Instruction manual
Contents
1. pipe and disc If the inside diameter of the connecting pipe is larger than dimension D below shaving is not necessary Nominal size Diameter D Ln eek fe eases Type55 TypeSSIS pre tte ts a 50mm 2 43mm 1 69 38mm 1 50 ele te 80mm 3 68mm 2 68 710mm 2 70 i 100mm 89mm 3 50 90mm 3 5 UL 125mm ll6mm_ 4 57 117mm 4 61 EA PAR 150mm 6 140mm 5 51 145mm 5 71 See fe diese 200mm 8 177mm __ 6 97 Ww 250mm 10 234mm 9 21 Torque wrench Spanner wrench Bolt Nut Washer AV gasket If necessary lt JIS 10K Standard gt Dimension of Insert Bolt Nom Size Bolt Minimum Pieces mm inch d L Nut Washer 50 2 130mm 5 11 35 4 8 80 7 M16 140mm 5 51 a 38 100 4 145mm 5 71 8 16 125 y 165mm 6 50 150 6 M20 180mm 7 18 40mm 200 g 195mm 7 68 1 57 12 24 250 10 M22 215mm 8 46 lt JIS 5K Standard gt Dimension of Insert Bolt Nom Size Bolt Minimum Pieces mm inch d L Nut Washer 9 af 30mm 50 2 M12 110mm 4 33 1 18 4 8 80 3 125mm 4 92 100 4 M16 135mm 5 31 40mm 125 5 140mm 5 51 1 57 8 16 150 6 155mm 6 10 200 8 M20 195mm 7 68 45mm 250 10 210mm 8 27 1 77 12 24 L Butterfly Valves Type 55 Type 551S 10 ASAHI AV VALVES Installation Operation and Maintenance Manual Procedure 1 Install the valve between flanges and open the valve slightly 2 Insert bolts2. Nominal Size Type Type Code Protection Grade To Lever Type ILS1 J IP67 50 250mm 2 10 Gear Type TA2 SB2 IP65 Limit Switch Rating Type Code Resistive Inductive Rate Voltage V Load A Load A AC125 10 6 AC250 10 6 HESL DC115 0 8 0 2 DC230 0 4 0 1 AC125 11 7 AC250 11 T TAD DC125 0 5 DC250 0 25 Butterfly Valves Type 55 Type 55IS Connection Diagram At intermediate opening D COM Gano Close SW lt 3 NO Sw 2 aca 4 COM ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Installation procedure A S When suspending and supporting a valve take care and do not stand under a suspended valve Warning 4h Be sure to conduct a safety check on all hand and power tools to be used before beginning work Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured Do not install the valve with the disc fully closed The disc may pinch into the seat resulting in a high operating torque and preventing the valve from operating properly When installing a valve the AV gasket is basically unnecessary But using a gasket gives more stable sealing ability in case of using a plastic flange where easy occurrence of dent mark or distortion can be expected A S When installing a pipe support by means of a U band or something similar take care not to over tighten Caution Exc
3. a XDon t be missing the o ring of case end 3 Tum to counter clockwise and remove the piping port protective cap 4 Draw the cable through the connector 5 Strip the cable with wire stripper 6 Connect the cable to terminal board with a screw driver in ring g accordance page 8 gt Tighten the screws Short circuit or shocks may occur 7 Tighten up the connector to fix the cable 8 The screws must be tightened in turn after set the casing with screws driver XBe sure to set the o ring when the casing is re set Short circuit or shocks may occur 9 Inset the indicator to the upper camshaft which must be set same direction of the seal s arrow Butterfly Valves Type 55 Type 551S 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Operating procedure A S The installed valve must never be opened or closed when foreign matter such as sand is present in the Caution pipeline Do not use the valve to fluid containing slurry The valve will not operate properly Q When operating the handle be sure to do so with your hand Using a tool may damage the handle I l l l l 3 I Do not exert excessive force in closing the valve l l l l I l 1 Open and close the valve by turning handle smoothly Turn clockwise to close and counterclockwise to open 2 Incase of lever type 50 125mm 2 5 the direction of handle is same
4. set nuts and washer then tighten temporarily the bolts and nuts by hand 2A VA Ite IA A The parallelism and axial misalignment of the flange surface should be under the values shown in the Caution following table to prevent damage the valve A failure to observe them can cause destruction due to stress application to the pipe Axial Unit mm inch POE Pa Nom Size misalignment Parallelism a b ce 1 0 0 04 0 8 0 03 E g 1 0 0 04 1 0 0 04 A on 1 5 0 04 1 5 0 06 3 Tighten the bolts and nuts gradually with torque wrench to the specified torque in a diagonal manner Refer to Fig 1 A 4 Tighten the bolts and nuts gradually with a torque wrench to the specified Fig 1 pe Caution torque level in a diagonal manner T A Recommended torque value Unit N m kgf cm Ib inch Nom Size 50mm 80mm 100mm 125mm 150mm 200mm 250mm i 3 5 6 8 dao Toraue value 22 5 30 0 30 0 40 0 40 0 55 0 55 0 z 55 230 306 306 408 408 561 561 ype 200 266 266 355 355 488 488 Nom Size 50mm 80mm 100mm 125mm 150mm gt 2 3 4 S 6 Toraue value 30 0 30 0 30 0 40 0 40 0 5515 306 306 306 408 408 ype 266 266 266 355 355 Butterfly Valves Type 55 Type 55IS 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Connection
