Installation, Operation & Maintenance Manual: HL Series Electric Linear Actuators

HL Series Electric Linear Actuator
Installation Operation & Maintenance Manual
HL Series Electric Linear Actuators
Installation, Operation & Maintenance Manual
Address : Seonggok-dong, 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do, South Korea

Tel : +82-31-488-8266, Fax : +82-31-488-8269, Home page : www.hkcon.co.kr, email : hkcon@hkcon.co.kr
Doc No. : HUMG-HL-16 Rev0 Page 1 / 25 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 ......................................................................................................4
2.3. Storage ...................................................................................................................4
3. General Information and Features .......................................................................................5
3.1. General ...................................................................................................................5
3.2. External Parts for Standard Models .........................................................................7
3.3. Internal Parts for Standard Models ..........................................................................7
4. Installation Instruction .........................................................................................................7
4.1. Pre-Installation for ..................................................................................................7
4.2. Actuator Mounting ..................................................................................................8
4.3. Limit Switch Setting .................................................................................................9
4.4. Force Switch Setting ..............................................................................................10
4.5. Position Feedback Potentiometer (Optional) ........................................................10
4.6. Current Position Transmitter CPT (Optional) .....................................................11
4.7. Proportional Control Unit (PCU-A) ........................................................................13
4.8. Proportional Control Unit (PCU-D) ........................................................................13
4.9. AC/DC Multi-Board ...............................................................................................17
5. Wiring ...............................................................................................................................18
5.1. Electrical Connections and Preliminary Test...........................................................18
5.2. Wiring Diagrams for Standard Models ...................................................................18
6. Maintenance .....................................................................................................................20
6.1. Maintenance .........................................................................................................20
6.2. Tools .....................................................................................................................21
7. Trouble Shooting ...............................................................................................................21
7.1. The actuator does not respond ..............................................................................21
7.2. The actuator is supplied with power but does not operate .....................................21
7.3. Actuator runs erratically ........................................................................................21
7.4. Optional Equipment(s) ..........................................................................................21
8. Installation and Maintenance Tips .....................................................................................22
9. Dimensions for actuator ....................................................................................................23
9.1. 5KN,7KN, 10KN, 12KN, 15KN, 18KN, 20KN, 25KN (Standard type) ........................23
9.2. 5KN,7KN, 10KN, 12KN, 15KN, 18KN, 20KN, 25KN (LCU-B type) ............................23
9.3. 5KN,7KN, 10KN, 12KN, 15KN, 18KN, 20KN, 25KN (RBP type) ................................24
APPENDIX Ⅰ. HL Series Coding System ....................................................................................25

1. Introduction
1.1. Purpose
The purpose of this manual is to introduce and explain the installation, operation and
maintenance of HL-series electric actuators. This IOM Manual is distributed as a hard copy
when delivered the ordered products to customer.
1.2. Safety Notices
Safety notices in this manual outline precaution the user must take to reduce the risk of
personal injury and damage to the equipment. User(s) must read these instructions before the
installation, operation or maintenance of HL-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. Alerts 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
① General
HL logo (trade mark), Electrical power supply, Model, Stroke, Rated current,
Force(Thrust), Operating time , Serial No. and Option on a type of sticker
ELECTRIC ACTUATOR
POWER: MODEL:HL-
STROKE: Max mm RATED CURRENT: A
FORCE: N OPERATION TIME: mm/SEC
SERIAL NO: OPTION::
② Explosion Proof for IECEx/ATEX

Manufacturer, Actuator type, Address, Model, Electrical power supply, Serial No.,
Manufactured year & month, Cable entry, Certification number, Explosion proof type and
application temperature range on a Stainless steel plate
③ Explosion Proof for KCs

Manufacturer, Actuator type, Address, Model, Electrical power supply, Serial No.,
Manufactured year & month, Cable entry, Certification number, Explosion proof type and
application temperature range on a Stainless steel plate

