HKC APL-4 Series Instruction manual

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 1 / 12 Valve Automation Leader, HKC
APL-4 Series Valve Position Monitor
Installation, Operation & Maintenance Manual
Address : 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, Republic of Korea
Tel : [phone], Fax : [phone], Home page : www.hkcon.co.kr, email : [e-mail]

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 2 / 12 Valve Automation Leader, HKC
Contents
1. General ........................................................................................................................................ 3
2. Ordering Information.............................................................................................................. 3
3. Standard specification ............................................................................................................ 3
4. Preparing for Installation....................................................................................................... 4
4.1. Marking ........................................................................................................................... 4
4.2. Pre-Installation for use in potentially explosive atmosphere .............................. 4
4.3. Initial inspection ............................................................................................................ 5
5. Standard Features ................................................................................................................... 5
6. Installation ................................................................................................................................. 5
6.1. Mounting bracket ......................................................................................................... 5
6.2. Mounting limit switch box .......................................................................................... 6
6.3. Cam setting .................................................................................................................... 6
6.4. Wiring .............................................................................................................................. 7
6.5. Setting Position Transmitter Unit (APL- 4*6) ........................................................ 10
7. Maintenance ............................................................................................................................ 10
8. Inspection ................................................................................................................................. 11
9. Storage ...................................................................................................................................... 11
10. Trouble shooting .................................................................................................................... 11
11. Tools .......................................................................................................................................... 11
12. Installation and Maintenance Tips .................................................................................... 11

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 3 / 12 Valve Automation Leader, HKC
1. General
1.1. HKC APL-4 series limit switch boxes are designed to provide accurate and reliable valve position signalling
and indicating of most valves or actuators manufactured.
1.2. APL-4 limit switch boxes consist 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 - 4 1 0 N
① ② ③
① Enclosure type of explosion proof is based on IECEx, [CNEX ITRI, --- 21 r1] :
[ Ex db IIB T6 Gb ---- 18 r0]
Enclosure type of explosion proof is based on ATEX :
[ II 2 G Ex db IIB T6 Gb --- 18 r0]
Enclosure type of explosion proof is based on KCs :
Ex d IIB T6 Gb
Enclosure type of explosion proof is based on CSA :
Cl I, Div 1, Gr C & D T6
Cl I, Zone 1, AEx d IIB T6
Ex d IIB T6
[NEMA 4X/6, IP 66/67/68 --- 17r0]
[Enclosure type of explosion proof is based on EAC :
1Ex d IIB T6 Gb X
0Ex ia IIC T6 Ga X (APL-420, APL-422 only)
Ex tb IIIC T85℃ Db ------------------------------------ 21 r1]
② Switch type
Mechanical switch
[10 : 2-SPDT (Zippy VA2-16)
11 : 3-SPDT (Zippy VA2-16)
12 : 4-SPDT (Zippy VA2-16)
13 : 2-SPST (Zippy VA2-16)
14 : 2-DPDT (Omron : DZ-10GW-1B)
15 : 2-SPDT + Potentiometer (Zippy VA2-16)
16 : 2-SPDT + Signal Unit(4~20mA) (Zippy VA2-16) ---18 r0]
Proximity switch
20 : Proximity sensor (P&F : NJ2-V3-N)
21 : Proximity sensor (Autonics : PS17-5DNU) (Except CSA)
22 : Proximity sensor (P&F : NJ4-12GM-N)
23 : Proximity sensor (P&F : NBB2-V3)
25 : Proximity sensor + Potentiometer (P&F : NJ2-V3-N)
26 : Proximity sensor + Signal Unit(4~20mA) (P&F : NJ2-V3-N)
[Reed switch
30A : Reed sensor (MS-B 301) for general purpose
30B : Reed sensor (MK21 model 85, 250V 1A max) for CSA certified use
31 : Reed sensor (MK21 model 66, 180V 0.5A max) for CSA certified use
32 : Reed sensor (MK21 model 90, 175V 0.52A max) for CSA certified use –17r0]
③ Enclosure material
N : Aluminium
3. Standard specification
Model APL-4**N
Enclosure Rating Please refer to “2. Ordering Information, ① Enclosure type”
Enclosure High grade aluminium alloy
Ambient Temperature [APL-41* : -40°C ≤ Ta ≤ +60 °C
APL-414, APL-42*, APL-43* : -20°C ≤ Ta ≤ +60 °C ---18 r0]
[-60°C ≤ Ta ≤ +60 °C @ only EAC --- 21 r1]
Cable Entries Standard : Two NPT 3/4”, or M25 for Ex type

