HKC HL Series Instruction manual

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 1 / 26 Valve Automation Leader, HKC
HL Series Electric Linear Actuators
Installation, Operation & Maintenance Manual
Address : 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, 15119, Republic of Korea
Tel : [phone], Fax : [phone], Home page : www.hkcon.co.kr, email : [e-mail]

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 2 / 26 Valve Automation Leader, HKC
Contents
1. Introduction ...................................................................................................................................... 3
1.1. Purpose .............................................................................................................................................. 3
1.2. Safety Notices .................................................................................................................................. 3
2. Product Identification ..................................................................................................................... 3
2.1. Product Identification ..................................................................................................................... 3
2.2. Initial inspection .............................................................................................................................. 4
2.3. Storage .............................................................................................................................................. 4
3. General Information and Features ............................................................................................... 5
3.1. General ............................................................................................................................................... 5
3.2. External Parts for Standard Models ............................................................................................. 7
3.3. Internal Parts for Standard Models ............................................................................................. 7
4. Installation Instruction ................................................................................................................... 7
4.1. Pre-Installation ................................................................................................................................. 7
4.2. Actuator Mounting .......................................................................................................................... 8
4.3. Limit Switch Setting ........................................................................................................................ 9
4.4. Force Switch Setting ..................................................................................................................... 10
4.5. Position Feedback Potentiometer (Optional) ......................................................................... 10
4.6. Current Position Transmitter – CPT (Optional)........................................................................ 11
4.7. Proportional Control Unit ............................................................................................................ 12
5. [Apply for optional communication protocol ......................................................................... 18
5.1. ProfiBus Controller (PBC) ............................................................................................................. 18
5.2. ModBus Controller (MBC) ............................................................................................................ 19
6. Wiring .............................................................................................................................................. 20
6.1. Electrical Connections and Preliminary Test ............................................................................ 20
7. Maintenance ................................................................................................................................... 21
7.1. Maintenance ................................................................................................................................... 21
7.2. Tools ................................................................................................................................................. 21
8. Trouble Shooting ........................................................................................................................... 21
8.1. The actuator does not respond .................................................................................................. 21
8.2. The actuator is supplied with power but does not operate ................................................. 21
8.3. Actuator runs erratically ............................................................................................................... 22
8.4. Optional Equipment(s).................................................................................................................. 22
9. Installation and Maintenance Tips ............................................................................................. 22
APPENDIX Ⅰ. HL Series Coding System .......................................................................................... 23
APPENDIX II . Wiring Diagrams for Standard Models .................................................................. 24
Appendix III: Grounding ...................................................................................................................... 26

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 3 / 26 Valve Automation Leader, HKC
1. Introduction
1.1. Purpose
The purpose of this manual is to introduce and explain the installation, operation and maintenance of
HL-series electric actuators. This IOM Manual is distributed as a hard copy when delivered the ordered
products to customer.
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. User(s) must read these instructions before the installation, operation or
maintenance of HL-series electric 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.
2. Product Identification
2.1. Product Identification
The actuator name plate is located on the opposite side of the cable entry. The name plate contains the
following:
2.1.1. Marking
① [General:
HL logo (trade mark), Model,
Maximum stroke, Option, Serial
No., Electrical power supply, Rated
current, Output force(Thrust) and
Operating time on a type of sticker
② [Flame proof for IECEx Ex db IIB T4 Gb, ATEX 2 II G Ex db IIB T4 Gb, KCs Ex d IIB T4 Gb, EAC 1Ex d
IIB T4 Gb :
③ Dust ignition proof for IECEx Ex tb IIIC T135’C Db, ATEX 2 II D Ex tb IIIC T135’C Db. KCs Ex tD A21
IP6X T135’C, EAC Ex tb IIIC T135’C Db X
Manufacturer, Actuator type, Model, Electrical power supply, Output force, Stroke, Operating speed,
Cable entry, Serial number, Address, Certification number, Explosion proof type and application
temperature range on a Stainless steel plate.
---21 Rev1]