5. AV VALVES Installation Operation and Maintenance Manual Lever Type 50 125mm 2 5 with Limit Switch LS1 J Option Ae Ed M l 5 REIA A No DESCRIPTION 30 Limit Switch 31 Limit Switch Pushing Plate Butterfly Valves Type 55 Type 55IS ASAHI AV VALVES Installation Operation and Maintenance Manual Gear Type 50 250mm 2 10 with Limit Switch Box TA2 SB2 tion EI Pg f S oe mo EE S H N Fd AA oN gt YY L_ J Bi jE Ly 50 V per ey C AO J j Ty C K h No DESCRIPTION 30 Limit Switch 38 Bracket A Butterfly Valves Type 55 Type 55IS 7 ASAHI AV VALVES 5 Working pressure vs temperature Ure Installation Operation and Maintenance Manual 6 Specification of limit switch
6. of limit switch procedure A S Shut down the power on the equipment before connecting wires There are risks of electrical Warning shock depending on the level of operating voltage A Q Be sure that the terminal cover and body cover are put on during the operation Caution If you use the limit switch at 1mA 100mA or 5 30V consult near Asahi dealer nee Necessary iteris aa ca aL a ia i Screw driver Connector G1 2 Crmp style terminal i Wire stripper Terminal crimping tool Procedure 1LS1 J 1 Loosen the three screws used to attach the limit switch cover with a fT T Teer screwdriver and remove the cover from the limit switch a OK These screws are captive y p 2 2 Pull and remove the protective cap made of resin from the cover Eo 3 Draw the cable through the connector 4 Strip the cable with a wire stripper 5 Install a crimp style terminal on the lead wire with a terminal crimping tool A A a 6 Connect the terminal screw with a screwdriver according to the PN A internal circuit diagram show in page 8 Tighten the screws If not electric leaks or shocks may occur 7 Tighten the above three screws with a screw driver to install the cover on the limit switch 8 Tighten the cable by connector Procedure TA2 SB2 PEIEE I RTN EEE EN A E AE ATE ANETA TT 1 Remove the indicator a ia danas Cea 2 Remove the fixed screws from casing using screw driver
7. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V029 E 14 Butterfly Valves Type 55 Type 55IS User s Manual Contents 1 Be sure to read the following warranty clauses of our product PEPEE E 1 2 General operating instructions adraia i ai aadiseeasaistdesidaides 2 3 General instructions for transportation unpacking and storage 3 4 Name of parts POI AERA SA PAEA TEENE EE APET TEE E TE 4 5 Working pressure vs temperature 8 6 Specification of limit swith 8 7 Installation procedure 9 8 Connection of limit switch procedure 12 9 Operating procedure e 13 10 Disassembly and assembly procedure 14 11 Adjustment procedure for stopper on gear type TERE EEEE EPEE EPET 15 13 Troubleshooting eettisten 16 14 Handling of residual and waste materials 16 ASAHI AV VALVES Butterfly Valve Type 55 Type 55IS ASAHI AV VALVES Installation Operation and Maintenance Manual This user s guide contains information important to the proper installation maintenance and safe use of an ASAHI AV Product Please store this manual in an easily accessible location lt Warning amp Caution Signs gt lt Prohibited amp Mandatory Action Signs gt A This symbol reminds the user to take caution due to the potential for serious arning injury or death This symbol reminds the user to take caution due to the potential for damage Caution to th
8. air or replace Adjust and retighten Valve does not operate The gear box is damaged The stem is damaged 14 Handling of residual and waste materials Repair or replace Replace the valve Warning Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic valves Poisonous gas is generated when the valve is burned improperly Butterfly Valves Type 55 Type 55IS 16 ASAHI AV VALVES Installation Operation and Maintenance Manual Butterfly Valves Type 55 Type 55IS fo ASAHI AV VALVES Distributor Asahi Organic Chemicals Industry s homepage http Awww asahi yukizai co jp en Information in this manual is subject to change without notice 2014 10 Butterfly Valves Type 55 Type 55IS
9. as the disc as shown in Fig 2 For the full shut position the handle is perpendicular to the piping axis direction For the full opened position the handle is parallel to the piping axis direction Full shut position Full opened position Fig 2 3 Incase of gear type 50 250mm 2 10 the indicator shows the position of the disc on the top of gearbox Fig 3 For the full closed position the indication shows Shut For the full opened position the indication shows Open Full shut position Full opened position Fig 3 Butterfly Valves Type 55 Type 551S 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Disassembly and assembly procedure 3 A S Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty Warning You may be injured A G When installing pipes and valves ensure that they are not subjected to tension compression bending Caution impact or other excessive stress When installing a valve the AV gasket is basically unnecessary But using a gasket gives more stable sealing ability in case of using a plastic flange where easy occurrence of dent mark or distortion can be expected Do not change or replace valve parts under line pressure Necessary items Protective gloves Goggles Spanner wrench Allen wrench Hammer Sc