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 4 / 12 Valve Automation Leader, HKC
(Option for Non-Ex : NPT1/2”, PT3/4”, PT1/2”, PF3/4”, PF1/2”, M20)
Travel Angle 90 degree +/- 10%
Position Indicator Open : Yellow, Close : Red
Language : English (option : French, German)
Mechanical Switch [Zippy VA2-16 (Zippy Technology Corp.) --- 18 r0]
16A 1/2HP 125/250Vac, 0.6A 125Vdc, 0.3A 250Vdc, 5A 125Vac
Proximity sensor NJ2-V3-N (PEPPERL+FUCHS) : 5~25Vdc , 15mA max.
PS17-5DNU(Autonics) : 12~24Vdc, 0.2mA max.
MS-B 301 : 250Vdc 3.0A max.
Potentiometer 1kΩ (option : 0~5kΩ , 0~10kΩ)
Current Output Signal Unit 4~20mA, 20~4mA
Terminal Strip 8 point (option : 9~14P)
External Coating Dry powder polyester coating
4. Preparing for Installation
4.1. Marking
 HKC logo / Trade mark
 Model
 Switches type
 Cert No.
 Applicable temp.
 Serial No.
 Manufactured YY-MM
 Cable entry size
 Warning letter
 [Maker address --- 18 r0]
4.2. Pre-Installation for use in potentially explosive atmosphere
Installation, commissioning, maintenance, repairs and modification work must only be performed by
qualified personnel with extensive knowledge on how to work on explosion-proof electrical equipment.
Warning : Read this installation and maintenance manual carefully and completely before
attempting to install, operate, or troubleshoot the HKC product
4.2.1. Cable Connection
① Sealing devices must be used and shall be fitted directly at enclosure wall when using conduit.
② Cable glands shall be suitable for the environment and shall be certified as flameproof if used in Zone 1
application of IECEx scheme in order to connect outside electric wire.
③ Cable glands and conduit to be installed minimum 8 full threads and the length of thread is minimum
8mm.
④ “Warning” : Please be sure that user should select the appropriate cable glands and minimum 2SQ of
wire for fear that the proper using temperature of cable entry and wire way exceed 70 ℃ or the
blanching point is over 80 ℃.
Usage as Ex db for IECEX & ATEX
Usage as Ex db for CSA
Usage as Ex db for KCs

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 5 / 12 Valve Automation Leader, HKC
⑤ When cable entries or conduit entries are not used, user or installer shall close by certified blanking
elements(stopping plugs) so that the flameproof properties of the enclosure are maintained.
4.2.2. Groundings
① 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 inside the body .
External ground connection : The ground bracket is located on the side of body.
(Min 2SQ wire required)
4.2.3. Special Condition for safe use (“X” marking)
① Electrostatic discharge from window(over 1GΩ) may cause the ignition on the explosive gas atmosphere.
By adapting the conducting window bolts make reduce the risk from electrostatic discharge.
② Before installation or maintenance products, shut off incoming power and grounding should be
connected.
③ The window must only be cleaned with a damp cloth in order to avoid ignition hazard caused by static
electricity.
4.3. Initial inspection
4.3.1. When the user receipts the product, inspect the condition of the product and ensure the name plate
comparing with order sheet.
4.3.2. Remove packing wrap or wooden box carefully. Inspect the product for any physical damage that may
have occurred during shipment.
4.3.3. Check the product specification with product ordered. If a wrong product has been shipped,
immediately notify our coordinator.
5. Standard Features
No. Part Name Q’ty Description
1 Window / Indicator 1 PC / ABS
2 Cover 1 Aluminium Die casting (ADC12)
3 Captive cover bolt 4 Stainless steel
4 Name plate 1 Stainless steel (A240 T304)
5 Shaft 1 Stainless steel (G4303 SUS303)
6 Cam 2 PC
7 Switch 2 Refer to the clause “2. Ordering Information-② Switch type”
8 Body 1 Aluminium Die casting (ADC12)
9 Terminal strip 1 8P (9~14P available)
10 Earth lug 2 Stainless steel
11 Blanking element 2 [Sticker---19 r0] If required by customer, optionally used Exp type plug
6. Installation
6.1. Mounting bracket
Caution ; Where limit switch box or one of parts are to be moved, installed, disassembled,
reassembled by a hand, care must not be taken to cause injury by the harmful sharp edges of corners
or rough surfaces or residual electricity.
4
2
3
1
5
9
10
7
6
1
1
8

