AMOT G Series Instruction Manual

Doc No: OMMGGE00217
Revision: 4
Date: MAY 2019
Model G Valve
(Electrically Actuated)
Operation, Installation and
Maintenance Manual

3
Introduction
OMMGGE00217 Rev 4 – MAY 2019
Introduction ......................................................................................................5
1.1 Scope ...........................................................................5
1.2 Safety...........................................................................6
1.3 Maintenance ..................................................................6
1.4 Product Support.............................................................6
1.5 Typographical Conventions..............................................6
1.6 European Union Directives...............................................7
System Overview.............................................................................................9
2.1 Description....................................................................9
2.2 Identification of Model Number ...................................... 11
2.3 Modes of Operation ...................................................... 12
2.4 System Components..................................................... 12
Valve Body .......................................................................................................13
3.1 Description.................................................................. 13
3.2 Installation.................................................................. 13
3.3 Operation.................................................................... 14
3.4 Maintenance ................................................................ 14
Electric Actuator ............................................................................................19
4.1 Description.................................................................. 20
4.2 Identification of EB Actuator Model Number..................... 25
4.3 Mechanical Installation.................................................. 26
4.4Electrical Installation .................................................... 27
4.5 Positioner.................................................................... 31
4.6 Option Configuration (Positioner option only)................... 33
4.7 Calibration (Positioner option only)................................. 38
4.8 Operation.................................................................... 39
4.9 Maintenance ................................................................ 40
4.10 Storage....................................................................... 58
4.11 Available Spares .......................................................... 60
PID Controller.................................................................................................61
5.1 Controller Systems ....................................................... 61
Temperature Sensor.....................................................................................63
6.1 Description.................................................................. 63
6.2 Installation .................................................................. 63
6.3 Maintenance ................................................................ 64
System Integration.......................................................................................65
7.1 Installation Guidance Notes ........................................... 65
7.2 System Wiring Diagrams ............................................... 69
Troubleshooting.............................................................................................77
8.1 Checklist ..................................................................... 77
8.2 EB Positioner Status Indicators ...................................... 79

4
Contents
Rev 4 – MAY 2019 OMMGGE00217
Servicing Schedule .......................................................................................81
9.1 Overview.....................................................................81
9.2 Service Intervals ..........................................................81
9.3 Service (every 2 years).................................................81
9.4 AMOT Field Service.......................................................83
Technical Data................................................................................................85
10.1 Selection of G Valve options ..........................................85
10.2 Technical Specifications.................................................93

5
Introduction
OMMGGE00217 Rev 4 – MAY 2019
Section 1
Introduction
Contents
Para Page
1.1 Scope ........................................................................................ 5
1.2 Safety........................................................................................ 6
1.3 Maintenance ............................................................................... 6
1.4 Product Support .......................................................................... 6
1.5 Typographical Conventions ........................................................... 6
1.6 European Union Directives ............................................................ 7
1.6.1 EU Machinery Directive...................................................... 7
1.6.2 Low Voltage Directive........................................................ 7
1.6.3 EMC Directive................................................................... 7
1.6.4 EU Pressure Equipment Directive ........................................ 7
1.1 Scope
This Manual details the installation, operation and maintenance of the AMOT
electrically actuated G Valve system.
Each item of equipment is described in a separate section as follows:
Actuator
Section 4
Valve Body Section 3
PID Controller
Section 5
&
OMM807100043
Temperature Sensor Section 6

6
Introduction
Rev 4 – MAY 2019 OMMGGE00217
1.2 Safety
Certain operations within this manual are potentially hazardous and could
cause injury to personnel or damage to equipment if the instructions are not
carried exactly as described. Where a significant, potential hazard exists, the
following text appears immediately before steps in the procedure that present
a particular hazard:
WARNING
A Warning identifies a hazard that could cause injury to personnel.
The text of the warning describes the hazard and details the
precautions that must be applied before the next step of the procedure
is carried out.
CAUTION
A Caution identifies a hazard that could cause damage to equipment.
The text of the caution describes the hazard and details the
precautions that must be applied before the next step of the
procedure is carried out.
Note
A Note contains supplementary information that may be useful to the
Operator before the next step of the procedure is carried out.
1.3 Maintenance
Maintenance of the valve and actuator should only be carried out by suitable
trained and competent persons, and only after they have read and understood
all applicable sections of this manual. Failure to observe this may result in
damage to equipment or to injury of personnel.
1.4 Product Support
All necessary settings and, where appropriate, alterations inside the equipment
are described in this Operating Manual. If any difficulties arise during start-up,
you are asked not to carry out any unauthorised actions on the unit. You could
endanger your rights under the equipment warranty.
For spares and service support, call the telephone number listed on the back
cover of this Manual.
1.5 Typographical Conventions
Footnotes
Where space in the text or figures to place a note is restricted, a footnote is
used. They consist of two parts:
•A mark indicating which part of the text or figure is affected by the note.
This takes the form of a superscript number e.g. Abc 1.
1This footnote applies to the part of the text or figure, marked with a superscript number 1.