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 4 / 26 Valve Automation Leader, HKC
2.1.2. Applied Standard
① [IEC60079-0:2017(Ed.7.0 +IS01, EN60079-0:2012 +A11-2013
② IEC60079-1:2014 (Ed.7), EN60079-1:2014
③ IEC60079-31:2013(Ed.2), EN60079-31:2014 -------------- 20 Rev0]
2.1.3. Certification
① [IECEx: for HL-05kN ~ HL-25kN, IECEx EPS 18.0123X
Ex db IIB T4 Gb, Ex tb IIIC 135’C Db, Ta -20℃ to +60℃,
② ATEX: for HL-05kN ~ HL-25kN, EPS 18 ATEX 1 246 X, CE 0344
II 2 G Ex db IIB T4 Gb, II 2 D Ex tb IIIC 135’C Db, Ta -20℃ to +60℃
③ KCs(KOSHA) for standard type HL-05/07kN with LCU Unit, 10-AV2BO-XXXX,
for standard type HL-10/12/15kN with LCU Unit, 10-AV2BO-XXXX,
for standard type HL-18/20/25kN with LCU Unit, 10-AV2BO-XXXX,
Ex d IIB T4, -20℃ ~ +60℃
KCs(KOSHA) for standard type HL-05/07kN with LCU Unit, 10-AV2BO-XXXX,
for standard type HL-10/12/15kN with LCU Unit, 10-AV2BO-XXXX,
for standard type HL-18/20/25kN with LCU Unit, 10-AV2BO-XXXX,
Ex tD A21 IP6X T135℃
④ EAC: 1Ex d IIB T4 Gb X, -60℃ ~ +60℃ ----------------------------- 20 Rev.0]
⑤ [CCC: Ex d IIB T4 Gb, Ex tD A21 IP6X T135℃, CNEX 2021 3123 0700 0206 ------- 21 rev1]
Notes :
 Sealing devices must be used and shall be fitted directly at enclosure wall when using conduit.
 Cable glands shall be suitable for the environment and shall be certified as flameproof if used in Zone
1 application.
 Cable glands and conduit to be installed minimum 6 full threads and the length of thread is minimum
8mm.
 Temperature of cable entry is maximum 100℃. Heat resistance wire is recommended when you install.
 Ex db and/or Ex tb certified cable glands suitable for 100℃ must be used.
 Users should confirm all information about dimensions of flamepath with the manufacturer
 All information about the material and the allowance of LCU fasteners
- Fasteners with yield stress≥ 210MPa (stainless steel)
- [Bolts type : M6*1.25, M8*1.25, M10*1.5, M12*1.75 (Tolerance Fit 6g) ---- 20 Rev0]
 Cable connection : Refers to the Appendix Ⅱ (Wiring Diagram)
 For cable entries or conduit entries that are not used, user or installer shall close by certified blanking
elements(stopping plugs) so that the flameproof properties of the enclosure are maintained.
 Always 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 in the terminal block #1. Refer to the
enclosed wiring diagram.
- External ground connection : The ground lug is located on the centre of cable entries.
- For more information, refer to the Appendix Ⅲ (Grounding)
 [Stainless steel name plate for the flame proof and dust ignition proof type shall be permanently attached
by rivets on the cover. ----- 20 Rev0]
2.2. Initial inspection
When the user receives the actuators, inspect the condition of the product and ensure the name plate
comparing with order sheet.
2.2.1. Remove packing wrap or wooden box carefully. Inspect the product for any physical damage that
may have occurred during shipment.
2.2.2. Check the product specification with product ordered. If an wrong product have been shipped,
immediately inform to our coordinator.
2.3. Storage
Actuators must be stored in a clean, cool and dray area. The unit should be stored with the cover
installed and the cable entry 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.

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 5 / 26 Valve Automation Leader, HKC
3. General Information and Features
3.1. General
HKC HL series electric actuators are designed for the operation of industrial valves, e.g. globe valves and
gate valves.
Actuator force ranges from 5,000N to 25,000N, currently eight models are available:
HL-5KN, 7KN, 10KN, 12KN, 15 KN, 18KN, 20KN, 25KN
3.1.1. [Performance --- 19 rev0]
Type
Max.
output
Force
Operating
time
(mm/sec)
Max.
Stroke
Rated current(A) Duty IEC
60034-1
Number
of handle
turn
Weight
DC AC 1 Ph, 50/60Hz AC 3 Ph, 50/60Hz
kN (50/60Hz) Mm 24V 110V 220 V 380 V 440 V 460 V S4(%) n kg
HL-05KN 5 0.44 / 0.53 60 2.1 1.0 / 1.0 0.6 / 0.5 0.3 / 0.3 0.6 / 0.4 NA 50 227 11
HL-07KN 7 0.44 / 0.53 60 2.7 1.2 / 1.1 0.6 / 0.6 0.3 / 0.4 0.6 / 0.5 NA 50 227 11
HL-10KN 10 0.69 / 0.82 70 3.9 1.9 / 1.8 0.9 / 0.9 0.6 / 0.4 0.6 / 0.4 0.6 / 0.3 50 184 21
HL-12KN 12 0.69 / 0.82 70 4.6 2.1 / 2.0 1.0 / 1.0 0.7 / 0.5 0.6 / 0.4 0.6 / 0.4 50 184 21
HL-15KN 15 0.69 / 0.82 80 5.6 2.2 / 2.1 1.1 / 1.1 0.7 / 0.5 0.7 / 0.4 0.6 / 0.4 50 210 21
HL-18KN 18 0.69 / 0.83 100 5.8 1.8 / 2.0 0.9 / 1.1 0.6 / 0.5 0.4 / 0.3 0.4 / 0.3 50 260 33
HL-20KN 20 0.69 / 0.83 100 6.4 2.1 / 2.4 1.0 / 1.2 0.7 / 0.6 0.7 / 0.5 0.7 / 0.5 50 260 33
HL-25KN 25 0.69 / 0.83 100 7.8 3.2 / 4.0 1.9 / 2.1 0.9 / 0.8 0.8 / 0.6 0.8 / 0.6 50 260 33
3.1.2. [Standard Technical Data --- 19 rev0]
Enclosure rated Weatherproof IP67
Power supply 24Vdc,110/220Vac 1Ph, 380/440/460Vac 3Ph, 50/60Hz, ±10%
Duty
(on
-
off)
S2 30min
@50% load, room temperature
(modulating) S4 40~70%, 800~1200 reposition/hr @ 50% load, room temperature
Motor Reversible induction motor
Limit
s
witches
2 x open/close
,
SPDT, 250 V
ac
16A rating
Auxiliary
l
imit
s
witches
2 x open/close SPDT, 250 V
ac
16A rating (except HL
0
5~
07K
N)
Force
s
witches
Open/close SPDT, 250V
ac
1
6
A
Stall protection Built–in thermal protection, open@150±5, close @97±15℃
Manual
o
verride
Declutch
ing mechanism
Self
-
l
ocking
Provided by double worm gear
Space heater
HL
-
05KN, 07KN: 5W
,
HL
-
10KN ~ 25KN:
10W
for anti-condensation, please see clause 3.1.5.
C
able
e
ntries
Standard:
2 x PF3/4”,
flameproof: 2 x NPT3/4
”
or 2 x M25
Lubrication
Standard: g
rease moly
(
EP
), for low temp.: Tribolube
-
18
Terminal
Spring loaded push lever type
Main body materials
Aluminu
m alloy,
aluminium
bronze, ductile cast iron
Ambient
t
emperature
Standard:
-
20
℃
~+
7
0
℃
,
Flameproof:
-
20
℃
~+
6
0
℃
,
A
pplicable humidity
Relative humidity 90% max @ no
-
condensation
External
c
oating
Anodizing and thermally hardened polyester powder coating
3.1.3. [Optional Technical Data --- 19 rev0]
EX
D
Flame
proof enclosure (Ex d
b
IIB T4)
EX
TB
Dust ignition proof enclosure (Ex tb IIIC T135
’
C)
WTA
Watertight enclosure (IP68 10m 72hr)
TIP
Temporary
immersion
protection (IP67)
PIU
Potentiometer unit (0~1
k
Ω
)
CPT
Current position transmitter(output 4~20mA
dc
)
PCU
Proportional control unit (in
put
/
output
:
0~10 V
dc
, 4~20mA
dc
)
IMS Integral magnetic starter (control power: 110/220 V ac 1ph, 50/60Hz, ±10%)
DCM
DC motor (24 V dc)
ADCM
Multi 24V ac/dc (integral type)
LCU
-
B
Local / remote control unit
LCU
-
C
Integral control unit (LCU+IMS+auto
phase discriminator)
RBP
Rechargeable battery backup for ESD(Emergency Shut Down)
MSB
Mounting support base & driving rod
for valve installation