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 6 / 12 Valve Automation Leader, HKC
6.1.1. HKC shall supply a NAMUR VDI/VDE standards’ bracket and a fixing stuff for mounting on actuator.
Brackets are able to applied any type of valves; manual valve, linear valve, pneumatic rotary valve.
① Ensure valve actuator alignment (fully open or closed).
② Place the mounting bracket on a horizontal plane of actuator
③ Tighten the bolts enclosed in a box using a proper tool.
6.2. Mounting limit switch box
Caution ;
Do not attempt to work on limit switch box without first shutting off incoming power
6.2.1. Prior to mounting the limit switch box must be checked for any damage.
6.2.2. Damaged parts must be replaced by original spare parts.
6.2.3. 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.
① Check to be sure the drive slot on the top of the actuator and the shaft of switch box are the same
direction.
② Insert the shaft of switch box carefully into the mounting bracket.
③ Tighten the bolts enclosed in a box using a proper tool.
④ Check the connection of shaft being assembled correctly.
6.3. Cam setting
Note :
Basically, cams shall be set by manufacturer before shipment.
6.3.1. The colour 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.
6.3.2. Loose the captive cover bolts with an applicable tool. (L-Hex. Wrench
recommended)
6.3.3. Turn the cover counter clockwise to open carefully.
6.3.4. Open cam setting
① Electric power or air supply of valve actuator on to operate the
actuator fully open
② Lift the bottom yellow cam [(optional green)-17 r0] up and rotate it until the switch is activated.
③ And then release it. Cam shall be back into a stable position by itself.
6.3.5. Close cam setting
① Electric power or air supply of valve actuator off to operate the actuator fully close
② Push the upper red cam down and rotate it until the switch is activated.
③ And then release it. Cam shall be back into a stable position by itself.
Open Open
camcam
Close cam
Close
cam

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 7 / 12 Valve Automation Leader, HKC
Mechanical switch
Pr
oximity
sensor
Splined cam
6.4. Wiring
Danger ; HAZARDOUS VOLTAGE. No electrical power should be connected until all wiring and
limit switch adjustments have been completely.
6.4.1. Open circuit before removing cover, and seal required within 450mm (18 inch) of the enclosure by CSA.
6.4.2. 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.
6.4.3. [The APL-4 limit switch box has two cable entries on the body, and is protected with a sticker to protect it
from moisture and foreign matter penetration. User or installer shall be use cable gland that satisfy the
protection grade and connect them through the cable entries.
6.4.4. If the cable entry remains after wiring, it must be strictly closed using a suitable blanking plug. The cable
gland must be applied by installer or user. --- 20 r0]
① Mechanical switch(2 SPDT)
② Mechanical switch (3 SPDT)

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 8 / 12 Valve Automation Leader, HKC
③ Mechanical Switch (4 SPDT)
④ Mechanical Switch (2 DPDT)
⑤ Mechanical switch (2 SPDT), include Potentiometer

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 9 / 12 Valve Automation Leader, HKC
⑥ Mechanical switch (2 SPDT), include signal unit
⑦ Mechanical Switch (2 SPDT) with output potentiometer
⑧ Mechanical Switch (2 SPDT) with current output signal
Caution ;
Grounding should be connected until all wiring had been completely.
Internal grounding wire square shall be min. 2SQ recommended.
External grounding wire square shall be min. 4SQ recommended .