2.1.2. Applied Standard

① IEC60079-0:2011, EN60079-0:2012
② IEC60079-1:2007, EN60079-1:2007
2.1.3. Certification
① IECEx: for HL-05kN ~ HL-25kN, IECEx EPS 14.0003X
Ex d IIB T4 Gb, Ta -20℃ to +60℃
② ATEX: for HL-05kN ~ HL-25kN, EPS 14 ATEX 1 636 X, CE 0344
II 2G Ex d IIB T4 Gb, Ta -20℃ to +60℃
③ KCs(KOSHA) for standard type HL-05/07kN, 10-AV2BO-0655,
for standard type HL-10/12/15kN, 10-AV2BO-0657,
for standard type HL-18/20/25kN, 10-AV2BO-0659, Ex d IIB T4, -20℃ ~ +60℃
for HL-05/07kN with SICU(LCU), 10-AV2BO-0656,
for HL-10/12/15kN with SICU(LCU), 10-AV2BO-0658,
for HL-18/20/25kN with SICU(LCU), 10-AV2BO-0660, Ex d IIB T4, -20℃ ~ +60℃
KCs(KTL) for standard type HL-05/07kN, 10-KB2BO-0190,
for standard type HL-10/12/15kN, 10-KB2BO-0191,
for standard type HL-18/20/25kN, 10-KB2BO-0189, Ex d IIB T4, -20℃ ~ +60℃
Notes :
n Sealing devices must be used and shall be fitted directly at enclosure wall when using conduit.
n Cable glands shall be suitable for the environment and shall be certified as flameproof if used
in Zone 1 application.
n Cable glands and conduit to be installed minimum 6 full threads and the length of thread is
minimum 8mm.
n Temperature of cable entry is maximum 100℃. Heat resistance wire is recommended when
you install.
n Ex d certified cable glands suitable for 100℃ must be used.
n Users should confirm all information about dimensions of flamepath with the manufacturer
n All information about the material and the allowance of LCU fasteners
- Fasteners with yield stress≥ 210MPa (stainless steel)
- Bolts type : M5*0.8, M6*1, M8*1.25, M10*1.5, M12*1.75 (Tolerance Fit 6g)
n Cable connection : Refers to the Appendix Ⅱ (Wiring Diagram)
n 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.
n 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 in the terminal block #1. Refer
to the enclosed wiring diagram.
- External ground connection : The ground lug is located on the centre of cable entries.
- For more information, refer to the Appendix Ⅲ (Grounding)
2.2. Initial inspection
When the user receives the actuators, inspect the condition of the product and ensure the name
plate comparing with order sheet.
2.2.1. Remove packing wrap or wooden 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 an wrong product have been
shipped, immediately inform 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
HKC HL series electric actuators are designed for the operation of industrial valves, e.g. globe
valves and gate valves.
Actuator force ranges from 5000n to 25,000Nm, currently eleven models are available:
HL-5KN, 7KN, 10KN, 12KN, 15 KN, 18KN, 20KN, 25KN
3.1.1. Performance
Max. Operating Duty Rated current(A) 50/60Hz No. of

Max.
Type output time IEC handle Wgt.
Stroke dc ac 1 Phase ac 3 Phase
HL- force (mm/sec.) 60034-1 turn
kN 50/60HZ mm S4(%) 24 V 110 V 220 V 380 V 440 V 460 V N kg
05kN 5 0.44/0.53 60 50 2.1 1.0/1.0 0.6/0.5 0.3/0.3 0.6/0.4 NA 227 11
07kN 7 0.44/0.53 60 50 2.7 1.2/1.1 0.6/0.6 0.3/0.4 0.6/0.5 NA 227 11
10kN 10 0.69/0.82 70 50 3.9 1.9/1.8 0.9/0.9 0.6/0.4 0.6/0.4 0.6/0.3 184 21
12kN 12 0.69/0.82 70 50 4.6 2.1/2.0 1.0/1.0 0.7/0.5 0.6/0.4 0.6/0.4 184 21
15kN 15 0.69/0.82 80 50 5.6 2.2/2.1 1.1/1.1 0.7/0.5 0.7/0.4 0.6/0.4 210 21
18kN 18 0.69/0.83 100 50 5.8 1.8/2.0 0.9/1.1 0.6/0.5 0.4/0.3 0.4/0.3 260 33
20kN 20 0.69/0.83 100 50 6.4 2.1/2.4 1.0/1.2 0.7/0.6 0.7/0.5 0.7/0.5 260 33
25kN 25 0.69/0.83 100 50 7.8 3.2/4.0 1.9/2.1 0.9/0.8 0.8/0.6 0.8/0.6 260 33
3.1.2. Standard Technical Data

Enclosure Rated Weatherproof IP67
Enclosure High grade aluminium alloy, corrosion coated
Power Supply 24Vdc,110/220Vac 1Ph, 380/440/460Vac 3Ph, 50/60Hz, ±10%
Duty type (on-off) S4 40~70% @ 50% load modulating, S2 30min @50% load on-off
Motor Reversible induction motor
Limit Switches 2 x open/close SPDT, 250 V ac 16A rating
Auxiliary Limit Switches 2 x open/close SPDT, 250 V ac 16A rating (except HL05~07KN)
Force Switches Open/close SPDT, 250V ac 16A
Stall Protection Builtin thermal protection, open@150±5, close @97±15℃
Manual Override Declutching mechanism
Self-Locking Provided by double worm gear
Space Heater for anti-condensation, please see clause 3.1.5.
Cable Entries Standard: 2 x PF3/4”, flameproof: 2 x NPT3/4” or 2 x M25
Lubrication Standard: grease moly(EP), for low temp.: Tribolube-18
Ambient Temperature Standard: -20℃~+70℃, Flameproof: -20℃~+70℃,
External Coating Anodizing and thermally hardened polyester powder coating
3.1.3. Optional Technical Data
EXD Flame proof enclosure (Ex d IIB T4)
WTA Watertight enclosure (IP68 10m 72hr)
PIU Potentiometer unit (0~1kΩ)
CPT Current position transmitter(output 4~20mA dc)
PCU Proportional control unit (input, output 0~10 V dc, 4~20mA dc)
IMS Integral magnetic starter (control 110/220 V ac 1ph, 50/60Hz, ±10%)
LCU-B Local / remote control unit
LCU-C Integral control unit (LCU+IMS+auto phase discriminator)
RBP Rechargeable battery backup for ESD(Emergency Shut Down)
MSB Mounting support base & driving rod