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 6 / 26 Valve Automation Leader, HKC
3.1.4. Duty Cycle 1)
Duty cycle rated IEC60034-1, S4 50% / S2 30min
Exceeding the actuator’s rated duty cycle may cause thermal overload.
Note 1) Type of duty expression according to VDE 0530 / IEC 60034-1
Short – time duty S2 Intermittent duty S4
The operation time at a constant load is
short, so that thermal equilibrium is not
reached. The pause is long enough for the
machine to cool down to ambient
temperature. Example, the duration of the
short –time operation is limited to 15min
The duty is a sequence of identical cycles which
consist of starting time, operation time with
constant load and rest period. The rest period
allows the machine to cool down so that thermal
equilibrium is not reached. Example, the relative on-
time at S4-25% or S4-50% is limited to 25% and
50% respectively.
3.1.5. Heater
Condensation in the actuator is possible due to wide fluctuation of the ambient temperature. The
heater integrated in the control unit prevents this in general.
Model
24V
dc
110V
ac 1ph
220V
ac 1ph
220~460V ac 3ph
HL
-
05/07kN
5W 200
Ω
J
5W 4.5k
Ω
J
5W 18k
Ω
J
5W 18k
Ω
J
HL
-
10/12/15kN
10W 100
Ω
J
10W 2k
Ω
J
10W 8k
Ω
J
10W 8k
Ω
J
HL
-
18/20/25kN
10W 100
Ω
J
10W 2k
Ω
J
10W 8k
Ω
J
10W 8k
Ω
J
[
F
or low temp. use
30W 20
Ω
J
30W 450
Ω
J
30W 1.6k
Ω
J
---
18 rev0]
3.1.6. Hand wheel and Declutching
HL actuators are provided a declutchable manual override system.
① In order to manually operate the actuator, pull the manual override engagement lever towards the
hand wheel until it remains in position.
② Turn the hand wheel until the valve reaches the required position
③ Turn clockwise to close(down) and counter-clockwise to open(up)
Note ; The override engagement lever returns automatically to auto position when the actuator is
electrically operated.
3.1.7. Lubrication
HL is a totally enclosed unit with a permanently lubricated gear train (Moly EP Grease). Once
installed lubrication should not be required. However, periodic preventative maintenance will extend
the operating life of the actuator.
Auto => Manual
Open (Up)
Close
(Down)

