Instruction manual （510.9 KB）
Contents
1. Fig 7 1 T T Fh 5 e f A h WO AUNE Di 5 ims Full Shut Close Position if ii Full Opened Position 3 Incase of gear type the indicator shows the position of the disc on the top of gear box For the full shut close position the indication shows Shut S Forthe full opened position the indication shows Open O Butterfly Valve Type 57L Lug Style PDCPD 11 ASAHI AV VALVES Installation Operation and Maintenance Manual Technical Data for Operation Nominal Size Stem Torque N m Required Operating Force N Somm B 20 1 80 J Uu gt 100mm 4 rm I5mm 40 15 21 150mm 6 200mm 8 250mm 10 300 S Note Data mentioned in the table above is reference only These data are measured in standard condition and it slightly rm ee ee Ee ee um umo um differs depending on conditions Required Operating Force is the data by turning handle with both hands 8 Disassembly and assembly procedure for parts replacement Q The handle part can be removed with line pressure present The stem holder can t be removed with lin2. 4 Tighten the bolts and nuts gradually with torque wrench to the specified A M l Bolt torque in a diagonal manner Fig 6 1 Lug insert E ep pt SZ 4 Inserted Nut T Zz GTA N Ty Body v Butterfly Valve Type 57L Lug Style PDCPD 10 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating procedure Q Do not use the valve to fluid containing slurry The valve will not operate properly Caution Q5 The installed valve must never be opened or closed when foreign matter such as sand is present in the pipeline Do not exert excessive force in closing the valve 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 the direction of handle is same as the disc as shown in Fig 7 1 For the full shut Close position the handle is perpendicular to the piping axis direction Forthe full opened position the handle is parallel to the piping axis direction
3. Flange Bolt Washer esseseoososooocooosooosooocooososooooooooscosoososeccocscsococososooosososocososooososososososooosooosooooosooooosoosooosocosccooososeccoososeoosocosoooso lioccesccsscccessssscesssscoscesesssessssossoceosccssosossesessscssssosccssssesscssoscssccsoscccsosssscssoscsssosesscsseceosscsccsoccescosocceccocceccococcoot Butterfly Valve Type 57L Lug Style PDCPD 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 2 Used for Wafer Style 2 vestiti Necessary items Q Torque Wrench 6 Spanner Wrench Bolt Nut Washer Bolt Length Flanges AV TS Flange Lu A Se Bolt B Size dl Ll Nominal Size d mm Mi imm mm 5 100mm 4 MI6 145mm 45mm 8 Quanti c DsmmG M20 Imm somm 8 150mm 6 M20 175mm 55mm 8 wes mn M20 Tm ms 8 M20 65mm gt 50mm M9 225mm s0mm 8 MD mm 8 n case of T standards 4 bolts are necessary k e 1 Remove the Lug insert 1e Fig 6 2 Fig 62 Tap lightly on the bolt 2 Install the valve between flanges and open the valve slightly 3 Insert bolts set nuts and washer and tighten the bolts and nuts temporarily pom by hand lt i
4. Butterfly Valve Type 57L Lug Style PDCPD 12 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 Insert the screw driver between body 1 and seat 3 Disc 2 and seat 3 are extruded by using screw driver 9 Remove the disc 2 seat bush A 183 and seat bush B 184 from the seat 3 10 Remove the O ring C 6 from the stem 7 lt lt Assembly gt gt Procedure 1 Before starting assembly grease Silicone should be spread on the O ring C 6 and O ring I 185 2 Put the O ring C 6 onto the stem 7 Put the O ring T 185 onto the stem bush A 183 and B 184 3 Grease Silicone should be spread on the top and bottom disc 2 the stem of the seat 3 4 Put the disc 2 seat bush A 183 and seat bush B 184 onto the seat 3 The set of seat disc call for combined parts 5 Put it into the state of open the valve slightly Insert the set of seat disc 3 into the body 1 Stem bush B o Make certain stem hole of seat are properly aligned The upper side stem hole of seat bush A 183 Caution has lager than seat bush B 184 of lower side When the stem bush is assembled oppositely the stem 7 cannot be inserted Upper side Stem hole is large size Lowe
