ASAHI Type 57 Butterfly Valve with Series 92 Electric Actuator
Contents
1. Gasket D ia mew o sew Butterfly Valves 40 400mm 2 ASAHI AV VALVES Installation Operation and Maintenance Manual Type56 Gear Type 400mm 16 Description Bolt C Butterfly Valves 40 400mm 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Comparison between Working Temperature and Pressure AN Caution Do not operate the valve beyond the range of working temperature and pressure The valve can be damaged Butterfly Valves 40 400mm 4 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Installation Procedure AN Caution 1 The valve disc is sent in the position indicated by solid lines in Fig 5 1 prior to shipment from the factory If the valve is opened or closed after unpacking it must be reset in this position before installation Failure to do so will result in dama2. For the full opened position the handle is parallel to the piping axis direction Full Shut Close Position Full Opened Position Fig 6 1 3 Incase of gear type 40 400 mm 1 1 2 16 the indicator shows the position of the disc on the top of gear box Fig 6 2 For the full shut close position the indication shows Shut S For the full opened position the indication shows Open O Full Shut Close Position Full Opened Position Fig 6 2 Butterfly Valves 40 400mm 8 ASAHI AV VALVES Installation Operation and Maintenance Manual Technical Data for Operation Required Hand Wheel Length of Lever and Torque Diameter of Handle Nin Nin mm re ae Pe ee oe fee De pe pe Pe pe e EL 2 1 2 80mm 3 100mm Stem Torque Required o Force e e oe e oe 5 w s s 7 s mo o e 6 200mm w mo s s s a o s s zoj os fo 10 wm m w sa 12 wy et tm a aal 9 7m fs oo 3 d 6 Note Data mentioned in the table above is reference only These data are measured in standard condition and it slightly differs depending on conditions Butterfly Valves 40 400mm 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Disassembly and As
3. 400mm 16 as follows gt Insert the stabilization ring 156 into the upper side slot of the seat 3 The upper side slot of seat 3 has larger stem hole than lower side A Caution Make certain tabs are properly aligned Both upper and lower stabilization ring 156 are identical 4 Insert the stem 7 about 1 3 into the body 1 Install the seat 3 into the body 1 by aligning upper seat stem hole with the stem 7 5 Collapse the left or right side of seat 3 in towards opposing side exposing lower stem hole by screw driver lt Nominal size 40mm 350mm 1 1 2 14 It advances 400mm 16 as follows gt Install the stabilization ring 156 into the body 1 aligning tabs of ring with center groove of the body 1 Seat 3 tabs should line up when bottom of seat is reset into body of valve 6 Remove the stem 7 7 Reset the seat 3 into the body 1 A Caution lt Nominal size 40mm 350mm 1 1 2 14 It advances 400mm 16 as follows gt Make certain stabilization rings 156 sit flush inside of seat 3 with tabs properly aligned If stabilization rings 156 are not installed correctly the seat 3 will not sit in the body 1 properly This is indicated by a visible gap between seat 1 and body 1 and disc 2 will not fit properly 8 To install disc 2 make certain valve size on disc 2 is in upright direction Install top of disc 2 into seat 3 aligning with upper stem hole 9
4. Do not exert excessive force in closing the valve Make sure to consult a waste treatment dealer to dispose of the valves Poisonous gas is generated when the valve is burned improperly Allow sufficient space for maintenance and inspection Keep the valve away from excessive heat or fire It can be deformed or destroyed Do not change or replace valve parts under line pressure The valve is not designed to bear any kind of external load Never stand on or place anything heavy on the valve at anytime Using a positive pressure gas with our plastic piping may pose dangerous condition due to the repellent force peculiar to compressed fluids even when the gas is under the same pressure as water Therefore be sure to take the necessary safety precautions such as covering the piping protective material For inquiries please contact us 2 General Instructions for Transportation Unpacking and Storage O O O O Keep the valve in its original packaging until needed for installation Avoid contact with any coal tar creosote insecticides vermicides or paint The force of swelling may damage the valve The valve is not designed to handle any kind of impact Avoid throwing or dropping the valve Avoid scratching the valve with any sharp object Butterfly Valves 40 400mm 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 Names of Parts Type57 40mm 1 1 2 350mm A Cap Bol Screw
