Introduction Introduction ...................... 5 Scope ................5 Safety................6 Maintenance ..............6 Product Support ............. 6 Typographical Conventions ..........6 European Union Directives..........7 System Overview ..................... 9 Description ..............9 Identification of Model Number ........11 Modes of Operation ............12 System Components .............
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Contents Servicing Schedule ..................81 Overview ..............81 Service Intervals ............81 Service (every 2 years) ..........81 AMOT Field Service ............83 Technical Data ....................85 10.1 Selection of G Valve options .......... 85 10.2 Technical Specifications ..........93 Rev 4 –...
EMC Directive ..............7 1.6.4 EU Pressure Equipment Directive ........7 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...
Introduction 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.
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.
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08GGS EN1092 PN10 EN1092 PN16 08GGH 10GGS (SEP) ASME ASME Users who are uncertain as to the applicability of the Directive should contact AMOT before installation, particularly if using more hazardous (Group 1) fluids. Rev 4 – MAY 2019 OMMGGE00217...
System Overview Section 2 System Overview Contents Para Page Description ................. 9 2.1.1 Features ................9 2.1.2 Typical Applications ............10 Identification of Model Number ............ 11 Modes of Operation ..............12 System Components ..............12 Description The G Valve and its ancillary equipment are designed for the control of fluid temperature by ‘diverting’...
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System Overview 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.
System Overview Identification of Model Number Example Code Description code Nominal Bore Size Comments 2 inch (DN50) High flow only 3 inch (DN80) Valve 4 inch (DN100) Size 5 inch (DN125) Standard flow only 6 inch (DN150) 8 inch (DN200) 10 inch (DN250) Standard flow only Valve...
System Overview Modes of Operation Fig 1 Modes of Operation 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 •...
Valve Body Section 3 Valve Body Contents Para Page Description ................13 Installation ................13 Operation ................. 14 Maintenance ................14 3.4.1 Dismantle and Assemble ..........14 3.4.2 Recommended Spares ............. 17 Description The G Valve is a compact and rugged 3-way control valve designed for temperature control using ‘diverting’...
Valve Body 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.
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Valve Body 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.
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Valve Body Remove the actuator from the valve body in accordance with Sect 4.9.1 (page 40). Knock out the coupling pin Fig 14 (see page 41, (6)) and remove the coupling. Back to Fig 4 (Page 15): remove screws and washers (2), remove retaining plate (5) and discard O Ring (6).
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Valve Body 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) Description Part Number (Qty)
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Valve Body Valve Type 08GGH (Fig 4, page 15) Description Part Number (Qty) O Ring, Cover 43603L002 (1) O Ring, Top Seal 43607L002 (1) O Ring, Upper Shaft 43611L002 (1) O Ring, Lower Shaft 43611L002 (1) O Ring, Lower Shaft 43600L002 (1) Coupling pin 43419L030 (1)
Electric Actuator Description 4.1.1 Mechanical Status LED x3 and Calibration Access Plug Terminal Box Cover EMC Cable Gland x2 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.
Electric Actuator 4.1.3 Versions The actuator is available in 115V ac and 230V ac versions, single phase only. All EB actuators have the option of a Positioner, which is fitted inside the terminal box (see Fig 6, page 21). The internal wiring for the various options are illustrated in (Fig 7, page 23). The external wiring is illustrated in the system wiring diagrams of Section 7, page 65 (System Integration).
Electric Actuator CAUTION The Alarm Outputs are from Solid State Relays which can switch dc within the following specifications – 100mA maximum current, 40V maximum open circuit voltage. Actuator terminals 22 and 24 are for the positive connection. 4.1.5 Actuator Internal Wiring For versions with a Positioner, versions are available with either 4-20mA position control or switched live control.
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Electric Actuator Fig 7 Wiring Diagram – EB Actuators OMMGGE00217 Rev 4 – MAY 2019...
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Electric Actuator Rev 4 – MAY 2019 OMMGGE00217...
Electric Actuator Identification of EB Actuator Model Number Example code EB 100 -AA Code Description Actuator Actuator Type Type Electric Actuator Size and Torque Comments Size and Torque 100 Nm Voltage Voltage 115 V ac 230 V ac Hardware options Hardware Options Without Positioner Positioner fitted...
