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HKC HQ-005 - User Manual

HKC HQ-005
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HQ Series Quarter-turn Electric Actuator
Installation Operation& Maintenance Manual
Doc No. : HumG-HQ-21 Rev2 Page 1 / 26 Valve Automation Leader, HKC
HQ Series Quarter-turn Electric Actuator
Installation, Operation & Maintenance Manual
Address : 26, Emtibeui 28-ro, Siheung-si, Gyeonggi-do, (15119) Republic of Korea
Tel : +82-31-488-8266, Fax : +82-31-488-8269, Home page : www.hkcon.co.kr, email : hkcon@hkcon.co.kr

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Questions and Answers

Summary

HQ Series Quarter-turn Electric Actuator

1. Introduction

1.2. Safety Notices

Outlines precautions for reducing the risk of personal injury and equipment damage.

2. Product Identification and Storage

4. Installation Procedures

4.1. Pre-installation Checks

Covers general service and potentially explosive atmosphere considerations before installation.

4.1.2. Potentially Explosive Atmosphere Use

Details requirements for using actuators in potentially explosive atmospheres, including safety precautions.

4.2. Actuator Mounting Guidelines

Provides guidance on mounting the actuator, including shaft alignment and secure fastening.

4.3. Limit Switch Setting Procedure

Details the procedure for setting the open and close limit switches using cam adjustments.

4.4. Torque Switch Setting

Explains the function of torque switches and advises contacting service for re-setting.

4.6. Mechanical Travel Stop Adjustment

Guides on adjusting mechanical travel stops to define the actuator's full open and close positions.

4.6.1. Travel Stopper Bolt Adjustment

Details the process of adjusting travel stopper bolts for setting open and close limits.

4.7. Potentiometer Setting and Replacement

Explains how to recalibrate or replace the potentiometer for accurate actuator feedback.

4.8. Current Position Transmitter (CPT)

Describes the CPT, its function in providing actuator position feedback via a 4-20mA signal.

4.8.2. CPT Zero and Span Calibration

Provides steps to calibrate the zero and span for the CPT to ensure accurate position reporting.

4.9. Proportional Control Unit (PCU)

Introduces the Proportional Control Unit (PCU) and its role in controlling actuator operation.

4.9.11. PCU Signal Setting

Guides on setting Zero and Span signals for the PCU to match command signal ranges.

4.9.12. PCU Output Signal Adjustment

Explains how to adjust the output (feedback) signal for the PCU to match desired 4-20mA or other outputs.

5. Optional Communication Protocols

6. Wiring and Connections

6.1. Electrical Connections & Preliminary Test

Provides instructions for electrical connections and preliminary testing, emphasizing safety precautions.

7. Maintenance and Care

7.1. General Maintenance

Outlines general maintenance procedures, safety warnings, and intervals for actuators.

8. Troubleshooting Common Issues

8.1. Actuator Does Not Respond

Provides troubleshooting steps for when the actuator fails to respond to commands.

8.2. Actuator Has Power, No Operation

Guides on troubleshooting issues where the actuator has power but does not operate.

8.3. Erratic Actuator Operation

Troubleshooting steps for erratic actuator operation, including temperature and duty cycle checks.

9. Installation & Maintenance Tips

Appendix II: Wiring Diagrams

Appendix III: Grounding

Overview

The HKC HQ Series Quarter-turn Electric Actuator is designed for the operation of industrial valves, such as butterfly and ball valves. This manual provides comprehensive instructions for its installation, operation, and maintenance.

Function Description:

The HQ Series electric actuators provide precise control for quarter-turn valves. They are equipped with a declutchable manual override system, allowing for manual operation in case of power failure or for initial setup. The actuators can be configured for clockwise (standard) or counter-clockwise rotation to close, by adjusting the wiring and PCU board settings.

The actuators feature limit switches to define the fully open and fully closed positions, and torque switches to prevent damage from overload conditions. An optional Current Position Transmitter (CPT) provides a 4-20mA output signal, indicating the current valve position. For more advanced control, a Proportional Control Unit (PCU) is available, offering various input and output signal types, dead time, and dead band settings. Communication protocols like ProfiBus and ModBus are also supported as optional features, enabling remote control and monitoring.

Important Technical Specifications:

