PowerFlow Paper Solutions

Actuator Setup & Zone Configuration

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Overview

Proper actuator configuration is essential for safe and effective dilution control. This section covers zone setup, position limits, and constraint configuration.

Zone Configuration

Configure the basic zone parameters:

Basic Zone Settings

Number of Zones 48 Typical: 24-96
Zone Numbering Front to Back Match physical layout
Default Position 50% Initial setpoint

Zone Modes

Mode Description Usage
Auto Automatic control based on profile Normal operation
Manual Operator sets position manually Testing, commissioning
Remote Position from external system QCS override mode
Local Position held at last value Service mode

Position Limits

Configure safe operating limits for each zone:

Position Limits

Minimum Position 0% Fully closed
Maximum Position 100% Fully open
Operating Low 10% Soft lower limit
Operating High 90% Soft upper limit
Safe Limits

Set operating limits with margin from 0% and 100% to avoid full closure (stock starvation) or full opening (excessive dilution).

Constraints

Constraints prevent aggressive or unsafe valve movements:

Stepping Limit

Maximum position change per control cycle:

Stepping Limit 5% Per control cycle

Bending Limit

Maximum difference between adjacent zones:

Bending Limit 15% Between neighbors

Deadband

Minimum error before control action:

Deadband 0.5 g/m² Profile error threshold

Zone Mapping

Configure how scanner databoxes map to actuator zones:

Mapping Configuration

Front Side Offset 10 Databoxes to skip at front
Back Side Offset 10 Databoxes to skip at back
Direction Front to Back Mapping direction

Verifying Zone Mapping

  1. Visual Check

    View profile display - ensure it matches scanner direction

  2. Test Response

    Move a single valve and observe profile change location

  3. Adjust Offsets

    If profile is shifted, adjust front/back offsets

Valve Flushing

Regular flushing prevents valve sticking and ensures reliable operation:

Flushing Sequence

  1. Open Flushing Dialog

    Go to Operations > Valve Flushing

  2. Configure Parameters

    • Flush Position: 100% (fully open)
    • Hold Time: 5 seconds
    • Return Position: Previous position

  3. Select Zones

    Select zones to flush (all zones or specific range)

  4. Execute Flush

    Click Start Flushing

Flushing Schedule

Perform valve flushing during sheet breaks or grade changes to minimize process impact. A typical schedule is once per shift.