HKC HQ-004 Instruction manual

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 1 / 9 Valve Automation Leader, HKC
HQ-004 Quarter-turn Electric Actuator
Installation, Operation & Maintenance Manual
Address : 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, South Korea (15119)
Tel : [phone], Fax : [phone], Home page : www.hkcon.co.kr, email : [email protected]

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 2 / 9 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 ........................................................................................................................ 3
2.3. Storage ............................................................................................................................................ 3
3. General Information and Features ........................................................................... 3
3.1. General information ................................................................................................................. 3
3.2. External Parts for Standard Models ................................................................................ 5
3.3. Internal parts for standard model ................................................................................... 5
4. Installation ................................................................................................................... 5
4.1. Pre-installation............................................................................................................................ 5
4.2. Actuator Mounting ................................................................................................................... 5
4.3. Limit Switch Setting ................................................................................................................. 6
5. Wiring ........................................................................................................................... 7
6. Maintenance ................................................................................................................ 7
6.1. Maintenance................................................................................................................................. 7
6.2. Tools ................................................................................................................................................. 8
7. Trouble Shooting ......................................................................................................... 8
7.1. The actuator does not respond ......................................................................................... 8
7.2. The actuator is supplied with power but does not operate .............................. 8
7.3. Actuator runs erratically ........................................................................................................ 8
8. Dimensions ................................................................................................................... 9

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 3 / 9 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
HQ-004 electric actuators.
1.2. Safety Notices
Safety notices are in this manual as outline precaution for the user must take to reduce the risk of
personal injury and damage by using the equipment. The user(s) must read this instruction before the
installation, operation or maintenance of HQ-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. Alert 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
HQ logo (trade mark), Model, Electrical power supply, Rated current, Torque, Serial No.
2.2. Initial Inspection
Upon on the receipt of the actuator, the user should inspect the condition of the product and ensure
that product specification stated in the name plate matches with the order sheet.
2.2.1. Remove the packing wrap or individual carton 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 a wrong product has been shipped,
immediately notify 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.
3. General Information and Features
3.1. General information
HKC HQ-004 electric actuator is designed for the operation of small size quarter-turn valves; e.g. ball,
butterfly valves, damper and etc with high reliability and efficiency.
3.1.1. Performance
Type
Max.
output
Torque
Operating
time(sec.)
60/50 Hz
Duty Cycle
IEC60034-1
Mounting
Size
Power
1 Phase
Rated Current (A)
60/50 Hz, 1 Phase
Weight
k
g
f
.m
90
°
S4 (%)
ISO 521
1
AC or DC
110V
220V
24V
kg
HQ-004 3 7/7 70 F03, F04, F05
85 ~ 265
V
ac
or 24 V dc 0.1A
0.1A 0.5A 1.2

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 4 / 9 Valve Automation Leader, HKC
② Manual lever
① Manual push button
3.1.2. Standard technical data
Enclosure Rated
Weatherproof IP67
Enclosure
High grade aluminum alloy,
anti
-
corrosion coated
Power Supply
110 / 220
V
ac
1
p
h
6
0/
5
0
Hz
,
24 V
dc
Duty Type
S4
7
0% / S2 30min (IEC 60034
-
1
)
Motor
DC motor
Limit Switches
2 x open/close SPDT, 250V
AC
5
A rating
Auxiliary Limit Switches
2 x open/close SPDT, 250V
AC
5
A rating
Indicator
Continuous position indicator
&
full position LED lamp
Manual Override
Manual push button & manual lever
Conduit Entries
1
x P
G11 & long (1.2m) wire type
Lubrication
Grease moly EP
Ambient Temperature
-
20 ℃~ +
8
0 ℃
External Coating
Dry powder polyester
[Deleted Space heater ---- 17 r1]
3.1.3. Duty Cycle *1
Duty cycle data were indicated Clause 3.1.1 Standard Technical Data
Exceeding the actuator’s rated duty cycle may cause thermal overload.
Note *1 Type of duty 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 cyc
l
es 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.
3.1.4. Manual override
3.1.5. Lubrication
HQ-004 electric actuator is a totally enclosed unit with permanent lubricated gear train
(Moly EP Grease). Once installed, further lubrication should not be required. However,
periodic preventative maintenance will extend the operating life of the actuator.

