HKC APL-5 Series Instruction manual

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 1 / 13
APL-5 Series Valve Position Monitor
Installation, Operation & Maintenance Manual

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 2 / 13
Contents
1. General ................................................................................................................. 3
2. Ordering Information ............................................................................................. 3
3. Standard specification ........................................................................................... 4
4. Preparing for Installation ....................................................................................... 4
4.1. Marking...................................................................................................... 4
4.2. Pre-Installation for use in potentially explosive atmosphere ........................ 5
4.3. Initial inspection ......................................................................................... 5
5. Standard Features ................................................................................................. 6
6. Installation ............................................................................................................ 6
6.1. Mounting bracket ....................................................................................... 6
6.2. Mounting limit switch box ........................................................................... 7
6.3. Cam setting ................................................................................................ 7
6.4. Wiring ........................................................................................................ 8
6.5. Setting for Position Transmitter Unit (APL- 5*6) ........................................ 10
7. Maintenance ....................................................................................................... 11
8. Inspection ........................................................................................................... 11
9. Storage ............................................................................................................... 12
10. Trouble shooting .............................................................................................. 12
11. Tools ................................................................................................................ 12
12. Installation and Maintenance Tips ..................................................................... 12

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 3 / 13
1. General
1.1. HKC APL-5… series limit switch boxes are designed to provide accurate and reliable valve
position signalling and indicating of most valves or actuators manufactured.
1.2. APL-5… limit switch boxes consists of a visual position indicator, quick-set cam ass’y, terminal
strip, switch ass’y and easy mounting bracket. Quick-set cam allows for a quick and simple
hand operation in the setting of switches.
2. Ordering Information
APL - 5 1 0 N
① ② ③
① Enclosure type of explosion proof is based on IECEx :
Ex d IIC T6 Gb
Ex ia IIC T6 Gb (APL-520 * only)
Ex tb IIIC T85℃ Db, IP67
Enclosure type of explosion proof is based on ATEX :
II 2 G Ex d IIC T6 Gb
II 2 G Ex ia IIC T6 Gb (APL-520 * only)
II 2 D Ex tb IIIC T85℃ Db, IP67
Enclosure type of explosion proof is based on KCs, NEPSI :
Ex d IIC T6 Gb
Ex ia IIC T6 Gb (APL-520 * only, KCs only)
Ex tD A21 IP67 T85℃ (KCs only)
Enclosure type of explosion proof is based on CSA :
Class I, Division 1, Group B, C & D T6
Class I, Zone 1, AEx d IIC T6
Ex d IIC T6
② Switch type
10 : 2-SPDT (Wonwoo : SZM-V16-5FA-61)
11 : 3-SPDT (Wonwoo : SZM-V16-5FA-61)
12 : 4-SPDT (Wonwoo : SZM-V16-5FA-61)
13 : 2-SPST (Wonwoo : SZM-V16-5FA-61)
14 : 2-DPDT (Omron : DZ-10GW-1B)
15 : 2-SPDT + Potentiometer (Wonwoo : SZM-V16-5FA-61)
16 : 2-SPDT + Signal Unit(4~20mA) (Wonwoo : SZM-V16-5FA-61)
20 : Proximity Sensor (P&F : NJ2-V3-N)
21 : Proximity Sensor (Autonics : PS17-5DNU) (Except CSA)
23 : Proximity Sensor (P&F : NBB2-V3)
25 : Proximity Sensor (P&F : NJ2-V3-N) + Potentiometer
26 : Proximity Sensor (P&F : NJ2-V3-N) + Signal Unit(4~20mA)
30 : Reed type Proximity Sensor (MS-B 301)
③ Enclosure Material
N : Aluminium Alloy
S : Stainless Steel