5. Operation and Maintenance Manual 4 Names of parts Nominal size 80 200mm 3 8 Nominal size 80 250mm 3 10 No Description No Description No Description le Lugdnset S Pin S Screw Rubber Washer Butterfly Valve Type 57L Lug Style PDCPD 4 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Working pressure vs temperature Working pressure MPa PSI Butterfly Valve Type 57L Lug Style PDCPD LUG BUTTERFLY VALVE TYPE57L Wafer Nominal Size 80 250mm 3 10 EE oN HH HR LEE TT TT TT NTE TN LITTLE 5 30 70 105 140 175 210 250 Temperature C C F 0 20 40 60 80 100 5 30 70 105 140 175 210 250 st p ei ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation procedure A Q When suspending and supporting a valve take care and do not stand under a suspended valve Warning 5 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 Q When ins
6. the deformation of seat due to improper installation of valve Check for the smoothness of handle operation Butterfly Valve Type 57L Lug Style PDCPD 15 ASAHI AV VALVES 12 Troubleshooting Installation Operation and Maintenance Manual Fluid is not stopped in the full closed position at the seat Fluid leaks to the outside The handle does not work smoothly Valve does not operate 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 The seat is damaged or worn The connecting bolts are not tightened in proper torque or evenly Foreign materials have adhered The gear box is damaged The connecting bolt is over tightened The gear box is damaged The stem is damaged Warning valves Poisonous gas is generated when the valve is burned improperly Adjust the stopper Replace the seat Clean it up Replace the disc Adjust and retighten Replace the seat Adjust and retighten Clean it up Repair or replace Adjust and retighten Repair or replace Replace the stem Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic e e e e OE OE OE OE OE OE OE OE OE OE OE i o mo mmo nd Butterfly Valve Type 57L Lug Style PDCPD 16 ASAHI AV VALVES Inst
7. ASAHI AV VALVES Installation Operation and Maintenance Manual Butterfly Valve Type 57L Lug Style PDCPD 80 250mm 3 10 Contents 1 Besureto read the following warranty clauses of our product ER 1 2 General operating instructions 2 3 General instructions for transportation unpacking and storage 999 3 4 Names of parts nnn 4 5 Working pressure vs temperature H 5 6 Installation procedure 9 6 T Operating procedure en 11 8 Disassembly and assembly procedure for parts replacement EEE A 12 9 Installation procedure for handle NE EEE 1 4 10 Adjustment procedure for stopper on gear type e 15 11 nspectionilemy esetet 15 12 Troubleshooting nn 16 13 Handling of residual and waste materials 16 ASAHI AV VALVES Butterfly Valve Type 57L Lug Style PDCPD 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 P amp Caution Signs This symbol reminds the user to take caution due to the potential for serious injury or death A This symbol reminds the user to take caution due to the potential for damage to the valve if used in such a A manner lt Prohibited amp Mandatory Action Signs gt Prohibited When operating the valve this
8. allation Operation and Maintenance Manual Butterfly Valve Type57L PDCPD Lug Style 80 250mm 3 10 8 ASAHI AV VALVES Distributor Asahi Organic Chemicals Industry s homepage http www asahi yukizai co jp en Information in this manual is subject to change without notice 2014 10 Butterfly Valve Type 57L Lug Style PDCPD
9. e Warning pressure present If stem holder needs to be removed there can not be line pressure present Wear protective gloves and safety goggles as fluid remains in the valve You may be injured When installing pipes and valves ensure that they are not subjected to tension compression bending Caution impact or other excessive stress Do not change or replace valve parts under line pressure Necessary items RGF amp Protective Gloves Vise Q Circular Stick Plastic or Wood Goggles Grease Silicone Pressing Machine Q Screw Driver Spanner Wrench Square Lumber Hammer Screw Driver 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 Lever Type Nominal size 80 200mm 3 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 A 8 Gear Type Nominal size 80 250mm 3 10 5 Loosen set bolt 28 for gear box 25 and pull off the gear box upward with gasket 158 6 Remove the stem holder A 8 Release 4 tapping screws 157 by using screw driver
