HKC APL-7 Series Instruction manual

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 1 / 10 Valve Automation Leader, HKC
APL-7 Series Valve Position Monitor
Installation, Operation & Maintenance Manual
Address : 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, 15119, Republic of Korea
Tel : [phone], Fax : [phone], Home page : www.hkcon.co.kr, email : [e-mail]

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 2 / 10 Valve Automation Leader, HKC
Table of Contents
1. General ..................................................................................................................................... 3
2. Ordering Information ........................................................................................................... 3
3. Standard specification .......................................................................................................... 3
4. Preparing for installation ..................................................................................................... 4
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- 7. 6) ......................................................................................8
7. Maintenance ........................................................................................................................... 9
8. Inspection ................................................................................................................................ 9
9. Storage ................................................................................................................................... 10
10. Trouble Shooting ................................................................................................................. 10
11. Tools ....................................................................................................................................... 10
12. Installation and Maintenance Tips ................................................................................... 10

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 3 / 10 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 - 7 1 0 N 0 1
① ② ③ ④ ⑤ --- 21 Rev.0]
① Enclosure type of flame proof is based on IECEx
7 : Explosion proof & Coil, [IECEx & CCC Ex db IIC T5 Gb, ATEX II 2 G Ex db IIC T5 Gb, KCs Ex d IIC T6 Gb
② Switch type
Mechanical switch (Ambient temperature : -20°C to +60 °C)
10 : 2-SPDT (Wonwoo SZM-V16-5FA-61, or Zippy VA2-16)
11 : 3-SPDT (Wonwoo SZM-V16-5FA-61, or Zippy VA2-16)
12 : 4-SPDT (Wonwoo SZM-V16-5FA-61, or Zippy VA2-16)
13 : 2-SPST (Wonwoo SZM-V16-5FA-61, or Zippy VA2-16)
14 : 2-DPDT (Omron: DZ-10GW-1B, -25°C to +60 °C)
15 : 2-SPDT + Potentiometer (Wonwoo SZM-V16-5FA-61, or Zippy VA2-16)
16 : 2-SPDT + Signal Unit(4~20mA) (Wonwoo SZM-V16-5FA-61, or Zippy VA2-16) --- 20 r0]
Proximity switch (Ambient temperature : -20°C to +60 °C)
20 : Proximity Sensor (P&F : NJ2-V3-N)
21 : Proximity Sensor (Autonics : PS17-5DNU)
22 : Proximity Sensor (P&F : NJ4-12GM-N)
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)
Reed switch (Ambient temperature : -20°C to +60 °C)
30 : Reed Sensor (MS-B 301) for general purpose
③ [Enclosure material (Body material)
N : Aluminum
④ Coil voltage
0 : 24 Vdc (±10%)
1 : 110 Vac (±10%)
2 : 220 Vac (±10%)
⑤ Solenoid valve
0 : 3-way, 760 L/min (5 bar), Cv 0.6, NPT 1/8” or G 1/8”
1 : 3-way, 1000 L/min (5 bar), Cv 1.0, NPT 1/4” or G 1/4”
2 : 3-way, 2000 L/min (5 bar), Cv 1.6, NPT 3/8” or G 3/8”
3 : 5-way, 760 L/min (5 bar), Cv 0.6, NPT 1/8” or G 1/8”
4 : 5-way, 1000 L/min (5 bar), Cv 1.0, NPT 1/4” or G 1/4”
5 : 5-way, 2000 L/min (5 bar), Cv 1.6, NPT 3/8” or G 3/8” --- 21 Rev.0]
3. Standard specification
Model APL-7**N,
Enclosure protection Weatherproof IP67 (Standard), IP68 (Option)
Enclosure Aluminum alloy ADC12
Ambient Temperature -20 °C ≤ Ta ≤ +60 °C
Cable Entries 3 x 3/4 NPT (Standard, Flameproof)
M20, M25 (Optional Flameproof), PF3/4”, PT3/4”(Optional General use)
Travel Angle 90 degree +/- 10%
Position Indicator Open: Yellow, Close: Red
Language: English (option: French, German)
Switch, Mechanical: 16A 1/2HP 125/250Vac, 0.6A 125Vdc, 0.3A 250Vdc, 5A 125Vac

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 4 / 10 Valve Automation Leader, HKC
Proximity sensor: NJ2-V3-N (PEPPERL+FUCHS) : 5~25Vdc , 15mA max.
PS17-5DNU(Autonics) : 12~24Vdc, 0.2mA max.
Reed type magnetic: 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 Thermally hardened polyester powder coating
4. Preparing for installation
4.1. Marking
 HKC Logo
 Trade mark
 Model
 Switches type
 Certification No.
 Ambient temperature
 Serial No.
 Cable entry size
 Warning
 Address
 Coil power rated voltage
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.
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.
③ [Transparency window must be wiped or cleaned with a damp cloth to avoid the possibility of
ignition hazard due to static electricity. ---- 20 r0]
[For IECEx and ATEX—20r0]
For KCs

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 5 / 10 Valve Automation Leader, HKC
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 inform to 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 Solenoid Valve 1 Built-in
12 Blanking Element 3 [Sticker. If required by customer, optionally used Exp type plug-19r0]
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.
Bracket shall be applicable to 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
11 12

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 6 / 10 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. Cam setting
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 (optional green) 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.
Mechanical switches
Proximity
sensors
Splined cam
Open cam Close cam

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 7 / 10 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. Solenoid valve may also be able to be wired through the APL enclosure. Two auxiliary terminals are
included as standard.
6.4.4. [APL-7 limit switch box has three cable entries on the body. User or installer must apply wiring
through the cable entry with a cable gland which meets the type of protection, and remained cable
entries after wiring shall be strictly protected with suitable blanking plug. The cable gland and the
blanking plug shall be applied by installer or user. --- 20r0]
① Mechanical Switch (2 SPDT)
② Mechanical Switch (3 SPDT)
③ Mechanical Switch (4 SPDT)

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 8 / 10 Valve Automation Leader, HKC
④ Mechanical Switch (2 DPDT)
⑤ Mechanical Switch (2 SPDT) with Potentiometer
⑥ Mechanical Switch (2 SPDT) with Signal Unit
Note ; Grounding should be connected until all wiring had been completely.
Wire square of the internal grounding shall be recommended min.2SQ recommended.
Wire square for the external grounding shall be recommended min.4SQ recommended.
6.5. Setting Position Transmitter Unit (APL- 7*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 (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 Operation Temperature -20 ~ 60℃
⑥ Dimension 40 * 60 * 15

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 9 / 10 Valve Automation Leader, HKC
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.
- Refer 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. [If the alignment among the valve, actuator and this limit switch
box are not correct, it can be a cause of damage on shaft due to metallic fatigue during operating.
--- 20 r1]
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 ware and replace if necessary
Warning ;
Flameproof enclosure! Before opening, ensure the absence of gas, dust and electrical power.
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 a 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.

APL-7 Series Limit Switch Box
Installation Operation & Maintenance Manual
Doc No. : HumG-APL7-21 Rev0 Page 10 / 10 Valve Automation Leader, HKC
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. Verify the current position transmitter resistance value.
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 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 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. 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