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 4 / 13
3. Standard specification
Model APL-5** *
Enclosure Rate Please refer to “2. Ordering Information, ① Enclosure type”
Enclosure Material High grade aluminium alloy or stainless steel
Ambient Temperature -20°C ≤ Ta ≤ +60 °C
Cable Entries Standard : Two NPT 3/4”, or M25 for Ex type
(Option for Non-Ex : NPT1/2”, PT3/4”, PT1./2”, PF3/4”, PF1/2”, M20)
Travel Angle 90 degree +/- 10%
Position Indicator Open : Yellow, Close : Red
Language : English (Option : French, German)
Mechanical Switch SZM-V16-5FA-61 (Wonwoo Starion)
16A 1/2HP 125/250Vac, 0.6A 125Vdc, 0.3A 250Vdc, 5A 125Vac
Proximity sensor NJ2-V3-N (PEPPERL+FUCHS) : 5~25Vdc , 15mA max.
PS17-5DNU(Autonics) : 12~24Vdc, 0.2mA max.
MS-B 301 : 250Vdc 3.0A max.
Potentiometer 1kΩ (Option : 0~5kΩ , 0~10kΩ)
Current Output Signal Unit 4~20mA, 20~4mA
Terminal Strip 8 point (option : 9~14P)
External Coating Thermally hardened polyester powder coating
4. Preparing for Installation
4.1. Marking
HKC logo / Trade mark
Model
Switches type
Cert No.
Applicable temp.
Serial No.
Manufactured year
Cable entry size
Warning letter
Maker address
Usage as Ex d & tb for APL-5***
Usage as Ex ia & tb for APL-520*
Usage as Ex d ia & tD for APL-5*** KCs

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 5 / 13
4.2. Pre-Installation for use in potentially explosive atmosphere
Installation, commissioning, maintenance, repairs and modification work must only be
performed by qualified personnel with extensive knowledge on how to work on explosion-proof
electrical equipment.
Warning : Read this installation and maintenance manual carefully and completely before
attempting to install, operate, or troubleshoot the HKC product
4.2.1. Cable Connection
①Sealing devices must be used and shall be fitted directly at enclosure wall when using
conduit.
②Cable glands shall be suitable for the environment and shall be certified as flameproof if
used in Zone 1 application of IECEx scheme in order to connect outside electric wire.
③Cable glands and conduit to be installed minimum 8 full threads and the length of thread
is minimum 8mm.
④“Warning” : Please be sure that user should select the appropriate cable glands and
minimum 2SQ of wire for fear that the proper using temperature of cable entry and wire
way exceed 70 ℃ or the blanching point is over 80 ℃.
⑤When cable entries or conduit entries are not used, user or installer shall close by certified
blanking elements(stopping plugs) so that the flameproof properties of the enclosure are
maintained.
4.2.2. Groundings
①Always ground the enclosure in accordance with local electric codes. The most effective
enclosure grounding method is a direct connection to earth ground with minimal
impedance. Methods for grounding the enclosure include:
Internal ground connection : The internal ground is located inside the body .
External ground connection : The ground bracket is located on the side of body.
(Min 2SQ wire required)
4.2.3. Special Condition for safe use (“X” marking)
①Electrostatic discharge from window(over 1GΩ) may cause the ignition on the explosive
gas atmosphere. By adapting the conducting window bolts make reduce the risk from
electrostatic discharge.
②Before installation or maintenance products, shut off incoming power and grounding
should be connected.
③The window must only be cleaned with a damp cloth in order to avoid ignition hazard
caused by static electricity.
4.3. Initial inspection
When the user receipts the product, inspect the condition of the product and ensure the name
plate comparing with order sheet.
4.3.1. Remove packing wrap or wooden box carefully. Inspect the product for any physical
damage that may have occurred during shipment.
4.3.2. Check the product specification with product ordered. If an wrong product have been
shipped, immediately report to our coordinator.
Usage as Ex d for APL-5*** CSA

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 6 / 13
5. Standard Features
No.
Part Name
Q’ty
Description
1
Window / Indicator
1
PC / ABS
2
Cover
1
Aluminium die casting (ADC12), Stainless steel (CF8M)
3
Captive Cover Bolt
4
Stainless steel
4
Name Plate
1
Stainless steel (A240 T304)
5
Shaft
1
Stainless steel (G4303 SUS303)
6
Cam
2
PC
7
Switch
2
Refer to the clause “2. Ordering Information ② Switch type”
8
Body
1
Aluminium die-casting(ADC12), Stainless steel(CF8M)
9
Terminal Strip
1
8P (9~14P available)
10
Earth Lug
2
Stainless steel
11
Blanking Element
2
Aluminium plug (ADC12)
6. Installation
6.1. Mounting bracket
Caution ; Where limit switch box or one of parts are to be moved, installed, disassembled,
reassembled by a hand, care must not be taken to cause injury by the harmful sharp edges
of corners or rough surfaces or residual electricity.
6.1.1. HKC shall supply a NAMUR VDI/VDE standards’ bracket and a fixing stuff for mounting on
actuator. Brackets are able to applied any type of valves ; manual valve, linear valve,
pneumatic rotary valve.
① Insure valve actuator alignment (fully open or closed).
② Place the mounting bracket on a horizontal plane of actuator
③ Tighten the bolts enclosed in a box using a proper tool.
4
3
2
1
5
6
7
8
9
10
11