Electric Actuator Mechanical Installation Fig 8 Actuator Mounting The installation of the actuator to the valve body is achieved by the use of a mounting plate (Fig 8, item 8). It is attached to the underside of the actuator with bolts (Fig 8 items 3 and 4). The mounting plate, complete with actuator is then secured with bolts (Fig 8 items 1 and 2) to the valve body.
Electric Actuator The actuator chassis must be correctly grounded. • Use the supplied EMC cable glands where possible for EMC compliance. • • All unused electrical entries must be blanked off with the appropriate plug. Make all splices or connections using the correct pin connector of terminal •...
Electric Actuator Slide the nylon insert to align with the end of the exposed wires. • Fold the screen braid back over the nylon insert as show in Fig 9. • • Push the cable through the gland body. Push the nylon insert and neoprene sealing ring fully into the body •...
Electric Actuator When using the optional Positioner, carry out the Option Configuration procedure. Refer to Section 4.6, page 33. When using the optional Positioner, carry out the Calibration procedure if required. Refer to Section 4.7, page 38. Check for correct operation of the Actuator. 4.4.3 Status LEDs &...
Electric Actuator Positioner An optional Positioner may be installed comprising two printed circuit boards mounted in the Terminal Box: Positioner Board, 49682X001 (Section 4.5.1) • Power Module, 49261X001 (Section 4.5.2) • 4.5.1 Positioner Board The Positioner Board contains the following components: Processor •...
Electric Actuator Table 4 Input Range Selection DIP Switch DIP Switch DIP Switch Input Range 1 – 5 V Down 0 – 5 V Down 0 – 10 V Down Down 2 – 10 V Down 4 – 20 mA Down Down 0 –...
Electric Actuator Option Configuration (Positioner option only) It is possible to change various configuration options, but for most applications, the default settings do not need to be changed. The available configuration options are: 1. Failsafe: a. Stop on loss of control signal (default) b.
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Electric Actuator If an EB actuator has not been connected to the PC before, then the PC will need to install a Device Driver. This should happen automatically, but if not, a suitable Device Driver can be obtained from: http://www.ftdichip.com/Drivers/VCP.htm Note This procedure may vary depending on the version of Windows used.
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Electric Actuator Click the File menu, and then Properties. Click OK on the information message. Click the arrow on the right of the Connect Using box, and scroll down to the COM number previously noted. Click on the Configure button, and ensure that the following settings are shown (change if necessary): Bits per second = 9600 Data bits = 8...
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Electric Actuator The following options are displayed: 1. Elec Cal – Factory use only as special test equipment is required. 2. Actuator Cal – Performs the same calibration function as pressing the button on top of the terminal box (Fig 6, page 21). 3.
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Electric Actuator Note Actuators which are controlled by a low level signal, such as 4-20mA stop short of the position limit cams, whereas switched live controlled actuators stop at the position limit cams. For switched live controlled actuators with a 4-20mA output, this setting adjusts what mA output value is given at the ends of stroke (3.11mA and 20.88mA or 4.0mA and 20.0mA).
Electric Actuator Calibration (Positioner option only) The calibration of the Positioner is performed using software embedded in the unit. No other test equipment is required. WARNING The calibration procedure automatically drives the valve through its complete range of movement. Ensure personnel are kept clear to avoid injury.
Electric Actuator 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. The actuator operates as soon as electrical power is applied, controlled by either an 8071D PID controller based system or an externally generated 4 –...
Electric Actuator Maintenance The following maintenance tasks are described in this section: Removal and installation onto valve body (4.9.1 – page 40) • Lubrication (4.9.2 – page 43) • Sensor Mounting Bracket replacement (4.9.3 – page 43) • Position Limit switch replacement (4.9.4 – page 45) •...
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Electric Actuator Fig 14 Actuator mounting Removal WARNINGS Lethal voltages are present in the actuator presenting a shock hazard to personnel. Ensure the power supply to the actuator is isolated before the cover is removed. If an actuator is removed from a valve fitted in a live system, the valve rotor may rotate uncontrollably in the body.
