HKC HM04 Manual

Installation and Maintenance Manual
HKC
HM-SERIES / ACTUATORS
Version- V1
Document No. HQOI-08-EV1
DATE : 2011.12.22
H K C
WWW.HKCON.CO.KR
HKC CO.,LTD.
HM – Series. ELECTRIC ACTUATORS
INTELLIGENT MULTI-TURN ELECTRIC ACTUATORS
VALVE AUTOMATON

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1. Introduction
1.1 Purpose 3
1.2 Manual Guidelines contents 3
1.3 External Parts for Standard Models 4
1.4 Safety Notices 4
2. Product Identification
2.1 Product Identification 6
2.1.1 Marking 6
2.2 Initial inspection 7
2.3 Storage 7
3. General Information and Features
3.1 General 7
3.2 Performance Data 8
3.2.1 AC 3 Phase Model & Torque (Nm) 8
3.2.2 AC 1 Phase Model & Torque (Nm) 8
3.2.3 Solid state design Model & Torque (Nm) 9
3.2.4 Mechanical Data 9
3.3 HM Standard Technical Data (Standard) 10
3.4 HM Option Technical Data (Optional) 11
3.5 Duty Cycle 11
3.6 Hand wheel and Declutching 11
3.7 Lubrication 12
3.8 Internal Parts for Standard Models 13
4. Installation and operation instruction
4.1 Pre-installation for use in general service 14
/ potentially explosive atmosphere
4.2 Actuator Mounting 14
4.3 Actuator Mounting Details (ISO5211 & 5210) 15
4.3.1 Mounting base 15
4.3.2 Disassembly and Assembly of Mounting Base 16
4.3.3 Disassembly and Assembly the Drive Bush in Thrust Base 17
4.3.4 Disassembly and Assembly the Drive Bush in Non-Thrust Base 18
4.4 Electrical Connections and Preliminary Test 18
5. Maintenance
5.1 Maintenance 20
5.2 Tools 20
6. Trouble shooting 21
7. Installation and maintenance tips 22
8 . Wiring Diagram
8-1~3. HM-Standard 3ph, CPT,PCU 23~25
9. Dimension 26
10. Grounding 27
APPENDIX I : HM-series Coding System 28

1
Introduction
1.1 Purpose
This Installation and operating manual
Multi -Turn
electric actuators.
There is no need for removal of the outer casing (exclude wiring), when operating t
HM Multi -
Turn electric actuator, due to its
The terminals for wiring and the internal electronics are sealed tight hence allowing
for unhindered removal procedures
When setting up the a
restrictions and
etc as they are individually displayed on screen
reduce the risk of danger as setup can be remotely carried out at a safer distance
The help menus for the control system of the valve and
screen hence user friendly
Configuration, alarm and status tests are given in English (default)
Movement of valve torque position values for the
1.2 Manual Outline
•
Electrical
•
Actuator
•
Basic configuration setup and actuation walkthroughs
•
Specific on
•
Maintenance and troubleshooting
•
Sales and A/S information
This manual contains important safety information
It is emphasized that the user understands the following material given in this document
before installation and setup of any product before operation and maintenance.
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Introduction
This Installation and operating manual
explains how to install, operate and maintain
electric actuators.
There is no need for removal of the outer casing (exclude wiring), when operating t
Turn electric actuator, due to its
Smart Intelligent electronic
actuat
The terminals for wiring and the internal electronics are sealed tight hence allowing
for unhindered removal procedures
.
When setting up the a
ctuator
utilize the remote control to set the torque,
etc as they are individually displayed on screen
.
This feature may
reduce the risk of danger as setup can be remotely carried out at a safer distance
The help menus for the control system of the valve and
Actuator
are ava
screen hence user friendly
.
Configuration, alarm and status tests are given in English (default)
.
Movement of valve torque position values for the
actuator
is displayed on screen
IP 68 Design
Electrical
and manual (local or remote) operation procedures
Actuator
or Valve installation guidelines
Basic configuration setup and actuation walkthroughs
Specific on
-site and custom control requirement tasks
Maintenance and troubleshooting
Sales and A/S information
This manual contains important safety information
.
It is emphasized that the user understands the following material given in this document
before installation and setup of any product before operation and maintenance.
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explains how to install, operate and maintain
the HM
There is no need for removal of the outer casing (exclude wiring), when operating t
he
actuat
ion capability .
The terminals for wiring and the internal electronics are sealed tight hence allowing
utilize the remote control to set the torque,
limit switches,
This feature may
reduce the risk of danger as setup can be remotely carried out at a safer distance
.
are ava
ilable on
.
is displayed on screen
.
and manual (local or remote) operation procedures
It is emphasized that the user understands the following material given in this document
before installation and setup of any product before operation and maintenance.

