Preparation before installation
1. Confirm technical parameters
Check whether the voltage (AC/DC), power, and control signal type (4-20mA, 0-10V, RS485, etc.) of the electric valve match the system.
Check whether the valve stroke (full open/full closed time) and torque requirements meet the pipeline working conditions (such as high viscosity media require greater torque).
2. Environmental adaptability verification
Protection level: Select the IP protection level according to the installation environment (such as IP65 for humid and dusty environments, IP68 for underwater).
Explosion-proof requirements: Explosion-proof motors (such as EXD II 2G) are required for flammable and explosive places.
Temperature range: Confirm whether the valve material and motor temperature rise meet the medium and ambient temperature requirements.
3. Preparation of tools and materials
Special wrenches for electric valves, torque wrenches, and electrician tools (wire strippers, wire crimping terminals).
Wiring materials (cables, shielded wires), sealing tape, and anti-rust treatment agents.
Installation precautions
1. Mechanical installation
Installation direction:
Ensure that the valve flow direction is consistent with the pipeline (refer to the valve nameplate or manual).
Enough space should be reserved for electric actuators (such as worm gears, servo motors) to avoid collision with pipelines or brackets when the valve is in motion.
Support and fixation:
When installing electric valves, a separate bracket must be set to prevent the weight and vibration of the motor from being transmitted to the pipeline.
Tighten the bolts according to the standard torque for flange connections (to avoid leakage or motor displacement due to stress).
2. Electrical installation
Wiring specifications:
The cables should be kept away from high temperature and corrosive media, and waterproof insulation treatment should be done (such as pipe penetration or waterproof connectors).
Power lines and signal lines should be wired separately to avoid interference (use shielded cables when necessary).
Grounding protection: The motor housing must be reliably grounded, and the grounding resistance must be ≤4Ω (to prevent safety accidents caused by leakage).
Sealing of the junction box: After the wiring is completed, fill the gap of the junction box with sealant to prevent water or dust from entering.
3. Inspection before commissioning
Manually test whether the valve can be opened and closed normally (manually operate the valve stem in the power-off state).
Check whether the motor direction is correct (after power on, observe whether the valve movement direction is consistent with the control signal).
Precautions for use
1. Operation specifications
Remote control
When sending signals through PLC or control system, it is necessary to confirm that the instruction format (such as Modbus, Profibus) matches the valve.
Emergency
Set a mechanical bypass or manual operation device to prevent the valve from failing to move during power failure.
Prohibited behavior
Frequently start and stop the valve (may shorten the life of the motor).
Forced operation of a stuck valve (need to turn off the power first to check).
2. Operation monitoring
Status feedback: Regularly check whether the valve opening signal and fault alarm (such as overload, stall) are normal.
Temperature monitoring: When the motor temperature rise exceeds the rated value (generally ≤70℃), it is necessary to stop and cool.
Abnormal noise: If an abnormal humming sound occurs, it may be due to bearing wear or rotor jamming, and immediate maintenance is required.
Maintenance and troubleshooting
1. Daily maintenance
Cleaning: Clean the actuator housing and junction box every month to prevent dust accumulation from affecting heat dissipation.
Lubrication: Add special grease to mechanical parts such as gears and bearings (avoid using ordinary butter).
Sealing inspection: Test the sealing of the valve seat every quarter, and replace the packing or O-ring if necessary.
2. Common fault handling
| Fault phenomenon | Possible causes | Workaround |
| Inability to move | Power outage/signal loss | Check power supply and line connection |
| Abnormal noise during operation | Bearing wear/foreign matter stuck | Clean foreign matter and replace grease |
| Internal leakage | Seat wear/seal failure | Replace valve seat or repair by grinding |
| Overheat protection triggered | Motor overload | Reduce valve opening or check torque |
3. Regular maintenance
Disassemble the actuator every year to check the wear of internal parts (such as turbine blades and gears).
Test the insulation resistance of the motor (generally ≥1MΩ) to avoid short circuit due to moisture.
Safety tips
1. Explosion-proof environment: When installing in explosion-hazardous areas, the installation specifications of explosion-proof electrical equipment (such as ATEX certification) must be followed. It is prohibited to disassemble the motor or line without power off.
2. Lightning protection measures: Surge protectors (SPDs) must be installed in areas prone to lightning to prevent lightning strikes from damaging the motor.
3. Energy-saving management: When not in use for a long time, cut off the power supply to reduce energy consumption; choose smart valves with "sleep mode".
Precautions for special scenarios
- High-pressure pipelines: Electric valves must be equipped with pressure sensors to monitor the pressure after the valve in real time to prevent overpressure.
- Corrosive media: Choose corrosion-resistant materials (such as 316L stainless steel, PTFE seals) and strengthen sealing protection.
- Low temperature environment: When the valve is not used in winter, the accumulated liquid in the valve body needs to be drained to prevent ice from damaging the actuator.
By strictly following the installation specifications and regular maintenance, the electric valve can operate efficiently and stably, significantly improving the automation level of the pipeline system. For specific operation suggestions, refer to the manufacturer's technical manual and adjust according to the actual working conditions!