AMOT G Series User manual

Doc No: OMMG00012
Revision: 12 – NOV 2019
G-Valve (electric actuator)
Operation and Maintenance
Manual

3
Contents
OMMG00012 Rev 12 – NOV 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 Conversion between Modes of Operation .............................. 12
2.5 System Components .......................................................... 13
Valve Body .......................................................................................................15
3.1 Description ....................................................................... 15
3.2 Installation ....................................................................... 15
3.3 Operation ......................................................................... 16
3.4 Maintenance ..................................................................... 16
Electric Actuator ............................................................................................23
4.1 Description ....................................................................... 23
4.2 Identification of Model Number............................................ 29
4.3 Mechanical Installation ....................................................... 29
4.4 Actuator Re-orientation ...................................................... 30
4.5 Electrical Installation.......................................................... 32
4.6 Positioner Configuration and Calibration ............................... 34
4.7 Operation ......................................................................... 35
4.8 Maintenance ..................................................................... 35
4.9 Storage ............................................................................ 50
4.10 Recommended Spares........................................................ 51
PID Controller.................................................................................................53
5.1 Controller Systems ............................................................ 53
Temperature Sensor.....................................................................................55
6.1 Description ....................................................................... 55
6.2 Installation ....................................................................... 55
6.3 Maintenance ..................................................................... 56
System Integration.......................................................................................57
7.1 Installation Guidance Notes ................................................ 57
7.2 System Wiring Diagrams .................................................... 61
Troubleshooting.............................................................................................69
8.1 Checklist .......................................................................... 69
8.2 Positioner Replacement ...................................................... 72

4
Contents
Rev 12 – NOV 2019 OMMG00012
Technical Data................................................................................................ 73
9.1 Selection of G-Valve options................................................73
9.2 Technical Specifications ......................................................78

5
Introduction
OMMG00012 Rev 12 – NOV 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 EU Low Voltage Directive ................................................... 7
1.6.3 EU 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
&
OMM47962X00013
Valve Body Section 3
PID Controller
Section 5
&
OMM807100043
Temperature Sensor Section 6

6
Introduction
Rev 12 – NOV 2019 OMMG00012
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 eg. abc 1.
•A note in smaller font at the bottom of the affected page beginning with
the corresponding number in the text or figure eg:
1. This footnote applies to the part of the text or figure, marked with a superscript number 1

7
Introduction
OMMG00012 Rev 12 – NOV 2019
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 EU Low Voltage Directive
All versions 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 EU EMC Directive
All versions 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 12 – NOV 2019 OMMG00012
Table 1 Pressure Equipment Directive Table
Valve
Material
Valve
Type
Flange
Class
Maximum
Working
Pressure
(BAR)
(PED)
suitable for
liquids to
group(s):
Cast Iron, Ductile Iron and Bronze
2GEF
3GEF
4GEF
6GEF
PN6 6
1 & 2
(SEP)
5K 7
PN10
10
PN16
10K
125lb
150lb
8GEF
10GEF
12GEF
14GEF
16GEF
PN6 6
2
(SEP)
5K 7
PN10
10
PN16
10K
125lb
150lb
Steel and Stainless Steel
2GEF
3GEF
4GEF
PN6 6
1 & 2
(SEP)
5K 7
PN10 10
10K 14
PN16 15
150lb
6GEF
8GEF
10GEF
12GEF
14GEF
16GEF
PN6 6
2
(SEP)
5K 7
PN10 10
10K 14
PN16 15
150lb
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
OMMG00012 Rev 12 – NOV 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 Conversion between Modes of Operation ...................................... 12
2.5 System Components .................................................................. 13
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 and sea 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.
•Manual override.
•Temperature up to 100°C (212°F).
•Local valve position indication.

10
System Overview
Rev 12 – NOV 2019 OMMG00012
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.
Sea Water Cooling
On sea water cooling applications,
bronze G Valves are recommended.
These can be used for mixing and
diverting applications.