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1.3 External Parts for Standard Models
1.4 Safety Notices
Safety notices throughout this manual detail precautions the user must take to reduce the risk
of personal injury and damage to the equipment. The user must read these instructions before
installation, operation 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.
External Parts
1 Body 11
Top Handle Cover Name Plate
2 Top Handle Cover 12
Hand wheel
3 Control Cover 13
Name Plate
4 Terminal Cover 14
Cable Plug
5 Mounting Base 15
Motor
6 Conduit Entries
(NPT 1”x4EA, 1
1
/
2
”x1EA) 16
Grease Plug
7 Control Knob
8 Window & Indicator
9 Lever Supporter
10 Hand/Auto Lever

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Note : Read carefully the following information as it is critical to the user’s understanding of the
actuator installation and operation procedures. This manual contains important safety
information. Please ensure it is thoroughly read and understood before installing, operating
or performing maintenance procedures for equipment.
CAUTION
1. Do not open cover during operation
in case of electrical shock
This manual contains critical information related to the operation of the
HM
series
Actuators
. It
is crucial that only trained personnel who understands thoroughly the setup, operations,
controls and inspection procedures due to safety concerns. Follow the manual guidelines
before setup. When misused, the Actuator can cause harm, severe injury or even death due
to high voltages and forces involved. It is highly recommended to request for training prior to
use.
Take extreme care when operating environments exceeds the range of -20°C~80°C. The
Actuator is intended to operate between the given ranges on the nameplate of each actuator.
In the case where products are exposed to temperature ranges that exceed the allowed
range, do not check for damage as it could result in severe injury. Consult with the
manufacturer as soon as possible. Do not attempt to alter the Actuator physically as this
could lead to leakage and malfunction of the product. Before performing maintenance in
potentially hazardous areas, make sure all electrical supplies are shutdown and actuator
relocated to an environmentally safe location.
WARNING
Housing Material: Up to the HM010~035 of the
HM-Series
, Aluminium is processed
to manufacture the housing. Bolts etc are manufactured of stainless steel and base
from Cast Iron. The Models from HM40 ~ IQ90 are a mixture of Aluminium and
Ductile Iron. Before operating an
Actuator
the user must verify environmental
compatibility to avoid chemical corrosion. Study to determine safety must be
conducted before use.
Self-heating motor temperature: In normal operation mode the temperature of the
Actuator cover may exceed 60⁰C and advise great caution when handling.
Motor thermal protection (By Pass): Whenever the configurations are set to
bypass the Actuator cover temperature, any Hazardous area handling certificates
becomes invalid. Keep in mind hen using this mode that the risk of electrical danger

increases. The user must
measures.
Actuator manual operation
follow as directed.
In remote mode, the Actuator can be controlled to be switched on and off.
2 Product
Identification
2.1
Product Identification
The
actuator name plate is located on the
plate contains the following
2.1.1
Marking
a) General
HQ logo
(trade mark)
Model
Speed

Base Size

Torque Max

Motor supply

Motor Rating
Option
Serial No.

Nominal Motor current

Indication contacts
Enclosure
Name of manufacturer and country shall not be printed based on OEM
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increases. The user must
utilize
protective equipment and take additional safety
Actuator manual operation
:Read the manual operation
section carefully and
follow as directed.
In remote mode, the Actuator can be controlled to be switched on and off.
Identification
Product Identification
actuator name plate is located on the
side of the opposite of
the conduit entry. The name
plate contains the following
information.
Marking
(trade mark)
Base Size
Torque Max
Motor supply
Motor Rating
Nominal Motor current
Indication contacts
Name of manufacturer and country shall not be printed based on OEM
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protective equipment and take additional safety
section carefully and
In remote mode, the Actuator can be controlled to be switched on and off.
the conduit entry. The name
Name of manufacturer and country shall not be printed based on OEM
.

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2.2 Initial inspection
When the inspecting the actuator, check the product for damage and ensure the name plate
concurs with the order sheet.
Remove packaging 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 an incorrect product has
been shipped, immediately report the issue to our coordinators.
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 placing an Actuator outdoors, they must
be stored off the ground, high enough to prevent being immersed in water or buried
in snow. If the Actuator cannot be placed immediately, make sure to store it in a dry
area. It is recommended that if the Actuator cables cannot be installed immediately
use the plastic plug with PTFE tape to block/seal where the metal plugs are located.
When sealed correctly, the internal electronics are preserved from external corrosion
for extended periods of time (up to 1 year). Note that there is no need, when working
on the Actuator, to remove any electronics. If the control cover is removed, the
warranty may be void. Each individual Actuator will be tested before delivered hence,
given instructions have been correctly followed, setup and operation should be
smooth.
3 General Information and Features
3.1 General
HM series electric multi-turn actuators are controlled via the Smart Intelligent actuator
system and suitable for various industrial plants such as ship construction, power
plants, petrochemical semiconductor plants and many other high-end industrial
uses. Additionally, depending on the specific application, 9 different models are
available.
HM-04,08,011,020,040,060,100,150,200,300