3.1.4. Duty Cycle 1)

Duty cycle rated IEC60034-1, S4 50% / S2 30min
Exceeding the actuator’s rated duty cycle may cause thermal overload.
Note 1) Type of duty expression according to VDE 0530 / IEC 60034-1
Short – time duty S2 Intermittent duty S4

The operation time at a constant load is The duty is a sequence of identical cycles
short, so that thermal equilibrium is not which consist of starting time, operation time
reached. The pause is long enough for with constant load and rest period. The rest
the machine to cool down to ambient period allows the machine to cool down so that
temperature. Example, the duration of thermal equilibrium is not reached. Example,
the short time operation is limited to the relative on-time at S4-25% or S4-50% is
15min limited to 25% and 50% respectively.
3.1.5. Heater
Condensation in the actuator is possible due to wide fluctuation of the ambient temperature. The
heater integrated in the control unit prevents this in general.
Model 24V dc 110V ac 1ph 220V ac 1ph 220~460V ac 3ph
HL-05/07kN 5W 200Ω 5W 4.5kΩ 5W 18kΩ 5W 18kΩ
HL-10/12/15kN 10W 100 Ω 10W 2kΩ 10W 8kΩ 10W 8kΩ
HL-18/20/25kN 10W 100 Ω 10W 2kΩ 10W 8kΩ 10W 8kΩ
3.1.6. Hand wheel and Declutching

HL actuators are provided a declutchable manual override system.
① In order to manually operate the actuator, pull the manual override engagement lever
towards the hand wheel until it remains in position.
② Turn the hand wheel until the valve reaches the required position
③ Turn clockwise to close(down) and counter-clockwise to open(up)
Open (Up)
Auto => Manual Close
(Down)
Note ; The override engagement lever returns automatically to auto position when the
actuator is electrically operated.
3.1.7. Lubrication
HL is a totally enclosed unit with a permanently lubricated gear train (Moly EP Grease).
Once installed lubrication should not be required. However, periodic preventative
maintenance will extend the operating life of the actuator.

3.2. External Parts for Standard Models
External Parts
④
1 Top Cover
① ⑤ 2 Body
3 Declutch lever
②
4 Cover bolt
③ 5 Cable Entries (NPT 3/4”)x2
6 Manual hand wheel
⑥
7 Upper Base
⑦ ⑮
8 Bridge Base
9 Guide rod
⑧
⑯ 10 Guide rod Holder
⑩
⑨ 11 Driving rod
⑪ 12 Locking plate
⑫ 13 Union joint & nut
14 Guide rod nut
⑬ ⑭ 15 LCU Unit (Optional)
16 Driving rod rubber (Optional)
3.3. Internal Parts for Standard Models
① ⑥
Internal Parts
1 Motor ② ⑦
2 Potentiometer
3 Terminal ③ ⑧
⑥4 Open force switch ④ ⑨
(RED Color)
Close force switch ⑤
⑦5 (BLUE Color)
⑩
6 Close limit switch
⑧7 Open limit switch
8 Capacitor
9 PCU Board
10 Heater
①
4. Installation Instruction
4.1. Pre-Installation for
4.1.1. use in general service
Verify the actuators nameplate to ensure correct model number, force, operating speed,
voltage and enclosure type before installation or use.
It is important to verify that the output force of the actuator is appropriate for the force
requirements of the valve and that the actuator duty cycle is appropriate of the intended
application.
4.1.2. use in potentially explosive atmosphere
Model HL - . . . 1 . 0 . . . 0 1)
Type of enclosure II 2G Ex d IIB T4

Ambient temperature -20 deg C ~ + 70 dec C

Installation, commissioning, maintenance, repairs and modification work must only be
performed by qualified personnel with extensive knowledge on how to work on flame-
proof electrical equipment.
Note : 1) Further information should be use of the HL electric actuator catalogue.

