QAD#IM6010 RevD 11.01.19
ELECTRIC ACTUATOR HQ006
INSTALLATION AND OPERATION
MANUAL
www.challengervalves.com.au
QAD#IM6010 RevD 11.01.19
CONTENTS
COMPANY OVERVIEW
INTRODUCTION
PRODUCT IDENTIFICATION
GENERAL INFORMATION AND FEATURES
INSTALLATION INSTRUCTION
OPERATION INSTRUCTIONS
MAINTENANCE
TROUBLE SHOOTING
DIMENSIONS FOR ACTUATOR
HEAD OFFICE
3 Glenn Street, Shepparton
Victoria 3630
P: 03 5822 1533
F: 03 5822 2277
E: sales@challengervalves.com.au
www.challengervalves.com.au
QAD#IM6010 RevD 11.01.19
COMPANY OVERVIEW
INTRODUCTION
Challenger Valves is a leading manufacturer, supplier and distributor of valving and actuation, providing products and soluti ons to
the water, mining, irrigation and general industries. We stock a wide range of products in various materials including ductile iron,
stainless steel, brass and uPVC to handle a wide range of industrial applications.
The companies’ head office is located in Shepparton, north of Melbourne in central Victoria, with a 2400m² purpose built faci lity,
which includes production, storage and testing. The commitment by the directors to re-invest profits back into the company
demonstrates Challenger’s commitment to it’s customers, employees and long term investment in the Australian market.
Challenger operate branches in Brisbane, Melbourne, Sydney, Perth and Newcastle, supporting an Australia wide distributor
network.
HISTORY
Challenger Valves and Actuators were established in 1984 and provide high quality product lines of performance and reliability,
backed by a professional team delivering superior service and cost effective solutions to our clients.
QUALITY
Challenger Valves provide in house testing and distributes a range of products that meet or exceed the highest Australian and
International Standards, many of which carry the coveted Australian Standard Mark. Customer testaments are available on
request.
OH&S
Challenger Valves management team are committed to ensuring the health, safety and welfare of it’s employees, visitors and
contractors by adhering to all statutory requirements.
NATIONAL CODE OF PRACTICE
Challenger is a compliant participant in the National Code of Practice for the Building and Construction Industry, details available
upon request.
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QAD#IM6010 RevD 11.01.19
HQ 006 INTRODUCTION
This installation and operating manual explains how to install, operate and maintain HQ-006 electric actuators.
Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury and damage to the
equipment. User must read these instructions before installation, operating, or maintenance.
DANGER: Refers to personal safety. Alerts the user to potential 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.
Note: Highlights information critical to the user’s understanding of the actuators’ installation and operation.
PRODUCT IDENTIFICATION
The actuator name plate is located on the top cover of the actuator.
The name plate contains the following:
HQ logo (trade mark)
Electrical power supply
Model
Type
Rated current
Operating time (seconds)
Serial No.
Option
Initial Inspection
Upon receipt of the actuator, inspect the condition of the product and ensure the name plate matches the order sheet or your
requirements, also check for any damage that may have occurred during shipment. If the wrong product has been shipped
immediately or is damaged report to the coordinator.
Storage
Actuators must be stored in a clean, cool and dry area. The unit shall be stored with the cover fastened and the conduit ope nings
sealed. Storage must be off the floor, covered with a seal dust protector.
When actuators are stored outdoors, they must be stored off the ground, high enough to prevent being immersed in water or
buried in snow.
ELECTRIC ACTUATOR
QUARTERTURN ELECTRIC ACTUATORS
POWER: TORQUE:
OPERATION TIME: SEC TYPE:
RATED CURRENT: A OPTION:
SERIAL NUMBER:
Name Plate
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QAD#IM6010 RevD 11.01.19
GENERAL INFORMATION AND FEATURES
HQ series electric actuators are designed to provide reliable and efficient operation of 90 degree quarter turn valves , damp ers,
etc.
Performance
HQ006 Standard Technical Data (optional)
Enclosure Rated Weatherproof IP67
Enclosure High grade aluminium alloy, corrosion coated
Power Supply 110/220 VAC 1 Ph, 24 VAC - 24VDC 50/60Hz
Motor Reversible motor
Limit Switches 2 x open/close SPDT, 250 VAC 10A rating
Auxiliary Limit Switches 2 x open/close SPDT, 250 VAC 10A rating
Indicator Continuous position indicator
Manual Manual Override Nut
Space Heater 2W
Conduit Entries 2 x PG 13.5
Lubrication Grease moly EP
Ambient Temperature -20ºC + 70ºC
External Coating Dry powder polyester
HQ Option Technical Data (optional)
PIU Potenometer unit (0 1K Ω)
PCU Proporonal control unit (input, output 0 10 VDC or 4 20mA DC)
CPT Current posion transmier (output 4 20mA DC)
Duty Cycle
Duty cycle is rated IEC60034 - S4 50% / S2 30 min
Exceeding the actuators rated duty cycle may cause thermal overload.
