AMOT 02GGH Installation, Operation And Maintenance Manual Download

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Summary of Contents for 02GGH

Page 1: ...Doc No OMMGGP00185 Revision 5 Date MAY 2019 Model G Valve Pneumatically Actuated Installation Operation and Maintenance Manual...

Page 2: ......

Page 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 Installati...

Page 4: ...bleshooting 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...

Page 5: ...w 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...

Page 6: ...e 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...

Page 7: ...ve 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 th...

Page 8: ...8 Introduction Rev 5 MAY 2019 OMMGGP00185...

Page 9: ...rature 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 f...

Page 10: ...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...

Page 11: ...mments 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...

Page 12: ...w 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 Ac...

Page 13: ...matic 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 maint...

Page 14: ...14 System Overview Rev 5 MAY 2019 OMMGGP00185...

Page 15: ...verting 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...

Page 16: ...ssible 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...

Page 17: ...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 Rem...

Page 18: ...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 Carefull...

Page 19: ...030 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...

Page 20: ...lve 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...

Page 21: ...2 Disassembly and Reassembly of Actuator 33 4 4 3 Actuation reversal 44 4 4 4 Service Kits 45 4 1 Description The 82046L is a single action spring return pneumatic actuator Air pressure is fed into th...

Page 22: ...Check the model code description Sect 2 2 page 11 to ensure that the Valve Actuator and Positioner are configured correctly for the application Note The following figures show the relationships of Va...

Page 23: ...23 Pneumatic Actuator 82046L OMMGGP00185 Rev 5 MAY 2019 Fig 5 Mode 32...

Page 24: ...24 Pneumatic Actuator 82046L Rev 5 MAY 2019 OMMGGP00185 Fig 6 Mode 23...

Page 25: ...25 Pneumatic Actuator 82046L OMMGGP00185 Rev 5 MAY 2019 Fig 7 Mode 12...

Page 26: ...26 Pneumatic Actuator 82046L Rev 5 MAY 2019 OMMGGP00185 Fig 8 Mode 21...

Page 27: ...27 Pneumatic Actuator 82046L OMMGGP00185 Rev 5 MAY 2019 Fig 9 Mode 13...

Page 28: ...28 Pneumatic Actuator 82046L Rev 5 MAY 2019 OMMGGP00185 Fig 10 Mode 31...

Page 29: ...te It is attached to the underside of the actuator with bolts The mounting plate complete with actuator is then secured with bolts to the valve body WARNING The actuator is heavy The appropriate manua...

Page 30: ...d causing rapid movement of the valve The valve must indicate 0 Direct acting or 90 Reverse acting before operation of the clutch lever to prevent possible injury and damage to the gearbox Ensure the...

Page 31: ...size and torque settings Manual Override Valve Type Mounting Plate to Actuator Mounting Plate to Valve Body Screw Size Torque Setting Screw Size Torque Setting No optional manual override 02GGH M8 x...

Page 32: ...n removing the actuator from valve types 02GGH 03GGS 03GGH 04GGS 04GGH and 06GGS the mounting plate will remain in position on the valve At this stage the mounting plate on these valve types can also...

Page 33: ...or Note check actuator type before disassembling If the actuator has the characteristics shown in Fig 12 continue with the steps in this manual Fig 12 If the actuator has the characteristics shown in...

Page 34: ...out length of the end cap screws Apply a strong sudden rotational and downward force to loosen all the end cap screws 10 for maximum 1 4 turn Uniformly loosen the screws 10 of the end caps 2 1 4 1 2...

Page 35: ...Cartridge Removal Remove the spring cartridges 5 Fig 15 Spring Cartridge Removal 4 Limit stop Removal Remove the limit stop screws 17 limit stop nuts 18 limit stop washers 19 and limit stop O rings 1...

Page 36: ...Piston Removal Use a wrench and turn the pinion counter clockwise 180 until the pistons 3 comes out of the body Remove the piston bearings 7 piston rack bearing strips 6 and piston O ring seals 13 Di...

Page 37: ...9 Remove the pinion 4 by pushing it downwards Remove the pinion O ring seals 12 and the pinion bearings 8 Discard all of these parts Fig 18 Pinion Removal 7 Cleaning the body In case of maintenance u...

Page 38: ...Part Section of part Amount of grease O rings A Completely Light film Housing Parts B Piston bore Light film C Top pinion bore Light film D Bottom pinion bore Light film Piston Parts E O ring bearing...

Page 39: ...inion bearings 8 and the O ring seals 12 on the pinion 4 Insert the pinion 4 on the housing Install the thrust washer 9 and mount the circlip 11 on the pinion top using circlip pliers Install the new...

Page 40: ...ssembly Code CW For reverse or Spring to Open Assembly Code CC Slightly push the pinion inward to engage with the pinion Ensure that smooth movement and 90 degree operation can occur without moving th...