Refers to the Cl.2.2 this manual.
Warning : Read this installation and maintenance manual carefully and completely before
attempting to install, operate, or troubleshoot the HKC actuator.
4.2. Actuator Mounting
Note :
n Prior to mounting the linear actuator must be checked for any damage.
n Damaged parts must be replaced by original spare parts.
Mounting is most easily done with the valve shaft pointing vertically upward. But mounting is also
possible in any other position.
The HL- Series actuators are supplied with a Union joint & nut.
The actuator Union joint is removable for ease of machining.
Caution ;
Do not attempt to work on your HKC actuator without first shutting off incoming power.
Do not attach ropes or hooks to the hand wheel for the purpose of lifting by hoist.
4.2.1. Actuator Mounting Details
If the linear actuator and the valve are supplied separately you will have to mount the linear
actuator on the valve.
Union Nut Joint

Ring
Guide Rod
Nuts 2ea

4.2.2. Preparing assembly
Warning : A non-attached valve causes damage!

If you operate the linear actuator without valve, the spindle nut may fall off due to the missing stop.
CAUTION: Always operate the linear actuator with a valve attached.
Allow for about 200 mm space above the cover at the site of installation. Check the working
environment before assembling and commissioning the linear actuator. Ensure that the valve is
correctly fitted. For details please see assembly instructions for valve. Determine the assembly position
of the linear actuator. Do not arrange linear actuators in a hanging position.
4.3. Limit Switch Setting
B
Assembly positions for linear actuator and valve
4.3.1. Rotate the actuator hand wheel manually to closed position

4.3.2. Using a hex wrench, loosen the set screw in the CLOSE limit switch cam
4.3.3. Rotate the CLOSE cam towards CW limit switch lever until the switch ‘clicks’ (Fig 1)
4.3.4. Tighten the set screw with hex wrench
4.3.5. Rotate the actuator hand wheel manually to open position
4.3.6. Using a hex wrench, loosen the set screw in the OPEN limit switch cam
4.3.7. Rotate the OPEN can towards CCW limit switch lever until the switch ‘clicks’ (Fig 2)
4.3.8. Tighten set screw with hex wrench
Danger : HAZARDOUS VOLTAGE. Make sure all power is disconnected before making
the setting.
Close limit switch
Close limit switch cam (Clockwise)
2mm hexagon socket screw key
Fig.1 Close Cam Setting

Fig.2 Open Cam Setting
2mm hexagon socket screw key

Close limit switch
Close limit switch cam (Counter Clockwise)
4.4. Force Switch Setting

Force spring which detects the variation of force during operation is installed for preventing
damage of valve and actuator under overload condition. Once actuator is under overload, force
switch is tripped and actuator stoped immediately.
The force switches are set by manufacturer on the production site basically.
Re-setting is necessary; please contact the HKC service or representative before setting.
Caution ; Do not reset force switch to a setting higher than the maximum recommended by
the manufacturer.
Open force switch & cam (Red color)
Close force switch & cam (Blue color)
Fig.3 Force Switch Setting
4.5. Position Feedback Potentiometer (Optional)

4.5.1. Calibration Potentiometer
The potentiometer has been calibrated at the factory. However, if re-calibration is
required, proceed as follows:
① Apply power (or use manual override) to drive the actuator to its true closed position
(clockwise rotation).
② Connect an ohmmeter to P1 (red) and P3 ( black ) resistance should be approximately
1000ohms
③ Put actuator full close(down) position.
④ Loosen the point shaft gear and connect the ohmmeter to P1 (red) and P2 (white) and
gently rotate until a reading of 80-120 Ω is achieved (100 ohms preferred).
{Full close range: 0~100Ω Full open range:700~900Ω}
While maintaining this reading tighten the point gear set screw with an hex
wrench(HL5,7KN).
⑤ Engage potentiometer spring between gear and pointer shaft (refer diagram B)
For HL 10,12,15,18,20,25KN
Open(up)100% →1kΩ Close(down) 0% →0Ω

For HL-05, 07kN
Close(down)
0% →0Ω
Open(up) *Tighten the point gear set screw
100% →1kΩ with a hex wrench.(HL-05,07KN)
Fix potentiometer by placing spring as per diagram A (HL 10,12,15,18,20,25KN)
Diagram B (HL 5,7KN)
4.6. Current Position Transmitter CPT (Optional)

The potentiometer is used for the actuator signal feedback. It reads a resistance value
corresponds to the current position of the actuator and transfers to CPT card. The CPT indicates
the current position of the actuator throughout the stroke by a 4 ~ 20mA output signal.

4.6.1. Standard Features

Model CPT
Power 220(110)Vac, 50/60Hz, 2VA max
Output Signal 4~20mA DC
Output Impedance 750Ω max
Resolution Min 1/1000
Position Conversion Accuracy ±0.5 ~ ±1.5%
Ambient Temperature -20 ℃ to +70 ℃
Ambient Humidity 90% RH max (Non-condensing)
1 sec at (Rated Vac x 2 + 1000) x1.2
Dielectric Strength
(from Input to power ground)
Insulation Resistance Above 500Vdc 30MΩ
Vibration 10g, 0~34Hz
DANGER:
HAZARDOUS VOLTAGE. Make sure all incoming power is disconnected before setting the
potentiometer
4.6.2. Calibration of Zero and Span CPT
The settings of Zero and Span have been
calibrated at the factory. However, if re-
calibration is required, proceed as follows:
① Use the manual override to drive the actuator
to a half open position.
② Apply power (or use the manual override) to
drive the actuator to its fully closed position
(clockwise rotation).
③ When the actuator is in the fully closed
position, adjust the ZERO dial on the CPT
board until a reading of 4mA is achieved.
④ Apply power (or use the manual override) to
drive the actuator to its fully open position
(counter-clockwise rotation).
⑤ When the actuator is in the fully open
position, adjust the SPAN dial on the CPT board until a reading of 20mA is achieved.

