HKC HL Series User manual

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Installation & Operation Manual
Doc.No:HKQI-610
Items listed herein were designed , manufactured , delivered in
Electric Actuator HL Series
accordance with contract specifications and quality control system
Edition: 01.2010
Linear Electric Actuator
Installation & Operation Manual
HL Series
Model: HL5KN,7KN,10KN,12KN,15KN,18KN,20KN,25KN
HKC Co., Ltd.
(5Ra - 503, Seonggok-dong), 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do, Republic of Korea(425-836)
Tel:[phone] / Fax:[phone] / Email: hk[email protected]r / Website: www.hkcon.co.kr

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Contents
1. Introduction
1.1 Purpose 5
1.2 Safety Notices 5
2. Product Identification
2.1 Product Identification 5
2.1.1 Marking 5
2.1.2 Certification 6
2.2 Initial Inspection 7
2.3 Storage 7
3. General Information and Features
3.1 General
3.1.1 Performance 8
3.1.2 HL standard technical data 8
3.1.3 HL technical data 9
3.1.4 Duty cycle 9
3.1.5 Heater 9
3.1.6 Hand wheel and declutching 10
3.1.7 Lubrication 10
3.2 External parts for standard models
3.2.1 HL-5,7,10,12,15,18,20,25KN 10
3.3 Internal parts for standard models 11
4. Installation instruction
4.1 Pre-installation for use in general service 12
/ potentially explosive atmosphere
4.2 Actuator mounting 12
4.2.1 Actuator mounting details 13
4.2.2 Preparing assembly 14
4.3 Limit switch setting 15
4.4 Force switch setting 16
4.5 Position feedback potentiometer 16
4.5.1 Calibration potentiometer 17
4.6 Proportional Control Unit –PCU (option) 18
4.6.1.Check point before using actuator
4.6.2.General 19
4.6.3.Standard specification 19
4.6.4 Function of PCU and how to set and to use it 20

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Select Input signal
Set DIP switch for fail position
Delay time
Resolution Adjustment
Manual operation
Special setting for full open and close
Auto-setting
Split range (CH1)
Reversal acting switch (CH2)
Select output signal
4.6.5 Check operation of PCU
4.6.6 Layout of PCU 24
4.6.7 Layout of PCU Card
4.7 Position feedback potentiometer-CPT 26
4.7.1 Standard features
4.7.2 Calibration zero span
5. Operation instruction
5.1 Electrical connections and preliminary test 27
5.2 Wiring diameters for standard models 28
5.2.1 On/off type
5.2.2 PCU type 29
6. Maintenance
6.1 Maintenance 30
6.2 Tools 31
7 Dimensions for actuator
7.1 5KN,7KN(ON/OFF type) 32
7.2 5KN,7KN(Control type) 33
7.3 10KN,12KN,15KN(ON/OFF type) 34
7.4 10KN,12KN,15KN (Control type) 35
7.5 18KN,20KN,25KN(ON/OFF type) 36
7.6 18KN,20KN,25KN (Control type) 37
8. Trouble shooting 38
9. Installation and maintenance tips 39
10.Grounding
Appendix Ⅰ: HL series coding system 40
HL-5KN abcdefg 41
HL-7KN abcdefg 42
HL-10KN abcdefg 43
HL-12KN abcdefg 44

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HL-15KN abcdefg 45
HL-18KN abcdefg 46
HL-20KN abcdefg 47
HL-25KN abcdefg 48
Explosion proof type actuator 49

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1 Introduction
1.1 Purpose
This Installation and operating manual explains how to install, operate and maintain HL electric actuators.
1.2 Safety Notices
Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the
equipment. User must read these instructions before installation, operating, or maintenance.
DANGER : Refers to personal safety. 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.
Note : Highlights information 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 side of the opposite the conduit entry. The name plate contains the following
2.1.1 Marking
a) General
HL logo(trade mark)
Electrical power supply
Model
Type
Rated current
Operating time(seconds)
Serial No.
Option