7
Introduction
OMMGGE00217 Rev 4 – MAY 2019
•A note in smaller font at the bottom of the affected page beginning with
the corresponding number in the text (see bottom of page):
1.6 European Union Directives
1.6.1 EU Machinery Directive
The AMOT Model G Valve, as a component, is not considered to be a machine.
To fully comply with the Directive however, the machine into which the valve is
installed must comply with the requirements of the machinery directive before
the valve is put into operation.
1.6.2 Low Voltage Directive
All version of Electric actuator described in this manual have been assessed
against the requirements of the Low Voltage Directive, and have found to be in
conformance.
1.6.3 EMC Directive
All version of Electric actuator described in this manual have been assessed
against the requirements of the EMC Directive, and have found to be in
conformance.
1.6.4 EU Pressure Equipment Directive
In its design application of a temperature control valve, the AMOT Model G
Valve is defined as a Pressure Accessory under the terms of the EU Pressure
Equipment Directive (PED).
Valves used with fluids defined as Group 2 in the Directive (such as water and
lubricating oil) fall into the Sound Engineering Practice (SEP) category.
Some valves are also rated for use with Group 1 liquids under the SEP
category.
Table 1 contains details of the groups each valve type falls into and the
associated maximum working pressure of the valve.

8
Introduction
Rev 4 – MAY 2019 OMMGGE00217
Table 1 Pressure Equipment Directive Table
Valve
Material
Valve
Type
Flange
Standard
Flange
Class
EU directive (PED)
suitable for liquids to
group(s):
Maximum
Working
Pressure (BAR)
Ductile Iron
02GGH
03GGS
03GGH
04GGS
04GGH
05GGS
06GGS
06GGH
08GGS
EN1092
PN6
1 & 2
(SEP)
6
JIS
5K
7
EN1092
PN10
10
PN16
ASME
125
150
JIS 10K
08GGH
10GGS
EN1092
PN6
2
(SEP)
6
JIS
5K
7
EN1092
PN10
10
PN16
ASME
125
150
JIS
10K
ASME
150
Users who are uncertain as to the applicability of the Directive should contact AMOT
before installation, particularly if using more hazardous (Group 1) fluids.

9
System Overview
OMMGGE00217 Rev 4 – MAY 2019
Section 2
System Overview
Contents
Para Page
2.1 Description ................................................................................. 9
2.1.1 Features .......................................................................... 9
2.1.2 Typical Applications......................................................... 10
2.2 Identification of Model Number.................................................... 11
2.3 Modes of Operation.................................................................... 12
2.4 System Components .................................................................. 12
2.1 Description
The G Valve and its ancillary equipment are designed for the control of fluid
temperature by ‘diverting’ or ‘mixing’ control techniques.
The valves can be used for fresh water, most lubricating oils and other liquids.
The compact construction of the G Valve enables unobstructed, full-bore flow,
thus minimising pressure losses.
2.1.1 Features
The G Valve system has the following main features:
•Any direction of rotation.
•Any rotor-port configuration (most models).
•Compact construction.
•Low pressure drop.
•High accuracy (±1°C or better).
•Mountable in any position.
•Manual override.
•Fluid temperature up to 100°C (212°F).
•Local valve position indication.