4.7. Proportional Control Unit (PCU-A)
PCU-Rev-4 High Performance Controller, using 10

bit A/D converter and 8bit microprocessor
technology
PCU-Rev-4 Features
Model PCU-Rev-4
Power 85 ~ 260 VAC Free Voltage ± 10%, 50/60Hz 4 VA Max
Input Signal 4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Input Impedance 250Ω
Output Signal 4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Output Impedance 750Ω Max
Output Contact 1 (Fault monitor)
Delay Time Adjustment 0.05~7.5 seconds
Deadband Adjustment 0.12mA DC Max
Resolution Adjustment 0.0625~1mA (0.0625mA + step no. x 0.0625mA, 15 steps total)
Ambient Humidity 90% RH Max (non-condensation)
NOTE :The factory settings of the PCU card are normally set according to the customer
requirements at the time of order. However, we strongly recommend that input power,
signal input selection and dip switches are to be verified prior to the actuator start up.
4.8. Proportional Control Unit (PCU-D)
PCU-Rev-D1 High Performance Controller, using 10

bit A/D converter and 8bit microprocessor
technology
PCU-Rev-D1 Features
Model PCU-Rev-D1
Power 24V DC Voltage ± 15% (36V DC Max)
Input Signal 4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Input Impedance 250Ω
Output Signal 4~20mA DC, 1~5V DC, 2~10V DC, 0~5V DC, 0~10V DC
Output Impedance 750Ω Max
Output Contact 1 (Fault monitor)
Delay Time Adjustment 0.05 ~ 7.5 seconds
Deadband Adjustment 0.12mA DC Max
Resolution Adjustment 0.0625~1mA (0.0625mA + step no. x 0.0625mA, 15 steps total)
Ambient Humidity 90% RH Max (non-condensation)

4.8.1. LED Signal Indication

LED State Indication
On Power on (auto)
Blue
Flickering Auto calibrating
On Fully closed
Green
Flickering Closing
On Fully open
Red
Flickering Opening
On Manual mode
Fault indication, either:
Yellow - no input signal
Flickering
- wrong input wiring
- wrong PIU setting
4.8.2. Setting PCU Functions

① Selecting Input Signal
User can select different types of input signal by adjusting the DIP switches as follows:
NOTE :
If not specified, the factory setting of the input signal is 4 - 20mA.
② Selecting Output Signal

User can select different types of output signal by adjusting the DIP switch as follows:
4 – 20mA dc Output
Signal
Switch
Input signal switch 1 “ON” 0 – 10V DC

Input signal switch 2 “OFF” 2 – 10V DC

NOTE : If not specified, the factory setting of the input signal is 4 - 20mA.

③ Fail Position Setting

User can select the fail position of the actuator in case of control signal failure by adjusting
the DIP switches as follows:
Fail Close
Fail
Position
Setting
Fail Open
Fail Last Position
Fail Close Switch

Fail Open Switch
Auto-Full Switch
CH 1 Switch
CH 2 Switch
④ Special Signal Setting for Fully Open and Fully Closed
Auto-Full Switch (Swit Signal: 4.3mA Fully Closed

ch 3) On (up) Signal: 19.7mA Fully Open
Auto-Full Switch (Swit Signal: 4mA Fully Closed

ch 3) Off (down) Signal: 20mA Fully Open
⑤ Auto Setting
l This function is used for automatic setting of the PCU card to the predefined limits.
l While the actuator is corrected mounted on the valve, check input power, input and
output signal connections. Press ASCAN button
once, regardless of the position of the actuator,
then the actuator will perform the Auto Setting
motion:
u The blue LED flicker
u Opening (the red LED flickering) for 5 seconds
u Pause for 2 seconds
u Fully closing (the green LED flickering)
u Pause (the green LED on) for 3 seconds
u Fully opening (the red LED flickering)
u Pause (the red LED on) for 3 seconds
u Moving back to the previous position
NOTE:
Since the unit is already set at the factory, no further setting is required unless
the user has adjusted the mounting state of Limit Switch or the Potentiometer.
⑥ Manual Operation
l This function allows the user to manually operate the

actuator.
l To access this function, press the ZERO (black) and
SPAN (white) buttons simultaneously for 2 seconds and
the yellow LED will be lit to indicate that the actuator is
in Manual Operation mode