Page 41: ...41 Pneumatic Actuator 82046L OMMGGP00185 Rev 5 MAY 2019 Fig 22 Piston Orientation...

Page 42: ...f the pinion is perpendicular to centreline of the housing Double check if the position of the slot and the cam on the pinion top is in the correct position see Fig 22 Screw in the right hand travel s...

Page 43: ...dentical position from where they were removed Before assembling the spring cartridges and end caps make sure that the pistons are completely inwards Grease the O ring seals 14 and B port seals 16 acc...

Page 44: ...turn 180 and reinstall per the instructions in Section 4 4 2 Refer to Fig 22 for piston positions CAUTION The direction of the Positioner must also be reversed Refer to Section 5 4 1 CAUTION When rev...

Page 45: ...on PTFE 25 carbon filled 8 2 Bearing pinion POM 9 1 Thrust washer POM black UV stabilized 10 8 End cap screw Stainless Steel 11 1 Circlip Spring steel 12 2 O ring seal pinion Nitrile rubber 13 2 O rin...

Page 46: ...5 The following service kits are required for maintenance of the actuator Table 4 Spares Kits for 82046L Actuator Valve Type Actuator Part Number Service Kit 02GGH 82046L1 82138X001 03GGS 03GGH 04GGS...

Page 47: ...stage displacement balance instrument providing step less positional control The basic design incorporates a high enhancement flapper and nozzle spool valve and an adjustable range and reversing mech...

Page 48: ...valve to decrease the air gap As the air gap is decreased the pressure to the top of the spool valve rises and the spool moves back to the neutral position The actuator maintains its position until t...

Page 49: ...y in place on the bottom of the positioner shaft Locate the positioner in place on top of the bracket making sure that the 4 mm tongue locates properly into its slot in the actuator spindle and the ce...

Page 50: ...ion of the positioner is automatic and no operator intervention is necessary 5 4 Maintenance There are no user serviceable parts in the positioner and maintenance is limited to Reversal of the actuati...

Page 51: ...re orientated to give the correct direction of movement for changes in signal input pressure Refer to Section 4 4 2 Ensure the Valve is positioned over the port corresponding to zero actuator pressure...

Page 52: ...age 23 Mode 23 Fig 6 page 24 Mode 12 Fig 7 page 25 Mode 21 Fig 8 page 26 Mode 13 Fig 9 page 27 Mode 31 Fig 10 page 28 Refit the rubber washer and secure the cam with the lock nut Fit the position indi...

Page 53: ...each other The zero is adjusted first but the whole process of adjusting zero and range must be repeated until both parameters require no further adjustment Fig 31 Adjustments Remove the access plug R...

Page 54: ...alue 1 02 bar 15 psi CAUTION If the knurled adjustment ring is turned too far anti clockwise it can disengage from the spring Be careful not to turn it too far If the actuator does not stop at the ful...

Page 55: ...erview 55 6 1 1 8064A 55 6 1 2 8064C 56 6 1 Overview The 8064A and 8064C elect pneumatic converters produce a 0 2 bar 1 bar 3 15 psi pneumatic output proportional to a 4 20 mA input 6 1 1 8064A The 80...

Page 56: ...Pneumatic Converter 8064A C Rev 5 MAY 2019 OMMGGP00185 6 1 2 8064C The 8064C is illustrated in Fig 33 Refer to OMM806400085 installation operation and maintenance manual Fig 33 8064C Elect pneumatic c...

Page 57: ...uated G Valve is the 8071D PID controller The 8071D is a compact powerful and versatile PID controller The inputs outputs and internal functions are fully configurable and it is capable of meeting the...

Page 58: ...58 PID Controller 8071D Rev 5 MAY 2019 OMMGGP00185...

Page 59: ...1 Overview 59 8 1 Overview The Pneumatic Indicator Controller produces a pneumatic control signal proportional to a sensed pressure or temperature It can be fitted with either a temperature sensor or...

Page 60: ...60 Pneumatic Indicator Controller SG80 Rev 5 MAY 2019 OMMGGP00185...

Page 61: ...A 1 2 Code Description Conduit Thread Size and Torque 1 M20 2 PG 13 5 3 PG 16 4 1 2 NPT Installation Thread Installation Thread 2 1 2 BSP Tr 3 1 2 NPT 9 2 Installation When installing the temperature...

Page 62: ...ensor 8060 Rev 5 MAY 2019 OMMGGP00185 Fig 36 Temperature Sensor Fig 37 Temperature Sensor Connections 9 3 Maintenance No maintenance is possible in the event of failure of the temperature sensor repla...

Page 63: ...es and slings etc must be suitably rated to ensure safe handling Suitable support of the valve during lifting must be given to ensure safe relocation of the equipment Lifting provision for the larger...

Page 64: ...e g bolting and gasket material requirements In situations where the valve has been subject to prolonged low temperatures such as on site or warehouse storage great care must be taken to raise the tem...

