Maintenance Guides 1 min read

Proportional Valve Calibration Guide: Zero Adjustment, Lift Adjustment and Hysteresis Correction

Technical analysis: Proportional valve calibration: zero-point adjustment, ramp tuning, and hysteresis correction

Гайд з калібрування пропорційного клапану: нульова налаштування, налаштування підйому та корекція гістерезису - UNITEC-D Industrial MRO
Цей гайд надає конкретні інструкції для калібрування пропорційного клапану. Включає кроки нульової налаштування, налаштування підйому та корекції гістерезису. Виконання процедури забезпечить точність

1. Content and purpose

This guide is intended for calibration of the proportional valve in gas and liquid control systems used in industrial systems of Ukraine. The purpose of calibration is to ensure the accuracy of the valve output signal, compliance with the established standards (DSTU, EN, ISO) and to ensure the safety and reliability of the system. This process is performed during scheduled maintenance or after detection of valve abnormalities.

2. Security

Turn off power and perform a lockout/tagout (LOTO) on all electrical components of the system.
Use PPE including work gloves, goggles and high pressure protection.
Before starting work, check for the presence of aggressive liquids or gases in the system. If present, perform drainage and pumping.

3. Tools and materials

Tool Specification Quantity
Torque screwdriver (electric) Rank 10-50 Nm 1
Multimeter Measurement of voltage 0-24 V, current 0-20 mA, resistance 0-20 MΩ 1
Alligator clips Length 150 mm 2
Means for measuring pressure Range 0-10 bar, accuracy ±0.1 bar 1
A laser for measuring parallelism Range 0-10 m, accuracy ±0.02 mm 1
Means for drainage Flask 5 l 1

4. Before servicing: Check

Point Verification Acceptance/rejection criteria Notes
1 LOTO done Blocked and marked power supply It is necessary
2 Availability of PPE Gloves, glasses, protective equipment It is necessary
3 Lack of fluids The system is clean It is necessary
4 Shutting down electrical equipment Power is off It is necessary

5. Step by step: Calibration procedure

  1. Preparation for calibration

    Place the valve on a test stand with measuring equipment. Provide connection to pressure measurement system and electrical signal.

    • Measure the pressure in the system - it should be 0.5 bar.
    • Make sure the power supply is turned off.
    • Use a laser to measure the parallelism between the inlet and outlet fittings - the permissible range is 0.01-0.05 mm.

    Error: Pressure measurement without using measuring tools.

  2. Zero settings

    Set the input voltage signal to 0 V. Start the measurement process.

    • The outlet pressure should be 0.5 bar ±0.1 bar.
    • Use a multimeter to check the input signal - should be 0V.
    • Make a record of the measured values.

    Error: Incorrect input signal setting.

  3. Lift Settings

    Set the input voltage signal to 5 V. Start the measurement process.

    • The outlet pressure should be 5 bar ±0.5 bar.
    • Measure the input signal - should be 5V ±0.1V.
    • Check that the output signal matches the input signal.

    Error: Deviation of the input signal from the specified one.

  4. Hysteresis correction

    Set the input voltage signal to 5V, then step down to 0V. Start the measurement process.

    • The output pressure at 5 V should be 5 bar ±0.5 bar.
    • The output pressure at 0 V should be 0.5 bar ±0.1 bar.
    • Make a record of the measured values.

    Error: Incorrect output signal setting.

  5. Final check

    Set the input voltage signal to 5 V. Start the measurement process.

    • The outlet pressure should be 5 bar ±0.5 bar.
    • Measure the input signal - should be 5V ±0.1V.
    • Check that the output signal matches the input signal.

    Error: Incorrect input signal setting.

6. After service: Inspection

Test Expected result Actual result Pass/Fail
1 Output pressure at 0 V 0.5 bar ±0.1 bar
2 Output pressure at 5 V 5 bar ±0.5 bar
3 Input signal 0 V or 5 V
4 Output signal Matches the incoming one

7. Troubleshooting

Symptom A possible reason Correction
The output signal is not stable Overvoltage protection Check the filters and settings.
No output signal Power outage Check LOTO and restore power.
Pressure deviation Incorrect valve setting Check the zero setting and measure the pressure.
Transitive compliance Input signal deviation Check the input signal and settings.

8. Recommended maintenance schedule

The task Frequency Estimated duration Skill level
Zero adjustment Every 6 months 30 minutes Average
Lift adjustment Every 6 months 30 minutes Average
Hysteresis correction Every 12 months 45 minutes Tall

9. References for spare parts

Description of the spare part Typical specification UNITEC-D category
Valve spring Material: stainless steel, diameter 6 mm Category 472
Mounting bearing Type: conical, material: steel Category 126
Oil seal Material: stainless steel, diameter 10 mm Category 345
Pressure sensor Range 0-10 bar, accuracy ±0.1 bar Category 589

For spare parts, visit the UNITEC-D website: https://www.unitecd.com/e-catalog/

10. References

This guide complies with the following standards:

  • DSTU 5880:2011 — Safety requirements for industrial systems
  • EN 60947-2 — Requirements for electrical devices
  • ISO 14617:2016 — Valve accuracy control
  • CE — General product requirements
  • UkrSEPRO — Requirements for industrial systems of Ukraine

Manufacturer's documentation applies:

  • Catalog of P100 series valves
  • Technical conditions for calibration

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