HKC APL-2 Series Instruction manual

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 1 / 10 Valve Automation Leader HKC
APL-2 Series Valve Position Monitor
Installation, Operation & Maintenance Manual

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 2 / 10 Valve Automation Leader HKC
Table of Contents
1 General. ........................................................................................................ 3
2 Ordering Information ..................................................................................... 3
3 Standard specification ................................................................................... 3
4 Marking ........................................................................................................ 3
5 Standard Features ......................................................................................... 4
6 Pre-Installation for ........................................................................................ 5
7 Installation .................................................................................................... 5
7.1 Mounting bracket .................................................................................. 5
7.2 Mounting limit switch box ...................................................................... 5
7.3 Setting cam ........................................................................................... 5
7.4 Wiring ................................................................................................... 6
8 Maintenance ................................................................................................. 8
9 Inspection ..................................................................................................... 8
10 Storage ......................................................................................................... 8
11 Trouble Shooting ........................................................................................... 8
12 Tools ............................................................................................................. 8
13 Installation and Maintenance Tips .................................................................. 9

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 3 / 10 Valve Automation Leader HKC
1 General
HKC APL series limit switch box is designed to provide accurate and reliable valve position signaling and
indicating of most valves or actuators manufactured.
APL limit switch box 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 - 2 1 0 N
① ② ③
① Enclosure type
l 2 : Weather proof
② Switch type
l 10 : 2-SPDT (Wonwoo : SZM-V16-5FA-61)
l 13 : 2-SPST (Wonwoo : SZM-V16-5FA-61)
l 20 : Proximity Sensor (P&F : NJ2-V3-N)
l 23 : Proximity Sensor (P&F : NBB2-V3)
③ Enclosure Material
l N : Aluminum Die-casting
3 Standard specification
Model APL-2..N
Enclosure Rated Weatherproof IP67/NEMA4&4X (Standard) IP68(Option)
Enclosure High grade aluminum alloy
Ambient Temperature -20 ℃ ~ + 80 ℃
Conduit Entries Standard: Two 1/2" NPT, Option: PF1/2”, PT1/2”, M20, PG13.5
Travel Angle 90 degree +/- 10%
Position Indicator Open : Yellow, Close : Red
Language : English (option : French, German)
Switch Mechanical switch : Wonwoo Starion
Proximity sensor : P&F
Terminal Strip 8 point (option : 9~14P)
External Coating Thermally hardened polyester powder coating, KARUMEL PX8576
4 Marking
n HKC Logo
n Model (APL-2..N)
n Micro Switches type
n Manufactured (YY-MM)
n CSA type 4X

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 4 / 10 Valve Automation Leader HKC
5 Standard Features
No.
Part Name
Q’ty
Description
1
Window / Indicator
1
PC / ABS
2
Captive Cover Bolt
4
Stainless steel
3
Cover
1
Stainless steel
4
Name Plate
1
Sticker
5
Shaft
1
Stainless steel
6
Body
1
Aluminum Die casting
7
Terminal Strip
2
8P (9~14P available)
8
Cam
1
PC
9
Switch
1
Mechanical or Proximity type
10
Earth Lug
1
Stainless steel
11
Blanking Element
2
PC
4
2
3
1
5
6
7
8
9
11
10

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 5 / 10 Valve Automation Leader HKC
6 Pre-Installation for
Ø Use in general service
Verify the nameplate to ensure correct model number, switch type, voltage before installation or use.
7 Installation
7.1 Mounting bracket
Caution ;
Where limit switch box or one of parts are to be moved, installed, disassembled, reassembled by a
hand, care must be taken not to cause injury by the harmful sharp edges of corners or rough surfaces
or residual electricity.
HKC shall supply a NAMUR VDI/VDE standards’ bracket and a fixing stuff for mounting on actuator. Bracket shall
be applicable to any type of valves ; manual valve, linear valve, pneumatic rotary valve.
Ø Ensure valve actuator alignment (fully open or closed).
Ø Place the mounting bracket on a horizontal plane of actuator
Ø Tighten the bolts enclosed in a box using a proper tool.
7.2 Mounting limit switch box
Note :
Prior to mounting the limit switch box must be checked for any damage.
Damaged parts must be replaced by original spare parts.
Caution ;
Do not attempt to work on limit switch box without first shutting off incoming power.
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.
Ø Check to be sure the drive slot on the top of the actuator and the shaft of switch box are the same
direction.
Ø Insert the shaft of switch box carefully into the mounting bracket.
Ø Tighten the bolts enclosed in a box using a proper tool.
Ø Check the connection of shaft being assembled correctly.
7.3 Setting cam
The color 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.
Note :
Basically, cams shall be set by manufacturer before shipment.