Type of duty according to VDE 0530 / IEC 60034-1
Type
Max
output
torque
Operating
Time (sec)
Duty
cycle IEC
34 - 1
Mounting
size
Power 1 Phase Weight Rated current (A) 50/60Hz 1 Phase
Kgf.m 50/60HZ S4(%) ISO 5210 AC,DC 110V AC 220V AC 24V DC Kg
HQ006 6 12/14 50
F03, F05,
F07
AC110V, 220V,
DC24V, 24 VAC
0.4A/0.39A 0.02A/0.19A 0.4A 3
Short - time duty S2 Intermittent duty S4
The operation time at a constant load is short, so that thermal equilibrium is not reached. The pause is long enough
for the machine to cool down to ambient temperature. The
duration of the short - time operation is limited to 15 min
(10 min, 30 min).
The duty is a sequence of identical cycles which consist of starting
time, operation time with constant load and rest period. The rest
period allows the machine to cool down so that so that thermal
equilibrium is not reached. The relative on-time at S4-25% or S450% is limited to 25% and 50% respectively
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QAD#IM6010 RevD 11.01.19
Heater
Condensation in the actuator is possible due to wide fluctuation of the ambient temperature. The heater integrated in the co ntrol
unit prevents this in general.
Manual Hand Wheel and Lever
HQ actuators are provided with a manual operation system.
The HQ006 actuator comes standard with a manual override nut.
This is located on the bottom of the unit, and can be easily operated with a 5M wrench.
Turn the hand wheel until the valve reaches the required position
Turn clockwise to open and counter clockwise to close
When nut becomes tight DO NOT FORCE further as this will cause serious damage to the gearing.
CAUTION: The manual nut is to facilitate the setting up of the actuator drive to the valve shaft at time of assembly or to drive the
valve to a fail safe position in the event of power failure. It is NOT designed to free up a jammed valve. Using the manual nut
when the valve is tight or jammed will damage the gears and void any warranty.
To free up a tight or jammed valve you must remove the actuator from the valve, using a spanner directly on the valve shaft, rotate
until it turns freely.
If the torque required to move the valve is greater than the rated output torque of the actuator the unit will not operate.
HQ006
Note: The override engagement lever returns automatically to auto position when the actuator is operated electrically.
Lubrication
HQ is a totally enclosed unit with a permanently lubricated gear train (Moly EP Grease). Once installed lubrication should n ot be
required. However, periodic preventative maintenance will extend the operating life of the actuator.
External Parts
1. Top Cover
2. Body
3. Cable Entry (PG 13.5) x2
4. Drive Shaft
5. Mounting Base (F03, F05, F07)
6. Manual Override Nut
7. Name Plate
8. Cover Bolt (captive design)
9. Indicator
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External Parts
QAD#IM6010 RevD 11.01.19
Internal Parts for Standard Models
Internal Parts - HQ006 Series
1. Motor
2. Indicator
3. Open Limit Switch
4. Additional Open Limit Switch
5. Close Limit Switch
6. Additional Close Limit Switch
7. Potentiometer Unit
8. Terminal
9. Heater
10. Capacitor
INSTALLATION INSTRUCTION
Pre-Installation (for use in General Services)
Verify the actuators name plate to ensure correct model number, force, operating speed, voltage and enclosure type before ins tallation and use.
It is important to verify that the output force of the actuator is appropriate for the force requirements of the valve and th at the
actuator duty cycle is appropriate for the intended application.
WARNING: Read this installation and maintenance manual carefully and completely before attempting to install , operate or
trouble shoot the HKC actuator.
Actuator Mounting
Note:
Prior to mounting the part-turn actuator it must be checked for damage.
Damaged parts must be replaced by original spare parts.
Mounting is most effectively carried out with the valve shafting pointing vertically upwards, however mounting is also possib le in
any other position.
The HQ series actuators are supplied with a Union Joint and nut which 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.