11
System Overview
OMMG00012 Rev 12 – NOV 2019
2.2 Identification of Model Number
4
GEF
C
B
A
0
32
-AA
Size
2 inch (DN50)
2
3 inch (DN80)
3
4 inch (DN100)
4
6 inch (DN150)
6
8 inch (DN200)
8
10 inch (DN250)
10
12 inch (DN300)
12
14 inch (DN350)
14
16 inch (DN400)
16
Type
Electric actuation
GEF
Materials
Bronze
B
Cast Iron
C
Ductile Iron
D
Steel
S
Stainless Steel
R
Connections
Flanged PN6
A
Flanged PN10
B
Flanged PN16
C
Flanged ASME 125lb
F
Flanged ASME 150lb
J
JIS 10K
L
JIS 5K
M
Basic Actuator
220/240 V ac
A
110/120 V ac
B
Actuator Options
Standard (1 kΩpotentiometer)
0
Standard (5 kΩpotentiometer)
1
Standard with positioner port.
2
Direct Mode
(Clockwise rotation with increasing demand current)
4
– 20 mA electronic positioner with position re-transmit
A
4 – 20 mA electronic positioner with input re-transmit
B
4 – 20 mA electronic positioner with position error output (4 mA ref)
C
4 – 20 mA electronic positioner with position error output (12 mA ref)
D
Reverse Mode
(Anti-clockwise rotation with increasing demand current)
4
– 20 mA electronic positioner with position re-transmit
E
4 – 20 mA electronic positioner with input re-transmit
F
4 – 20 mA electronic positioner with position error output (4 mA ref)
G
4 – 20 mA electronic positioner with position error output (12 mA ref)
H
Electronic positioner for re-transmission only
J
Electronic positioner for re-transmission only (reverse acting)
K
Modes of Operation (refer to para 2.3)
Movement with rising temperature
Rotor type
Anti-clockwise Port 3 to Port 2
Standard 90°
32
Anti-clockwise Port 2 to Port 1
Standard 90°
21
Clockwise Port 1 to Port 2
Standard 90°
12
Clockwise Port 2 to Port 3
Standard 90°
23
Anti-clockwise Port 1 to Port 3
180°(2”, 3”, 4”, 6”, 8” & 10” only)
13
Clockwise Port 3 to Port 1
180°(2”, 3”, 4”, 6”, 8” & 10” only)
31
Special Features
(consult Manufacturer)

12
System Overview
Rev 12 – NOV 2019 OMMG00012
2.3 Modes of Operation
Fig 1 Modes of Operation
2.4 Conversion between Modes of Operation
The mode of operation is defined in the model code section “Rotor Type” on
the previous page. It is possible to change the mode of operation in some
circumstances, as follows:
Table 2 Mode Conversion – See notes
From
To
Mode
12
Mode
13
Mode
21
Mode
23
Mode
31
Mode
32
Mode
12 5 3 2 1 4
Mode
13 5 1 5 3 1
Mode
21 3 1 4 5 2
Mode
23 2 5 4 1 3
Mode
31 1 3 5 1 5
Mode
32 4 1 2 3 5

13
System Overview
OMMG00012 Rev 12 – NOV 2019
1 = Requires a different rotor.See section 3.4, page 16.
2 = Rotor needs to be turned with respect to the actuator.See section 3.4,
page 16.
3 = Direction of operation needs to be changed with a Configurator if a
Positioner is fitted, or connections to terminals 11 and 12 swapped for
switched live versions.See section 4.6, page 34.
4 = Both 2 and 3 above apply.
5 = Both 1 and 3 above apply.
2.5 System Components
The system comprises 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

14
System Overview
Rev 12 – NOV 2019 OMMG00012

15
Valve Body
OMMG00012 Rev 12 – NOV 2019
Section 3
Valve Body
Contents
Para Page
3.1 Description ............................................................................... 15
3.2 Installation ............................................................................... 15
3.3 Operation ................................................................................. 16
3.4 Maintenance ............................................................................. 16
3.4.1 Dismantle and Assemble 2 and 3 inch Valves ..................... 16
3.4.2 Dismantle and Assemble 4, 6 and 8 inch Valves.................. 17
3.4.3 Dismantle and Assemble 10 and 12 inch Valves.................. 19
3.4.4 Recommended Spares..................................................... 21
3.1 Description
The G Valve is a compact and rugged 3-way control valve designed for
temperature control using ‘diverting’ or ‘mixing’ techniques.
The valve can be constructed from a variety of materials making it suitable for
sea and fresh water, most lubricating oils and other liquids (see Section 2.2
“Identification of model code”).
3.2 Installation
WARNING
The valve body is heavy, refer to Section 9 (Technical Data) Sect 9.1.3
– page 76. The appropriate manual handling precautions must be
applied to avoid personnel injury.
When installing the valve, the following factors must be considered:
•Position the valve as close as possible to the point where it can best effect
control.
•Install a minimum of 6 pipe diameters in length from any intersection to
ensure a good mix of fluids. Too great a distance may induce unnecessary
time lags into the system affecting accuracy and stability of temperature
control.
•Future maintenance is simplified if the valve is installed in the upright
position in an accessible location.
•Do not install the valve in a position that inhibits the operation of the
manual override handle (if fitted).
•If possible, avoid installation in areas with a risk of water spray or
extreme dirt.