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Electric Actuator WARNING The actuator is heavy (EB100 – 16.6 kg). The appropriate manual handling precautions must be applied to prevent personnel injury. Carefully lift the actuator complete with mounting plate from the valve. Note that when removing the actuator from valve types 02GGH, 03GGS, 04GGH, 05GGS and 06GGS, the mounting plate will remain in position on the valve.
Electric Actuator Energise the actuator power supply and control circuits and check for correct operation. 4.9.2 Lubrication To enable the actuator to be mounted in any position, a totally sealed and permanently lubricated gear case is used. During long periods of storage, it is not unusual for a very small amount of lubricant to weep from shaft seals.
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Electric Actuator Remove the screw (26) in the centre of the position indicator disc (25) and remove the indicator disc and the Belleville washers (24) from the position indicator shaft. Disconnect the Hall Sensor (8) at the in-line connector (21). Remove the cable ties that secure the Actuator side Hall Sensor wiring to the Sensor Mounting Bracket (22).
Electric Actuator nut (10, 11) underneath the Sensor Mounting Bracket. The stiff nut engages in a machined slot to prevent it turning. Fit the two caps crews (1) and (6) with spring washers (2) and (7) but do not fully tighten at this stage. Fit the Hall Sensor Pulley (12) to the Hall Sensor shaft and secure with cap screw (13).
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Electric Actuator Fig 16 Limit Switch Assembly and Cams Turn the manual drive handle as necessary to access the • setscrews (2 and 6) in both the upper and lower limit switch cams (3 and 5). Undo the setscrews to loosen both upper and lower limit switch •...
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Electric Actuator Remove the two screws (11) and slide the limit switch assembly, • both cams and cam spacer (4) from the shaft (7). Note the position of the wires and disconnect the limit switch pair • wires from the switches to be replaced (the switches identified as item 12 are the CW switches and item 14 are the ACW switches).
Electric Actuator 4.9.5 Sensor Replacement This section covers the replacement procedure for the Hall Sensor. Disassemble the sensor bracket, and remove the Hall Sensor by • following the steps in section 4.9.3. Fit the replacement Hall Sensor, and reassemble the sensor •...
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Electric Actuator Fig 17 Limit Switch Adjustment WARNING Lethal voltages are exposed when the actuator cover is removed, presenting an electric shock hazard to personnel. Electrical power supplies must be isolated from the actuator before the cover is removed. Switch off and isolate the actuator electrical power supply. Loosen the socket head cap screws and carefully lift off the cover.
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Electric Actuator ACW limit switch adjustment: Manually wind the actuator fully anti-clockwise to the mechanical end stop. Wind the manual handle clockwise to take up backlash (approx. ¼ turn). Wind the manual handle clockwise a further one complete turn. Loosen the grub screw (6) in the lower limit switch cam (5). Turn the cam until the limit switch is on the flat of the cam (switch not pressed).
Electric Actuator Remove any electrical continuity circuits connected to the terminal board. Ensure that the actuator cover O ring is correctly fitted and undamaged. Refit the actuator cover and secure with the socket head cap screws. CAUTION Adjustment of the Position Limit Switches affects the calibration of the optional Positioner.
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Electric Actuator Loosen the grub screw (6) in the lower limit switch cam (5). Turn the cam until the limit switch is on the flat of the cam (switch not pressed) Slowly turn the cam clockwise until the first switch (Open limit switch `OLS`) just operates.
Electric Actuator CAUTION Adjustment of the limit switches affects the calibration of the optional Positioner. If fitted, it must be re-calibrated before the actuator is brought into service. 5. If fitted, calibrate the positioner (refer to 4.7 , page 38) 6.
Move the Hall Sensor to tension the Timing Belt and tighten the • two cap screws (6). The belt should be tight enough to take up the slack, but no tighter. Belt tensioning tool, AMOT part number 81573X, can be used to aid sensor positioning. Hall Sensor Fine Alignment.
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Electric Actuator Fig 19 Anti-Condensation Heater There is a connector fitted in-line with the heater wires, inside the main body of the actuator. To allow for optimum access, remove the sensor mounting bracket, as described in 4.9.3 on page 43. Locate the plug/socket connector for the heater, near to the base of the actuator.