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QAD#IM6010 RevD 11.01.19
ACTUATOR MOUNTING DETAILS
*Direct mounting / ISO (ISO standard) *Bracket Mounting
F03, F05, F07
HQ006: ISO5211 F03/F05 and F07
Star Adapter 14mm - 11 mm
11mm - 9mm
Square Adapter 14mm - 11 mm
11mm - 9mm
Danger: HAZARDOUS VOLTAGE (Make sure all power is disconnected prior to mounting)
Limit Switch Setting
Rotate the actuator hand wheel manually to closed position
Using hex wrench, loosen the set screw on the CLOSE limit switch cam
Rotate the CLOSE cam towards CW limit switch lever until the switch “clicks” Tighten the set screw with hex wrench
Rotate the actuator hand wheel manually to open position
Using hex wrench, loosen the set screw in the “open” limit switch cam
Rotate to “open” cam towards CCW limit switch lever until the switch “clicks” (fig 2)
Tighten set screw with hex wrench
Danger: HAZARDOUS VOLTAGE (Make sure all power is disconnected before prior to mounting)
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QAD#IM6010 RevD 11.01.19
Close Cam Setting
Close Limit Switch
Close limit Switch Cam (clockwise)
2mm Hexagon socket screw Key
OPERATION INSTRUCTION
Electrical Connections and Preliminary Test
Loosen the screws on the actuator cover and lift it off
Make sure that the power supply voltage is in accordance with the data on the actuator name plate
Connect wires according to the enclosed wiring diagram
Move the valve manually to a half-open position, operate and electrical opening and check that the motor rotates in the right
direction
Standard units are counter-clockwise to open set
Test the actuator and check the limit switches work correctly
Check all the cable glands are correctly tightened, applicable cable glands should be selected to be meet the applications
condition. Over the grade IP67 of cable gland recommended in potentially explosive atmospheres.
Mount cover and tighten cover bolts
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QAD#IM6010 RevD 11.01.19
Wiring Diagrams for Standard Models - 240V AC
HQ006 240V AC
PCU Type
Wiring Diagram
Number HQ-150-B
HQ006 240V AC
On/Off type
Wiring Diagram
Number HQ-110-A
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QAD#IM6010 RevD 11.01.19
DC Wiring Diagram - 24V DC
On/Off type
Wiring Diagram
Number HQ-840-B
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Wiring Diagrams for Standard Models - 24V
AC Wiring Diagram - 24V AC
On/Off type
Wiring Diagram Number HQ-740-B
QAD#IM6010 RevD 11.01.19
TORQUE AND LIMIT SWITCH OPERATION
SWITCH CLOSE INTERMEDIATE OPEN
CLS 1-2
CLS 1-3
OLS 1-2
OLS 1-3
ACLS 1-2
ACLS 1-3
AOLS 1-2
AOLS 1-3
SYMBOL DESCRIPTION RATING
CLS CLOSE LIMIT SWITCH 250 VAC
OLS OPEN LIMIT SWITCH 250 VAC
ACLS AUX. CLOSE LIMIT SWITCH 250 VAC
AOLS AUX. OPEN LIMIT SWITCH 250 VAC
* EACH ACTUTAOR SHOULD BE POWERED THROUGH IT’S
INDIVIDUAL SWITCH OR RELAY CONTACTS TO PREVENT FEED
BETWEEN TWO OR MORE ACTUATORS
DRAW B.R.LEE CHECK
DESIGN S.K.KANG APPR S.M.
PART NAME 1 PH WIRING DIAGRAM PCU
DWG.NO HQ-250-
HQ-006 ISSU. DEPT. HADR DATE: 2011
APPLICATION HKC - H K C CO. LTD
HQ 006-2
AC OPERATION DIP SWITCH 1 DOWN - DIP SWITCH 2 UP
HQ 006-2
DC OPERATION DIP SWITCH 1 UP - DIP SWITCH 2 DOWN
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PCU Wiring Diagram 24V DC
Wiring Diagram Number HQ-850-c
NOTE:
The HQ006 24V Unit requires the relay panel to be programmed ot suit either AC or DC operation.
Use the below photos to set Dip Switches to suit.
QAD#IM6010 RevD 11.01.19
Tools
1 Metric Allen Key (Hex Wrench)
1 Screw Driver
1 Metric Spanner
1 Wrench 200mm
1 Wrench 300mm
1 Wire Stripper Long Nose
1 Multi Meter (AC, DC, Resistance)
1 DC Signal Generator (4 -20mA): PCU Board Opon
1mA Meter (0 25mA): PCU & CPT Board Option
MAINTENANCE
Caution: Turn off all power services before attempting to perform a service on the actuator. POTENTIAL HIGH PRESSURE
VESSEL. Before removing or disassembling the actuator ensure the valve or other actuated devices are isolated and not under
pressure.