10. e valve if used in such a manner S Prohibited When operating the valve this symbol indicates an action that should not be taken B Mandatory action When operating the valve this symbol indicates mandatory actions that must be adhered to 1 Be sure to read the following warranty clauses of our product Always observe the specifications of and the precautions and instructions on using our product We always strive to improve product quality and reliability but cannot guarantee perfection Therefore should you intend to use this product with any equipment or machinery that may pose the risk of serious or even fatal injury or property damage ensure an appropriate safety design or take other measures with sufficient consideration given to possible problems We shall assume no responsibility for any inconvenience stemming from any action on your part without our written consent in the form of specifications or other documented approval The related technical documents operation manuals and other documentation prescribe precautions on selecting constructing installing operating maintaining and servicing our products For details consult with our nearest distributor or agent Our product warranty extends for one and a half years after the product is shipped from our factory or one year after the product is installed whichever comes first Any product abnormality that occurs during the warranty period or
11. essive force may damage the pipe gb When installing pipes and valves ensure that they are not subjected to tension compression bending impact or other excessive stress Use flat faced flanges for connection to AV Valves Ensure that the mating flanges are of the same standards The gasket is unnecessary The seat carries out the role of the gasket The valve disc is in the position indicated by solid lines in figure to the right prior to shipment from the installation Failure to do so will result in damage to the surface of the valve seat during handling and installation Care must be used during piping installation to ensure that the pipes or flanges are properly aligned so that the valve disc does not contact them in any setting Misalignment as in figure below will result in damage to the valve factory If the valve is opened or closed after unpacking it must be reset in this position before Butterfly Valves Type 55 Type 55IS 9 ASAHI AV VALVES Installation Operation and Maintenance Manual In case of an abutting thick walled flange and pipe shave the flange or the pipe inner diameter in order to avoid contact of
12. et with water or other liquid Take care in storage and handling After unpacking the products check that they are defect free and meet the specifications These chemicals may cause damage to the valve Butterfly Valves Type 55 Type 551S 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts Butterfly Valves Type 55IS Lever Type 50 125mm 2 5 Gear Type 50 150mm 2 6 Butterfly Valves Type 55 Lever Type 50 125mm 2 5 Gear Type 50 250mm 2 10 No DESCRIPTION No DESCRIPTION No DESCRIPTION 1 Body 8 Gear Box 17 Bolt C 2 Disc 9 Bolt B 18 Locking plate 3 Seat 11 Cap 19 Screw 4 Stem 12 Handle 48 Gasket C 5 Bush 13 Handle lever 51 O ring B 6 O ring A 14 Pin 52 O ring C 7 Bolt A 15 Spring 53 Rubber Washer Butterfly Valves Type 55 Type 55IS 4 ASAHI AV VALVES Type55 Gear Type 50 250mm 2 10 with Handle Lock Option TypeSsIS Gear Type 50 150mm 2 6 with Handle Lock Option Installation Operation and Maintenance Manual e a m H o No DESCRIPTION 49 Lock Plate A 50 Lock Plate B Butterfly Valves Type 55 Type 55IS ASAHI
13. r cap of Full closing Full opening adjuster back gt Adjuster for full shut position on gearbox Adjuster for full opened position 12 Inspection items A a Perform periodic maintenance Leakage may develop due to temperature changes or over periods of Caution prolonged storage rest or operation Inspect the following items 1 Check for flaw crack or deformation on the valve 2 Check for leaks to the outside 3 Check for the deformation of seat due to improper installation of valve 4 Check for the smoothness of handle operation Butterfly Valves Type 55 Type 551S 15 ASAHI AV VALVES 13 Troubleshooting Phenomenon Installation Operation and Maintenance Manual Cause Treatment Fluid is not stopped in the full closed position at the seat The stopper is not set correctly The seat is damaged or worn Foreign materials are caught The disc is damaged or worn The connecting bolts are over tightened or tightened unevenly Adjust the stopper Replace the valve Clean it up Replace the valve Adjust and retighten Fluid outside leaks to the The seat is damaged or worn The connecting bolts are not tightened in proper torque or evenly Replace the valve Adjust and retighten The handle does not work smoothly Foreign materials have adhered The gear box is damaged The connecting bolt is over tightened Clean it up Rep