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 7 / 13
6.2. Mounting limit switch box
Caution ;
Do not attempt to work on limit switch box without first shutting off incoming power
6.2.1. Prior to mounting the limit switch box must be checked for any damage.
6.2.2. Damaged parts must be replaced by original spare parts.
6.2.3. Limit switch boxes are available 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.
②Insert the shaft of switch box carefully into the
mounting bracket.
③Tighten the bolts enclosed in a box using a proper tool.
④Check the connection of shaft being assembled
correctly.
6.3. Cam setting
Note :
Basically, cams shall be set by manufacturer before shipment.
6.3.1. The colour of cams harmonized with position indicator help us to set the cams easily
without wiring diagram. Cams shall be easily set without tool. APL series cams are splined
and can be setting lift up or push down the cam from gear by hand in a seconds without
setting tools. Self-locking, spring loading make never slip out of adjustment.
6.3.2. Loose the captive cover bolts with an applicable tool. (L-Hex. Wrench recommended)
6.3.3. Turn the cover counter clockwise to open carefully.
6.3.4. Open cam setting
① Electric power or air supply of valve actuator on to operate the actuator fully open
② Lift the bottom yellow cam up and rotate it until the switch is activated.
③ And then release it. Cam shall be back into a stable position by itself.
6.3.5. Close cam setting
① Electric power or air supply of valve actuator off to operate the actuator fully close
② Push the upper cam down and rotate it until the switch is activated.
③ And then release it. Cam shall be back into a stable position by itself.
Mechanical switches
Proximity sensors
Splined cam

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 8 / 13
6.4. Wiring
Danger ; HAZARDOUS VOLTAGE. No electrical power should be connected until all
wiring and limit switch adjustments have been completely.
6.4.1. [Open circuit before removing cover, and seal required within 50mm
(2 inch) of the enclosure by CSA ---- 15 r0]
6.4.2. 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.
6.4.3. Solenoid valve may also can be wired through the APL enclosure. Two auxiliary terminals
are included as standard.
6.4.4. APL limit switch box has two cable entries on the body and supply a blanking plug not a
cable gland which meet the type of protection. Cable gland shall be applied by installer or
user.
①Mechanical Switch (2 SPDT)
②Mechanical Switch (3 SPDT)

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 9 / 13
③ Mechanical Switch (4 SPDT)
④ Mechanical Switch (2 DPDT)
⑤ Mechanical Switch (2 SPDT) with Potentiometer

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 10 / 13
⑥ Mechanical Switch (2 SPDT) with Signal Unit
Note ;
Grounding should be connected until all wiring had been completely.
Internal/External grounding wire square shall be min. 2SQ recommended.
6.5. Setting for Position Transmitter Unit (APL- 5*6)
6.5.1. Potentiometer reads the current position of actuator and transfers a resistance value to a
current position transmitter card. Transmitter indicates the actuator position throughout
the stroke by a 4~20mA output signal.
6.5.2. Technical Features
①Power Supply Range 12.5 ~ 37VDC (24V typical)
②Current Signal Output 4~20mA
③Max. Load Resistance Max. Resistance (ohm) = (Supply voltage  12.5) / 0.02
④Potentiometer 0~500 ohm / 10k ohm
⑤Operating Temperature -20 ~ 60 ℃
⑥Dimension 40 * 60 * 15

