Butterfly Valves - Chemline Plastics Limited
Contents
1. orking pr Butterfly Valves 40 400mm ASAHI AV VALVES 6 Installation Procedure Warning B AS Caution In suspending and supporting a valve take enough care and do not stand under a suspended valve Be sure to conduct a safety check on the machine tools and motor driven tools to be used before beginning work Wear protective gloves and safety goggles as fluid remains in the valve You may be injured When installing a pipe support by means of a U band or something similar take care not to fasten it too much Excessive tension may damage it 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 When installing the piping do not do so with the valves fully closed The disc may pinch into the seat resulting in a high operating torque thus disabling opening and closing The gasket is unnecessary The seat carries out the role of the gasket Installation Operation and Maintenance Manual A L The valve disc is sent in the position indicated by solid lines in Figure prior to shipment from2. Release 4 tapping screws 157 by using screw driver Butterfly Valves 40 400mm 14 ASAHI AV VALVES Installation Operation and Maintenance Manual 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 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 gt h advances 400mm 16 as follows gt Remove the stabilization ring 156 and the O ring C 6 from the stem 7 lt lt Assembly gt gt Procedure 1 Put the 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 Nominal size 40mm 350mm 1 1 2 14 It advances 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
3. 57 400mm 18 Type 56 ASAHI AV VALVES Asahi Organic Chemicals Industry s homepage http www asahi yukizai co jp en Information in this manual is subject to change without notice 2008 5 Butterfly Valves 40 400mm
4. ae 200mm 8 179mm 7 05 ee oe 250mm 10 234mm 9 21 Los 4 fo 300mm 12 284mm 11 18 Butterfly Valves 40 400mm 350mm 1 336mm 13 23 400mm 16 370mm 14 58 ASAHI AV VALVES Installation Operation and Maintenance Manual Necessary items Torque Wrench Spanner Wrench Procedure A Caution o The disk 2 is prevented from overflowing The disk 2 is damaged Se 1 Install the valve between flanges and open the valve slightly T 2 Insert bolts set nuts and washer and tighten the bolts and nuts temporarily by 30d hand A When you insert a valve between Caution 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 aa cP a e E kg Sn pe ee E a a ae Seng ee pe A nee etn ae ae ge ee ere age fee HE eel A G 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 Unit mm inch Axial Misalignment Parallelism a b 40 830mm 1 0 E Axial Misalignment Parallelism 11273 0 04 aah 4 6 0 04 n ewe Te 8 16
5. by using a plastic hammer Nominal Size 40 100mm 125 200mm 1 1 2 4 5 8 Bolt Size M6x15L M8x15L Socket Size 10 13 Butterfly Valves 40 400mm 16 ASAHI AV VALVES Installation Operation and Maintenance Manual Remove Procedure 1 To remove the cap push up the side of the cap by using screw driver T 2 Loose the bolts and washer by using socket wrench then remove the handle A S Do not give any unjust force to cap in installing or removing the cap Caution It can be damaged 10 Adjustment Procedure for Stopper Gear Type Necessary Items e Allen Wrench The adjustments for full opened and full shut position are step less and it can be done with the stopper adjuster OS Adjustment for Full shut Full opened position Rubber Cap E 1 Remove the rubber cap of Full closing Full opening adjuster 2 Loosen the first stopper hex bolt completely by allen 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 by hand Butterfly Valves 40 400mm 17 ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Inspection Items A ds Perform periodic maintenance Caution Leakage may develop due to temperature changes or changes with time during prolonged storage rest or operation Inspect the following items 1 Check fo