16
Valve Body
Rev 12 – NOV 2019 OMMG00012
3.3 Operation
CAUTION
Damage can be caused to the valve assembly if a cheater or extension
bar is used on the handwheel. Do not use any mechanical aid to turn
the handwheel.
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 handwheel.
On failure of the valve to operate correctly, refer to the troubleshooting guide
in 0.
3.4 Maintenance
3.4.1 Dismantle and Assemble 2 and 3 inch Valves
Dismantle Valve (refer to Fig 3, page 16)
It is possible to dismantle the valve without the need to remove it from the
pipework as follows:
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 3 2 and 3 inch Valves

17
Valve Body
OMMG00012 Rev 12 – NOV 2019
1Switch off and isolate power to the actuator.
2Using the handwheel, turn the valve to the low temperature position.
3Mark adjacent points on the actuator and coupling and also on the
coupling and cover (5) to aid reassembly.
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.
4Remove the actuator from the valve body in accordance with Sect 4.8.1
(page 36).
5Mark adjacent points on the valve body and cover to aid reassembly.
6Remove the pillars (4) and washers securing the valve cover (5).
Note
There are two jacking holes in the valve cover to aid removal.
7Taking care that the rotor is not lifted with the cover, carefully lift off the
cover.
8Remove and discard the cover O ring (6).
9Remove the rotor assembly from the valve body.
10 Remove and discard the upper and lower shaft O rings (2).
11 Inspect the valve internals for wear, damage and cleanliness. Clean and
replace if necessary.
Note
It is recommended that the bearings (1 and 8) are replaced at this stage.
Reassemble Valve (refer to Fig 3, page 16)
1Fit two, new shaft O rings (2) to the shaft.
2Carefully insert the rotor assembly into the valve body with the rotor in
the low temperature position.
3Fit a new cover O ring (6) to the cover (5) and position the cover on the
valve, aligning the marks made during disassembly.
4Fit the pillars (4) and washers and tighten to 54 Nm (2 “ valve) or 80 Nm
(3” valve).
5Install the actuator onto the valve body in accordance with para 4.8.1
(page 36).
3.4.2 Dismantle and Assemble 4, 6 and 8 inch Valves
Dismantle Valve (refer to Fig 4, page 18)
If the valve is installed in the upright position, it is possible to dismantle the
valve whilst still installed in the pipework as follows:
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.
1Switch off and isolate power to the actuator.

18
Valve Body
Rev 12 – NOV 2019 OMMG00012
2Using the handwheel, turn the valve to the low temperature position.
3Mark adjacent points on the actuator and coupling and also on the
coupling, retaining plate (5) and cover (7) to aid reassembly.
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.
4Remove the actuator from the valve body in accordance with Sect 4.8.1
(page 36).
5Remove the retaining plate (5) and discard the O ring (3).
6Mark adjacent points on the valve body and cover to aid reassembly.
7Remove the bolts (1) and washers securing the valve cover (7).
Note
There are two jacking holes in the valve cover to aid removal.
8Taking care that the rotor is not lifted with the cover, carefully lift off the
cover.
9Remove and discard the cover O ring (8).
10 Remove the rotor assembly from the valve body.
Fig 4 4, 6 and 8 inch Valve

19
Valve Body
OMMG00012 Rev 12 – NOV 2019
11 Remove and discard the upper and lower shaft O rings (9 & 11).
12 Inspect the valve internals for wear, damage and cleanliness. Clean and
replace if necessary.
Note
It is recommended that the upper and lower composite bearings (6 & 10)
are replaced at this stage.
Reassemble Valve (refer to Fig 4, page 18)
1Fit new upper and lower shaft O rings (9 & 11) to the rotor shaft.
2Carefully insert the rotor assembly into the valve body with the rotor in
the low temperature position.
3Fit a new cover O ring (8) to the cover and position the cover on the
valve, aligning the marks made during disassembly.
4Fit the cover bolts (1) and washers and tighten to a torque of 244 Nm (4”
& 6” valves) or 476 Nm (8” valve).
5Fit the retaining plate (5) and new O ring (3).
6Install the actuator onto the valve body in accordance with Sect 4.8.1
(page 36).
3.4.3 Dismantle and Assemble 10 and 12 inch Valves
Dismantle Valve (refer to Fig 5, page 20)
If the valve is installed in the upright position, it is possible to dismantle the
valve whilst still installed in the pipework as follows:
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.
1Switch off and isolate power to the actuator.
2Using the handwheel, turn the valve to the low temperature position.
3Mark adjacent points on the actuator and coupling and also on the
coupling and cover (6) to aid reassembly.
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.
4Remove the actuator from the valve body in accordance with Sect 4.8.1
(page 36).
5Remove the bolts (2) and retaining plate (5).
6Remove and discard the O ring (3).
7Mark adjacent points on the valve body and cover to aid reassembly.
8Remove the bolts (1) and washers securing the valve cover.
Note
There are two jacking holes in the valve cover to aid removal.

20
Valve Body
Rev 12 – NOV 2019 OMMG00012
Fig 5 10 and 12 inch Valves
9Taking care that the rotor is not lifted with the cover, carefully lift off the
cover (6).
10 Remove and discard the cover O ring (7).
11 Remove the rotor assembly from the valve body.
12 Remove and discard the upper and lower shaft O rings (10).
13 Inspect the valve internals for wear, damage and cleanliness. Clean and
replace if necessary.
Note
It is recommended that the upper and lower composite bearings (8 & 9)
are replaced at this stage. The lower bearing is more accessible if the end
cover is removed. When refitting the end cover, a new O ring (11) must
be fitted.
Reassemble Valve (refer to Fig 5, page 20)
1Fit new upper and lower shaft O rings (10) to the shaft.