HKC HQ-020 - User Manual

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

Summary

1. Introduction

1.2. Safety Notices

Outlines precautions to reduce risk of injury and damage.

4. Installation

4.1. Pre-installation

Covers general service and checks before installation.

4.1.2. Use in potentially explosive atmosphere

Guidelines for installation in potentially explosive environments.

4.2. Actuator Mounting

Details on how to mount the actuator to the valve.

4.3. Limit Switch Setting

Step-by-step guide to setting limit switches.

4.4. Torque Switch Setting

Information on setting and resetting torque switches.

4.6. Mechanical Travel Stop Adjustment

Procedure for adjusting mechanical travel stops.

4.7. Setting Potentiometer (Replacement and Setting)

Guide for recalibrating the potentiometer.

4.8.2. Calibration of Zero and Span - CPT

Steps to calibrate Zero and Span for the CPT.

4.9. Proportional Control Unit

Introduction to the Proportional Control Unit (PCU).

4.9.4. Main function and usage for PCU

Explains DIP switch settings for PCU input and output signals.

4.9.5. Deadband setting

Guide on setting the deadband for actuator response.

4.9.6. Deadtime setting

Explains how to set the deadtime for signal stability.

4.9.8. Fail close (FC), fail open (FO) and fail stop

Configuration for fail-safe positions based on signal loss.

4.9.11. Random command signal setting

Procedure to set Zero and Span for command signals.

4.9.12. Adjust output (feedback) signal

Guide to adjust Zero and Span for the output feedback signal.

4.9.13. Manual operation mode

How to enter and use manual operation mode.

5. [Apply for optional communication protocol

5.1. ProfiBus Controller (PBC)

5.2. ModBus Controller

6. Wiring

6.1. Electrical Connections and Preliminary Test

Guides on electrical connections and initial testing.

6.1.1. WARNING

Crucial safety warning about welding and electrical shock.

6.1.2. General safety for explosive atmospheres

Safety guidelines for working in explosive atmospheres.

7. Maintenance

7.1. Maintenance

8. Trouble Shooting

Common problems and their solutions.

8.1. The actuator does not respond

Troubleshooting steps for a non-responsive actuator.

8.2. The actuator is supplied with power but does not operate

Steps to diagnose power issues when actuator doesn't operate.

8.3. Actuator runs erratically

Troubleshooting steps for erratic actuator operation.

8.4. Optional Equipment(s)

9. Installation and Maintenance Tips

9.5. Flame path gap inspection

Appendix II: Wiring Diagram

HQ-008;010 Standard 1 Ph.

HQ-008;010 Standard DC

HQ-015 ~ 300 Standard 1 Ph.

HQ-015 ~ 300 Standard 1 Ph. PCU

HQ-015 ~ 030 Standard DC

Appendix III: Grounding

[HQ-008;010

HQ-015 and bigger size

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

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-020 Specifications