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 11 / 13
6.5.3. Calibration Potentiometer
① Apply power or air to the actuator to operate fully closed position
② Connect an ohm meter to P1 and P3 resistances, the values shall be approximately 1kΩ.
③ Loosen the shaft gear and connect the ohm meter to P1 and P3 and gently rotate until 80
~ 120 ohm is achieved (100ohm preferred). While maintaining the value, tighten a lock
screw with a hex wrench.
6.5.4. Calibration Zero Span
Zero span setting has been calibrated by manufacturer. However if re-calibration is
required
① Operate a actuator to 50% position and then fully closed position.
② When the actuator is in the fully closed position, adjust the “zero” button on the card until
a value of 20mA is achieved.
7. Maintenance
Caution ;
- Shut off incoming power or air supply on the valve actuator before maintenance limit
switch box.
- Be sure that the area is clean before disassemble and maintenance limit switch box. Clean
all parts and housing before re-assemble.
- Refer to the part list when ordering replacement or spare parts.
7.1. Maintenance, under normal conditions at six month intervals or 10,000 cycle operation.
But when conditions are more severe, more frequent inspections may be required.
7.1.1. Insure valve actuator alignment
7.1.2. Insure wiring is insulated, connected and terminated properly
7.1.3. Insure all screws are present and tight
7.1.4. Insure cleanliness of internal electrical devices
7.1.5. Insure conduit connections are installed properly and are dry
7.1.6. Check internal devices for condensation
7.1.7. Check enclosure O rings seals and verify that the O ring is not pinched between housing
7.1.8. Visually inspect during open/close cycle
7.1.9. Inspect identification labels for ware and replace if necessary
Warning ;
Flameproof enclosure! Before opening, ensure the absence of gas, dust and voltage.
Treat cover with care. Gap surfaces must not be damaged or dirtied in any way.
8. Inspection
8.1. The limit switch box should be inspected upon receipt to ensure that no damage has been
sustained on transit.
8.2. Check the item and quantity of products with packing list or related documents.
8.3. Check the limit switch box o-ring. Where damage on it, it caused the corrosion of internal parts.
8.4. Check the adjustment of cams. Cams shall be released when those have been used for a long
period of operating. If do so, they don’t work correctly with switches.

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 12 / 13
9. 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. Storage must be off the floor, covered with a sealed dust
protector.
10. Trouble shooting
The following instructions are offered for the most common difficulties encounter during installation
and start-up.
Signal fails to main control room.
① Check the wiring of limit switch box in accordance with wiring diagram.
② Check where the cams or switches are damaged or broken.
③ Check the main signal wire from the terminal strip.
④ Re-set the limit switch box.
⑤ Verify the current position transmitter resistance value.
⑥ Check potentiometer gear jamming.
⑦ Check the zero and span calibration.
⑧ Check the card damaged or not.
11. Tools
① 1 Set Metric Allen Key (Hex Wrench)
② Set Screw Drivers
③ 1 Set Metric Spanner
④ 1 Wire Stripper long Nose
⑤ 1 Needle nose plier
⑥ 1 Multi Meter (AC, DC, Resistance)
⑦ 1 ohm Meter (0~25mA) : if applicable 16 adapted
12. Installation and Maintenance Tips
For any installation and maintenance work, the following should be observed :
Caution :
ü A regular inspection and maintenance performed by qualified and trained personnel
ü When working in potentially explosive areas, observe the standard EN 60079-14 “Electrical
Installations in Hazardous Areas”.
ü 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.
ü Observe additional national regulations.
12.1. Check the limit switch box visually. Ensure that no outside damage or changes are visible. The
electric connecting cables must be without damage and wired correctly.
12.2. Cable entries, cable glands, plugs etc. have to be checked for correct tightness and sealing.
12.3. Check whether Ex-connections are fastened correctly.
12.4. Take care of possible discolouration of the terminals and wires.
12.5. Check the flame path gaps of flameproof enclosures for dirt and corrosion. Since the
dimensions of all Ex gaps are strictly defined and inspected, no mechanical work shall be
performed on them.
12.6. Ensure that all housing covers are handled carefully and that the seals are checked.
12.7. All cable has to be checked.

APL-5 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL5-16 Rev0 Page 13 / 13
12.8. If defects which affect the safety are detected during maintenance, repair measures have to be
taken immediately.
12.9. Any kind of surface coating for the gap surface is not permitted.
12.10. When exchanging parts, seals etc. only original spare parts shall be used.
Warning ;
Flameproof enclosure! Before opening, ensure the absence of gas, dust and voltage.