6. gloves and safety goggles as fluid remains in the valve When installing pipes and valves ensure that they are not subjected to tension compression bending impact or other excessive stress Do not change or replace valve parts under line pressure Necessary items 7 Protective Gloves Vise Circular Stick Plastic or Wood Goggles Grease Silicone Pressing Machine Screw Driver Spanner Wrench Square Lumber Hammer Screw Driver 3 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 Nominal Size 400mm is gasket 25 6 lt Nominal size 40mm 350mm 1 1 2 14 gt I advances 400mm 16 as follows gt To take off stem holder 8
7. 0 06 E A a Tighten the bolts and nuts gradually with a torque wrench to the Caution specified torque level in a diagonal manner Butterfly Valves 40 400mm 9 ASAHI AV VALVES Installation Operation and Maintenance Manual Recommended torque value Unit N m kgf cm Ib inch 40mm 1 1 2 50 65mm 2 21 2 80 100mm 3 4 20 0 204 177 22 5 230 200 30 0 306 266 125 150 mm 5 6 200 250 mm 8 10 300 350mm 12 14 400 mm 16 40 0 408 355 55 0 561 488 60 0 612 532 80 0 816 710 Caution Avoid excessive tightening The valve can be damaged Body Material PVC PP PVDF lt JIS Standard gt Dimension of Insert Bolt A Nom Size Bolt um Nut Washer d L S 40mm 11 2 125mm 4 92 50mm 3 125mm 4 92 33 5 65mm 212 M16 130mm 5 12 a 38 M16 ar 80mm 3 130mm 5 12 100mm 4 145mm 5 71 125mm 27 165mm 630 P 150mm 6 M20 175mm 6 89 M20 0797 200mm 8 190mm 7 48 40mm i 250mm 10 220mm 8 66 1 57 35 300mm 12 M22 245mm 9 65 M22 087 350mm 14 250mm 9 82 3 ify 45mm 24mm 400mm 16 M24 300mm 11 81 ATT M24 094 Dimension of Insert Bol HB Bolt Minimum Nom Size d L S S Nut Washer H 120mm 45mm 27mm 24
8. 16 the indicator shows the position of the disc on the top of gear box Fig 7 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 A amp The adjustments for full opened and full shut position are step less and it can be done with the Caution stopper adjuster Butterfly Valves 40 400mm 12 ASAHI AV VALVES Technical Data for Operation Required Hand Wheel Torque Stem Torque 1 1 2 50mm 2 65mm 2 1 2 80mm G Omm mm R 1 LR L 6 0mm 8 0mm ao 300mm 12 2 2 N aja a2 400mm 16 Note Data mentioned in the table above is reference only Installation Operation and Maintenance Manual Length of Lever and Diameter of Handle Required Operating Force These data are measured in standard condition and it slightly differs depending on conditions Butterfly Valves 40 400mm 13 ASAHI AV VALVES Installation Operation and Maintenance Manual A SO The handle part can be removed with line pressure present The stem retainer can t be removed with line Warning pressure present If stem retainer needs to be removed there can not be line pressure present A Caution You may be injured 8 Disassembly and Assembly Procedure for Parts Replacement Wear protective
9. 24 290mm 11 43 236 M24 0 947 Dimension of Insert Bolt H Bolt Minimum Nom Size d L S S Nut Washer 0 100mm 60mm 30mm 24mm By 16 ess 3 94 2 36 1 18 M24 0 9 Butterfly Valves 40 400mm 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating Procedure A S Do not use the valve to fluid containing slurry Caution The valve will not operate properly Caution pipeline Do not exert excessive force in closing the valve A B The installed valve must never be opened or closed when foreign matter such as sand is present in the When operating the handle be sure to do so with your hand Using a tool may damage the handle 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 For the full opened position the handle is parallel to the piping axis direction Full Shut Close Position Full Opened Position Po E DX 4 ENY YT H k ji mre i a Fig 7 1 3 Incase of gear type 40 400 mm 1 1 2
10. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V036E 8 Butterfly Valves Type 57 40 mm 1 Zn 350 mm 14 Contents Body PVC PP PVDF Type 56 400 mm 16 1 Be sure to read the following description of our Body PP PVDF product warranty se l Type 56D 400 mm 16 Body PDCPD 2 General Operating Instructions 9 2 3 General Instructions for Transportation Unpacking and Storage viii 3 a eee 5 Comparison between Working Temperature and Pressure PNE PE O EEE EEN 6 6 Installation Procedure s 7 8 Disassembly and Assembly Procedure for Parts Replacement A ES 1 4 9 Installation Procedure for Handle PaE R 6 10 Adjustment Procedure for Stopper on Gear Type d7 l 1 Inspection Items EEEIEE IENEN EAIA IA IE E A AAAS 8 13 Handling of Residual and Waste Materials 19 ASAHI AV VALVES Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual This User s Guide contains information important to the proper installation maintenance and safe use of the ASAHI AV product store in an easily accessible location lt Warning amp Caution Signs gt A This remark expresses the user to take caution due to the potential for serious injury or death laming A This remark expresses the user to take caution due to the potential for damage to the valve if used in Caution such a manner lt Prohibiti
