AMOT G Series User manual

Doc No: OMMGGP00185
Revision: 5
Date: MAY 2019
Model G Valve
(Pneumatically Actuated)
Installation, Operation and
Maintenance Manual

3
Contents
OMMGGP00185 Rev 5 – MAY 2019
Introduction ...................................................................................................... 5
1.1 Scope of Manual ............................................................ 5
1.2 Safety........................................................................... 5
1.3 Product Support ............................................................. 6
1.4 Typographical Conventions .............................................. 6
1.5 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 ....................................................................................................... 15
3.1 Description .................................................................. 15
3.2 Installation .................................................................. 15
3.3 Operation .................................................................... 15
3.4 Maintenance ................................................................ 16
Pneumatic Actuator 82046L ...................................................................... 21
4.1 Description .................................................................. 21
4.2 Installation .................................................................. 22
4.3 Operation .................................................................... 30
4.4 Maintenance ................................................................ 31
Pneumatic Positioner 47224X .................................................................. 47
5.1 Description .................................................................. 47
5.2 Installation .................................................................. 49
5.3 Operation .................................................................... 50
5.4 Maintenance ................................................................ 50
Elect/Pneumatic Converter 8064A/C .................................................... 55
6.1 Overview .................................................................... 55
PID Controller 8071D .................................................................................. 57
7.1 Overview .................................................................... 57
Pneumatic Indicator Controller SG80 .................................................... 59
8.1 Overview .................................................................... 59
Temperature Sensor 8060 ......................................................................... 61
9.1 Description .................................................................. 61
9.2 Installation .................................................................. 61
9.3 Maintenance ................................................................ 62
System Integration ....................................................................................... 63
10.1 Installation Guidance Notes ........................................... 63
10.2 System Options ........................................................... 67

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Contents
Rev 5 – MAY 2019 OMMGGP00185
Troubleshooting............................................................................................. 69
11.1 Troubleshooting ........................................................... 69
Servicing Schedule ....................................................................................... 70
12.1 Overview ..................................................................... 70
12.2 Service Intervals .......................................................... 70
12.3 Minor Service (every 2 years) ........................................ 70
12.4 Major Service (every 4 years) ........................................ 71
12.5 AMOT Field Service ....................................................... 73
Technical Data ................................................................................................ 74
13.1 Selection of G-Valve options .......................................... 74
13.2 Technical Specifications ................................................. 83

5
Introduction
OMMGGP00185 Rev 5 – MAY 2019
Section 1
Introduction
Contents
Para Page
1.1 Scope of Manual .......................................................................... 5
1.2 Safety ........................................................................................ 5
1.3 Product Support .......................................................................... 6
1.4 Typographical Conventions ........................................................... 6
1.5 European Union Directives ............................................................ 7
1.5.1 EU Machinery Directive ...................................................... 7
1.5.2 EU Pressure Equipment Directive ........................................ 7
1.1 Scope of Manual
This manual contains the information to install, operate and maintain the
pneumatically operated G Valve system. It is divided into sections as follows:
Section 1 Introduction ........................................... Page 5
Section 2 System overview ..................................... Page 7
Section 3 Valve body ............................................. Page 15
Section 4 Pneumatic actuator ................................. Page 21
Section 5 Pneumatic positioner ............................... Page 47
Section 6 Electro-pneumatic converter ..................... Page 55
Section 7 PID controller ......................................... Page 57
Section 8 Pneumatic indicator controller ................... Page 59
Section 9 Temperature sensor ................................ Page 61
Section 10 System integration .................................. Page 63
Section 11 Troubleshooting ...................................... Page 69
Section 12 Servicing Schedule .................................. Page 70
Section 13 Technical data ........................................ Page 74
1.2 Safety
Some operations in this manual can be hazardous and cause injury to people
or damage to equipment if the procedure is not done exactly as written. Where
there is a hazard, the following text appears immediately before the steps in a
procedure that can cause a hazard:

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Introduction
Rev 5 – MAY 2019 OMMGGP00185
WARNING
A Warning identifies a step in a procedure that can cause injury to
people. The warning identifies the hazard and lists the precautions
that must be taken before the next step of the procedure is done.
CAUTION
A Caution identifies a step in a procedure that can cause damage to
equipment. The caution identifies the hazard and lists the precautions
that must be taken before the next step of the procedure is done.
Note
A Note contains more information that may be useful to the Operator and
can appear before or after a procedure step.
When installing, commissioning, operating or carrying out maintenance on the
unit, personnel must use safe working practices and observe all relevant local
health and safety requirements and regulations.
1.3 Product Support
All necessary settings are described in this 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 rapid spares and service support, call the telephone number listed on the
back cover of this manual.
1.4 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.
 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 This footnote applies to the part of the text or figure, marked with a superscript number 1.

7
Introduction
OMMGGP00185 Rev 5 – MAY 2019
1.5 European Union Directives
1.5.1 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.
1.5.2 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.
Table 1 Pressure Equipment Directive Table
Valve
Material
Valve
Type
Flange
Standard
Flange
Class
(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
Users who are uncertain as to the applicability of the Directive should contact
AMOT before installation, particularly if using more hazardous (Group 1) fluids.