14. ration Gear Operator Operation we utilize a self locking worm gear design on our manual operators This design Handle lock allows flow control of the valve in intermediate positions in normal process conditions In applications where very high velocity turbulence flow or vibration is present and an intermediate setting is required it is recommended to install a locking device The locking device will prevent the possibility of the valve drifting in severe condition form itis original intermediate setting Butterfly Valves Type 55 Type 55IS 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General instructions for transportation unpacking and storage A S When suspending and supporting a valve take care and do not stand under a suspended valve Warning A S This valve is not designed to handle impacts of any kind Avoid throwing or dropping the valve Caution Avoid scratching the valve with any sharp object Do not over stack cardboard shipping boxes Excessively stacked packages may collapse Avoid contact with any coal tar creosote insecticides vermicides or paint When transporting a valve do not carry it by the handle as Store products in their corrugated cardboard boxes Avoid exposing products to direct sunlight and store them indoors at room temperature Also avoid storing products in areas with excessive temperatures Corrugated cardboard packages become weaker as they become w
15. rew driver Screw driver Silicone grease AV gasket If necessary lt lt Disassembly gt gt Procedure 1 Drain fluid completely from the pipeline 2 Leave the valve slightly opened 3 Loosen the connecting bolts and nuts 4 Remove the valve from the pipeline 5 Lever Type To take off handle 12 first take off cap 11 by using screw driver and release bolt C 17 by using socket wrench then pull up the handle 12 by holding handle lever 13 To take off locking plate 18 release four tapping screws 19 first by using screwdriver Gear Type Loosen set bolts B 9 for gearbox and pull out the gear box 8 upward lt lt Assembly gt gt Procedure 1 The procedure of the assembly is the almost reverse of disassembly 2 After assembly make sure that the valve can be fully opened and closed smoothly Butterfly Valves Type 55 Type 551S 14 ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Adjustment procedure for stopper on Gear Type Allen wrench The adjustments for full opened and full shut position are step less and it can be done with the stopper adjuster Adjustment for Full shut Full opened position y p F aS o 1 Remove the rubber cap of Full closing Full opening adjuster ay oe 2 Loosen the stopper hex bolt with Allen wrench Oy y i W n 3 Adjust the disc of valve to required position a S ri y 4 Tighten the stopper hex bolts 5 Put the rubbe
16. s covering the piping with protective material For inquiries please contactus For conducting a leak test on newly installed piping be sure to check for leaks under water pressure If absolutely necessary to use a gas in testing please consult your nearest service station beforehand When installing a valve the AV gasket is basically unnecessary But using a gasket gives more stable sealing ability in case of using a plastic flange where easy occurrence of dent mark or distortion can be expected A S Do not step on or apply excessive weight on valve It can be damaged Caution Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly t Keep the valve away from excessive heat or fire It can be damaged or destroyed Always operate the valve within the pressure vs temperature range The valve can be damaged or deformed by operating beyond the allowable range Allow sufficient space for maintenance and inspection Select a valve material that is compatible with the media For chemical resistance information refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE Some chemicals may damage incompatible valve materials Keep the valve out of direct sunlight water and dust Use cover to shield the valve The valve will not operate properly Perform periodic maintenance Leakage may develop due to temperature changes or periods of prolonged storage rest or ope
17. which is reported to us will be investigated immediately to identify its cause Should our product be deemed defective we shall assume the responsibility to repair or replace it free of charge Any repair or replacement needed after the warranty period ends shall be charged to the customer The warranty does not cover the following cases 1 Using our product under any condition not covered by our defined scope of warranty 2 Failure to observe our defined precautions or instructions regarding the construction installation handling maintenance or servicing of our product 3 Any inconvenience caused by any product other than ours 4 Remodeling or otherwise modifying our product by anyone other than us 5 Using any part of our product for anything other than the intended use of the product 6 Any abnormality that occurs due to a natural disaster accident or other incident not stemming from something inside our product Butterfly Valve Type 55 Type 55IS i a a i pany a Fas ag rn cp ge E en Sig Sg E E a cask ag a E ps pc eas Pv ep Spe aaa ae ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General operating instructions A g Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the repellent Waming force particular to compressible fluids even when the gas is under similar pressures used for liquids Therefore be sure to take the necessary safety precautions such a
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