Page 65: ...ng washers to each bolt if fitting and fit and tighten the remaining nuts as per the relevant pattern shown in Fig 38 in at least 4 stages to compress gasket uniformly Note stages 2 5 should be comple...

Page 66: ...obe is a close as possible to the centre of the flow path Do not run cables in very hot areas which can cause cable failure and inaccurate measurement Avoid installation in areas of high vibration Avo...

Page 67: ...ws Pneumatic control Electro pneumatic control 10 2 1 Pneumatic Control Temperature is monitored by the integral sensor of the SG80 pneumatic indicator controller and a pneumatic output is generated T...

Page 68: ...on with the 8071D PID controller a 4 20 mA electrical signal is produced and transmitted to the 8064A or 8064C electro pneumatic converter The converter produces a pneumatic control signal from the 4...

Page 69: ...ic and remedial actions Fault Indication Diagnostic Action Remedial Action Valve is oscillating Check PID values on PID Controller Adjust PID values Check dead band settings on PID Controller Adjust d...

Page 70: ...years and major servicing every four years The four year service covers all items in the two year service plus additional items 12 3 Minor Service every 2 years The minor service comprises two distin...

Page 71: ...h spares kit to order Table 7 Spares Kit required Kit description Kit part number 2 HIGH FLOW KIT 82380X002 3 STANDARD FLOW KIT 3 HIGH FLOW KIT 82380X003 4 STANDARD FLOW KIT 4 HIGH FLOW KIT 82380X004...

Page 72: ...he major service comprises two distinct actions inspection and replacement of key parts The inspection items for the major service are the same as for the minor service Table 8 details which parts are...

Page 73: ...r repaired on site please contact your nearest AMOT Service Centre see back cover to arrange for an Engineer to visit Kit description Kit part number 2 HIGH FLOW KIT 82382X002 3 STANDARD FLOW KIT 3 HI...

Page 74: ...13 1 4 Bypass Flow rates 78 13 1 5 Valve Dimensions 79 13 1 6 Valve Weights 81 13 2 Technical Specifications 83 13 2 1 Actuator 83 13 2 2 Positioner 83 13 1 Selection of G Valve options The selection...

Page 75: ...75 Technical Data OMMGGP00185 Rev 5 MAY 2019 13 1 1 Valve Flow Rate Selection Fig 41 Valve Selection Curve...

Page 76: ...cient correction factor can be established The correction figure obtained from the graph should then be multiplied by the original flow coefficient which can then be used in the standard valve sizing...

Page 77: ...e the table below for examples of Kv and Cv for the G valves Size DN Inch Standard flow 80 3 100 4 125 5 150 6 200 8 250 10 High flow 50 2 80 3 100 4 150 6 200 8 Kv 82 207 323 729 1296 Cv 96 242 378 8...

Page 78: ...in a reasonably balanced pressure system there will be some small amounts of leakage between ports The actual amount of leakage will vary with the pressure difference between these ports Consult AMOT...

Page 79: ...79 Technical Data OMMGGP00185 Rev 5 MAY 2019 13 1 5 Valve Dimensions Fig 43 Valve Dimensions...

Page 80: ...0 406 D 6 496 7 874 7 874 9 016 8 819 10 000 11 220 11 220 13 504 13 386 15 984 C 170 207 227 242 281 296 312 346 371 418 455 C 6 693 8 150 8 937 9 528 11 063 11 654 12 283 13 622 14 606 16 457 17 913...

Page 81: ...r Type Valve Material Ductile Iron kg lbs 02GGH 90 Rotor 23 51 180 Rotor 24 53 03GGS 90 Rotor 35 77 180 Rotor 36 79 03GGH 90 Rotor 36 79 180 Rotor 37 82 04GGS 90 Rotor 46 101 180 Rotor 48 106 04GGH 90...

Page 82: ...Material Ductile Iron kg lbs 02GGH 90 Rotor 25 55 180 Rotor 26 57 03GGS 90 Rotor 37 82 180 Rotor 38 84 03GGH 90 Rotor 37 82 180 Rotor 39 86 04GGS 90 Rotor 48 106 180 Rotor 50 110 04GGH 90 Rotor 52 11...

Page 83: ...at 6 bar Air Consumption 15 l min at 6 bar Min actuator volume 0 1 l Temperature 20 to 80 C 4 to 176 F Enclosure IP 54 Option IP65 Mounting VDI VDE 3845 Air Entry G 1 4 in Air Supply 6 to 8 bar 87 116...

Page 84: ...amot com AMOT Controls GmbH Rondenbarg 25 Asia and Australasia 22525 Hamburg Germany AMOT China Bd 7A No 568 Long Pan Rd Malu Jiading Shanghai Shanghai 201801 China Tel 86 0 21 5910 4052 Fax 86 0 21...

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