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 7 / 26 Valve Automation Leader, HKC
3.2. External Parts for Standard Models
3.3. Internal Parts for Standard Models
4. Installation Instruction
4.1. Pre-Installation
4.1.1. For use in general service
Verify the actuators nameplate to ensure correct model number, force, operating speed, voltage
and enclosure type before installation or use.
It is important to verify that the output force of the actuator is appropriate for the force
requirements of the valve and that the actuator duty cycle is appropriate of the intended
application.
4.1.2. For use in potentially explosive atmosphere
Model HL - . . . 1 . 0 . . . 0 1)
Type of enclosure [IECEx : Ex db IIB T4 Gb, Ex tb IIIC T135˚C Db
ATEX : II 2 G Ex db IIB T4 Gb, II 2 D Ex tb IIIC T135˚C Db
[KCs : Ex d IIB T4 Gb, Ex tD A21 IP6X T135℃
EAC : 1Ex d IIB T4 Gb X ----------------------------- 20 Rev0]
Ambient temperature [IECEx, ATEX & KCs : -20 ˚C ~ + 60 ˚C
EAC : -60 ˚C ~ + 60 ˚C ------------------------------ 20 Rev0]
External Parts
1 Top Cover
2 Body
3 Declutch lever
4 Cover bolt
5 Cable Entries (NPT 3/4”)x2
6 Manual hand wheel
7 Upper Base
8 Bridge Base
9 Guide rod
10 Guide rod Holder
11 Driving rod
12 Locking plate
13 Union joint & nut
14 Guide rod nut
15 LCU Unit (Optional)
16 Driving rod rubber (Optional)
Internal Parts
1 Motor
2 Potentiometer
3 Terminal
4
Open force switch
(RED Color)
5
Close force switch
(BLUE Color)
6 Close limit switch
7 Open limit switch
8 Capacitor
9 PCU Board
10 Heater
①
③
⑥
⑦
⑧
④
⑤
⑨
⑯
⑩
⑪
⑫
⑬
⑭
⑮
②
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 8 / 26 Valve Automation Leader, HKC
Installation, commissioning, maintenance, repairs and modification work must only be performed by
qualified personnel with extensive knowledge on how to work on flame-proof electrical equipment.
Note : 1) Further information should be use of the HL electric actuator catalogue.
Refers to the Cl.2.1 in this manual.
Warning : Read this installation and maintenance manual carefully and completely before
attempting to install, operate, or troubleshoot the HKC actuator.
4.2. Actuator Mounting
Note :
Prior to mounting the linear actuator must be checked for any damage.
Damaged parts must be replaced by original spare parts.
4.2.1. Mounting is most easily done with the valve shaft pointing vertically upward. But mounting is also
possible in any other position.
4.2.2. The HL- Series actuators are supplied with a Union joint & nut.
4.2.3. The actuator Union joint is removable for ease of machining.
Caution ;
Do not attempt to work on your HKC actuator without first shutting off incoming power.
Do not attach ropes or hooks to the hand wheel for the purpose of lifting by hoist.
4.2.4. Actuator Mounting Details
If the linear actuator and the valve are supplied separately you will have to mount the linear actuator
on the valve.
4.2.5. Preparing assembly
Warning : A non-attached valve causes damage!
If you operate the linear actuator without valve, the spindle nut may fall off due to the missing stop.
CAUTION: Always operate the linear actuator with a valve attached.
Allow for about 200 mm space above the cover at the site of installation. Check the working
environment before assembling and commissioning the linear actuator. Ensure that the valve is
correctly fitted. For details please see assembly instructions for valve. Determine the assembly position
Union Nut Joint
Ring
Guide Rod
Nut
s 2ea

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 9 / 26 Valve Automation Leader, HKC
of the linear actuator. Do not arrange linear actuators in a hanging position.
Assembly positions for linear actuator and valve
4.3. Limit Switch Setting
4.3.1. Rotate the actuator hand wheel manually to closed position
4.3.2. Using a hex wrench, loosen the set screw in the CLOSE limit switch cam
4.3.3. Rotate the CLOSE cam towards CW limit switch lever until the switch ‘clicks’ (Fig 1)
4.3.4. Tighten the set screw with hex wrench
4.3.5. Rotate the actuator hand wheel manually to open position
4.3.6. Using a hex wrench, loosen the set screw in the OPEN limit switch cam
4.3.7. Rotate the OPEN can towards CCW limit switch lever until the switch ‘clicks’ (Fig 2)
4.3.8. Tighten set screw with hex wrench
Danger : HAZARDOUS VOLTAGE. Make sure all power is disconnected before making the setting.
Fig.1
Close Cam Setting
Close limit switch
Close limit switch cam (Clockwise)
2mm hexagon socket screw key
Fig.2 Open Cam Setting
2mm hexagon socket screw key
Close limit switch
Close limit switch cam (Counter Clockwise)

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 10 / 26 Valve Automation Leader, HKC
4.4. Force Switch Setting
Force spring which detects the variation of force during operation is installed for preventing damage of
valve and actuator under overload condition. Once actuator is under overload, force switch is tripped and
actuator stoped immediately.
The force switches are set by manufacturer on the production site basically.
Re-setting is necessary; please contact the HKC service or representative before setting.
Caution ; Do not reset force switch to a setting higher than the maximum recommended by the
manufacturer.
4.5. Position Feedback Potentiometer (Optional)
4.5.1. Calibration Potentiometer
The potentiometer has been calibrated at the factory. However, if re-calibration is required,
proceed as follows:
① Apply power (or use manual override) to drive the actuator to its true closed position (clockwise
rotation).
② Connect an ohmmeter to P1 (red) and P3 ( black ) resistance should be approximately 1000ohms
③ Put actuator full close(down) position.
④ [Loosen the point shaft gear and connect the ohmmeter to P1 (red) and P2 (blue) and gently
rotate until a reading of 80-120Ω is achieved (100 Ω preferred). {Full close range: 0~100Ω Full
open range:700~900Ω} --- 16Rev1]
While maintaining this reading tighten the point gear set screw with an hex wrench(HL5,7KN).
⑤ Engage potentiometer spring between gear and pointer shaft (refer diagram B)
Fig.
3
Force Switch
Setting
Open force switch & cam (Red color)
Close force switch & cam (Blue color)

