1、 Precautions before installation

1. Environmental adaptability inspection
   • Temperature and HumidityEnsure that the installation environment temperature is within the working range of the valve (usually -20 ℃~+60 ℃), and avoidharshTemperature causes electronic component failure or aging of sealing materials. The humidity should be below 85% RH to prevent condensation from damaging the circuit board.
   • Corrosive gasIf used in chemical or coastal environments, corrosion-resistant valves (such as 316L stainless steel valve body, PTFE seal) should be selected, and direct contact with strong acid and alkali vapors should be avoided.
   • Vibration and impactKeep away from vibration sources such as pumps and compressors. If unavoidable, install shock absorbers or choose anti vibration actuators.
2. Fluid compatibility verification
   • medium characteristicsConfirm whether the corrosiveness, viscosity, and particle content of the fluid (water, steam, oil, gas, etc.) match the valve material. For example, the use of ordinary stainless steel valve bodies should be avoided for chloride containing ion media.
   • Pressure and FlowCheck whether the rated pressure (such as PN16, PN25) and flow coefficient (Cv value) of the valve meet the system requirements to prevent overload or insufficient flow.
3. Confirmation of electrical conditions
   • Power SpecificationsCheck whether the power supply voltage of the actuator (such as AC220V, DC24V) is consistent with the on-site power supply to avoid misconnection and burning.
   • signal typeConfirm that the control signals (such as 4-20mA, 0-10V, RS485) are compatible with the control system, and install signal isolators or converters if necessary.
   • grounding protectionEnsure that the metal casing of the valve is reliably grounded to prevent lightning strikes or static electricity from damaging electronic components.

2、 Precautions during installation process

1. Pipeline Connection Specification
   • Correctness of directionThree way valves have two structures: diversion (one inlet and two outlets) and merging (two inlets and one outlet). Before installation, it is necessary to check that the arrow markings on the valve body are consistent with the fluid flow direction to avoid control failure caused by reverse direction.
   • pipe cleaningBefore installation, clean the welding slag, rust and other impurities inside the pipeline to prevent valve blockage or scratching of the sealing surface.
   • Alignment and concentricityWhen connecting valves and pipeline flanges, gaskets should be used to adjust concentricity, with a deviation of no more than 0.5mm, to avoid stress concentration and leakage.
2. Installation of actuators
   • Levelness requirementsThe installation surface of the electric actuator should be horizontal, with a tilt angle not exceeding 5 °, to prevent leakage of lubricating oil from the gearbox or overheating of the motor.
   • Manual operation testAfter installation, manually operate the valve to the fully open/fully closed position, confirm that there is no jamming or abnormal noise, and then power on for debugging.
3. Wiring specifications
   • Separation of signal line and power lineTo avoid strong electrical interference with weak electrical signals, signal lines should be threaded through metal pipes or shielded cables should be used, and the shielding layer should be grounded at one end.
   • Reserved cable lengthReserve a 10% -15% margin in the cables between the actuator and the control cabinet to prevent wire breakage during valve operation.

3、 Debugging and operation precautions

1. Initial debugging steps
   • Zero and full calibrationSet the valve fully closed (0%) and fully open (100%) positions through the actuator or control system, ensuring that the signal corresponds linearly with the opening.
   • Dead zone settingAccording to the system response speed requirements, adjust the control dead zone (usually 1% -3%) to avoid frequent micro movements of the valve causing wear.
   • Selection of traffic characteristicsSelect equal percentage, linear or quick opening characteristics according to process requirements, such as commonly used equal percentage characteristics in HVAC systems to achieve precise temperature control.
2. Key points of operation monitoring
   • Leak checkRegularly inspect the valve flange and packing box for leaks. If leaks are found, tighten the bolts or replace the seals.
   • temperature monitoringThe temperature of the actuator casing should not exceed 70 ℃. If it is too high, it may be damaged due to overload or poor heat dissipation.
   • Noise controlIf the noise during valve operation exceeds 85dB, it is necessary to check whether the fluid flow rate is too high or whether the valve selection is reasonable.
3. Emergency handling of faults
   • power failureEquipped with UPS or manual bypass device to ensure that the valve can maintain its current position or switch to a safe state when power is cut off.
   • Signal lostSet signal loss protection function (such as staying in place, fully open or fully closed) to prevent system loss of control.
   • Card lag handlingIf the valve is stuck, do not forcefully power it on. First, cut off the power and manually shake the actuator handle to try resetting.

4、 Maintenance and upkeep precautions

1. regular cleaning
   • External cleaningWipe the surface dust of the valve body and actuator with a dry cloth every quarter to avoid dust accumulation affecting heat dissipation or entering the interior.
   • internal cleaningDisassemble the valve annually (requires professional personnel), clean the valve core and seat deposits, and replace deteriorated lubricating grease.
2. Lubrication and sealing maintenance
   • Actuator lubricationReplace the gearbox lubricating oil (such as ISO VG320 gear oil) every 2 years and check the gear wear.
   • Seal replacementReplace the packing box seal ring and O-ring every 3-5 years to prevent aging and leakage.
3. Calibration and Testing
   • Signal calibrationEvery year, use a standard signal source (such as a 4-20mA generator) to verify the relationship between valve opening and signal correspondence, and adjust if the deviation exceeds ± 2%.
   • Response time testRecord the time from receiving the signal to reaching the target opening of the valve. If the delay exceeds the design value, check the actuator or control system.