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Name of manufacturer and country shall not be printed based on OEM.
b) Explosion proof
HKC logo
Model
Motor spec.
Electrical power supply
Ambient temperature
KTL cert. No.
Serial No.
Manufacturer’s address
Warning
Applied standards : EN50014 / EN50018
2.1.2 Certification (pended)
a) KTL (Korea Testing Laboratory)
HL-5KN
Cert.No. : 1454-051
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
HL-7KN
Cert.No. : 1454-165
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
HL-10KN
Cert.No. : 1454-255
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
HL-12KN
Cert.No. : 1471-272
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
HL-15KN
Cert.No. : 1454-051
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
HL-18KN
Cert.No. : 1454-165
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
ELECTRIC ACTUATOR
L I N E A R M O T I O N E L E C T R I C A C T UAT O R
POWER:
STROKE: Max mm
FORCE: N
SERIAL NO:
MODEL:HL-
RATED CURRENT: A
OPERATION TIME: mm/SEC
OPTION::

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HL-20KN
Cert.No. : 1454-255
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
HL-25KN
Cert.No. : 1471-272
IP68
Applied Standard : KS C IEC 60529(2002) & IEC 60529(2001)
NOTE :
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.
Cable connection : Refers to theAppendix 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. Refers to the enclosed
wiring diagram.
External ground connection : The ground lug is located on the centre of cable
entries.
▶More information, refers to the Appendix Ⅲ(Grounding)
2.2 Initial inspection
When the user receipt the actuator, inspect the condition of the product and ensure the name plate comparing with order
sheet.
Remove packing wrap or wooden box carefully. Inspect the product for any physical damage that may have
occurred during shipment.
Check the product specification with product ordered. If a wrong product have been shipped, immediately
report to our coordinator.
2.3 Storage
Actuators 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.
When actuators be stored outdoor, they must be stored off the ground, high enough to prevent being immersed in water
or buried in snow.
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 5000n to 25,000Nm, currently eleven models are available:
HL-5KN, 7KN, 10KN, 12KN, 15 KN, 18KN, 20KN, 25KN