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 11 / 26 Valve Automation Leader, HKC
------ 20 Rev 0]
4.6. Current Position Transmitter – CPT (Optional)
The potentiometer is used for the actuator signal feedback. It reads a resistance value corresponds to the
current position of the actuator and transfers to CPT card. The CPT indicates the current position of the
actuator throughout the stroke by a 4 ~ 20mA output signal.
4.6.1. Standard Features
Model
CPT
Power
220(110)V
ac
, 50/60Hz
,
2VA
m
ax
Output Signal
4~20mA
dc
Output Impedance
750Ω
m
ax
Deadband
m
in 1/1000
Position Conversion Accuracy
±
0.5 ~
±
1.5%
Ambient Temperature
-
20
℃
to +70
℃
Ambient Humidity
90% RH
m
ax (Non
-
condensing)
Dielectric Strength
[1 sec at (rated V ac x 2 + 1000) x1.2
(from Input to power ground) ------ 15 Rev0]
Insulation Resistance
a
bove 500V
dc
30MΩ
Vibration
10g, 0~34Hz
[Delete “Danger” --- 16 Rev1]

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 12 / 26 Valve Automation Leader, HKC
4.6.2. Calibration of Zero and Span – CPT
The settings of Zero and Span have
been calibrated at the factory. However,
if re-calibration is required, proceed as
follows:
① Apply power (or use the manual
override) to drive the actuator to its
fully closed position (clockwise
rotation).
② When the actuator is in the fully
closed position, adjust the ZERO dial
on the CPT board until a reading of
4mA is achieved.
③ Apply power (or use the manual
override) to drive the actuator to its
fully open position (counter-clockwise rotation).
④ When the actuator is in the fully open position, adjust the SPAN dial on the CPT board until a
reading of 20mA is achieved.
4.7. Proportional Control Unit
[Never welding should be done while the power line is connected to the actuator. Electrical shock
can cause serious damage to the microprocessor of the actuator. ----- 17 Rev1]
4.7.1. [PCU EB-V1.5D for AC, Optional
Front Back
4.7.2. [PCU DC-V2.1C for DC, Optional
Front Back

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 13 / 26 Valve Automation Leader, HKC
4.7.3. Standard Specification
Table 1: Standard specification of the Proportional Control Unit
Model PCU EB-V1.5D (for AC) PCU DC-V2.1C (for DC)
Indicated on the board PCU_EB_V1.5D-CONTROL HKC-PCU_DC-MAIN-V2.1C
Special function
Applied Electronic Breaking system
(EB) for high resolution control. NA
Power
110V/220V ac ±10%, 50/60Hz, 4VA max
24V dc ±10%, 7A max
Input signal (set point) 4~20mA dc, 0~20mA dc, 1~5V dc , 0~5V dc , 2~10V dc, 0~10V dc
Input impedance 100 kΩ and over
Output signal (feedback)
4~20mA dc, 0~20mA dc, 1~5V dc , 0~5V dc , 2~10V dc, 0~10V dc
Output impedance 100 Ω and less
Position resistance 100~10 kΩ
Dead time
0.2~7.5 sec (It can be set in 16 step)
•
Step 0 : 0.2 sec
•
Step 1~4 : 0.25~1sec (0.25sec/step)
•
Step 5~15 : 2.5~7.5sec (0.5sec/step)
Dead band
0.
3
~7.5 % (It can be set in 16 step)
•
Step 0 ~ 4 : 0.3~0.7 % (0.1 %/step)
•
Step 5 ~ 9 : 1 ~ 1.8 % (0.2 %/step)
•
Step10 ~15 : 5 ~ 7.5 % (0.5 %/step)
0.4~7.5 % (It can be set in 16 step)
•
Step 0~4 : 0.4~0.8 % (0.1 %/step)
•
Step 5~9 : 1 ~ 1.8 % (0.2 %/step)
•
Step10~15 : 5 ~ 7.5 % (0.5 %/step)
Fault mode Fail close, Fail open, Fail stop
Position conversion accuracy
±(0.2 to 5)% (may vary depending on conditions)
Ambient temperature -25℃ to 80℃
Ambient humidity 90% RH max. (non-condensing condition)
Dielectric strength 1500V ac, 1 minute 500V ac, 1 minute
Insulation resistance 500V dc, 50MΩ or more
Vibration and shock
X, Y, Z axis 10g (@ 6g RMF), frequency: 0.2-34 Hz, time: within 30 minutes
4.7.4. Main function and usage for PCU
① Select input signal switch
Dip Switch PCU model Power source
SW7 PCU-EB-V1.5D for AC
SW2 PCU-DC-V2.1C for DC
Depending on the system environment, the user can select the required command signal type by
setting the DIP switch SW7 or SW2 as above table.
Notes : DIP switch is commonly set with 4~20mA dc before shipping.
Please make sure whether the input signal and DIP switches are correct as intended use.
Caution : Zero switch (No. 3) is applied to input and output signals equally.
② Select output feedback signal switch
Dip Switch PCU model Power source
SW8 PCU-EB-V1.5D for AC
SW3 PCU-DC-V2.1C for DC
Depending on the system environment, the user can select the required output feedback signal by
setting the DIP switch as above table.