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 6 / 10 Valve Automation Leader HKC
Ø Un-tighten the captive cover bolts with an applicable tool. (Spanner.+ Driver recommended)
Ø Remove the cover carefully.
Ø Open cam setting
Electric power or air supply of valve actuator on to operate the actuator fully
open
Lift the bottom yellow cam up and rotate it until the switch is activated.
And then release it. Cam shall be back into a stable position by itself.
Ø Close cam setting
Electric power or air supply of valve actuator off to operate the actuator fully
close
Push the upper cam down and rotate it until the switch is activated.
And then release it. Cam shall be back into a stable position by itself.
Mechanical switches
Proximity sensors
Splined cam
7.4 Wiring
Danger ;
HAZARDOUS VOLTAGE. No electrical power should be connected until all wiring and limit switch
adjustments have been completely.
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.
Solenoid valve may also be wired through the APL enclosure. Two auxiliary terminals are included as standard.
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.

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 7 / 10 Valve Automation Leader HKC
Ø MECHANICAL SWITCH(2 SPDT)
Ø MECHANICAL SWITCH(2 SPST)
Note ;
Grounding should be connected until all wiring have been completely.
Internal grounding wire square shall be min.2SQ. recommended.
External grounding wire square shall be min.4SQ. recommended .

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 8 / 10 Valve Automation Leader HKC
8 Maintenance
HKC APL 2..N Series limit switch box is designed to provide accurate and reliable valve position signaling and
indicating of most valves or actuators manufactured
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.
Refers to the part list when ordering replacement or spare parts.
Maintenance, under normal conditions at six month intervals or 100,000 cycle operation. But when conditions
are more severe, more frequent inspections may be required.
Ø Ensure valve actuator alignment
Ø Ensure wiring is insulated, connected and terminated properly
Ø Ensure all screws are present and tight
Ø Ensure conduit connections are installed properly and are dry
Ø Check internal devices for condensation
Ø Check enclosure O rings seals and verify that the O ring is not pinched between housing
Ø Visually inspect during open/close cycle
Ø Inspect identification labels for ware and replace if necessary
Warning :
Treat cover with care. Gap surface must not be damaged or dirtied in any way
9 Inspection
Ø Check the item and quantity of products with packing list or related documents.
Ø Check the limit switch box o-ring. Where a damage on it. It caused the corrosion of internal parts.
Ø 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.
10 Storage
The products must be stored in a clean, cool and dry area. The unit shall be stored with the cover installed and
the cable entry openings sealed. Storage must be off the floor, covered with a sealed dust protector.
11 Trouble Shooting
The following instructions are offered for the most common difficulties encounter during installation and start-
up.
Signal fails to main control room.
Ø Check the wiring of limit switch box in accordance with wiring diagram.
Ø Check where the cams or switches are damaged or broken.
Ø Check the main signal wire from the terminal strip.
Ø Re-set the limit switch box
12 Tools
Ø 1 Set Metric Allen key (Hex Wrench)
Ø 1 Set Screw drivers
Ø 1 Set Metric spanner
Ø 1 Wire Stripper long nose
Ø 1 Needle nose pliers
Ø 1 Multi Meter (AC, DC, Resistance)
Ø 1 Ohm Meter (0~25mA) : IF APL - . 16 adapted

APL-2 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL2-16 Rev0 Page 9 / 10 Valve Automation Leader HKC
13 Installation and Maintenance Tips
For any installation and maintenance work, the following should be observed :
Caution :
A regular inspection and maintenance performed by qualified and trained personnel
When working in potentially explosive areas, observe the standard EN 60079-14 “Electrical
Installations in Hazardous Areas”.
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.
Observe additional national regulations.
Ø 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.
Ø Cable entries, cable glands, plugs etc. have to be checked for correct tightness and sealing.
Ø Check whether enclosure connections are fastened correctly.
Ø Take care of possible discolorations of the terminals and wires.
Ø Check the enclosure gaps whether contaminated dirt and corrosion. Since the dimensions of all enclosure
gaps are strictly defined and inspected, no mechanical work shall be performed on them.
Ø Ensure that all housing covers are handled carefully and that the seals are checked.
Ø All cables have to be checked.
Ø If defects which affect the safety are detected during maintenance, repair measures have to be taken
immediately.
Ø Any kind of coating for the gap surface shall not be permitted.
Ø When exchanging parts, seals etc. only original spare parts shall be used.