l Pressing the ZERO button will move the actuator to close and pressing the SPAN
button will move the actuator to open
l If no operation occurs within 5 seconds, the PCU automatically terminates the
Manual Operation mode or alternatively press the ZERO and SPAN buttons
simultaneously for 2 seconds. In either case, the yellow LED will be lit off to indicate
the termination of the Manual Operation Mode.
Note:
During the Manual Operation mode, the input signal is ignored.
⑦ Customizing Set-points (CH 1 Switch)

l This function is used when the user wants Set-points Adjustable Range
to set different set-points for fully open Fully Closed 3 – 8mA DC
and fully closed positions.
Fully Open 16 – 21mA DC
l For example, if the user wants to assign 5mA
as the set-point for fully closed position, first
of all switch-on (move up) the CH1 switch
(switch 4). Supply a 5mA signal and push
the ZERO button once. Hereafter, the
actuator will acknowledge 5mA signal as the
set-point for fully closed position and
transmits 4mA feedback signal. Similarly, for
setting the set-point for the fully open position, supply the desired signal (for
example, 19mA) and push the SPAN button once. Switch-off (move down) the CH1
switch to complete the setting.
⑧ Reversal Acting (CH 2 Switch)
CH 2 Switch 4mA DC Fully Open
l This function allows the user to (Switch 5) On (up) 20mA DC Fully Closed
reverse the input and output signals CH 2 Switch 4mA DC Fully Closed
for the operation of the actuator. (Switch 5) Off (down) 20mA DC Fully Open
l For standard operation (CH 2 switch down),
the input signal of 4mA operates the
actuator to fully close and the actuator
transmits the output signal of 4mA.
However, when CH 2 switch is on (move up)
the input signal of 4mA operates the
actuator to fully open and still transmits 4mA output signal.
l Manually move the actuator to half-open position and push ASCAN button once to
execute the Auto Setting (see 4.10.2 ➄). Supply signal and check the operation.
⑨ Delay Time
l The actuator starts to move if and only if the
change in the input signal value is greater than
the resolution set value (see 4.8.2 J) and when
the signal value is maintained for the duration
of the delay time.
l This prevents malfunction of the actuator
caused by unwanted signals in the input signal
such as noise and interferences
l Turning the Delay Time Dial in clockwise
direction will increase the delay time (Range
0.05 to 7.5 seconds).
Dial 0 1 2 3 4 5 6 7
sec 0.05 0.2 0.4 0.6 0.8 2.5 3.0 3.5
Dial 8 9 A B C D E F
sec 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5

⑩ Resolution
l The deadband adjusts the limits of the valve’s deviation between an actual position
and a target position. The deadband is set to 0.12mA DC Max.
l Resolution indicates the extent of the reaction on the input signal.
l Low resolution setting may cause the actuator to hunt or to unnecessarily respond to
a fluctuating input signal.
If so, the resolution must be increased.
l Turning the Resolution Dial in clockwise
direction will increase the resolution (Range
0.0625mA to 1mA).
Dial 0 1 2 3
mA DC 0.0625 0.125 0.1875 0.25
Dial 4 5 6 7
mA DC 0.3125 0.375 0.4375 0.5
Dial 8 9 A B
mA DC 0.5625 0.625 0.6875 0.75
Dial C D E F
mA DC 0.8125 0.875 0.9375 1
4.9. AC/DC Multi-Board
4.9.1. Power Open and Close terminal

① Power 24V AC/DC (DC + signal block)
② None
③ None
④ Open signal
⑤ Close signal
⑥ Power 24V AC/DC (DC signal block)
4.9.2. Chooses switch for power signal

① As using for AC Mode, #1 switch turn on and #2 switch turn off
② As using for DC Mode, #1 switch turn off and #2 swithc turn on
NOTE: Don’t turn on both switch #1 and #2 at the same time that
become a reason of damage of the board
③ Motor connect Block

l Red motor wire to connect #1 block
l Black motor wire to connect #2 block

5. Wiring
5.1. Electrical Connections and Preliminary Test
WARNING:
ü When working in potentially explosive atmospheres, observe the European Standards EN
60079-14 “Electrical Installation in Hazardous Areas” and EN 60079-17 “Inspection and
Maintenance of Electrical Installations in Hazardous Areas”.
Work on the electrical system or equipment must only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such an
electrician and in accordance with the applicable electrical engineering rules.
ü For cable gland or cable entries that are not used, user or installer shall close by certified
blanking elements so that the flameproof properties of the enclosure are maintained
ü Flameproof enclosure! Treat cover with care. Gap surfaces must not be damaged in any way. Do
not jam cover during fitting.
5.1.1. For testing purposes, loosen the bolts on the actuator cover and remove the cover.
5.1.2. Make sure that the power supply voltage is in accordance with the data on the nameplate
of the actuator.
5.1.3. Pass cables through the cable glands: NPT 3/4” or M25 for Ex “d”
5.1.4. Connect wires according to the enclosed wiring diagram.
5.1.5. Manually move the valve to half-open position. Then electrically operate the actuator to
fully open position and check if the motor rotates in correct direction; standards units are
counter-clockwise to open.
5.1.6. Test the actuator and check whether the limit switches work correctly
5.1.7. After the testing, check that all cable glands are correctly tightened. Applicable cable
glands should be selected to meet the application’s condition. It is recommended to use
the grade of IP67 cable gland or higher in potentially explosive atmosphere.
5.1.8. Put carefully the cover on the body and tighten the bolts.
5.2. Wiring Diagrams for Standard Models
5.2.1. On/off type
(HL 5KN,7KN,10KN,12KN,15KN)