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 5 / 9 Valve Automation Leader, HKC
1 Manual push shaft
2 Indicator
3 On/off PCB & Heater
4 Additional close limit switch set
5 Additional open limit switch set
6 Close limit switch set
7 Open limit switch set
8 Fully closed LED lamp (red)
9 Fully open LED lamp (blue)
3.2. External Parts for Standard Models
3.3. Internal parts for standard model
4. Installation
4.1. Pre-installation
4.1.1. Use in general service
Verify the actuator’s nameplate to ensure correct model number, torque output,
operating speed and voltage before installation or use.
It is important to verify that the torque output of the actuator is appropriate for the
torque requirements of the valve and that the duty cycle of the actuator is appropriate
for the intended application.
4.2. Actuator Mounting
Note: Prior to mounting, the 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; the actuator may be mounted in any
position.
4.2.2. The HQ-004 electric actuators are supplied with a female drive output. The ISO5211 bolt
patterns are provided for actuator mounting. High tensile bolts or studs with spring
locking washers must be used.
4.2.3. The valve output shaft must be in lined with the actuator output drive to avoid side-
loading the shaft. To avoid backlash, flexibility in the mounting bracket or mounting
should not be allowed.
CAUTION: Do not attempt to work on your HKC actuator without first shutting off
the incoming power.
1
Top Cover
2
Body
3
Cable entry (PG 11)x1 & wire(1.2m)
4
Draft shaft (star 11mm)
5
M
ounting base (F03, F04, F05)
6
Manual lever hole
7
Name Plate
8
Cover bolt (captive
design
)
9
Indicator
10
Fully closed LED lamp (red color)
11
Manual push button
12
Fully open LED lamp (blue color)

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 6 / 9 Valve Automation Leader, HKC
4.2.4. Actuator Mounting Base Details
Note:
Make sure both actuator and valve are fully closed.
DANGER:
HAZARDOUS VOLTAGE. Make sure all incoming power is disconnected
before setting the limit switch
4.3. Limit Switch Setting
4.3.1. Rotate slowly and smoothly handle of the actuator to fully closed position
4.3.2. Using a hex wrench, loosen the set screw in CLOSE limit switch cam
4.3.3. Rotate the CLOSE cam towards CW limit switch until the switch ‘clicks’
4.3.4. Tighten the set screw with a hex wrench
4.3.5. Rotate slowly and smoothly the handle of the actuator to opened position
4.3.6. Using the hex wrench, loosen the set screw in OPEN limit switch cam
4.3.7. Rotate the OPEN cam towards CCW limit switch until the switch ‘clicks’ (see Figure below)
4.3.8. Tighten the set screw with the hex wrench
Direct mounting
(ISO standard)
Actuator : fully closed
Valve
: fully closed
Bracket mounting
Actuator mounting base:
F03/F05 and F04
F04 bolt circle (45
˚
)
F03/F05 bolt circles
Star adapter 14mm
→
11mm
11mm
→9mm
Open limit switch cam (CCW)
Open limit switch
2mm Hexagon socket head screw key

