HKC APL-8 Series Instruction manual

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 1 / 12 Valve Automation Leader, HKC
APL-8 Series Valve Position Monitor
Installation, Operation & Maintenance Manual
Address : Seonggok-dong, 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do, South Korea
Tel : [phone], Fax : [phone], Home page : www.hkcon.co.kr , email : [e-mail]

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 2 / 12 Valve Automation Leader, HKC
Table of 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
5. Standard Features ..................................................................................................... 5
6. Installation ................................................................................................................. 5
6.1. Mounting bracket .............................................................................................. 5
6.2. Mounting limit switch box.................................................................................. 6
6.3. Setting cam ....................................................................................................... 6
6.4. Wiring ............................................................................................................... 7
6.5. Setting Position Transmitter Unit (APL- 8 . 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-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 3 / 12 Valve Automation Leader, HKC
1. General
1.1. HKC APL series limit switch box is designed to provide accurate and reliable valve position signaling and
indicating of most valves or actuators manufactured.
1.2. 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 - 8 1 0 N
① ② ③
① Enclosure type of flame proof is based on IECEx EPS 13.0043X: Ex d IIC T 6 Gb
Enclosure type of flame proof is based on ATEX EPS 14 ATEX 1 695 X: II 2 G Ex d IIC T 6 Gb
Enclosure type of flame proof is based on KCs 15-AV2BO-0650X : Ex d IIC T6 Gb
② Switch type
10 : 2-SPDT (Wonwoo : SZM-V16-5FA-61)
11 : 3-SPDT (Wonwoo : SZM-V16-5FA-61)
12 : 4-SPDT (Wonwoo : SZM-V16-5FA-61)
13 : 2-SPST (Wonwoo : SZM-V16-5FA-61)
14 : 2-DPDT (Omron : DZ-10GW-1B)
15 : 2-SPDT + Potentiometer (Wonwoo : SZM-V16-5FA-61)
16 : 2-SPDT + Signal Unit(4~20mA) (Wonwoo : SZM-V16-5FA-61)
20 : Proximity Sensor (P&F : NJ2-V3-N)
21 : Proximity Sensor (Autonics : PS17-5DNU)
23 : Proximity Sensor (P&F : NBB2-V3)
25 : Proximity Sensor (P&F : NJ2-V3-N) + Potentiometer
26 : Proximity Sensor (P&F : NJ2-V3-N) + Signal Unit (4~20mA)
30 : Reed type Proximity Sensor (MS-B 301)
③ Enclosure material (Body & Cover)
N : Aluminum alloy
S : Stainless steel
3. Standard specification
Model APL-8..N/S,
Enclosure Rate Weatherproof IP67(Std), IP68(Option), Flame proof Ex d IIC T6(Option)
Enclosure Aluminum alloy ADC12
Ambient Temperature -20 ℃ ~ + 60 ℃
Cable Entries 4 x 3/4 NPT (Standard, flame proof)
M20, M25 (Optional flame proof), PF3/4”, PT3/4” (Optional)
Travel Angle 90 degree +/- 10%
Position Indicator Open : Yellow, Close : Red
Language : English (option : French, German)
Mechanical switch SZM-V16-5FA-61 Wonwoo Starion,
16A 1/2HP 125/250Vac, 0.6A 125Vdc, 0.3A 250Vdc, 5A 125Vac
Proximity sensor NJ2-V3-N(P&F) 5~25 Vdc, 15mA max
PS17-5DNU(Autonics) 12~24 Vdc, 0.2mA max
MS-B 301 Reed type proximity sensor, 250 Vdc 3.0 A 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 Thermally hardened polyester powder coating

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 4 / 12 Valve Automation Leader, HKC
4. Preparing for Installation
4.1. Marking
HKC Logo / Trade mark
Model
Switches type
Enclosure type & Cert No. for flame proof:
Ambient temperature
Serial No.
Manufacturred year & month (YY-MM)
Cable entry size
Warning letter
Maker address
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 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 it used in
Zone 1 application.
③ Cable glands and shall be installed minimum 6 full threads and the length of thread is minimum
8mm.
④ The temperature at cable entry and blanching point may exceed 70℃ and 80℃ respectively
therefore select the appropriate cable gland and min 2SQ of wire is recommended when you install”
⑤ 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.
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
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.
4.3. Initial inspection
When the user receipts the product, inspect the condition of the product and ensure the name plate
comparing with order sheet.
4.3.1. Remove packing wrap or wooden box carefully. Inspect the product for any physical damage that
may have occurred during shipment.
4.3.2. Check the product specification with product ordered. If a wrong product has been shipped,
immediately inform to our coordinator.
For IECEx and ATEX
For KCs