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 14 / 26 Valve Automation Leader, HKC
Notes : DIP switch is commonly set with 4~20mA dc before shipping.
Caution : Please refer to Zero switch (No. 3) of the clause “6.1 Select input signal switch“.
4.7.5. Deadband setting
① Deadband means maximum allowable tolerance of the actuator stop position according to
command signal.
② It is also minimum variation value of command signal to operate the actuator.
③ Adjustable setting range : (16 steps available)
 Step 0~4 : increase 0.1% increment per step
(0.3 ~ 0.7 % for PCU-EB-V1.5D ac)
(0.4 ~ 0.8 % for PCU-DC-V2.1C dc)
 Step 5~9 : increase 0.2% increment per step (1.0% ~ 1.8%)
 Step A~F : increase 0.5% increment per step (5.0% ~ 7.5%)
 Initial setting is “4”
④ If the setting value is too low, the actuator may not be found the target point and it may be
repeatedly operated in forward or reverse direction. This is called “Hunting” and the user must
appropriately adjust the deadband to avoid from the hunting.
⑤ Continuous hunting causes a failure of the actuator parts such as motor, PCU board,
potentiometer and etc.
4.7.6. Deadtime setting
① This is necessary to apply the command signal.
② It is the minimum time for maintaining the state of the input signal satisfying the deadband.
③ Actuator only accepts input signal satisfying the setting value of the deadtime as normal and
operates. It is for preventing from abnormal operation of the actuator by external disturbance
such as noise.
④ Adjustable setting range : 0.2~7.5 sec (16 steps available)
 Step 0 : 0.2 sec (minimum value)
 Step 1~4 : increase 0.25 sec increment per step (0.25~1 sec)
 Step 5~F : increase 0.50 sec increment per step (2.5~7.5 sec)
 Initial setting is “4”
4.7.7. Auto setting

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 15 / 26 Valve Automation Leader, HKC
① Check connection status of the input power and input/output signal after actuator and valve are
correctly assembled.
② If there is no problem with the wiring, push the auto setting button once (ASCAN).
③ Then the LED lights on the PCU board will be flickering and perform the auto setting function.
④ Auto setting details
② Blue LED will be continuously flickering.
③ Green LED will be flickering while closing and it will be ‘ON’ after fully closed.
If the actuator is already in closed position, the closing operation will be skipped.
④ Red LED will be flickering while opening and it will be ‘ON’ after fully opened.
⑤ Green LED will be flickering while closing and it will be ‘ON’ after fully closed.
⑥ When all of the sequences are automatically and successfully completed, Blue LED will be ‘ON’
and then actuator will move to pre-set position
Notes: If you press any button of ZERO/SPAN/ASCAN during the auto setting processes, the auto
setting mode will be cancelled.
4.7.8. Fail close (FC), fail open (FO) and fail stop
Dip Switch PCU model Power source
SW3 PCU-EB-V1.5D for AC
SW1 PCU-DC-V2.1C for DC
When an analogue command signal does not come in or a wrong signal is received, the PCU
board will detect the Fault and operates actuator automatically in open, close and stop position
according to pre-set fail position.
4.7.9. Auto full action (AF)
Dip Switch PCU model Power source
SW3 PCU-EB-V1.5D for AC
SW1 PCU-DC-V2.1C for DC
① Turn on the AF (Auto Full) DIP switch No3
② Response of the actuator
 Move to fully closed position on input signal of 4.3 mA or
lower.
 Move to fully opened position on input signal of 19.7 mA
or higher.
4.7.10. Reverse mode (RV)
Dip Switch PCU model Power source
SW3 PCU-EB-V1.5D for AC
SW1 PCU-DC-V2.1C for DC
① It is used when user want to operate actuator by inverting input
signal and output signal.
② When the command signal is 4 mA, the actuator moves to fully
opened position, and makes 4 mA dc as an output signal.
③ When the command signal is 20 mA, the actuator moves to fully
closed position, and makes 20 mA dc as an output signal.

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 16 / 26 Valve Automation Leader, HKC
4.7.11. Random command signal setting
Dip Switch PCU model Power source
SW3 PCU-EB-V1.5D for AC
SW1 PCU-DC-V2.1C for DC
① This function is intended to change the Zero (fully close) and Span (Fully open) signal.
② Adjustable setting range of the Zero signal : about 3~8mA dc
③ Adjustable setting range of the Span signal : about 16~21mA dc
※ Example: Set 5 mA dc as Zero and 19 mA dc as Span signal
 Turn up No. 4 switch (I/S input set) of the dip switch.
 Both Red and Green LED will be flickering quickly.
 About 1.5 seconds later, only the Green LED will be flickering.
 Input 5mA to command signal on the input terminal and then press the ZERO (black) button
to unlock.
 If the setting is successfully done, Yellow LED will flicker once and Green LED will be ON
(setting completed). Then, Red LED will be flickering for input setting.
 Input 19mA to command signal on the input terminal and then press the SPAN (white)
button to unlock.
 If the setting is successfully done, Yellow LED will flicker once and Red LED will be ON
(setting completed).
 Wait until only the Green LED flickers after both Red and Green LED flicker for about 1.5
second.
 Turn down No. 4 of the dip switch (I/S input set) to finish the setting.
※ If No. 4 switch of the dip switch is turned down during setting, the setting will be cancelled.
※ If there is no input for 2 minutes, the setting process will also be cancelled.
4.7.12. Adjust output (feedback) signal
Dip Switch PCU model Power source
SW7 PCU-EB-V1.5D for AC
SW2 PCU-DC-V2.1C for DC
① Adjust Zero (4mA) and Span (20mA) value of the output signal.
② Each time the zero button (Black) is pressed, the output signal will be decreased.
③ Each time the span button (White) is pressed, the output signal will be increased.
※ Example: Set 4 mA dc as Zero and 20 mA dc as Span signal.
 Turn up No. 4 switch of the dip switch.
 Wait until only the Green LED flickers after both Red and Green LED flicker for about 1.5
second.
 Adjust output signal value to 4 mA by pushing the Zero or Span button.
 After checking the 4 mA output signal, press ASCAN button (Red).
 Yellow LED will be ON and OFF.
 Confirm the Green LED is ON and Red LED is flickering.
 Adjust the output signal value to 20 mA by pushing the Zero or Span button.
 After checking the 20 mA output signal, press ASCAN button (Red).
 Yellow LED will be ON and OFF.
 Confirm the Red LED is ON.