10
System Overview
Rev 4 – MAY 2019 OMMGGE00217
2.1.2 Typical Applications
Lubricating Oil Temperature
Control
Lubrication oil temperature control is
normally configured in a mixing
application controlling the return
temperature to the heat load.
The temperature is normally measured
as close as possible to the sump
return.
Jacket Water Cooling
Jacket water cooling in diverting
applications regulates the outlet
coolant water temperature from a
diesel or gas engine. The valve either
sends water to a cooler or bypass
loop, accurately maintaining the
temperature.
The temperature is normally measured
at the outlet from the heat source.
Charge Air Temperature Control
The intercooler is used to cool high
temperature turbo charger air. In this
application, the G Valve regulates the
flow of cooling water through an
intercooler, which can increase
efficiency, enhance performance and
help meet stringent environmental
requirements
Central Cooling
For large flow central cooling, mixing
or diverting applications where
accurate temperature control is
required. The capabilities of the G
Valve provide the ideal solution.

11
System Overview
OMMGGE00217 Rev 4 – MAY 2019
2.2 Identification of Model Number
Example
code
06 GG S D B S 32 E B B CA AA Code Description
Valve Body Selection
Valve
Size
Nominal Bore Size
Comments
02
2 inch (DN50)
High flow only
03
3 inch (DN80)
04
4 inch (DN100)
05
5 inch (DN125)
Standard flow only
06
6 inch (DN150)
08
8 inch (DN200)
10
10 inch (DN250)
Standard flow only
Valve
Model
Model Type
GG
Model G Valve
Valve Flow Type
Valve Flow Type
S
Standard Flow
H
High Flow
Valve Body Material
Body Material
D
Ductile Iron
Valve Flange Connection
Standard and Class
Flange Class
Flange
Standard
Comments
A
PN6
EN 1092
B
PN10
EN 1092
C
PN16
EN 1092
F 125 ASME
J
150
ASME
L
10K
JIS
M
5K
JIS
Rotor Type
Rotor Type
S
Standard Rotor
Valve Mode of Operation
Rotor
Position
Rotor
Position
Rotor starting from
Cold Posn.
Cold Process
Hot
Process
12
Port 1
Port 2
Clockwise
23
Port 2
Port 3
31
Port 3
Port 1
21
Port 2
Port 1
Anticlockwise
32
Port 3
Port 2
13
Port 1
Port 3
Actuator Selection
Valve Actuation Type
Actuator Type
E
EB Type Electric Actuator
Actuator Power Supply
Power Supply
A
100 – 120 Vac 50/60Hz
B
200 – 240 Vac 50/60Hz
Actuator Control Input Signal
Input Signal
A
Relays, Switched Live Supply
B
4-20mA (Cold to Hot)
C
20-4mA (Cold to Hot)
Actuator Feedback Signal
Feedback Signal
A
None
C
4-20mA (Cold to Hot) Position Retransmit
E
20-4mA (Cold to Hot) Position Retransmit
Other Options
A
Reserved
Customer Special Options
Options
-AA
Standard product
-***
Customer special code assigned

12
System Overview
Rev 4 – MAY 2019 OMMGGE00217
2.3 Modes of Operation
Fig 1 Modes of Operation
2.4 System Components
The system comprises of the following main components which are described
in other sections of this manual:
Fig 2 System Components
•Valve Body – Section 3
•Electric Actuator – Section 4
•PID Controller and accessories –Section 5
•Temperature Sensor –Section 6
•System Integration –Section 7

13
Valve Body
OMMGGE00217 Rev 4 – MAY 2019
Section 3
Valve Body
Contents
Para Page
3.1 Description ............................................................................... 13
3.2 Installation ............................................................................... 13
3.3 Operation ................................................................................. 14
3.4 Maintenance ............................................................................. 14
3.4.1 Dismantle and Assemble.................................................. 14
3.4.2 Recommended Spares..................................................... 17
3.1 Description
The G Valve is a compact and rugged 3-way control valve designed for
temperature control using ‘diverting’ or ‘mixing’ techniques.
3.2 Installation
Refer to Section 7 (System Integration) for valve installation details.