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 5 / 12 Valve Automation Leader, HKC
5. Standard Features
No.
Part Name
Q’ty
Description
1
Window / Indicator
1
PC / ABS
2
Cover
1
Aluminium die casting (ADC12), Stainless steel (CF8M)
3
Name Plate
1
Stainless steel (A240 T304)
4
Captive Cover Bolt
4
Stainless steel
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), Stainless steel(CF8M)
9
Terminal Strip
1
8P (9~14P available)
10
Earth Lug
2
Stainless steel
11
Blanking elements
4
PE
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 be taken not to cause injury by the harmful sharp edges of corners
or rough surfaces or residual electricity.
6.1.1. HKC shall supply a NAMUR VDI/VDE standards’ bracket and a fixing stuff for mounting on actuator.
Brackets are able to be 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.
4
3
2
1
5
6
7
8
9
10

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 6 / 12 Valve Automation Leader, HKC
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. Setting cam
Note :
Basically, cams shall be set by manufacturer before shipment.
6.3.1. 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.
6.3.2. Loose the captive cover bolts with an applicable tool. (L-Hex. Wrench recommended)
6.3.3. Remove the cover 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 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 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.
Mechanical switches
Proximity sensors
Splined cam

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 7 / 12 Valve Automation Leader, HKC
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
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. APL-8 limit switch box has four cable entries on the body. Blanking plugs or cable glands shall be
applied by installer or user. The blanking plugs or cable glands shall be met with approved protection
grade minimum.
① MECHANICAL SWITCH(2 SPDT)
② MECHANICAL SWITCH(3 SPDT)

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 8 / 12 Valve Automation Leader, HKC
③ MECHANICAL SWITCH(4 SPDT)
④ MECHANICAL SWITCH(2 DPDT)

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 9 / 12 Valve Automation Leader, HKC
⑤ MECHANICAL SWITCH(2 SPDT) WITH OUTPUT POTENTIOMETER
⑥ MECHANICAL SWITCH(2 SPDT) WITH CURRENT OUTPUT SIGNAL
Note ; Grounding should be connected until all wiring have been completely.
Internal grounding wire square shall be recommended min.2SQ.
External grounding wire square shall be recommended min.4SQ.

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 10 / 12 Valve Automation Leader, HKC
6.5. Setting Position Transmitter Unit (APL- 8 . 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 a
4~20mA output signal.
6.5.2. Technical features
① Power Supply Range 12.5 ~ 37VDC (25V 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 Operation Temperature -20 ~ 60℃
⑥ Dimension 40 * 60 * 15
6.5.3. Calibrating potentiometer
① Apply power or air to the actuator to operate fully closed position
② Connect an ohm meter to P1 and P3 resistance, the value 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 (100 ohm preferred). While maintaining the value, tighten a lock screw with a hex
wrench.
6.5.4. Zero and Span Calibration
Zero and 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
20 mA 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.
Refers to the part list when ordering replacement or spare parts.
7.1. 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.
7.1.1. Ensure valve actuator alignment
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 conduit connections are installed properly and are dry

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 11 / 12 Valve Automation Leader, HKC
7.1.5. Check internal devices for condensation
7.1.6. Check enclosure O rings seals and verify that the O ring is not pinched between housing
7.1.7. Visually inspect during open/close cycle
7.1.8. Inspect identification labels for ware and replace if necessary
Warning :
Flameproof enclosure! Before opening ensure the absence of gas and voltage.
Treat cover with care. Gap surface must not be damaged or dirtied in any way
8. Inspection
8.1. Check the item and quantity of products with packing list or related documents.
8.2. Check the limit switch box o-ring. Where a damage on it. It caused the corrosion of internal parts.
8.3. 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 cable entry 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.
10.1. Check the wiring of limit switch box in accordance with wiring diagram.
10.2. Check whether the cams or switches are damaged or broken.
10.3. Check the main signal wire from the terminal strip.
10.4. Re-set the limit switch box
10.5. Check the resistance value of the potentiometer.
10.6. Check potentiometer gear jamming
10.7. Check the zero and span calibration
10.8. Check whether the card is damaged or not.
11. Tools
11.1. 1 Set Metric Allen key (Hex Wrench)
11.2. 1 Set Screw driver
11.3. 1 Set Metric spanner
11.4. 1 Wire Stripper long nose
11.5. 1 Needle nose pliers
11.6. 1 Multi Meter (AC, DC, Resistance)
11.7. 1 Ohm Meter (0~25mA) : IF APL - . 16 adapted
12. Installation and Maintenance Tips
For any installation and maintenance work, the following should be observed :
Caution :
ü A regular inspection and maintenance performed by qualified and trained personnel
ü When working in potentially explosive areas, observe the standard EN 60079-14 “Electrical
Installations in Hazardous Areas”.
ü 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.
ü 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.

APL-8 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HUMG-APL8-16 Rev0 Page 12 / 12 Valve Automation Leader, HKC
12.3. Check all of the connections are fastened correctly.
12.4. Take care of possible discolorations 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.
12.8. If defects which affect the safety are detected during maintenance, repair measures have to be taken
immediately.
12.9. Any kind of coating for the gap surface shall not be permitted.
12.10. When exchanging parts, seals etc. only original spare parts shall be used.
HKC Co., Ltd.
Sales Office Tel: [phone], Fax: [phone]
Head Office & Plant Tel: [phone], Fax: [phone]
Address (Seonggok-dong) 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do,15417
South Korea
Website www.hkcon.co.kr