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 17 / 26 Valve Automation Leader, HKC
 Wait until only the Green LED flickers after both Red and Green LED flicker for about 1.5
second.
 Turn down No. 4 switch of the dip switch.
※ If No. 4 switch of the dip switch is turned down during the setting process, the setting will be
cancelled.
※ If there is no input for 2 minutes, the setting process will also be cancelled.
4.7.13. Manual operation mode
① This function allows the user to manually operate the actuator.
② To access this function, press ZERO (Black) and SPAN (White) buttons simultaneously for 1 second.
Then, yellow LED will be ON to indicate that the actuator is in Manual Operation mode.
③ Pressing the ZERO button will move the actuator to close position and pressing the SPAN button
will move the actuator to open position.
④ If user do not operates within 10 seconds or press ZERO and SPAN buttons again simultaneously
for 1 second, PCU board will automatically terminate the Manual Operation mode.
4.7.14. LED display
① Operating display
Status LED Color Display Function
Open Red On Fully opened
Flicker Moving to open position
Auto Blue On Power on
Flicker Auto setting
Close Green On Fully closed
Flicker Moving to close position
Fault Yellow On Manual mode
Flicker Malfunction
② Error display on the PCU-EB-V1.5D board for AC
PCU-EB-V1.5D board for AC indicates an error condition when the yellow LED is flickering.
At this time, when user presses the ZERO (Black button), user can get the error type from LED status
as below.
No Error type
(Malfunction)
LED display
Red Blue Green Yellow
1 EEPROM error Off Off Off On
2 Input signal initialization error Off Off On Off
3 Auto setting initialization error Off Off On On
4 Input signal error Off On Off Off
5 Reverse turn the motor Off On Off On
6 Command signal selector switch error Off On On Off
7 Abnormal of potentiometer Off On On On
8 Open position error On Off Off Off
9 Close position error On Off Off On
10 Limit switch error On Off On Off
③ Error display on the PCU-DC-V2.1C board for DC
PCU-DC-V2.1C board for DC also indicates an error condition when the yellow LED is flickering. At
this time, when user push the ZERO (Black button), user can get the error type from LED status as
below.

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 18 / 26 Valve Automation Leader, HKC
No Error type
(Malfunction)
LED display
Red Blue Green Yellow
1 Input signal initialization error Off Off Off On
2 Reverse turn the motor Off Off On Off
3 Auto setting initialization error Off Off On On
4 EEPROM error Off On Off Off
5 Input signal error Off On Off On
6 Open position error Off On On Off
7 Close position error Off On On On
8 Command signal selector switch error On Off Off Off
9 Limit switch error On Off Off On
10 Torque switch trip On Off On Off
----------- 21 Rev2]
4.8. [ac/dc Multi-board --- 16 Rev1]
4.8.1. Power, Open and Close terminal
① Power 24V ac/dc (dc + signal block)
② None
③ None
④ Open signal
⑤ Close signal
⑥ Power 24V ac/dc (dc – signal block)
4.8.2. [Chooses for Power input switch
① As using for ac mode,
#1 switch On, #2 switch Off
② As using for dc mode,
#1 switch off, #2 swithc on --16 Rev1]
NOTE: Don’t turn on both switch #1 and #2
at the same time that become a reason of damage of the board
③ [Motor terminal block
 Red wire of motor to connect #1
 Black wire of motor to connect #2 --- 16 Rev1]
5. [Apply for optional communication protocol
5.1. ProfiBus Controller (PBC)
5.1.1. ProfiBus Controller is to provide multiple functions of communication by using 8 bit microprocessor
and Profibus Controller.
5.1.2. Generate long-life contacts to operate actuator in direct or reverse with semiconductor device for
open and close by using data from remote controller.
5.1.3. Provide the user actuator status information to confirm if Profibus is working correctly as the user
want.
5.1.4. Max. transmission speed is 12Mbit/sec
5.1.5. Easy to switch between PCU type and ON-OFF type.
5.1.6. Provide System Redundancy by using dual port and high reliability
5.1.7. LED lamps provide the status of actuator.
5.1.8. Application
①
②