5. e indication line at the top o stem Roli 2 Fix the handle at the top of stem with the attached bolts and washer i Wacher by using socket wrench andle o 3 Set the convex part at the side of the cap and the concave of the handle and set in the cap by striking lightly by using a plastic Naicator hammer 40 100mm 125 200mm 1 1 2 4 5 8 M6x15L M8x15L Removel Procedure MnnnnnnNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNENNNNNANNNNNENANNNNNANNNNNANENNNNNANENNNENENNNNNANNNNNANENNNNNANENNNENEENEg 1 To remove the cap push up the side of the cap by using screw driver Egi 2 Loose the bolts and washer by using socket wrench then remove the o 4 handle L GN Butterfly Valves 40 400mm 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Adjustment Procedure for Stopper Gear Type po Necessary 1 00 eee ee eee ee ee ee ae a A E ener ee eee l e Hexagon 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 Rubber Cap 1 Remove the rubber cap of Full closing Full opening adjuster 2 Loosen the first stopper hex bolt completely by Hex Wrench 3 Adjust the disc of valve to required position 4 Tighten the stopper hex bolts 5 Put the rubber cap of Full closing Full opening adjuster back on gearbox 10 Inspection Items Inspect the fo
6. 2 14 It advances 400mm 16 as follows gt To take off stem holder 8 Release 4 tapping screws 157 by using screw driver Lever amp Gear Type 7 Hold flat surface of Stem 7 with vise and pull off valve body 1 8 A Set the valve body 1 on square lumbers at edges of valve body on the press and put a lumber on the disc 2 bee ESE REC UCU UR ECO CU eee CeCe rere rer re eres errr errr rere rrr rec cer rere errr rec rrr resect rere s rer re rere rrr rrr rrr rer rrr errr rrr Operate the press slowly and push disc 2 and seat 3 out if the valve body 1 B Set the valve body 1 on square lumbers at edges of valve body and put a circular stick on the disc 2 Strike the circular stick with a hammer and remove disc 2 and seat 3 out of the valve body 1 9 Set the disc 2 parallel to the working desk to half opened position Push the seat 3 and remove the disc 2 10 lt Nominal size 40mm 350mm 1 1 2 14 It advances 400mm 16 as follows gt Remove the stabilization ring 156 and the O ring C 6 from the stem 7 Butterfly Valves 40 400mm 10 ASAHI AV VALVES Installation Operation and Maintenance Manual lt lt Assembly gt gt Procedure 1 Putthe O ring C 6 onto the stem 7 2 Before starting assembly grease Silicone should be spread on the top and bottom disc 2 the stem hole of the seat 3 and the stem O ring C 6 3 lt Nominal size 40mm 350mm 1 1 2 14 It advances
7. 25mm 4 92 125mm 492 __ gt 3 16 Mi6 130mm 5 12 eee ae f 30mm 5 127 drones 29 12 to O 145mm 5 71 O 7 125mm S M20 mmes F o 8 190mm 7 48 O M2 Ammos oh 250mm 9 82 i vomas E Ea of Insert En B Bolt Minim ant e 1 1 120mm 45mm 27mm 16 no 4 72 1 77 1 06 ne lt ANSI Standard gt Dimension of Insert Bolt A Bolt Minimum CE L O Sma n 92 50mm E 52 jz 5 8 11 L38 5 8 11 100mm g sem 125mm 5 150mm 6 3 4 10 ec aa 3 4 10 Omm oon a Omm re i 57 7 8 9 Dimension of Insert E B Nom Size 39 _ 120mm 45mm am am eee 79 24mm 0 94 5 8 Flat 0 63 3 4 Flat 0 79 7 8 Flat 0 87 AN Caution The gasket is unnecessary The seat 3 carries out the role of the gasket Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Operating Procedure A Caution The lever operation and the steering wheel operation are done by the hand 1 Open and close the valve by turning handle smoothly Turn clockwise to close and counterclockwise to open 2 Incase of lever type 40 200 mm 1 1 2 8 the direction of handle is same as the disc as shown in Fig 6 1 For the full shut Close position the handle is perpendicular to the piping axis direction
