Unlocking Efficiency with the Electro-pneumatic Positioner: Enhance Your Pneumatic Cement Unloader Today!

When operating pneumatic cement unloaders like the Kovako and Kintec models, achieving precise and reliable control over the butterfly valve is crucial because it directly impacts the efficiency and safety of material handling. Precise control ensures consistent flow rates, minimises material waste and prevents potential blockages or overflows. Reliable valve operation also reduces wear and tear on system components, extending their lifespan and reducing maintenance costs. One of the most impactful upgrades you can make to your system is integrating an electro-pneumatic positioner, such as the Serie 6A available at LionTech.shop. But what makes this positioner a game-changer compared to traditional pneumatic actuators with mechanical activators controlled by the PLC? Let’s explore the advantages and the practical benefits it brings to your pneumatic unloading system.

The Basics: Pneumatic vs. Electro-pneumatic Valve Control

Traditional Pneumatic Actuator with Mechanical Activator

In traditional systems, butterfly valve control relies on a pneumatic actuator combined with a mechanical activator. This setup uses a mechanical potentiometer to provide feedback, which is then managed pneumatically by two separate blocks under PLC control. The PLC continuously adjusts the valve position between 0° and 90°, striving to maintain the required balance.

While this method works, it is prone to:

• Inconsistencies: Continuous balancing introduces variability, reducing control precision.
• Slow Response Times: Adjustments take longer due to the reliance on pneumatic-only mechanisms.
• Complexity: Multiple components and manual calibration increase the potential for errors and maintenance needs.

Modern Control with Electro-pneumatic Positioner

Enter the Serie 6A Electro-pneumatic Positioner, which brings valve control directly to the actuator. Instead of relying on external balancing, this system integrates:

• Direct Valve Control: The positioner manages valve movement independently, using the PLC’s angle request (0° to 90°) to ensure precise and stable positioning.
• Analog Communication: With a 4-20mA analogue signal, the system provides consistent and reliable communication.
• Fail-Safe Features: In case of electrical power failure, the positioner moves to a predefined safety position and depressurises the actuator, adding an extra layer of protection.

Key Benefits of the Electro-pneumatic Positioner

1. Enhanced Precision The Electro-pneumatic positioner delivers fixed positioning per degree, ensuring unparalleled accuracy. Whether your valve needs to open at 25° or 75°, the positioner executes with exacting precision.
2. Improved Efficiency Faster response times and reduced variability mean your unloading process runs more smoothly, minimizing delays and optimizing productivity.
3. Fail-Safe Reliability The integrated fail-safe functionality offers peace of mind. Even if auxiliary power is lost, your system will default to a safe state, protecting both your equipment and personnel.
4. Durability and Compatibility Constructed with a robust polycarbonate housing and equipped with a threaded G¼ connection (M20x1.5 bolt size), the Serie 6A positioner is built to withstand challenging industrial environments. It’s compatible with pneumatic linear and part-turn actuators, making it versatile for various applications.

Practical Applications in Pneumatic Cement Unloaders

Butterfly valves play a critical role in controlling the flow of materials in pneumatic unloaders. Upgrading to an electro-pneumatic positioner is especially beneficial for:

• Primary Material Flow Control: Ensures stable and accurate regulation of cement flow.
• Safety-Critical Operations: Provides reliable fail-safe measures to prevent material spillage or equipment damage during power interruptions.
• High-Precision Tasks: Ideal for applications requiring exact valve positioning to maintain consistent process conditions.

Essential Components for the Upgrade

To fully leverage the benefits of an electro-pneumatic positioner, you will only need two additional components and some programming work from our engineers:

• Feedback Module: Feedback Module IY for analog current output signal integration.
• Electro-pneumatic Positioner: Serie 6A Electro-pneumatic Positioner for precise and reliable valve control.
• Programming: Programming Some programming work from our engineers.

Conclusion: A Smart Investment for Your Unloader

Upgrading to an electro-pneumatic positioner like the Serie 6A is a smart move for anyone looking to improve the efficiency, reliability, and safety of their pneumatic cement unloader. By replacing traditional pneumatic systems with this advanced solution, you’ll unlock many benefits that translate directly into better performance and lower operational costs.

Explore the Serie 6A Electro-pneumatic Positioner and other compatible components at LionTech.shop and take your unloading system to the next level today.

Please feel free to reach out to us for any questions or remarks you might have regarding your valve operations.