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 7 / 9 Valve Automation Leader, HKC
5. Wiring
DANGER: HAZARDOUS VOLTAGE.
No electrical power should be connected until all wiring and limit switch adjustments
have been completed. Once the power is supplied to the unit, exercise caution when
the cover is not installed.
6. Maintenance
6.1. Maintenance
WARNING:
Turn off all power before attempting to perform maintenance on the actuator.
POTENTIALLY HIGH PRESSURE VESSEL. Before removing or disassembling your actuator,
ensure that the valve or other actuated device is isolated and not under pressure.
Under the normal conditions, maintenance should be carried out at six month intervals. But when the
conditions are more severe, more frequent inspections may be advisable.
6.1.1. Ensure that the actuator is properly aligned with the valve or other actuated device
6.1.2. Ensure that all wirings are insulated, connected and terminated properly
6.1.3. Ensure that all screws are present and tight
6.1.4. Ensure cleanness of internal electrical devices
6.1.5. Ensure that cable connections are properly installed and are dried
6.1.6. Check the internal devices for any condensation
6.1.7. Check the power to the internal heater
6.1.8. Check enclosure O-rings seals and verify that the O ring is not pinched between each joint.
6.1.9. Verify the declutch mechanism
6.1.10. Visually inspect the open/close cycle
6.1.11. Inspect the identification labels for wear and replace it if necessary

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 8 / 9 Valve Automation Leader, HKC
WARNING:
Treat cover with care. Gap surfaces must not be damaged or dirtied in any way.
Do not jam the cover during fitting.
6.2. Tools
6.2.1. Metric Allen Key (Hex Wrench) × 1
6.2.2. Screw Driver × 1
6.2.3. Metric Spanner × 1
6.2.4. Wrench 200mm × 1
6.2.5. Wrench 300mm × 1
6.2.6. Wire Stripper Long Nose × 1
6.2.7. Multi-meter (Ac, Dc, Resistance) × 1
7. Trouble Shooting
The following instructions are listed in the order of the most common difficulties encountered during
the installation and start-up.
7.1. The actuator does not respond
7.1.1. Visually inspect the actuator to check no shipping or handling damage has occurred
7.1.2. Verify the line voltage supplied to the actuator; check that the line voltage matches with
the rating on the actuator’s nameplate
7.1.3. Check the internal wiring against the supplied wiring diagram of the actuator
7.1.4. Check the limit switch cams
7.2. The actuator is supplied with power but does not operate
7.2.1. Verify the line voltage supplied to the actuator; check that the line voltage matches with
the rating on the actuator’s nameplate.
7.2.2. Check that the actuator torque is greater than the valve torque
7.2.3. Check the limit switch cams
7.2.4. Check that the torque switches have not been tripped
7.2.5. Check the mechanical travel stop adjustment
7.2.6. Verify that the actuator against the rotation of the valve (standard units are counter-
clockwise rotation to open)
7.2.7. Check for any corrosion and condensation that any of the electrical or mechanical devices
have not been contaminated
7.2.8. Verify that coupler/bracket is correctly installed and is not causing any binding
7.3. Actuator runs erratically
7.3.1. Check the ambient temperature
7.3.2. Verify that the duty cycle has not been exceeded
7.3.3. Check the position of manual override lever
Symptom
Probable
Cause
Corrective Action
Motor will not run
Open in control circuit Refer to appropriate wiring diagram and
check for continuity
Insulation resistance breakdown
in motor Perform megger Test
No power available to actuator Tripped circuit breaker Reset circuit breaker
Manual Override Nut hard to
turn
Valve stem improperly lubricated
Lubricate with grease
Clean out old grease and replace with
recommended lubricant
Actuator lubrication has broken
down
Valve packing gland too tight Loosen packing gland nuts as necessary
Jammed valve Refer to valve maintenance
Valve only opens or closes
partially with motor Limit switch improperly set Check setting and reset if necessary
Manual Override Nut will not
operate valve
Stripped gearing Replace as necessary
Broken hand wheel shaft Replace as necessary
Broken valve stem Repair or replace as necessary
Motor runs but will not operate
valve Stripped gearing Replace as necessary

HQ-004 Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ004-21 Rev0 Page 9 / 9 Valve Automation Leader, HKC
8. Dimensions
HKC Co., Ltd Address 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, (15119), Republic of Korea
Tel : [phone], Home page: www.hkcon.co.kr
Fax: Head O. [phone], Domestic S. [phone], Overseas S. [phone]