14
Valve Body
Rev 4 – MAY 2019 OMMGGE00217
3.3 Operation
CAUTION
Damage can be caused to the valve assembly if a cheater or extension
bar is used on the hand wheel. Do not use any mechanical aid to turn
the hand wheel.
Under normal conditions, the valve is operated electrically by the actuator.
Manual operation is possible at any time by disengaging electrical drive with
the actuator declutching lever and turning the hand wheel.
If the valve fails to operate correctly, refer to the troubleshooting guide in
Section 8.
3.4 Maintenance
3.4.1 Dismantle and Assemble
Fig 3 General Arrangement

15
Valve Body
OMMGGE00217 Rev 4 – MAY 2019
Dismantle Valve (refer to Fig 4, page 15)
It is possible to dismantle the valve without removing it from the pipework as
follows:
Note
Ensure replacement seals are available before dismantling the valve (refer
to Section 3.4.2 for spare parts detail).
WARNING
The valve may contain hot/pressurised fluid. Ensure the valve is
isolated, drained and allowed to cool to a safe working level before
dismantling.
Fig 4 Section View (04GGH illustrated)
1Switch off and isolate power to the actuator.
2Using the hand wheel, turn the valve to the low temperature position.
3Note position of actuator in relation to valve body.
WARNING
If an actuator is removed from a valve fitted in a live system, the valve
rotor may rotate uncontrollably in the body. An actuator must never
be removed from a valve installed in a live system.
7
2
6
4
5
3
1
8
9

16
Valve Body
Rev 4 – MAY 2019 OMMGGE00217
4Remove the actuator from the valve body in accordance with Sect 4.9.1
(page 40).
5Knock out the coupling pin Fig 14 (see page 41, (6)) and remove the
coupling.
6Back to Fig 4 (Page 15): remove screws and washers (2), remove
retaining plate (5) and discard O Ring (6).
7Mark adjacent points on the valve body and cover (3) to aid reassembly.
8Remove the bolts (7) securing the valve cover (3).
9Taking care that the rotor is not lifted off, carefully lift off the cover.
10 Remove and discard the cover O ring (1).
11 Remove the rotor assembly (4) from the valve body.
12 Remove and discard the upper and lower shaft O Rings (8 & 9)
13 Inspect the valve internals for wear, damage and cleanliness. Clean and
replace if necessary.
Reassemble Valve (refer to Fig 4, page 15)
14 Apply Molykote®55 O-Ring grease or similar to new upper and lower
shaft O Rings (8 & 9) and fit to the rotor shaft.
15 Carefully insert the rotor assembly (4) into the valve body with the rotor
in the low temperature position.
16 Apply Molykote®55 O-Ring grease or similar to a new cover O ring (1)
and fit to the cover (3).
17 Carefully position the cover (3) on the valve, aligning the marks made
during disassembly.
18 Fit the nuts (7) and washers and tighten to:
#M16 – 245 Nm
19 Apply Molykote®55 O-Ring grease or similar to new O Ring (6), fit into
groove and position retainer plate (5). Fasten in place with screws and
washers (2).
20 Install the actuator onto the valve body in accordance with para. 4.9.1
(page40).

17
Valve Body
OMMGGE00217 Rev 4 – MAY 2019
3.4.2 Recommended Spares
It is recommended that all the spares listed below are replaced each time the
valve is disassembled. These are available in kit form (see servicing schedule,
Section 9, page 81).
Note
All O rings are Viton
Valve Type 02GGH and 03GGS (Fig 4, page 15)
Ref Description Part Number (Qty)
1 O Ring, Cover 43636L002 (1)
6 O Ring, Top Seal 43709L002 (1)
8 O Ring, Upper Shaft 43727L002 (2)
9 O Ring, Lower Shaft 43727L002 (1)
Coupling pin 43419L030 (1)
Valve Type 03GGH and 04GGS (Fig 4, page 15)
Ref Description Part Number (Qty)
1
O Ring, Cover
43630L002 (1)
6 O Ring, Top Seal 43655L002 (1)
8 O Ring, Upper Shaft 43615L002 (2)
9 O Ring, Lower Shaft 43615L002 (1)
Coupling pin 43409L035 (1)
Valve Type 04GGH, 05GGS and 06GGS (Fig 4, page 15)
Ref Description Part Number (Qty)
1 O Ring, Cover 46980L002 (1)
6 O Ring, Top Seal 43613L002 (1)
8 O Ring, Upper Shaft 43726L002 (1)
9 O Ring, Lower Shaft 43726L002 (1)
Coupling pin 43420L040 (1)
Valve Type 06GGH and 08GGS (Fig 4, page 15)
Ref Description Part Number (Qty)
1 O Ring, Cover 43638L002 (1)
6 O Ring, Top Seal 43607L002 (1)
8 O Ring, Upper Shaft 43607L002 (1)
9 O Ring, Lower Shaft 43600L002 (1)
Coupling pin 43423L045 (1)