(HL 18KN,20KN,25KN)
5.2.2. PCU TYPE

(HL 5KN,7KN)

5.2.3. HL 10KN,12KN,15KN,18KN,20KN,25KN
6. Maintenance
6.1. Maintenance
WARNING:
ü Turn off all power before attempting to perform maintenance on the actuator.
ü 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. Verify the declutch mechanism
6.1.9. Visually inspect the open/close cycle
6.1.10. Check whether the o-ring for Ex d enclosure is damaged or not
6.1.11. Inspect the identification labels for wear and replace it if necessary

WARNING:
ü Flameproof Enclosure! Before opening, ensure the absence of any gas and voltage
ü 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
6.2.8. PCU Board Option: DC Signal Generator (4 20mA DC) × 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
7.4. Optional Equipment(s)
7.4.1. Potentiometer Current Position Transmitter
① Check the resistance value
② Check potentiometer gear for jamming
③ Check ZERO and SPAN calibration
④ Check the board for any damage
7.4.2. Current Position Transmitter
① Verify the input signal
② Check the configuration of the dip switches
③ Check the board for any damage

8. Installation and Maintenance Tips
WARNING:
ü When working in potentially explosive areas, be sure to comply with the standard EN 60079-
14 “Electrical Installations in Hazardous Areas”.
ü Working on the actuator that is in open position and under voltage must only be performed if
it is assured that there is no danger of explosion for the duration of the work.
ü Flameproof Enclosure! Before opening, ensure the absence of any gas and voltage
ü [When operation, maintenance, or installation shall be verified that O-rings are not damaged
or pinched between their parts. ---- 15 Rev1]
CAUTION:
ü A regular inspection and maintenance should be performed by qualified and trained

personnel
ü Treat cover with care. Gap surfaces must not be damaged or dirtied in any way. Do not jam
the cover during fitting.
ü Pay attention to national regulations
For any installation and maintenance work, the followings should be noted:
8.1. Check the quarter turn actuators visually. Ensure that no external damage or changes are
visible. The electrical cables must not be damaged and wired correctly.
8.2. Cable entries, cable glands, plugs, etc. have to be checked whether they are correctly tightened
and sealed.
8.3. Check that the Ex-connections are correctly fastened.
8.4. Check for the possible discoloration of the terminals and wires as this may indicate an increased
temperature.
8.5. Check the flame path gaps of the flameproof enclosures for any dirt and corrosion. Since the
dimensions of all Ex gaps are strictly defined and inspected, no mechanical work shall be
performed on them.
8.6. All cables and motor protection elements have to be checked.
8.7. During the maintenance if any defects are detected that may affect the safety, repair measures
have to be taken immediately.
8.8. Any kind of surface coating for the gap surface is not permitted.
8.9. When replacing parts, seals, etc., only original spare ones must be used.

9. Dimensions for actuator

9.1. 5KN,7KN, 10KN, 12KN, 15KN, 18KN, 20KN, 25KN (Standard type)
9.2. 5KN,7KN, 10KN, 12KN, 15KN, 18KN, 20KN, 25KN (LCU-B type)

9.3. 5KN,7KN, 10KN, 12KN, 15KN, 18KN, 20KN, 25KN (RBP type)

APPENDIX Ⅰ. HL Series Coding System
HL XXkN a b c d e f g (XX : 05,07,10,12,15,18,20,25)

a= Enclosure
1 : Weather proof (IP 67)
2 : Submersible (IP 68, 10m / 72 hr)
3 : Ex type (Ex d IIB T4 IP 67)
b= Input Voltage
1 : 110 V ac / 1 Ph
2 : 220 V ac / 1 Ph
3 : 220 V ac / 3 Ph
4 : 380 V ac / 3 Ph
5 : 440 V ac / 3 Ph
6 : 460 V ac / 3 Ph
7 : 24 V ac
8 : 24 V dc
c= Option 1 : Control Unit

0 : Without control unit
1 : ICU (Intelligent Digital Control Unit : LCU+IMS+Auto Phase Discriminator)
2 : SICU (Semi-Integral Control Unit : LCU+IMS+Phase Protect Indicator)
d= Option 2 : Software
0 : Without PIU / CPT / PCU
1 : PIU (Potentiometer Unit : 0~1kΩ)
2 : CPT (Current Position Transmitter : 4~20mA)
3 : PCU (Proportional Control Unit : IN/OUT 0~10V , 4~20mA)
e= Option 3 : Additional Switches