Maintenance under normal conditions at six month intervals, however when conditions are more severe, more frequent
inspections may be advisable.
Ensure valve actuator alignment
Ensure wiring is insulated, connected and terminated properly
Ensure all screws are present and tight
Ensure cleanliness of internal electrical devices
Ensure conduit connections are installed properly and are dry
Check internal devices for condensation
Check power to internal heater
Check enclosure O-ring seals and verify the O-ring is not pinched between flange
Verify declutch mechanism
Visually inspect during open /close cycle
Inspect identification labels for ware and replace if necessary
Warning: Treat cover with care. Gap surfaces must not be damaged or dirtied in any way. Do not jam cover during fitting.
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QAD#IM6010 RevD 11.01.19
TROUBLE SHOOTING
The following instructions are offered for the most common difficulties encountered during installation and start up.
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Motor not running Open in control unit Refer to appropriate wiring diagram and check for continuity
Insulation resistance breakdown in motor Perform megger test
No power available to actuator Tripped circuit breaker Reset circuit breaker
Manual override nut hard to turn Valve stem improperly lubricated.
Actuator lubricant has broken down
Lubricate with grease
Clean out old grease and replace with recommended lubricant
Valve packing gland too tight Loosen gland nuts as necessary
Jammed valve Refer to valve maintenance.
IMPORTANT: Do not un-jam valve using the manual override.
Remove actuator from valve and un-jam valve.
Valve only opens or closes partially with motor Limit switch improperly set Check setting and reset if necessary
Stripped gearing Replace as necessary Manual override nut will not operate valve
Broken hand wheel shaft Replace as necessary
Broken valve stem Repair or replace as necessary
Motor runs but will not operate valve Stripped gearing Replace as necessary
Actuator does not respond
Verify the line voltage to the actuator
Check that the voltage matches the rating on the actuator nameplate
Check internal wiring against actuator wiring diagram
Check limit switch cams
Actuator is receiving power but does not operate
Verify the line voltage to the actuator
Check actuator force to see if it’s greater than the valve force
Check limit switches and cams
Check that the force switches have not tripped
Check mechanical travel stop adjustment
Verify the actuator against valve rotation (standard units are anti-clockwise open)
Check internal wiring
Check for corrosion and condensation
Verify coupler/bracket are correctly installed and is not causing binding
Actuator runs erratically
Check ambient temperature
Verify that the duty cycle has not been exceeded
Check the position of manual override lever
Optional Equipment
Potentiometer Current Position Transmitter
Check resistance value
Check potentiometer gear for jamming
Check zero and span calibration
Check board for damage
Current Position Transmitter
Verify input signal
Check dip switch configuration
Check Board for damage
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QAD#IM6010 RevD 11.01.19
DIMENSIONS FOR ACTUATOR
HQ006
HQ006 On/Off Type
125.5
103.6
Cable Entry: PG 13.5
Indicator
M5 Bolt Hexagon Socket Head Cap Screws
Enclosure: IP67
Torque: 6Kg.m
Operation Time: 13sec
Position Switch: 4 SPDT Switch
Cable Entry: PG 13.5 x 2
Mounting Flange: F03, F05, F07
acc to DIN/ISO5211
147.5
126.4
105.4
132.3
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Ø 70/F07 ISO 4 - M8TAP DP12
Ø 50/F05 ISO 4 - M6TAP DP12
Ø 36/F03 ISO 4 - M5TAP DP12
Hand wheel 1
M6 Hexagon socket head cap
Hand wheel 2
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QAD#IM6010 RevD 11.01.19
HQ006 PCU TYPE
103.6
125.5
Cable Entry: PG 13.5
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Handwheel
Ø70/F7ISO 4-M8TAP DP12
Ø6.8 DRILL DP14
Ø50/F5ISO 4-M6TAP DP12
Ø5 DRILL DP14
Ø36/F3ISO 8-M5TAP DP12
Ø4.2 DRILL DP14
133
108
126.4
212.4
147.5
148
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QAD#IM6010 RevD 11.01.19
www.challengervalves.com.au
HEAD OFFICE AND WAREHOUSE
3 Glenn Street
Shepparton Victoria 3630
P: 1800 120 751
Email:
sales@challengervalves.com.au
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