Electric Actuator 4.9.10 Capacitor Replacement WARNING Lethal voltages are exposed when the actuator cover is removed, presenting an electric shock hazard to personnel. Electrical power supplies must be isolated from the actuator before the cover is removed. Remove Capacitor Switch off and isolate the actuator power supply. Loosen the socket head cap screws and carefully lift off the actuator cover.
Electric Actuator 4.9.11 Terminal Board Replacement Fig 20 Terminal Board WARNING Lethal voltages are exposed when the actuator cover is removed, presenting an electric shock hazard to personnel. Electrical power supplies must be isolated from the actuator before the cover is removed.
Electric Actuator Remove the Power Module (12) or Power Module Cover by undoing the four screws (5) and pulling the unit away from the Terminal Board. Remove the six shoulder screws (7). They will be retained under the terminal board. Carefully hinge the terminal board out from the bottom, and then up to the horizontal position.
Electric Actuator Permitted temperature range -20° C to +70° C. • All covers must be fitted and secured. • If electrical power is not connected, place a packet of desiccant in the • motor compartment as follows: Ensure that electrical power to the actuator is isolated. ...
Electric Actuator 4.11 Available Spares The following is a list of available spares for the actuator. Description Part Number Actuator Lid O ring 82434X001 Hall Sensor 82434X005 Heater (110V) 82434X006 Heater (220V) 82434X007 Capacitor (110V) 82434X010 Capacitor (220V) 82434X008 Position Limit Switch Set 82434X012 Handwheel Kit 82434X015...
8072D controller The installation, operation and maintenance of the 8071D and related equipment is fully detailed in AMOT publication OMM807100043. The actuator can also be controlled by an external 4 – 20 mA generated signal applied to an optional Positioner.
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PID Controller Rev 4 – MAY 2019 OMMGGE00217...
Temperature Sensor Section 6 Temperature Sensor Contents Para Page Description ................65 Installation ................69 Description The 8060A temperature sensor is ideal for use with the 8071C and 8072C PID controllers and other PT100 applications. It is a 3 wire RTD with stainless steel thermal well and IP54 aluminium connection head.
Temperature Sensor Fig 21 Temperature Sensor Fig 22 Temperature Sensor Connections Maintenance No maintenance is possible, in the event of failure of the temperature sensor, replace with new item. Rev 4 – MAY 2019 OMMGGE00217...
The following section gives valve installation guidance notes, and manual operational instructions. Prior to Installation The AMOT GG Valve should be checked upon receipt for damage sustained during shipping. Contact AMOT (refer back page for contact details) in case of any concerns regarding the valve’s integrity. Handling Devices WARNING The valve, its components and its actuator are heavy.
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System Integration Do not install the valve in a position that inhibits the operation of the • manual override handle or access to any electrical actuator connections. If possible, avoid installation in areas with a risk of water spray or •...
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System Integration Using suitable lifting and supporting equipment, fit the valve to the flanged • pipe, ensuring the correct valve port is fitted. Use a suitable lubricant on the flange bolt threads to achieve the required • coefficient of friction. Ensuring the flange gasket is seated correctly on the flange faces, fit the •...
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System Integration Temperature Sensor Installation Position as close as possible to the point of control. • • Ensure positioned at least 6 pipe diameters in length from any junction. Ensure the end 40 mm of probe is a close as possible to the centre of the •...
System Integration System Wiring Diagrams The System wiring depends on the controller components selected for use. The following options are available: 8071D controller with 2 Fig 24, page 70 solid state relays 8071D controller with an 8073C-DDT solid state relay Fig 25, page 71 module Fig 26, page 72...
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System Integration Fig 24 8071D controller with 2 solid state relays Rev 4 – MAY 2019 OMMGGE00217...
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System Integration Fig 25 8071D controller with an 8073C-DDT solid state relay module OMMGGE00217 Rev 4 – MAY 2019...
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System Integration Fig 26 8072D controller Rev 4 – MAY 2019 OMMGGE00217...
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System Integration Fig 27 8072D controller (Actuator with Positioner) OMMGGE00217 Rev 4 – MAY 2019...
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System Integration Fig 28 4 – 20 mA input with optional Positioner Rev 4 – MAY 2019 OMMGGE00217...
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System Integration Fig 29 Switched mains voltage input with optional Positioner OMMGGE00217 Rev 4 – MAY 2019...
