Circor IMO GA Series Manual

Installation and Service Instruction
GA
Valves
This instruction is valid for all GA-valves
Contents Page
Valve identication/Installation 2
Start-up/Trouble shooting 4
Sectional view 5
List of components/Ordering code 6
Useful tools/GAD springs 7
GAR/GAS dismantling/reassembly 8
GAD dismantling/reassembly 10
Before commencing any work, read this instruction carefully! Failure to comply
with these instructions may cause damage and personal injury!
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A

2www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
These instructions are valid for all valves as specied in the Valve identication chart below.
Installation
BEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!
Design limitations and technical data for each valve are found in the Product description.
Installation of IMO AB valves does not require special skills. However, these instructions presume that the
work is carried out by experienced tters.
Failure to comply with these instructions
may cause damage and personal injury!
Valve identication
Valve Size Generation Valve Valid for Comments
name spring option
pressure
GAR 012 Threaded
034 pipe
100 connections
112
GAS 015 SAE
020 anged
025 pipe
040 connections
GAD 065 DIN
anged
pipe
connections
Identification of safety instructions
Non compliance of safety instructions
identified by the following symbol -
could affect safety for persons.
Safety instructions where
electrical safety is involved,
are identified by:
Safety instructions which shall be considered for
reasons of safe operation of the valve unit and/or
protection of the valve unit
itself are marked by the sign: ATTENTION
01
T008
T040
T075
T100
A078
A308
A313
All work carried out on the valve has to be
performed in such a manner that risks for
personal injury are observed!
Transport and storage
Always protect the valve against ingress of water and other impurities. Store the valve in a clean, dry and
warm environment. The valve is delivered with the internals oiled and with protective covers over the pipe
connections. These covers should remain in place for as long as possible during the mounting and installa-
tion procedure.

3www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
Fig. 1
Mounting
The valve can be mounted in any position, horizon-
tally or vertically. It should be mounted as close as
possible to the unit it shall protect or control. It is
preferred that the outlet connection is led back to the
tank. See g. 1.
In any case the return connection should not be
connected to the pump suction line as this might
result in overheating and too high volume of free gas
entering the pump. If long pipes are connected to
the valve the friction losses in the pipes might inter-
fere with the valve performance in which case bigger
pipe dimensions should be considered.
When handling liquids that may harm skin
use gloves and/or protective clothing.
When handling liquids which may involve
re hazards appropriate precautions to
avoid danger are to be taken.
Pressure testing and ushing
The system must be ushed and pressure tested
before connecting the valve. If corrosive liquid, such
as water is used for the test, the system must be
thoroughly drained, dried and protected against cor-
rosion after having been ushed.
Oil leakage may make the oor slippery
and cause personal injury.
Deaeration
In installations with positive head on the outlet port,
the valve must be deaerated at start, or whenever
it can be assumed that the valve has been emptied
(see g 2).
Pipe connections
The pipe work should be installed and supported so
as not to exert any signicant load and transfer it on
the valve housing.
The pipe work should be tight in order to avoid leak-
age and inltration of foreign particles and/or air.
Fig. 2
If operating temperature exceeds 60°C
(149°F), appropriate measures to avoid
burn injury shall be provided.
Use hearing protections whenever high
noise can be expected from pump, motor
and/or environment.

4www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
Start-up
Before starting
Check that all valves necessary for the operation
are fully open and set the pressure to minimum by
turning the set screw CCW.
Starting
Start the pump (or system).
Deaerate the valve and slowly increase the pressure
to the desired value by using the set screw.
In horizontal installations with the outlet downwards
and in vertical installations this is done by opening
the deaeration plug on the spring housing a few
turns and when liquid is coming out, closing the plug.
In horizontal installations with the outlet upwards the
deaeration will be done automatically.
If the valve does not work properly see ”Trouble
shooting”.
- The pressure relief valve is set
too low.
- Counter pressure in the pump
discharge line is too low due to a
major leakage.
- The valve piston of the pres-
sure relief valve is stuck in open
position.
- The valve is too small.
- Improper valve spring.
Pressure too low
What to doProblem Cause
Pressure too high
Pressure is uctuating
”Hunting”
Pressure accumulation too big
Pressure drops below set value
when overow increases
- The pressure relief valve is set
too high.
- The valve is too big.
- Trapped air in the valve
- Too high viscosity.
- Liquid too cold.
- Valve internals damaged due to
wear or corrosion.
- The throttle screw is not tuned to
the system.
- The throttle screw is not tuned to
the system.
Re-adjust the pressure relief
valve.
Check the components in the
discharge line inclusive the
recipients.
Check the valve. See under
”dismantling”.
Contact your IMO AB representative.
Contact your IMO AB representative.
Re-adjust the pressure relief
valve.
Contact your IMO AB representa-
tive.
See ”Starting”
The compensation in the valve is
too high for the conditions. The
Compensator piston must be
adjusted. Contact your IMO AB
representative.
Run the system till operating tem-
perature is reached. If problem
still remains, see above.
Open the valve. See under ”Dis-
mantling”.
Adjust the throttle screw 647 CW.
Adjust the throttle screw 647
CCW.
Fig. 3
Trouble shooting
Deaeration
plug
537
Set
screw
608