  • Torque Output: Ranges from 40 Nm to 8,830 Nm (350 In-Lbs to 78,120 in-Lbs), with 19 models available.
  • Operating Time (90°): Varies by model, e.g., HQ-004 (12/12 sec), HQ-080 (37/31 sec), HQ-900 (117/99 sec).
  • Power Supply: Available in AC (1 phase 50/60 Hz, 3 phase 50/60 Hz) and DC (24V dc, 12V dc).
  • Rated Current: Varies significantly by model and power supply, e.g., HQ-008 (0.5/0.5 A for 220Vac 1ph), HQ-080 (1.1/0.7 A for 440Vac 3ph).
  • Enclosure Rating: Ingress protection IP67, NEMA 4, 4X & 6 (Weatherproof). Optional IP68 (10m / 72hr) for watertight applications.
  • Explosion Proof Options: IECEx, ATEX, CSA, KCs, EAC certified for Ex db IIB T4 Gb and Ex tb IIIC T135°C Db.
  • Ambient Temperature: -20 °C to +60 °C (except on CPT & PCU board, which is -25°C to 80°C).
  • Motor: Squirrel caged induction motor with built-in thermal protection.
  • Switches:
    • Limit Switches: 2 x open/close SPDT, 250 Vac 16A rating.
    • Auxiliary Limit Switches (Optional): 2 x open/close SPDT, 250 Vac 16A rating (except HQ-008/010).
    • Torque Switches: Open/close SPDT, 250Vac 16A Rating (except HQ-008/010).
    • Additional Torque Switches (Optional): 2 x SPDT 250V ac 16A Rating.
  • Travel Angle: 90 degrees +/- 10%.
  • Self-Locking: By means of worm gear.
  • Mechanical Travel Stops: 2 x external adjustable mechanical travel stops.
  • Cable Entries: [2xNPT 3/4", 2xM25 for Ex db, additionally M20, M25 and NPT3/4" with M30 adaptor for Ex tb (by user selection)].
  • Lubrication: Grease moly EP, almost permanently lubricated.
  • External Coating: Dry powder polyester coating, max thickness 2mm for Ex tb application.
  • Duty Cycle: Short-time duty S2 or Intermittent duty S4, as per VDE 0530 / IEC 60034-1. Exceeding rated duty cycle may cause thermal overload.
  • Space Heater: Ceramic housing with thermostat (60°C set temperature) to prevent condensation.
  • Proportional Control Unit (PCU) Specifications:
    • Input Signal: 4~20mA dc, 0~20mA dc, 1~5V dc, 0~5V dc, 2~10V dc, 0~10V dc.
    • Output Signal (feedback): 4~20mA dc, 0~20mA dc, 1~5V dc, 0~5V dc, 2~10V dc, 0~10V dc.
    • Dead Time: 0.2~7.5 sec (16 steps).
    • Dead Band: 0.3~7.5% (AC PCU), 0.4~7.5% (DC PCU) (16 steps).
    • Fault Mode: Fail close, Fail open, Fail stop.
  • Current Position Transmitter (CPT) Specifications:
    • Output Signal: 4~20mA dc.
    • Output Impedance: 7500 max.
    • Position Conversion Accuracy: ±0.5 ~ ±1.5%.
  • ProfiBus Controller (PBC) Specifications:
    • Communication: Profibus communication (RS-485 base).
    • Max. Range: 1000m @ 9.6 ~ 187.5 k Baud.
    • Bit Rate: Up to 12mega.
  • ModBus Controller (MOB) Specifications:
    • Communication: Modbus-RTU (RS-485 communication).
    • Supported Baud Rates: 1200 to 115200.

Usage Features:

  • Easy Mounting: Designed for mounting with the valve shaft pointing vertically upward, but can be mounted in any position. ISO5211 bolt patterns are provided, and the drive bush is removable for machining.
  • Manual Override: A declutchable hand wheel allows for manual operation by pulling the engagement lever.
  • Limit Switch Setting: Simple adjustment of CLOSE and OPEN limit switch cams using a hex wrench.
  • Potentiometer Setting: Factory-calibrated, but can be re-calibrated by rotating the potentiometer gear to achieve desired resistance values.
  • CPT Calibration: Zero and Span dials on the CPT board allow for calibration to achieve 4mA (closed) and 20mA (open) output signals.
  • PCU Configuration: DIP switches on the PCU board enable selection of input signal type, output feedback signal, deadband, deadtime, fail-safe modes (fail close, fail open, fail stop), auto full action, and reverse mode.
  • Auto Setting Function: The PCU board can automatically set the actuator's positions by pushing the ASCAN button, with LED indicators showing the progress.
  • Manual Operation Mode: Allows manual control of the actuator's open and close positions via ZERO and SPAN buttons on the PCU board.
  • LED Display: Provides visual feedback on the actuator's status (Open, Auto, Close, Fault) and error conditions, aiding in troubleshooting.

Maintenance Features:

  • Regular Inspections: Recommended every six months, or more frequently in severe conditions.
  • Visual Checks: Inspect for external damage, proper alignment with the valve, secure wiring, tight screws, and cleanliness of internal electrical devices.
  • Condensation Check: Verify the absence of condensation and proper functioning of the internal heater.
  • Seal Integrity: Check enclosure O-rings for damage and proper seating.
  • Declutch Mechanism Check: Verify proper operation of the manual override.
  • Wiring Diagram: Detailed wiring diagrams are provided for various models and power configurations (1Ph, DC, PCU), facilitating electrical connections and troubleshooting.
  • Troubleshooting Guide: A comprehensive section addresses common issues such as the actuator not responding, operating erratically, or failing to operate despite power supply, with suggested countermeasures.
  • Grounding: Instructions for internal and external grounding connections are provided, emphasizing the importance of proper grounding for safety and performance.
  • Parts Replacement: Emphasizes the use of original spare parts for seals and other components.
  • Explosion Proof Considerations: Specific warnings and instructions for working in potentially explosive atmospheres, including requirements for certified cable glands, blanking elements, and surface cleaning.
  • Cover Bolt Tightening Torque: Specified tightening torques for cover bolts (e.g., M8 x 35: 12.5 Nm, M12 x 55: 42.0 Nm) to ensure proper sealing and safety.

HKC HQ-005 Specifications

General IconGeneral
BrandHKC
ModelHQ-005
CategoryController
LanguageEnglish

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