Maintenance Guides 1 min read

Setup Guide for a Proportional Valve: Zero Setting, Slope Adjustment and Hysteresis Correction

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

Setup Guide for a Proportional Valve: Zero Setting, Slope Adjustment and Hysteresis Correction

1. General purpose and field of application

This guide is intended for performing adjustments on a proportional valve, specifically zero setting, slope adjustment and hysteresis correction. It applies to proportional valves used in hydraulic control systems on industrial installations in Ukraine. The technician must perform these procedures during scheduled maintenance or upon detection of deviations in the valve operation.

2. Precautionary Measures

Turn off the system power before starting any work.
Use protective equipment (PPE) including gloves, goggles and protective clothing.
Perform the lockout/tagout procedure to eliminate the risk of accidental activation.
Check for pressure in hydraulic lines before disconnecting the fittings.

3. Required Tools and Materials

Tool Name Specification Quantity
Torque wrench (20-100 Nm) Range 20-100 Nm, accuracy ±2% 1
Multimeter (0-200 V, 0-20 MOhm) Electrical Parameter Measuring Device 1
Laser for Parallelism Measurement Accuracy ±0.01 mm 1
Pressure gauge (0-100 bar) Measurement range 0-100 bar 1
Hydraulic pump with pressure stabilization device Pressure 10-100 bar, stability ±1 bar 1

4. Preliminary Inspection Checklist

Item Check Acceptance criteria Notes
1 Power Supply Availability Power Off Perform blocking/marketing
2 Pressure in the hydraulic system Pressure during pipe disconnection Use the pressure gauge
3 Valve functionality Absence of leakage or damage Check for damage
4 Valve Seat Availability of hydraulic connection Check the connection for tightness

5. Step by step procedure

  1. Remove the pipes

    Use a torque wrench to remove the pipes. The system pressure must be turned off. Measure the system pressure before removing the pipes.

    Pressure in the system: 0 bar

    Unscrew the pipes: 10-15 Nm

    Visual indication: No leakage or dripping

    Error: Do not use tools without blocking/marking.

  2. Zero Position Setup

    Connect the hydraulic pump to the valve. Set the pressure to 0 bar. Measure the voltage on the valve input line.

    Voltage: 0-5 V

    Visual indication: No deviation in the position of the valve

    Error: setting zero position without power supply.

  3. Slope Setting

    Increase the pressure on the valve to 100 bar. Measure the valve's output voltage. Adjust the valve's slope to ensure stable regulation.

    Pressure: 100 bar

    Output voltage: 0-5 V

    Visual indication: No deviations in output voltage

    Error: incorrect tilt scale used.

  4. Hysteresis Correction

    Reduce the pressure to 0 bar. Measure the output voltage. Adjust the valve hysteresis to ensure stable position recovery.

    Pressure: 0 bar

    Output voltage: 0-5 V

    Visual indication: No deviations in output voltage

    Error: use of incorrect hysteresis correction mode.

  5. Valve Reinstallation

    Install the valve in place. Tighten the pipes using a torque wrench. Measure the system pressure.

    Pressure: 0-100 bar

    Visual indication: No leakage or dripping

    Error: use of incorrect tightening torque.

6. After-sales verification checklist

Test Expected result Actual Result Pass/Fail
1 System pressure 0-100 bar
2 Input line voltage 0-5 V
3 Output Voltage 0-5 V

7. Problem Tracking

Symptom Possible cause Correction action
Unstable valve operation Incorrect tilt setting Check the valve tilt and perform adjustment
Output Voltage Deviation Clapet hysteresis Perform hysteresis correction
Unstable restoration of position Contamination of the hydraulic system Clean the system and perform the flushing

8. Recommended Maintenance Schedule

Task Frequency Estimated duration Skill Level
Zero setting Annual 2 years Average
Slope Setting Annual 2 years Average
Hysteresis Correction Annual 2 years Average

9. Special Parts

Part description Typical Specification Category UNITEC-D
Proportional valve Maximum pressure 100 bar Category 123
Hydraulic pipe Diameter 12 mm Category 456
Pressure gauge Range 0-100 bar Category 789

Зверніться до UNITEC-D e-catalog для отримання деталей про спеціальні частинки.

10. Additional Documents

  • CE Certificate
  • Certificate UkrSEPRO
  • Manufacturer's documentation according to standards EN 60335, ISO 9001

Застосовується стандарти: EN 60335, ISO 9001, DSTU 3047-2005

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