5www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
Sectional view
GAD
GAR/GAS
Fig. 4
Fig. 5
646
648
647
608
609
605
626
658
601
497A
497B
4800
614
618
625
617
451
615
612B
602
612A
212
497
497C
537
537A
612C
213
623
626A
626
609
6010
611
615
451
602
612
617
618
625
614
480
646
647
609A
605
537A
537
flow out
flow in
608
537
537A
601A
T040-T100
T008
601A

6www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
List of components
Item Denomination Qty GAD GAR GAS Note
212 Retaining ring 1 x
213 Retaining ring 1 x
423 O-ring 2 1
427 Split ange 4 1
427A Pipe weld 2 1
428 Screw 8 1
428A Washer 8 1
451 Screw 4/8 x x x
4800 Valve housing 1 x x x
497 Valve seat 1 x
497A Nut 1 x
497B Tension pin 1 x
497C Pin 1 x
537 Deaeration plug 1 x x x
537A Sealing washer 1 x x x
601 Valve cover 1 x x x
601A Threading adapter 1 x x 2
602 O-ring 1 x x x
605 O-ring 1 x x x
608 Set screw 1 x x x
609 Stop washer 1 x x
609 Nut 1 x
609A Screw 2 x x Remarks: 1) Accessories to one GAS valve
2) Included in valves GAR 100 and 112, GAS 025 and 040
3) Valid for GAD T040, T075 and T100 *
4) Valid for GAD T008, all GAR and GAS versions
5) Valid for GAD T008
Ordering code
Item Denomination Part. No Part. No Part. No Part. No Part. No
GAR 012 GAR 034 GAR 100 GAR 112
GAS 015 GAS 020 GAS 025 GAS 040 GAD 065
Valve GAR T008 135244 134049 134346 134973 --
” GAR T040 135236 134031 134338 134965 --
” GAR T075 135228 134023 134320 134957 --
” GAR T100 149112 141192 145201 153924 --
” GAS T008 136085 136119 136143 136176 --
” GAS T040 136077 136101 136135 136168 --
” GAS T075 136069 136093 136127 136150 --
” GAS T100 189495 145409 143867 144394 --
” GAD T008 -- -- -- -- 132928
” GAD T040 -- -- -- -- 132902
” GAD T075 -- -- -- -- 132894
” GAD T100 -- -- -- -- 132910
423 O-ring * 152447 016717 016733 016782 --
602 O-ring * 016741 016766 016790 016857 016956
605 O-ring * 016675 016675 016675 144519 152447
614 Poppet 052506 052654 052829 053017 053199
615 Valve spring T008 022426 022533 022590 022665 095240
” T040 022400 022517 022574 022640 022699
” T075 022392 022491 022558 022624 022681
” T100 022418 022525 022582 022657 022681
617 Compensator piston 052514 052662 052837 053025 053207
618 Spring T040/075/100 022442 022509 022566 022632 022715
” T008 022459 022541 022608 022673 022723
625 Compensator sleeve 052522 052670 052845 053033 053215
627 Sealing washer -- -- -- -- 017889
646 O-ring * 146076 146076 088062 144519 016725
* Not valid for A078
Item Denomination Qty GAD GAR GAS Note
611 Set screw washer 1 x x
612 Spring washer 1 x x
612A Spring washer 1 x
612B Sleeve 1 x
612C Spring washer 1 x
614 Poppet 1 x x x
615 Valve spring 1 x x x 4
615 Valve spring 1 x 3
617 Compensator
piston 1 x x x
618 Auxiliary spring 1 x x x
623 Stop washer 1 x 5
625 Compensator
sleeve 1 x x x
626 Cap 1 x x x
626A Screw 2 x x
627 Sealing washer 1 x
646 O-ring 1 x x x
647 Throttle screw 1 x x x
648 Tension pin 1 x
658 Distance sleeve 1 x
* See g. 7 on page 7 for amount of washers included
** See g. 7 page 7
**
**
**
**

7www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
L
D
Allen
keys
Screw-
drivers
Necessary for dismantling/reassembly
Useful tools
Fig. 6
213
612C
623
615
213
612C
615
213
612C
615
213
612C
615
T008 T040 T075 T100
1 Valve spring 26 Washers 25 Washers 32 Washers
GAD spring 615 – Assembly drawings
Fig. 7
O-rings
Range: 2-8 bar Range: 6-40 bar Range: 15-75 bar Range: 30-100 bar
Washer positions
Washer positions
A pair of
pliers
All O-rings found to be hard or damaged
shall be replaced.

