................................................................................. 8
6. Inspection.....................................................................................................................................8
7. Storage ......................................................................................................................................... 8
8. Trouble shooting..........................................................................................................................8
9. Tools ............................................................................................................................................9
10. Installation and Maintenance Tips ............................................................................................9


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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May 16, 2016
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Iom08074
1. General
TRIAC Controls APL-9 series limit switch box is designed to provide accurate and reliable valve position
signaling and indicating of most valves or actuators manufactured. The press-formed, all stainless-steel
housing provides a lightweight and compact design with high corrosion resistance.
APL-9 limit switch boxes consist of a visual position indicator, quick-set cam assembly, terminal strip,
switch assembly and integral mounting bracket. Quick-set cam allows for a quick and simple hand
operation in the setting of switches.
2. Standard specification
Model
APL-9** *
Electrical Ratings
Type 4x / 6, IP66 / 67
Enclosure Material
304 stainless steel
Ambient Temperature
-20°C ≤Ta ≤+80°C
Conduit Entries
Two NPT 1/2”
Travel Angle
90 degree +/- 10%
Position Indicator
Open: Green
Close: Red
Language: English
Mechanical Switch
SPDT (10, 12): 16A 1/2HP 125/250Vac, 0.6A 125Vdc, 5A 125Vac
SPDT Gold Plated (18): 0.1A 125Vac/30Vdc
Proximity sensor
NAMUR P&F NJ2-V3-N (20): Uo = 8.2V nominal @ Ri = 1kΩ.
PNP Sourcing 3-wire P&F NBB2-V3-E2 (23): 10-30Vdc, 100mA@30Vdc
SPST Reed Switch (30): 50W Max, 250Vdc 3.0A max.
Terminal Strip
8 position


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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May 16, 2016
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3. Standard Features


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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May 16, 2016
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4. Installation
Caution; Where limit switch box or one of parts are to be moved, installed, disassembled,
reassembled, care must be taken to not cause injury by sharp edges of corners or rough
surfaces or residual electricity.
4.1. Mounting bracket
4.1.1. TRIAC Controls APL-9 is supplied with integral NAMUR VDI/VDE standard bracket and
hardware for mounting on actuator. Bracket is configurable to several standard VDI/VDE
mounting patterns.
①Arrange adjustable bracket feet for (80 x 30) or (130 x 30) mounting.
②Position bracket feet at desired height (20mm, 30mm, 40mm or 50mm).
③Tighten the screws using a proper tool.
30mm bracket height
4.2. Mounting limit switch box
Caution: Do not attempt to work on limit switch box without first shutting off incoming power
4.2.1. Prior to mounting the limit switch, enclosure must
be checked for any damage.
4.2.2. Damaged parts must be replaced with original
spare parts.
4.2.3. Limit switch boxes are standard with a NAMUR
shaft that enables direct attachment to actuator
pinion without a coupler. These shafts feature a
4mm wide tang that engages the 4mm slot in
NAMUR actuators.
①Check to be sure the drive slot on the top of
the actuator and the shaft of switch box are
the same direction.
②Ensure proper mounting configuration of
bracket feet.
③Tighten the bolts using the proper tool.
④Check the assembly for proper operation.

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APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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May 16, 2016
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4.3. Cam setting
4.3.1. The color of cams matches the position indicator to help set the cams easily without wiring
diagram. Cams can be easily set without tools. APL series cams are splined and can be set
by lifting up or pushing down on the cam to be set.
Self-locking, spring loading ensures cams never slip out of adjustment.
4.3.2. Loosen the captive cover bolts with an applicable tool. (Wrench or Screwdriver recommended)
4.3.3. Remove cover carefully.
4.3.4. Open cam setting
①Operate the actuator to fully open position
②Lift the bottom green cam up and rotate it until the switch is activated.
③Release the cam so it fits back over the cam gear.
4.3.5. Close cam setting
①Operate the actuator to fully closed position
②Push the upper red cam down and rotate it until the switch is activated.
③Release the cam so it fits back over the cam gear.
4.4. Wiring
Danger: HAZARDOUS VOLTAGE. No electrical power should be connected until all
wiring and limit switch adjustments have been completed.
4.4.1. APL limit switch box enclosure feature prewired switches. All user connections are made at a
numbered terminal strip. A wiring diagram, located inside the cover, indicates which terminal
numbers correspond to switch contacts, such as normally open (NO), normally closed (NC),
etc. Follow the wiring diagram and electrical code to connect the switches to your system.
4.4.2. Solenoid valve may also can be wired through the APL enclosure. Two auxiliary terminals are
typically included as standard.
4.4.3. APL limit switch box has two cable entries on the body. A blanking plug that meets the type of
protection must be installed in unused cable entries. Cable gland is not supplied by TRIAC
Controls and shall be provided by installer or user.
Note;
Grounding must be connected once all wiring had been completed.
Internal/External grounding wire square shall be min. 18AWG recommended