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3.1.1 Performance
Type
Max.
output
force
Operating
time(mm/s
ec.)
Max.
Stroke
Duty
cycle
Rated current(A) 50/60Hz
Number
of
handle
turn
Weig
ht
IEC34-1
1 Phase
3 Phase
k N
50/60HZ
mm
S4(%)
110 V
220 V
220 V
380 V
440 V
460 V
N
kg
HL-5KN
5
0.44/0.53
60
50
0.96/0.97
0.47/0.46
N/A
0.42/0.33
0.57/0.43
N/A
227
11
HL-7KN
7
0.44/0.53
60
50
0.96/0.97
0.47/0.46
N/A
0.42/0.33
0.57/0.43
N/A
227
11
HL-10KN
10
0.69/0.82
70
50
1.51/1.62
0.72/0.84
0.69/0.50
0.35/0.27
0.55/0.34
0.23/0.19
184
21
HL-12KN
12
0.69/0.82
70
50
1.51/1.62
0.72/0.84
0.69/0.50
0.35/0.27
0.55/0.34
0.23/0.19
184
21
HL-15KN
15
0.69/0.82
80
50
1.51/1.62
0.72/0.84
0.69/0.50
0.35/0.27
0.55/0.34
0.23/0.19
210
21
HL-18KN
18
0.69/0.83
100
50
1.37/1.67
0.68/0.81
0.49/0.41
0.33/0.27
0.43/0.30
0.27/0.24
260
33
HL-20KN
20
0.69/0.83
100
50
4.27/3.56
1.37/1.27
0.86/0.72
0.51/0.42
0.66/0.46
0.44/0.32
260
33
HL-25KN
25
0.69/0.83
100
50
4.27/3.56
1.37/1.27
0.86/0.72
0.51/0.42
0.66/0.46
0.44/0.32
260
33
3.1.2 HL Standard Technical Data (optional)
Enclosure Rated Weatherproof IP67, NEMA 4 & 6
Enclosure High grade aluminium alloy, corrosion coated
Power Supply 110 / 220 VAC 1 Ph, 220 / 380 / 440 / 460 VAC 3 Ph, 24 VDC 50/60Hz
Duty type 1) S4 50% / S2 30min (IEC 60034)
Motor reversible motor
Limit Switches 2 x open/close SPDT, 250 VAC 16A rating
Auxiliary Limit Switches 2 x open/close SPDT, 250 VAC 16A rating (except HL5~15KN)
Force Switches Open/close SPDT, 250VAC 10A
Stall Protection Built –in thermal protection
Travel Angle 90 degree +/- 10%
Indicator Continuous position indicator
Manual Override Declutchable manual override
Self Locking By means of TM Screw(KSB0227)
Space Heater 2W ceramic housed
Conduit Entries 2 x PF3/4” , M20 or G 3/4 for EXA
Lubrication Grease moly EP
Ambient Temperature -20 deg C ~ + 80 dec C (except on CPT & PCU board )
External Coating Dry powder polyester
3.1.3 HL Option Technical Data (optional)
EXA Explosion proof enclosure (EEx d II B T4 IP67)
WTA Watertight enclosure (IP68 10m / 72hr)
PIU Potentiometer unit (0~1KΩ)
PCU Proportional control unit (input,output 0~10 VDC, 4~20mA DC)
SICU Semi-Integral control unit(LCU+IMS+phase protect indicator)
ICU Intelligent Digital control unit(LCU+IMS+auto phase discriminator)
CPT Current position transmitter(output 4~20mA DC)
ALS Additional limit switches (SPDT X 2EA 250 VAC 16A Rating)
FPA1 Fire proofing actuator 1050° ± 5° / 50min
FPA2 Fire proofing actuator 250° ± 5° / 150min
Note : 1)based on 20°C ambient temperature
See Appendix Ⅰ.

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3.1.4 Duty Cycle *1
Duty cycle rated IEC60034 –S4 50% / S2 30min
Exceeding the actuator’s rated duty cycle may cause thermal overload.
Note *1
Type of duty according to VDE 0530 / IEC 60034-1
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.
2W, Ceramic housing with thermostat to prevent over heating with 60℃set temperature
Heating element Self-regulating
Voltage ranges 110 V 2W 12KΩJ
(based on control power) 220 V 2W 30KΩJ
24 VDC 2W 470ΩJ
3.1.6 Hand wheel and Declutching
HL actuators are provided a declutchable manual override system.
In order to manually operate the actuator, pull the manual override
engagement lever towards the hand wheel until it remains in position.
Turn the hand wheel until the valve reaches the required position
Turn clockwise to close(down) and counter-clockwise to open(up)
open(up)
close(down)
AUTO HAND
Note ;
The override engagement lever returns automatically to auto position when the actuator is
operated electrically.
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. The duration of
the short –time operation is limited to 15min
(10min, 30min)
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. The
relative on-time at S4-25% or S4-50% is
limited to 25% and 50% respectively.

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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.
3.2 External Parts for Standard Models
3.2.1 HL 5,7,10,12,15,18,20,25KN
①
④
⑤
②⑥
③
⑦
⑧
⑨
⑩
⑪
OPTION: LCU UNIT
⑫⑬
OPTION: Driving rod rubber
⑭
External Parts
HL SERIES
1
Top Cover
2
Body
3
Auto & manual Lever
4
Cover bolt
5
Conduit Entries (PF 3/4”)x2
6
Hand wheel
7
Upper Base
8
Bridge Base
9
Guide rod
10
Rod Holder
11
Driving rod
12
Locking plate
13
Union joint & nut
14
Guide rod nut