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 19 / 26 Valve Automation Leader, HKC
① Multiple remote control of valve actuator with AC power
5.1.9. Specification
Item
Description
Unit
Input power
87V ~ 270V
ac
±
10% , 50/60Hz
±
2% 4VA
max
.
Input power must match motor ratings V, A
Communication
Profibus communication (RS
-
485
b
ase)
M
ax. range
1000m @ 9.6 ~ 187.5
k
Baud
m
Bit rate
Up to 12
m
ega
Baud
Wiring terminals
SMW250
-
3P * 4 ( Profibus signal )
YW396-5P (Main power & Motor)
SMW250-8P (CTS, OTS, CLS, OLS contact input)
SMW250-6P (Firmware update connector)
SMW250-4P (Debug connector)
Visual indicators
Power
w
hite,
b
lue LED
Fault yellow LED
Motor open red LED
Motor close green LED
Control configuration
PC
s
oftware
Output contact
Triac 250V
ac,
16A
max
. (Inductive
l
oad)
V
Ambient temperatur
e
-
10
℃
~ +60
℃
℃
Ambient humidity
90% RH
max
. (
n
on
-
c
ondensing)
%
For more detail information, please refer to separate ProfiBus operation manual.
5.2. ModBus Controller (MBC)
5.2.1. This clause explains the Modbus-RTU Slave Module (MBRSM).
Positioned at level 7 of the OSI model, MODBUS is an application
layer messaging protocol that provides client/server communication
between devices connected on different types of buses or networks.
5.2.2. As a MODBUS Serial Line protocol, MODBUS-RTU (Remote Terminal
Unit) is a Master-Slave protocol which takes place at level 2 (Data
Link layer) of the OSI model. The master initiates the communication
by transmitting the Function Code (a ‘request’) to the address of a
slave and after receiving and processing the Function Code, the slave
returns a message (a ‘response’).
5.2.3. The slaves shall not communicate with each other without the request of the master. Since the
MBRSM is based on the 2 wire (half-duplex) RS-485 communication, the network length limit or the
number of station should follow the standards of the RS-485 communication. To extend the
network, such as adding another segment, repeaters can be used. To ensure stability of the network
system, the network redundancy can be configured to slave redundancy.
5.2.4. MODBUS manages the access of data simply and flexibly. MODBUS supports two data types: a

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
Doc No. : HumG-HL-21 Rev2 Page 20 / 26 Valve Automation Leader, HKC
Boolean value and an unsigned 16-bit integer. Generally, it is common for field devices to have
certain values defined as inputs while other values are outputs, such as current temperature or valve
position.
5.2.5. Specification
① Communication Protocol : Modbus-RTU according to IEC 61158 and IEC 61784
② Topology : Line topology with termination
③ Number of nodes : 32 nodes in each segment without repeater, with repeaters expandable to 247
④ Number of repeaters : Max. 9 with signal refreshing
⑤ Cable length : Max. 1.2 Km with Repeater 10 Km
⑥ Transfer Mode : RS-485
⑦ Transmission Medium : Twisted, shielded 2-Wire cable according to IEC 61158
⑧ Bus Access : Polling between master and slaves (query response)
⑨ Supported Baud Rates : 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200
⑩ Supported Parity Bit : Odd, Even, None
⑪ Supported Stop Bit : 1, 2
For more detail information, please refer to separate ModBus operation manual. –19 rev0]
6. Wiring
6.1. Electrical Connections and Preliminary Test
WARNING:
 [You must never do any welding work while the actuator is connected with electrical line.
If an electrical shock occurs on the actuator, it makes a cause of serious damage to the
microprocessor of the actuator.----- 19 Rev0]
 When working in potentially explosive atmospheres, observe the European Standards EN 60079-14
“Electrical Installation in Hazardous Areas” and EN 60079-17 “Inspection and Maintenance of
Electrical Installations in Hazardous Areas”. Work on the electrical system or equipment must only
be carried out by a skilled electrician himself or by specially instructed personnel under the control
and supervision of such an electrician and in accordance with the applicable electrical engineering
rules.
 For cable entries that are not used, user or installer shall close by [Ex db IIC or Ex tb IIIC certified
blanking element suitable for each type of protection, Ex d or Ex tb so that type of protection of
the enclosure is maintained. ----- 17 Rev0]
 [Dust ignition proof enclosure! Use a damped cloth for equipment surface cleaning. --- 15 Rev1]
 [Flame proof enclosure!--- 17Rev0] Treat cover with care. Gap surfaces must not be damaged in any
way. Do not jam cover during fitting.
 [Dust ignition proof enclosure! It may be charged electrostatic potential. Therefore it shall be
installed in such way that the risk from electrostatic discharge and propagation brush discharge
caused by rapid flow of dust is avoided. --- 15 Rev.1]
6.1.1. For testing purposes, loosen the bolts on the actuator cover and remove the cover.
6.1.2. Make sure that the power supply voltage is in accordance with the data on the nameplate of the
actuator.
6.1.3. [Pass cables through the cable glands: NPT 3/4” or M25 for Ex “db”, additionally NPT 3/4”, M25 and
M20 with M30 adapter which shall be only applied for Ex ”tb”. ----- 17 Rev0]
6.1.4. Connect wires according to the enclosed wiring diagram.
6.1.5. Manually move the valve to half-open position. Then electrically operate the actuator to fully open
position and check if the motor rotates in correct direction; standards units are counter-clockwise to
open.
6.1.6. Test the actuator and check whether the limit switches work correctly
6.1.7. After the testing, check that all cable glands are correctly tightened. Applicable cable glands should
be selected to meet the application’s condition. It is recommended to use the grade of IP67 cable
gland or higher in potentially explosive atmosphere.
6.1.8. Put carefully the cover on the body and tighten the bolts.
6.1.9. [Tightening torque of the cover bolts should be applied as below.
Model
Cover
bolt size (mm)
Tightening Torque
Allowable range
HQ
-
008/010
M8 x 35
12.5 Nm
10 ~ 15 Nm
HQ
-
015/020
M10 x 50
24.5 Nm
20 ~ 30 Nm
HQ
-
030~300
M12 x 55
42.0 Nm
35 ~ 50 Nm