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APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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①2 SPDT
②4 SPDT
③2 NAMUR Output P&F NJ2-V3-N


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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May 16, 2016
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5. Maintenance
Caution: Shut off incoming power and air supply on the valve actuator before maintenance of
limit switch box.
Be sure that the area is clean before disassembly and maintenance of limit switch box.
Clean all parts and housing before reassembly.
- Refer to the part list when ordering replacement or spare parts.
5.1. Maintenance, under normal conditions at six-month intervals or 100,000 cycle operation.
When conditions are more severe, more frequent inspections may be required.
①Ensure valve actuator alignment
②Ensure wiring is insulated, connected and terminated properly
③Ensure all screws are present and tight
④Ensure cleanliness of internal electrical devices
⑤Ensure conduit connections are installed properly and are dry
⑥Check internal devices for condensation
⑦Check enclosure O rings seals and verify that the O ring is not pinched between housing
⑧Visually inspect during open/close cycle
⑨Inspect identification labels for wear and replace if necessary
Warning;
Treat cover with care. Mating surfaces must not be damaged in any way.
6. Inspection
6.1. The limit switch box should be inspected upon receipt to ensure that no damage has been sustained
on transit.
6.2. Check the item and quantity of products with packing list or related documents.
6.3. Check the limit switch box o-ring. Damage to it can cause the corrosion of internal parts.
6.4. Check the adjustment of cams and make sure they are securely held on the shaft gear.
7. Storage
The products must be stored in a clean, cool and dry area. The unit shall be stored with the cover installed
and the conduit openings sealed with metal plugs. Storage must be off the floor, covered with a sealed
dust protector.
8. Trouble shooting
The following instructions are offered for the most common difficulties encountered during installation and
start-up.
Signal fails to main control room.
①Check wiring of limit switch box is in accordance with wiring diagram.
②Check if the cams or switches are damaged or broken.
③Check the main signal wire from the terminal strip.
④Check if the cams are set properly.
⑤Adjust mounting of the limit switch box.


APL-9 SERIES
Stainless Steel Limit Switch
Installation & Maintenance Manual
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May 16, 2016
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9. Tools
①1 Set Metric Allen Key (Hex Wrench)
②Set Screw Drivers
③1 Set Metric Wrench
④1 Wire Stripper long Nose
⑤1 Needle nose plier
⑥1 Multi Meter (AC, DC, Resistance)
⑦1 4-20mA Loop Calibrator (if applicable 16 adapted)
10. Installation and Maintenance Tips
For any installation and maintenance work, the following should be observed:
Caution:
A regular inspection and maintenance performed by qualified and trained personnel.
When working in potentially explosive areas, observe the standard EN 60079-14 “Electrical
Installations in Hazardous Areas”.
Work at the open actuator under voltage must only be performed if it is assured that for the
duration of the work there is no danger of explosion.
Observe additional national regulations.
10.1. Check the limit switch box visually. Ensure that no outside damage or changes are visible.
10.2 Check electric connecting cables and ensure they are without damage and are wired correctly.
10.3. Cable entries, cable glands, plugs etc. have to be checked for correct tightness and sealing.
10.4. Check whether enclosure connections are fastened correctly.
10.5. Take care of possible discoloration of the terminals and wires.
10.6. Check the enclosure joints for dirt and corrosion.
10.7. Ensure that all housing covers are handled carefully and that the seals are checked.
10.8. If defects which affect the safety are detected during maintenance, repair measures have to be
taken immediately.
10.9. Any kind of surface coating for the mating surfaces between housing and cover is not permitted.
10.10. When exchanging parts, seals etc. only original TRIAC Controls spare parts shall be used.
A-T Controls product, when properly selected, is designed to perform its intended function safely during its useful life. However, the purchaser or user of A-
T Controls products should be aware that A-T Controls products might be used in numerous applications under a wide variety of industrial service
conditions. Although A-T Controls can provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser
/ user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of A-T Controls
products. The user should read and understand the installation operation maintenance (IOM) instructions included with the product, and train its employees
and contractors in the safe use of A-T Controls products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only. Because A-
T Controls is continually improving and upgrading its product design, the specifications, dimensions and information contained in this literature are subject
to change without notice. Should any question arise concerning these specifications, the purchaser/user should contact A-T Controls.
For product specifications go to http://download.a-tcontrols.com/
A-T Controls, Inc. • 9955 International Boulevard, Cincinnati, OH 45246 • Phone: [phone] • Fax: [phone] • www.atcontrols.com