8
Introduction
Rev 5 – MAY 2019 OMMGGP00185

9
System Overview
OMMGGP00185 Rev 5 – 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 supporting 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).
 Mount in any position.
 Optional manual override.
 Temperature up to 100 C (212 F).
 Local valve position indication.

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System Overview
Rev 5 – MAY 2019 OMMGGP00185
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
OMMGGP00185 Rev 5 – MAY 2019
2.2 Identification of Model Number
Example code 06 GG S D B S 32 P 1 1 -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
P Pneumatic
Actuator Air Connections and Manual Override
Air Connection Manual Override
1 G1/4 (1/4” BSP(P)) Not Fitted
2 1/4” NPT
3 G1/4 (1/4” BSP(P)) Fitted
4 1/4” NPT
Actuator Control Input Signal
Input Signal
100 3-15psi (On increasing temperature)
200 15-3psi (On increasing temperature)
Customer Special Options
Options
-AA Standard product
-*** Customer special code assigned

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System Overview
Rev 5 – MAY 2019 OMMGGP00185
2.3 Modes of Operation
Fig 1 Modes of Operation (viewed from above – actuator end)
2.4 System Components
The components of the G Valve control system are listed below. Refer to
Section 10 (System Integration) for the interconnection details.
Component Further
information
Valve body
Three way temperature control valve in
various DN sizes
Section 3, page 15
Pneumatic Actuator
Single action pneumatic operation in
two sizes to match valve body sizes.
Section 4, page 21
47224X Positioner
Produces pneumatic actuator drive
pressure from pneumatic control signal.
Section 5, page 47

13
System Overview
OMMGGP00185 Rev 5 – MAY 2019
Component Further
information
8064A Electro pneumatic converter
Produces pneumatic output from 4 – 20
mA electrical control signal.
Section 6, page 55
8064A manual
8064C Electro pneumatic converter
Produces pneumatic output from 4 – 20
mA electrical control signal.
Section 6, page 55
Installation,
operation and
maintenance
manual
OMM806400085
8071D PID controller Section 7, page 57
Installation,
operation and
maintenance
manual
OMM807100043
SG80 Pneumatic indicator controller
Outputs a pneumatic control signal
proportional to a pressure or
temperature input.
Section 8, page 59
Installation &
maintenance
instructions
46307L004
8060 Temperature sensor Section 9, page 61

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System Overview
Rev 5 – MAY 2019 OMMGGP00185

15
Valve Body
OMMGGP00185 Rev 5 – MAY 2019
Section 3
Valve Body
Contents
Para Page
3.1 Description ............................................................................... 15
3.2 Installation ............................................................................... 15
3.3 Operation ................................................................................. 15
3.4 Maintenance ............................................................................. 16
3.4.1 Dismantle and Assemble .................................................. 16
3.4.2 Recommended Spares ..................................................... 19
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 10 (System Integration) for valve installation details.
3.3 Operation
CAUTION
Damage can be caused to the valve assembly if an extension bar is
used on the handwheel. Do not use any mechanical aid to turn the
handwheel.
Under normal conditions, the valve is operated pneumatically by the actuator.
Manual operation is possible at any time by using the geared manual override
(if fitted).
If the valve fails to operate correctly, refer to the troubleshooting guide in
Section 11.

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Valve Body
Rev 5 – MAY 2019 OMMGGP00185
3.4 Maintenance
3.4.1 Dismantle and Assemble
Fig 2 General Arrangement
Dismantle Valve (refer to Fig 3, page 17)
It is possible to dismantle the valve without the need to remove 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.

17
Valve Body
OMMGGP00185 Rev 5 – MAY 2019
Fig 3 Section View (04GGH illustrated)
1. Switch off and isolate power to the actuator.
2. Using the handwheel, turn the valve to the low temperature position.
3. Note 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.
4. Remove the actuator from the valve body in accordance with Sect 4.4.1
(page 31).
5. Knock out the coupling pin and remove the coupling.
6. Remove screws and washers (2), remove retaining plate (5) and discard
O Ring (6).
7. Mark adjacent points on the valve body and cover to aid reassembly.
8. Remove the bolts (7) securing the valve cover (3).
9. Taking care that the rotor is not lifted with the cover, carefully lift off the
cover.
10. Remove and discard the cover O ring (1)
11. Remove the rotor assembly (4) from the valve body.
7
2
6
4
5
3
1
8
9

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Valve Body
Rev 5 – MAY 2019 OMMGGP00185
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 3, page 17)
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 Section 4.4.1

19
Valve Body
OMMGGP00185 Rev 5 – 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 12).
Note
All O rings are Viton
Valve Type 02GGH and 03GGS (Fig 3, page 17)
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 3, page 17)
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 3, page 17)
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 3, page 17)
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)

20
Valve Body
Rev 5 – MAY 2019 OMMGGP00185
Valve Type 08GGH (Fig 3, page 17)
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, Upper Shaft 43600L002 (1)
Coupling pin 43419L030 (1)