11. anty period or 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 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A a Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the Waming repellent force particular 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 with protective material For inquiries please contact us For conducting a leak test on newly installed pipi
12. dy material PVC PP PVDF No Description No Description No Description 1 Body 17 Handle Lever 24 Cap A Sem a mew H 0 sew H d Butterfly Valves 40 400mm 4 ASAHI AV VALVES Installation Operation and Maintenance Manual Type56 Gear Type 400mm 16 Body material PP PVDF PDCPD T Ag 25 lt 26 6 L l IG 7 Po Re i Lo L I 128 Description Description O mune B Gasket A Reference figure Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Comparison between working temperature and pressure A Jominal size 40 minal size 400mm 16
13. g device will prevent the possibility of the valve drifting in severe condition form it is original intermediate setting Handle lock Butterfly Valves 40 400mm 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General Instructions for Transportation Unpacking and Storage A S Insuspending and supporting a valve take enough care and do not stand under a suspended valve Warning A S The valve is not designed to handle any kind of impact Avoid throwing or dropping the valve Caution Avoid scratching the valve with any sharp object Do not pile up corrugated cardboard packages one on top of another too much Excessively piled up packages may collapse Avoid contact with any coal tar creosote insecticides vermicides or paint The force of swelling may damage the valve When transporting a valve do not carry it by the handle A SL Keep the piping in the corrugated cardboard boxes avoid direct sunlight and store it indoors at Room Caution Temperature Also avoid storing it in a place which may become very hot Corrugated cardboard packages become weaker as they become wet with water or other liquid Take enough care in storage and handling After unpacking the products check that they are defect free and meet the specifications Butterfly Valves 40 400mm 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Names of Parts Type57 40mm 1 1 2 350mm 14 Bo
14. intenance Manual a A 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 9 Installation procedure for handle pae GT T ePlastic Hammer eSocket Wrench eScrew Driver eGoggles eProtective Gloves A Caution Do not give any unjust force to cap in installing or removing the cap It can be damaged Installation Procedure 1 Install the handle on the stem Set the direction of handle in the indication line at the top of stem 2 Fix the handle at the top of stem with the attached bolts and washer by using socket wrench 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
15. mm Aom 16 Ma 412 1 77 1 06 Me 0 94 Body Material PDCPD lt JIS Standard gt Dimension of Insert Bolt A Nom Size Boli um Nut Washer d L S 400mm 16 M24 290mm 11 43 60mm 2 36 M24 ola Dimension of Insert Bolt_B Nom Size Bolt um Nut Washer d Li 400mm 16 M24 100mm 3 94 M24 jon Butterfly Valves 40 400mm 10 ASAHI AV VALVES Installation Operation and Maintenance Manual lt ANSI Standard gt Body Material PVC PP PVDF Dimension of Insert Bolt A Bolt Mini Nom Size olt Minimum Nut Washer d L S 40mm 112 125mm 4 92 50mm 23 125mm 4 92 g 65mm 212 5 8 11 130mm 5 12 cs 5 8 11 S S d 80mm 3 130mm 5 12 100mm 4 145mm 5 71 125mm KR 165mm 0 30 A 150mm 6 3 4 10 175mm 6 89 3 4 10 a a 200mm 8 190mm 7 48 40mm i 250mm 10 220mm 8 66 1 57 der Flat 300mm 12 7118 9 245mm 9 65 7 8 9 0 sr 350mm 14 250mm 9 82 l 5 S 45mm s 1 Flat 400mm 16 1 8 300mm 11 81 177 1 8 094 Dimension of Insert Bolt_B E Bolt Minimum Nom Size ai L S S Nut Washer 7 4 120mm 45mm 27mm s 1 Flat date liag 4 72 177 106 wee 094 lt ANSI Standard gt Body Material PDCPD Dimension of Insert Bolt A s pi 60mm 24mm 400mm 16 M