18
Valve Body
Rev 4 – MAY 2019 OMMGGE00217
Valve Type 08GGH (Fig 4, page 15)
Ref Description Part Number (Qty)
1 O Ring, Cover 43603L002 (1)
6 O Ring, Top Seal 43607L002 (1)
8 O Ring, Upper Shaft 43611L002 (1)
9 O Ring, Lower Shaft 43611L002 (1)
10 O Ring, Lower Shaft 43600L002 (1)
Coupling pin 43419L030 (1)

19
Electric Actuator
OMMGGE00217 Rev 4 – MAY 2019
Section 4
Electric Actuator
Contents
Para
4.1 Description ............................................................................... 20
4.1.1 Mechanical..................................................................... 20
4.1.2 Electrical ....................................................................... 20
4.1.3 Versions ........................................................................ 21
4.1.4 Optional Positioner.......................................................... 21
4.1.5 Actuator Internal Wiring .................................................. 22
4.2 Identification of EB Actuator Model Number .................................. 25
4.3 Mechanical Installation ............................................................... 26
4.4 Electrical Installation.................................................................. 27
4.4.1 Cable Glands.................................................................. 28
4.4.2 Wire Connection ............................................................. 29
4.4.3 Status LEDs & Alarm States ............................................. 30
4.4.4 Electrical Position Feedback.............................................. 30
4.5 Positioner ................................................................................. 31
4.5.1 Positioner Board ............................................................. 31
4.5.2 Power Module................................................................. 32
4.6 Option Configuration (Positioner option only) ................................ 33
4.7 Calibration (Positioner option only) .............................................. 38
4.8 Operation ................................................................................. 39
4.9 Maintenance ............................................................................. 40
4.9.1 Removal and Installation onto Valve Body ......................... 40
4.9.2 Lubrication..................................................................... 43
4.9.3 Sensor Mounting Bracket replacement............................... 43
4.9.4 Position Limit Switch Replacement .................................... 45
4.9.5 Sensor Replacement ....................................................... 48
4.9.6Position Limit Switch Adjustment – Rotor Not Visible ........... 48
4.9.7 Limit Switch Adjustment – Rotor Visible............................. 51
4.9.8 Sensor Alignment ........................................................... 53
4.9.9 Anti-Condensation Heater Replacement ............................. 54
4.9.10 Capacitor Replacement.................................................... 56
4.9.11 Terminal Board Replacement............................................ 57
4.10 Storage.................................................................................... 58
4.10.1 On-Site Storage.............................................................. 58
4.10.2 Warehouse Storage......................................................... 59
4.11 Available Spares........................................................................ 60

20
Electric Actuator
Rev 4 – MAY 2019 OMMGGE00217
4.1 Description
4.1.1 Mechanical
Fig 5 Actuator General Arrangement
The EB Electric Actuator is a rugged, compact and lightweight quarter-turn
actuator providing enclosure protection to IP67. The actuator is powered by an
electric motor driving a double-worm gear chain. The double-worm drive
construction of the gearbox provides high reliability gearing whilst preventing
fluid forces in the valve from reverse driving the actuator. Manual override is
fitted as standard, enabling valve operation without electrical power. The
manual override is automatically disengaged when electrical power is re-
applied, preventing risk of injury from the handwheel.
4.1.2 Electrical
The actuator contains the following electrical equipment:
•Electric motor with integral bi-metallic cut-outs which disconnect the
power to the motor if the temperature exceeds 150°C and reset when the
motor cools to approx. 97°C.
•End of travel micro switches disconnect power to the motor when the end
of travel is reached.
•Auxiliary micro switches operate just before the end of travel to provide
indication signals.
•Torque limit micro switches disconnect power to the motor if a factory set
torque is exceeded.
•Anti-condensation heater.
•Terminal strips for external connections.
Status LED x3
and Calibration
Access Plug
Terminal Box
Cover
EMC Cable Gland x2