8. ASAHI AV VALVES Butterfly Valves Type 57 40mm lt 1 350mm 14 Type 56 400mm 16 User s Manual Butterfly Valves 40 400mm Installation Operation and Maintenance Manual Contents 1 General Operating Instructions 90 rr 1 2 General Instructions for Transportation Unpacking and Storage M EEE ES 3 Names of Parts E E E E EA 2 4 Comparison between Working Temperature and Pressure rr 4 5 Installation Procedure en ee eT Te ne eR A eee 5 6 Operating Procede teeeeitaleaee et g 7 Disassembly and Assembly Procedure for Parts Replacement E E AT 1 0 9 Adjustment Procedure for Stopper on Gear Type 13 10 Inspection Items eee 13 11 Troubleshooting rennin 14 12 Handling of Residual and Waste Materials 14 I3 Blac tq Meee ree ee 15 ASAHI AV VALVES ASAHI AV VALVES Installation Operation and Maintenance Manual 1 General Operating Instructions O O OO OOOO O Operate the valve within the pressure Vs temperature range The valve can be damaged by operating beyond the allowable range Select a valve material that is compatible with the media refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE Some chemicals may damage incompatible valve materials Do not use the valve on condition that fluid has crystallized The valve will not operate properly Do not step on the valve or apply excessive weight on valve It can be damaged
9. Rotate disc 2 to 75 Approx closed position and install stem 7 about 50 into the body 1 10 Press in bottom of disc 2 to lower stem hole AN Caution Look into valve body 1 to be certain full square in disc 2 is centered with upper valve 1 stem hole If not repeat step 8 9 and 10 Make certain line scribed on top of stem 7 indicates disc 2 position while installing stem 7 11 Install the stem 7 into valve body 1 and disc 2 If disc 2 is properly aligned stem 7 should slide in smoothly If stem 7 does not slide in smoothly report from step 8 to properly align the disc 2 in the valve body 1 12 lt Nominal size 40mm 350mm 1 1 2 14 It advances 400mm 16 as follows gt Install stem holder 8 onto valve body 1 with countersunk holes facing up using 4 screws 157 13 To install lever or gear operator reverse disassembly procedure 5 14 After assembly make sure that the valve can be fully opened and closed smoothly Butterfly Valves 40 400mm 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Installation procedure for handle poe Necessary items iy e Plastic Hammer Socket Wrench eScrew Driver H e Goggles Protective Gloves A Caution Do not give any unjust force to cap in installing or removing the cap It can be damaged Installation Procedure E ee 1 Install the handle on the stem Set the direction of handle in the Cd
10. d from overflowing The disk 2 is damaged a 1 Install the valve between flanges and open the valve slightly Ly Y Z te 2 Insert bolts set nuts and washer and tighten the bolts and nuts temporarily by Rod hand Caution When you insert a valve between flanges please insert after extending the fields of flanges fully If you insert a valve by force without fully extending fields of flanges a liner may be turned over and suffer a crack The parallelism and axial misalignment of the flange surface should be under the values shown in the following table to prevent damage the valve A failure to observe them can cause destruction due to stress application to the pipe Unit mm inch Axial Misalignment Parallelism a b 1 1 2 3 0 04 0 03 a 6 0 04 0 04 ee 3 16 0 06 0 04 3 Tighten the bolts and nuts gradually with torque wrench to the specified torque in a diagonal manner Refer to Fig 5 3 ntti Recommended torque value Unit N m kgf cm Ib inch Fig 5 3 40mm 50 65mm 80 100 mm Nom Size Nom Size 125 150mm 200 250mm 300 350mm 56 8 10 12 14 Caution Avoid excessive tightening The valve can be damaged Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual lt JIS Standard gt Dimension of Insert Bolt A Bolt N Nom Nom sie Wiser Poe 50mm Caa l 1
11. ge to the surface of the valve seat during handling and installation 2 The valve most not be dropped or thrown against other objects since the sealing surface of the disc and the sealing surface of the valve seat may easily be damaged 3 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 Fig 5 2 will result in damage to the valve 4 The installed valve must never be opened or closed when foreign matter such as sand is present in the pipeline Fig 5 1 Fig 5 2 NOT RECOMMENDED Seal DISC m Connected flange or pipe LI 4 7 7 LIN l 4 th j ji 7 2 eee 7 IN WNTALLIIWTIAN A thao IN A a AN CN N hs LA RRES U i l i ES V Vo Va gt EE 3 fee N i INTERFERENCE OF THE DISK S qs x ty eel x N Z RECOMMENDED 500 a f i In case of the thick wall of the connection part flange and pipe is too thick shave the flange or the pipe inside in order to avoid the contact of pipe and disc Ifinside diameter of the connection part is larger than size D shaving is not necessity oo an j ieee Butterfly Valves 40 400mm 5 ASAHI AV VALVES Installation Operation and Maintenance Manual Necessary items Torque Wrench A Caution Segt The disk 2 is prevente
