How to install a positioner on an air actuated valve?

Hey there! If you're in the market for air actuated valves, you've come to the right place. As a leading supplier of [Air Actuated Valves], I've had my fair share of experience when it comes to these important pieces of equipment. One common task that often comes up is installing a positioner on an air actuated valve. In this blog post, I'll walk you through the process step - by - step, so you can do it like a pro.

Why Use a Positioner on an Air Actuated Valve?

Before we dive into the installation process, let's quickly talk about why you might want to use a positioner in the first place. A positioner helps to accurately control the position of the valve. It takes an input signal (usually a 4 - 20 mA signal) and adjusts the air pressure to the actuator to move the valve to the desired position. This results in more precise control, which is crucial in many industrial applications. Whether you're dealing with a 1 Inch Air Actuated Three Way Ball Valve or an Air Actuated True Union Ball Valve, having a positioner can improve the valve's performance significantly.

Step 1: Gather Your Tools and Materials

First things first, you'll need to collect all the necessary tools and materials. Here's a basic list:

• The positioner itself. Make sure it's compatible with your air actuated valve.
• Wrenches: You'll typically need an adjustable wrench or a set of socket wrenches to loosen and tighten bolts.
• Screwdrivers: Both flat - head and Phillips - head screwdrivers may be required, depending on the positioner's design.
• Sealant: To prevent air leaks, you'll need a good quality sealant. Teflon tape or pipe dope can work well.
• Electrical connectors: If your positioner is electrically - controlled, you'll need the appropriate connectors to make the wiring connections.

Step 2: Prepare the Valve and Actuator

Before you start installing the positioner, you need to make sure the valve and actuator are ready. First, shut off the air supply to the actuator. This is a safety measure to prevent any unexpected movement of the valve during installation. Next, clean the mounting surface on the actuator where the positioner will be attached. Remove any dirt, debris, or old sealant. A clean surface will ensure a good seal and a secure mounting.

Step 3: Mount the Positioner

Now it's time to mount the positioner on the actuator. Most positioners come with a mounting kit. Align the positioner with the actuator according to the manufacturer's instructions. In general, you'll need to position it so that the linkage from the positioner can easily connect to the valve stem. Use the bolts and washers provided in the mounting kit to secure the positioner to the actuator. Make sure the bolts are tightened evenly to avoid any misalignment.

Step 4: Connect the Air Lines

Once the positioner is mounted, it's time to connect the air lines. There are usually at least two air connections on the positioner: one for the input air supply and one for the output to the actuator. Use the appropriate size of tubing or piping for the connections. Before making the connections, apply some sealant to the threads to prevent air leaks. Be careful when tightening the fittings, as over - tightening can damage the threads.

Step 5: Make the Electrical Connections (if applicable)

If your positioner is electrically - controlled, you'll need to make the electrical connections. First, turn off the power supply to the control circuit. Then, connect the electrical wires from the control system to the positioner according to the wiring diagram provided by the manufacturer. Make sure the connections are tight and that there are no exposed wires. After making the connections, you can turn the power back on.

Step 6: Calibrate the Positioner

Calibration is a crucial step to ensure that the positioner is working correctly. Most modern positioners have a built - in calibration procedure. Start by setting the zero position. This is usually done by adjusting the positioner so that the valve is fully closed when the input signal is at its minimum (e.g., 4 mA). Next, set the span. This involves adjusting the positioner so that the valve is fully open when the input signal is at its maximum (e.g., 20 mA). During calibration, you may need to use a calibration tool, such as a multimeter or a pressure gauge, to verify the settings.

Step 7: Test the Valve

Once the positioner is calibrated, it's time to test the valve. Turn on the air supply to the actuator and send an input signal from the control system. Monitor the valve's movement to make sure it opens and closes smoothly and accurately. Check for any air leaks around the positioner and the valve. If you notice any issues, such as uneven movement or leaks, you may need to go back and re - check your connections or calibration.

Troubleshooting Common Issues

• Valve not moving: Check the air supply. Make sure the air pressure is sufficient and that there are no blockages in the air lines. Also, check the electrical connections if the positioner is electrically - controlled.
• Inaccurate positioning: This could be due to incorrect calibration. Try re - calibrating the positioner. Another possibility is a mechanical issue with the valve or actuator. Check for any binding or misalignment.
• Air leaks: Inspect all the air connections. Tighten any loose fittings and re - apply sealant if necessary.

Conclusion

Installing a positioner on an air actuated valve may seem like a daunting task, but with the right tools and a little know - how, you can do it yourself. Remember to follow the manufacturer's instructions closely, and don't hesitate to seek help if you run into any problems.

If you're looking for high - quality air actuated valves like Pneumatic Actuated Ball Valve, or need more advice on valve installation and maintenance, we're here to assist you. Contact us to discuss your specific requirements and explore our extensive product range. We're eager to partner with you to meet your industrial valve needs.

References

• Manufacturer's manuals for the air actuated valve and positioner
• Industry standards for valve installation and calibration