0 : Without 2ALS / 2ATS
1 : 2ALS (Additional Limit Switches)
2 : 2ATS (Additional Force Switches)
f= Option 4 : Signal Lamp / 90° mounting Plate

0 : Without LPA
1 : SLU (Signal Lamp Unit)
2 : LPA (Lever Plate Actuator 90°)
3 : SLU + LPA
g= Option 5 : Fire Proofing Actuator

0 : Without FPA 1 / FPA 2
1 : FPA 1 (Fire Proofing Actuator : 1050 ± 5℃ / 50min)
2 : FPA 2 (Fire Proofing Actuator : 250 ± 5℃ / 150min)
HKC Co., Ltd.

Sales Office Tel: +82 2 2138 8266, Fax: +82 2 2138 8269
Head Office & Plant Tel: +82 31 488 8266, Fax: +82 31 488 8269
Address (Seonggok-dong) 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do, 15417
South Korea
Website www.hkcon.co.kr

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Installation, Operation & Maintenance Manual: HL Series Electric Linear Actuators

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HL Series Electric Linear Actuator

Installation Operation & Maintenance Manual

HL Series Electric Linear Actuators

Installation, Operation & Maintenance Manual

Address : Seonggok-dong, 155, Byeolmang-ro, Danwon-gu, Ansan-si, Gyeonggi-do, South Korea

Doc No. : HUMG-HL-16 Rev0 Page 1 / 25 Valve Automation Leader, HKC

Doc No. : HUMG-HL-16 Rev0 Page 2 / 25 Valve Automation Leader, HKC

WARNING: Refers to personal safety. Alerts the user to potential danger

② Explosion Proof for IECEx/ATEX

③ Explosion Proof for KCs

Doc No. : HUMG-HL-16 Rev0 Page 3 / 25 Valve Automation Leader, HKC

2.1.2. Applied Standard

Doc No. : HUMG-HL-16 Rev0 Page 4 / 25 Valve Automation Leader, HKC

3. General Information and Features

Max. Operating Duty Rated current(A) 50/60Hz No. of

3.1.2. Standard Technical Data

Doc No. : HUMG-HL-16 Rev0 Page 5 / 25 Valve Automation Leader, HKC

3.1.4. Duty Cycle 1)

Short – time duty S2 Intermittent duty S4

3.1.6. Hand wheel and Declutching

Doc No. : HUMG-HL-16 Rev0 Page 6 / 25 Valve Automation Leader, HKC

3.2. External Parts for Standard Models

Doc No. : HUMG-HL-16 Rev0 Page 7 / 25 Valve Automation Leader, HKC

Ambient temperature -20 deg C ~ + 70 dec C

Note : 1) Further information should be use of the HL electric actuator catalogue.

4.2. Actuator Mounting

Union Nut Joint

Doc No. : HUMG-HL-16 Rev0 Page 8 / 25 Valve Automation Leader, HKC

4.2.2. Preparing assembly

Warning : A non-attached valve causes damage!

4.3.1. Rotate the actuator hand wheel manually to closed position

Close limit switch

Close limit switch cam (Clockwise)

2mm hexagon socket screw key

Fig.1 Close Cam Setting

Doc No. : HUMG-HL-16 Rev0 Page 9 / 25 Valve Automation Leader, HKC

Fig.2 Open Cam Setting

2mm hexagon socket screw key

4.4. Force Switch Setting

Open force switch & cam (Red color)

Close force switch & cam (Blue color)

Fig.3 Force Switch Setting

4.5. Position Feedback Potentiometer (Optional)

Open(up)100% →1kΩ Close(down) 0% →0Ω

Doc No. : HUMG-HL-16 Rev0 Page 10 / 25 Valve Automation Leader, HKC

For HL-05, 07kN

Fix potentiometer by placing spring as per diagram A (HL 10,12,15,18,20,25KN)

Diagram B (HL 5,7KN)

4.6. Current Position Transmitter ­ CPT (Optional)

Doc No. : HUMG-HL-16 Rev0 Page 11 / 25 Valve Automation Leader, HKC

4.6.1. Standard Features

Doc No. : HUMG-HL-16 Rev0 Page 12 / 25 Valve Automation Leader, HKC

4.7. Proportional Control Unit (PCU-A)

PCU-Rev-4 High Performance Controller, using 10

4.8. Proportional Control Unit (PCU-D)

PCU-Rev-D1 High Performance Controller, using 10

Doc No. : HUMG-HL-16 Rev0 Page 13 / 25 Valve Automation Leader, HKC

4.8.1. LED Signal Indication

4.6. Current Position Transmitter CPT (Optional)

HL XXkN a b c d e f g (XX : 05,07,10,12,15,18,20,25)