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3.2 Performance Data
3.2.1 AC 3Phase Model & Torque(Nm)
RPM
MODEL & TORQUE(Nm)
3Phase
50HZ
60HZ
HM04
HM08
HM11
HM20
HM40
HM 60
HM100
HM150
HM200
HM300
18 21 35 80 110
200
400
600 1000
1500
2000
24 29 35 80 110
200
400
600 1000
1500
2000
3000
36 43 35 80
200
300
540 850 1300
1700
48 57 35 68
200
250
470 680 1000
1360
72 86 35 48
176
250
470 680 1000
1360
96 115
35 40
142
230
370 540 750 1000
144
173
105
150
260 400 650 860
192
230
540 730
3.2.2 AC 1Phase Model & Torque(Nm)
RPM MODEL & TORQUE(Nm) 1Phase
AC110~220V (HM040 은 220V 이상)
50HZ
60HZ
HM04
HM08
HM11
HM20
HM40
HM 60
HM100
HM150
HM200
HM300
18 21 - 65 - 165
450
- - - - -
24 29 - 60 - 130
400
- - - - -
36 43 - 45 - 130
350
- - - - -
48 57 - 40 - 125
320
- - - - -
72 86 - 30 - 100
230
- - - - -
96 115
- 25 - 80 190
- - - - -
144
173
- - - 60 135
- - - - -
192
230
- - - - - - - - - -
*(RED) At high speeds, do not operate without a GEAR BOX mechanism as this may result in problems!
*Maximum torque for actuator is shown. (BLUE) Operation for AC 220V or over have been outlined.

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3.2.3 Solid state design Model & Torque(Nm)
RPM
MODEL & TORQUE(Nm)
Solid state type 3Phase (AC380V~)
50HZ
60HZ
HM04 S3
HM08 S3 HM11 S3 HM20 S3 HM40 S3
18 21 35 80 110 200 400
24 29 35 80 110 200
36 43 35 80
48 57 35 68
72 86 35 48
RPM
MODEL & TORQUE(Nm)
Solid state type 1Phase
50HZ
60HZ
HM08 S1
(AC110~240V)
HM20 S1
(AC220~240V)
18 21 65 165
24 29 60 130
36 43 45 130
48 57 40 125
72 86 30 100
96 115
25 80
3.2.4 Mechanical Data
Mechanical Data
MODEL
HM04
HM08
HM11
HM20
HM40
HM60
HM100
HM150
HM200
HM300
Flange size(ISO5211)
F10
F10
F10
F14
F14
F16
F25 F30 F25 F30
Weight
30 30 30 65 65 70 190 190 200 200
Thrust rating(Nm)
44 44 44 100
100
150
220 220 334 445
Stem acceptance diameter maximum size (BASE) unit: mm
Thrust
Rising
32 32 32 38 38 54 64 70 70 83
Non-rising
26 26 26 32 32 45 51 57 57 73
Non
large type
42 42 42 60 60 80 100 100 120 120
Thrust
ISO type
20 20 20 30 30 40 50 50 50 N/A
blank type
20 20 20 30 30 44 50 60 60 N/A
Hand wheel ratio
Direct
Direct
Direct
Direct
Direct
Direct
Direct
18:1 18:1 18:1
Option
15:1
15:1
15:1
15:1
15:1
23:1
54:1 54:1 54:1 54:1
Cable entry
STANDARD PF 1”x 4EA PF 1½”x1 OPTION NPT 1”x 4EA NPT 1½”x1

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3.3 HM Standard Technical Data ( Standard )
Enclosure Rated Weatherproof IP67, IP68 (10m 72Hr) IEC60529
Enclosure High grade aluminium alloy, corrosion coated (HM04~HM60)
Nodular graphite cast iron& High grade aluminium alloy corrosion
coated (HM100~HM300)
Power Supply 110 / 220 VAC 1 Ph, (HM08,20,40) *HM40 Only 220V~
220 / 380 / 420 / 440/ 460/ 480V ~600V AC 3 Ph, 50/60Hz
Power voltage tolerance ± 10%
Starting voltage drop - 15%
(maximum)
Duty Rating HM04~300 3ph: 60starts/hour 15Minutes rated
HM08,20,40 1ph: 60starts/hour 15Minutes rated
HMS04~40: 1200starts/hour S4-50%
Torque HM04~300 3ph: 14~3000Nm direct drive. When combined with
gear box, up to 43000Nm or 500,000Nm quarter-turn available
HM08,20,40 1ph: 25Nm~450Nm
HMS04~40: 25Nm~450Nm
Motor induction motor
Monitoring Switches 4 Switches, 250 VAC 16A rating option: 8 Switches ~16 Switches
Travel Angle 0~10,000,000 turn
Indicator Digital Display position indicator
Signal lamp unit red : open , green : close , yellow : fault
Manual Override Declutch able manual override
Self Locking By means of worm gear
Conduit Entries PF1” x4 PF1½”X1
option(Explosion) : NPT1” x4EA, NPT1½”X1EA
Design Life Torque & thrust test: 50,000 Cycles
Lubrication Grease moly EP
Ambient Temperature -30 °C ~ + 70 °C
External Coating Anodizing & Dry powder polyester
Anti Vibration XYZ 1G 10~1000HZ
Anti Shock 5g Peak acceleration
Valve to” HM “interface Multi turn/ ISO5210 Part turn/ ISO5211
Local control & set up Two rotary selectors (control mode & local control)
Setup: setting tool ( remocon: remote control )
LCD’s displays