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System Integration Rev 4 – MAY 2019 OMMGGE00217...
Troubleshooting Section 8 Troubleshooting Contents Para Page Checklist .................. 77 EB Positioner Status Indicators ............ 79 Checklist The following table lists a number of possible faults that could be observed in the system, with the relevant diagnostic and remedial actions. Fault Indication Diagnostic Action Remedial Action...
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Troubleshooting either direction Check actuator motor If motor running, replace running shear pin between valve and actuator If not running, ensure local power supply is compatible with nameplate voltage and current rating. Check if motor overheated Refer to “Motor overheating” below Check motor run capacitor Replace capacitor...
Troubleshooting EB Positioner Status Indicators Note LEDs are only operational when optional Positioner is installed. ALARM Condition Green Amber Healthy Flashing Healthy Healthy 1 Hz Input out of Flashing Fault Healthy range 2 Hz Motor thermal Flashing Healthy Fault trip 2 Hz Position feedback Flashing...
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Troubleshooting Rev 4 – MAY 2019 OMMGGE00217...
The service comprises two distinct actions – inspection, and replacement of key parts. Due to the complexity of the G Valve system, it is recommended that this service be carried out by an AMOT Service Engineer either onsite or at an AMOT manufacturing and service facility.
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Servicing Schedule Table 7 details the parts that are to be replaced, and references where the replacement procedure can be found in this manual. Table 7 Service component replacement Item description Refer to section number Valve body cover O Ring 3.4.1 Top Seal O Ring 3.4.1...
8” STANDARD FLOW, 230V ac AMOT Field Service If a valve is required to be serviced or repaired on site, please contact your nearest AMOT Service Centre (see back cover) to arrange for an Engineer to visit. OMMGGE00217 Rev 4 – MAY 2019...
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Servicing Schedule Rev 4 – MAY 2019 OMMGGE00217...
Technical Data 10.1.2 Viscosity Correction For the selection of valves for more viscous fluids than water, the following must be calculated: Viscosity: Find the viscosity of the fluid in which the valve is to operate. The viscosity is normally expressed in Centistokes. Where ISO oil is used, the grade number is also the viscosity e.g.: ISO VG46 is 46 Centistokes at 40°...
10.1.3 Valve Sizing Calculations Pressure Drop The G valve is designed to produce minimal pressure drop. The normal recommendation when determining the size of an AMOT G valve is a pressure drop between 0.01 and 0.1 bar (0.145 and 1.45 psi). Note Kv and Cv values are applicable to 90°...
Technical Data 10.1.4 Bypass Flowrates The AMOT G Valve is not a tight shutoff valve. When used in a reasonably balanced pressure system, there will be a small amount of leakage between ports. The actual amount of leakage will vary with the pressure difference between these ports.
Technical Data 10.1.5 Valve Dimensions Fig 32 Valve Dimensions Rev 4 – MAY 2019 OMMGGE00217...
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Technical Data Note that bolt hole dimensions (quantity, angular deviation, diameter, PCD) meet the requirements of the individual flange standard selected in the model code (Section 2.2). OMMGGE00217 Rev 4 – MAY 2019...
Technical Data 10.1.6 Valve Weights The approximate weights of the valve complete with actuator are as follows: Valve Material Ductile Iron Valve Type Rotor Type 90° Rotor 02GGH 180° Rotor 90° Rotor 03GGS 180° Rotor 90° Rotor 03GGH 180° Rotor 90°...
Technical Data 10.2 Technical Specifications 10.2.1 Actuator Power supply Motor thermal Hall Sensor protection 110 V/220 V ac ± 10% Open 150°C nominal 5 V dc power supply 50/60 Hz single phase Close 97°C nominal Linear voltage output Limit Switches Operating angle Two x open/close SPDT 110°...
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Tel: +44 (0) 1284 762222 Fax: +1 (713) 559 9419 Fax: +44 (0) 1284 760256 Email: sales@amotusa.com Email: info@amot.com AMOT Controls GmbH Rondenbarg 25 22525 Hamburg Germany Asia and Australasia Tel: +49 (0) 40 8537 1298 AMOT China Tel: +49 (0) 40 8537 1331 Bd 7A, No 568, Long Pan Rd.
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