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 10 / 12 Valve Automation Leader, HKC
6.5. Setting Position Transmitter Unit (APL- 4*6)
6.5.1. Potentiometer reads the current position of actuator and transfers a resistance value to a current
position transmitter card. Transmitter indicates the actuator position throughout the stroke by a
4~20mA output signal.
6.5.2. Technical Features
① Power Supply Range 12.5 ~ 37VDC (24V typical)
② Current Signal Output 4~20mA
③ Max. Load Resistance Max. Resistance (ohm) = (Supply voltage – 12.5) / 0.02
④ Potentiometer 0~500 ohm / 10k ohm
⑤ Operating Temperature -20 ~ 60 ℃
⑥ Dimension 40 * 60 * 15
6.5.3. Calibration Potentiometer
① Apply power or air to the actuator to operate fully closed position
② Connect an ohm meter to P1 and P3 resistances, the values shall be approximately 1kΩ.
③ Loosen the shaft gear and connect the ohm meter to P1 and P3 and gently rotate until 80 ~ 120 ohm is
achieved (100ohm preferred). While maintaining the value, tighten a lock screw with a hex wrench.
6.5.4. Calibration Zero Span
Zero span setting has been calibrated by manufacturer. However if re-calibration is required
① Operate an actuator to 50% position and then fully closed position.
② When the actuator is in the fully closed position, adjust the “zero” button on the card until a value of
20mA is achieved.
7. Maintenance
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.
- Refer to the part list when ordering replacement or spare parts.
7.1. Maintenance, under normal conditions at six month intervals or 10,000 cycle operation. But when
conditions are more severe, more frequent inspections may be required.
7.1.1. Ensure valve actuator alignment. [If the alignment is not correct, the shaft may be damaged by metallic
fatigue during operation. --- 20 r0]
7.1.2. Ensure wiring is insulated, connected and terminated properly
7.1.3. Ensure all screws are present and tight
7.1.4. Ensure cleanliness of internal electrical devices
7.1.5. Ensure conduit connections are installed properly and are dry
7.1.6. Check internal devices for condensation
7.1.7. Check enclosure O rings seals and verify that the O ring is not pinched between housing
7.1.8. Visually inspect during open/close cycle
7.1.9. Inspect identification labels for wear and replace if necessary

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 11 / 12 Valve Automation Leader, HKC
Warning ;
Flameproof enclosure! Before opening, ensure the absence of gas and voltage.
Treat cover with care. Gap surfaces must not be damaged or dirtied in any way.
8. Inspection
8.1. The limit switch box should be inspected upon receipt to ensure that no damage has been sustained on
transit.
8.2. Check the item and quantity of products with packing list or related documents.
8.3. Check the limit switch box o-ring. Where damage on it, it caused the corrosion of internal parts.
8.4. 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.
9. Storage
The products 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.
10. Trouble shooting
The following instructions are offered for the most common difficulties encounter during installation and start-
up.
Signal fails to main control room.
① Check the wiring of limit switch box in accordance with wiring diagram.
② Check where the cams or switches are damaged or broken.
③ Check the main signal wire from the terminal strip.
④ Re-set the limit switch box.
⑤ Verify the current position transmitter resistance value.
⑥ Check potentiometer gear jamming.
⑦ Check the zero and span calibration.
⑧ Check the card damaged or not.
11. Tools
① 1 Set Metric Allen Key (Hex Wrench)
② Set Screw Drivers
③ 1 Set Metric Spanner
④ 1 Wire Stripper long Nose
⑤ 1 Needle nose plier
⑥ 1 Multi Meter (AC, DC, Resistance)
⑦ 1 ohm Meter (0~25mA) : if applicable 16 adapted
12. 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.
12.1. 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.
12.2. Cable entries, cable glands, plugs etc. have to be checked for correct tightness and sealing.
12.3. Check whether Ex-connections are fastened correctly.
12.4. Take care of possible discolouration of the terminals and wires.
12.5. Check the flame path gaps of flameproof enclosures for dirt and corrosion. Since the dimensions of all Ex
gaps are strictly defined and inspected, no mechanical work shall be performed on them.
12.6. Ensure that all housing covers are handled carefully and that the seals are checked.
12.7. All cables have to be checked.

APL-4**N Series Limit Switch Box
Installation, Operation & Maintenance Manual
Doc No. : HumG-APL4-21 Rev.1 Page 12 / 12 Valve Automation Leader, HKC
12.8. If defects which affect the safety are detected during maintenance, repair measures have to be taken
immediately.
12.9. Any kind of surface coating for the gap surface is not permitted.
12.10. When exchanging parts, seals etc. only original spare parts shall be used.
HKC Co., Ltd. 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, 15119, Republic of Korea
Head Office & Plant: Tel) [phone], Fax) [phone]
Fax) Overseas sales office: [phone], Domestic sales office: [phone]
Website www.hkcon.co.kr