12. llowing items 1 Check for flaw crack or deformation on the valve o Check for leaks to the outside om Check for the deformation of seat due to improper installation of valve 2 3 4 Check for the smoothness of handle operation Butterfly Valves 40 400mm 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Troubleshooting The stopper is not set correctly Adjust the stopper The seat is damaged or worn Replace the seat Fluid is not stopped in the full Foreign materials are caught Clean it up closed position at the seat The disc is damaged or worn Replace the disc The connecting bolts are over tightened or Adjust and retighten tightened unevenly Replace th The seat is damaged or worn eplace the seat Fluid leaks to the outside The comeco bolis are not Meniened in Adjust and retighten proper torque or evenly Foreign materials have adhered Clean it up The handle does not work Te pear bos im Repair or replace smoothly The connecting bolt is over tightened Adjust and retighten The gear box is damaged Repair or replace Valve does not operate The stem 1s damaged Replace the stem 12 Handling of Residual and Waste Materials A Caution Make sure to consult waste treatment dealer to dispose valves Poisonous gas is generated when the valve is burned improperly Butterfly Valves 40 400mm 14 ASAHI AV VALVES Installation Operation and Maintenance Man
13. sembly Procedure for Parts Replacement Sate WNC Selly MUA See a ae ae a te este eee pe ee ee Protective Gloves Vise Circular Stick Plastic or Wood i Goggles Grease Silicone Pressing Machine Screw Driver i Spanner Wrench Square Lumber Hammer Screw Driver i AN Caution Wear protective gloves and goggles in case some dangerous fluid remains in the valve body You might be injured by working without them The handle part can be removed with line pressure present The locking plate 22 can t be removed with line pressure present If locking plate 22 needs to be removed there can not be line pressure present Stabilization Ring 157 lt lt Disassembly gt gt Seat 3 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 Lever Type lt Nominal size 40mm 200mm 1_1 2 8 5 To remove handle 16 first take off the cap 24 by using screw driver and release bolt 21 by using socket wrench then pull up the handle 16 while holding handle lever 17 6 To take off locking plate 22 release 4 self tapping screws 23 by using screw driver and take off stem holder 8 Gear Type lt Nominal size 40mm 400mm 1 1 2 16 5 Loosen set bolt 28 for gear box 25 and pull off the gear box upward with gasket 158 6 lt Nominal size 40mm 350mm 1 1
14. ual 13 Inquiries ASAHI ORGANIC CHEMICALS INDUSTRY CO LTD Nobeoka Head Office 2 5955 Nakanose Cho Nobeoka City Miyazaki Pref Japan Tel 81 982 35 0880 Fax 81 982 35 9350 Tokyo Head Office Furukawachiyoda Bldg 15 9 Uchikanda 2 Chome Chryoda Ku Tokyo Japan Tel 81 3 3254 8177 Fax 81 3 3254 3474 Singapore Branch Office 16 Raffles Quay 40 03 Hong Leong Building Singapore 048581 Tel 65 220 4022 Fax 65 324 6151 Europe Representative Office Kaiser Friedrich Promenade 61 D 61348 Bad Homburg v d H Germany Tel 49 6172 9175 0 Fax 49 6172 9175 25 Shanghai Branch Office Room 1301 P Shanghai Kerry Center 1515 Nanjing Xi Road Shanghai China Tel 21 5298 6900 Fax 21 5298 6556 ASAHT AMERICA Inc 35 Green Street P O Box 653 Malden Massachusetts 02148 U S A Tel 1 781 321 5409 Fax 1 781 321 4421 Distributor Butterfly Valves 40 400mm 15 ASAHI AV VALVES Installation Operation and Maintenance Manual Butterfly Valves 40mm 350mm 1 1 2 14 Type 57 400mm 16 Type 56 ASAHI AV VALVES Information in this manual is subject to change without notice 2006 2 Butterfly Valves 40 400mm
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