16. ng be sure to check for leaks under water pressure If absolutely necessary to use gas in testing please consult your nearest service station beforehand A S Do not step on the valve or apply excessive weight on valve Caution It can be damaged Keep the valve away from excessive heat or fire It can be damaged or destroyed gL Operate the valve within the pressure Vs temperature range The valve can be damaged by operating beyond the allowable range Allow sufficient space for maintenance and inspection 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 Keep the valve away from places 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 changes with time during prolonged storage rest or operation Gear Operator Operation we utilize a self locking worm gear design on our manual operators This design 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 lockin
17. on amp Mandatory Action Signs gt S Prohibition When operating the valve this remark indicates an action that should not be taken 05 Mandatory action When operating the valve this remark indicates mandatory actions that must be adhered to 1 Be sure to read the following description of our product warranty Butterfly Valves 40 400mm 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 technicaldocuments 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 factoryor one year after the product is installed whichever comes first Any product abnormality that occurs during the warr
18. r 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 12 Troubleshooting Phenomenon Cause Treatment 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 The seat is damaged or worn Replace the seat Fluid leaks to the outside Adjust and retighten The connecting bolts are not tightened in proper torque or evenly Foreign materials have adhered Clean it up The handle does not work Repair or replace smoothly The gear box is damaged The connecting bolt is over tightened Agusan nen The gear box is damaged Repair or replace Valve does not operate The stem is damaged Replace the stem Butterfly Valves 40 400mm 18 ASAHI AV VALVES Installation Operation and Maintenance Manual 13 Handling of Residual and Waste Materials A E Make sure to consult a waste treatment dealer to dispose of the valves Caution Poisonous gas is generated when the valve is burned improperly Butterfly Valves 40mm 350mm 1 1 2 16 Type
19. the Caution factory Ifthe valve is opened or closed after unpacking it must be reset in this position before installation Failure to do so will result in damage to the surface of the valve seat during handling and installation NOT RECOMMENDED Deal SEU low L EZ SST WS N KZA Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual A g Care must be used during piping installation to ensure that the pipes or flanges are properly aligned so 1 Caution that the valve disc does not contact them in any setting Misalignment as in Figure below will result in damage to the valve Fig 6 2 in vonnected flange or pipe L LE A ee ee A C A interruption lve t T aasre i L J 5 i lfi p ee 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 If inside diameter of the connection partis larger than size D shaving is not necessity E Nominal Size Diameter D 40mm 1 1 2 30mm 1 18 d g at Nar Mise aoe 50mm _ 2 44mm 1 73 fp ____idt 65mm 21 2 67mm 2 64 ZDN 80mm 3 71mm 2 80 l ia 100mm 4 90mm 3 54 125mm 5 115mm 4 53 150mm 6 136mm 5 35 K er
20. 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 YI 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 h 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 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 Butterfly Valves 40 400mm 15 ASAHI AV VALVES Installation Operation and Ma
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