8www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
Dismantling, replacement of components and
reassembly, GAR/GAS
A. B.
D.
• Remove the valve from the system. Use ap-
propriate vessels to collect oil spillage when
removing and opening the valve.
C.
Fig. 10
• Loosen screws 451. Remove valve cover 601
and collect the washers 611 and 612 and the
valve spring 615.
611
615
612
601
451
Fig. 9
617
618
625
614
• Carefully pull out the compensator piston 617,
auxiliary spring 618, compensator sleeve
625 and poppet 614.
626A
626
• Loosen the cap screws 626A and remove the
cap 626.
• Turn the set screw 608 CCW to ease the
spring tension.
Fig. 11
Fig. 12

9www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
E. F.
• Replace the O-ring 602.
• Grease the new O-ring before mounting it.
Fig. 14
G. H.
Fig. 16Fig. 15
• Loosen and remove the throttle screw 647
and replace the O-ring 646 if hardened or
damaged. Fit the throttle screw back into
place.
• Grease the new o-ring before mounting it.
• Unscrew the screws 609A and remove the
nut 609.
• Unscrew the set screw 608 and replace the
O-ring 605. Fit the set screw 608 back
into place again.
• Grease the new O-ring before mounting it.
I.
• Reassemble in reversed order. Put the valve back into the system.
• Readjust the pressure and start-up according to the instructions under ”Start-up”.
Fig. 17
602
646
647
609
A
609
605
608
• Replace the springs if necessary.
• Check the outer surface on the compensa-
tor piston 617 and the inner surface on the
compensator sleeve 625. If you nd wear or
corrosion, replace these parts.
• Check the poppet 614. Replace it if damaged.
Fig. 13

10 www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
Dismantling, replacement of components and
reassembly, GAD
626
609
605
608
601
451
Fig. 18
Fig. 19 Fig. 20
Fig. 21
• Remove the valve from the system. Use appropriate vessels to collect oil spillage when removing
and opening the valve.
• Remove the cap
626 and the nut
609 and unscrew
the set screw 608 a
few turns until you
see the O-ring 605.
Replace the O-ring
if necessary. • Loosen and remove the screws 451. Re-
move the valve cover 601 and collect the
valve assembly.
A.
B. C.
D.
213 623
(for
T008)
615
(for T008)
612C
213
612C
615
(T040)
(T075)
(T100)
Fig. 22
E.
If you need another pressure range:
• Remove the retaining ring 213 with a pair
of pliers.
• Remove the spring washer 612C and the
stop washer 623 (for T008).
• Remove the spring 615.
• Mount the washers
according to g. 7 at
page 7 or the T008
spring.
• Mount (the washer 623
if you mount the T008)
the spring washer
612C and the retaining
ring 213.
Spring size change, D+E

11www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
617
212
618
617
614
625
Fig. 23
• Carefully remove the retaining ring 212 with
a pair of pliers while keeping the compen-
sator piston 617 on place with the other
hand *.
• Carefully pull out the compensator piston
617, auxiliary spring 618, compensator
sleeve 625 and poppet 614.
602
• Replace the spring if necessary. Check the
outer surface on the compensator sleeve.
If you nd wear or corrosion, replace these
parts. Check the poppet 614, especially the
groove for the retaining ring 212. Replace it
if damaged.
Fig. 24
Fig. 25
Fig. 26
• Replace the O-ring 602 if necessary. Lubri-
cate the new O-ring before mounting it.
646
647
• Note the position of the throttle screw 647.
Loosen and remove it and replace the O-
ring 646 if hardened or damaged. Lubricate
the new O-ring before mounting it. Fit the
throttle screw back into place.
Fig. 27
• Reassemble in reverse order. Lubricate
parts 614, 625 and 617 before reassembly.
• Put back the valve into the system. Read-
just the pressure and proceed according to
instructions under ”Start-up”.
F. G.
H. I.
J.
K.
Fig. 28
* Use a press as a help for T040, T075, T100

12 www.imo.se
GA 0601.03 en-GB, ID-No.: 901930331, 161-490/A
Adress:
IMO AB
PO Box 42090, 126 14 Stockholm
Sweden