10. gt ZEN damage to the surface of the valve seat during handling and RECOMMENDED Body installation 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 part is larger than size D shaving is not necessity ju Butterfly Valve Type 57L Lug Style PDCPD 6 ASAHI AV VALVES stress application to the pipe 100 150mm 4 6 1 0 0 04 flanges fully turned over and suffer a crack torque level in a diagonal manner Recommended torque value Nominal Size 80 100mm 3 4 Torque value 30 0 306 266 Butterfly Valve Type 57L Lug Style PDCPD Axial Misalignment 80mm 3 1 0 0 04 0 8 0 03 200 250mm 8 10 1 5 0 06 1 0 0 04 When you insert a valve between flanges please insert after extending the fields of If you insert a valve by force without fully extending fields of flanges a liner may be Tighten the bolts and nuts gradually with a torque wrench to the specified Avoid excessive tightening The valve can be damaged Installation Operation and Maintenance Manual The parallelism and axial misalignment of the flange surface should be under the values shown in the Canton following table to prevent damage the valve A failure to observe them can cause destruction due to Axial
11. 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 it is original intermediate setting Q When suspending and supporting a valve take care and do not stand under a suspended valve Warning Q 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 These chemicals may cause damage to the valve When transporting a valve do not carry it by the handle 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 wet 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 Ll ee ee ee eS l Butterfly Valve Type 57L Lug Style PDCPD 3 ASAHI AV VALVES Installation
12. maged 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 operation Before opening or closing a lubricant free product be sure to apply water f you install this valve to the end of the piping we recommend to use E the Blind Flange at the opposite side of the valve to prevent Blind Flange accidental opening of the valve SB Butterfly Valve Type 57L Lug Style PDCPD 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 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
13. misalignment parallelism Unit mm inch i 1 0 0 04 Unit N m kgf cm Ib inch TT 125 150mm 5 6 200 250mm 8 10 40 0 408 355 55 0 561 488 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 1 Used for Lug Style Aniedanded Necessary items RERUM Rm Torque Wrench Spanner Wrench Bolt Washer DE of flow YAN LZ E MNT ME MN B pstream olde z LZ NM 1 Bolt Length Flanges AV TS Flange Unit mm inch Thickness of Washer ickness of Flange Body Insertion Part Face to Face Nominal Upstream Downstream Upstream Downstream Upstream Downstream Dmi Size Side Side Side Side Side Side 80mm 3 26mm 26mm a c e 2 6mm 2 6mm 43 5mm 52 5mm The length c and c above shows the minimum value Nominal Lug Insert Bolt Recommended Bolt Length noA a Thread Across Flats of Lug Nut 80mm 3 Mio 24mm 40mm Ml6 45mm 8 40mm 8 100mm 4 MI6 24mm 40mm Mi 55mm 8 domm 8 125mm 5 M20 30mm 50mm M20 60mm 8 dmm 8 I50mm 6 M20 30mm S0mm M20 65mm 8 S mm 8 200mm 8 M20 30mm 60mm M20 75mm 12 55mm D M22 In case of DIN standards 8 bolts are necessary 2 Bolt Length Flanges Except for AV TS Flange Bolt Length L1 Thickness of Washer a Body Insertion Part c Thickness of Flange Imm B
14. mm 125 200mm 37 4 57 107 M xISL M8x15L 10 ST DNIUN NMNII Procedure 1 To remove the cap push up the side of the cap by using screw driver 2 Loose the bolts and washer by using socket wrench then remove y the handle jx y Butterfly Valve Type 57L Lug Style PDCPD l4 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Adjustment procedure for stopper gear type M Necessary Items Allen Wrench The adjustments for full opened and full shut position are step less and it can be done with the stopper adjuster EE PAOIISRUEDCLOBEUISSDUDOPUMICODSHOR DOSIIOR Rubber Cap po 1 Remove the rubber cap of Full closing Full opening 7 peus adjuster 0 2 Loosen the first stopper hex bolt completely by Allen 3 Adjust the disc of valve to required position Adjuster for Full Shut Positi 4 Tighten the stopper hex bolts Adjuster for Full Opened Position 5 Put the rubber cap of Full closing Full opening adjuster back on gearbox j Perform periodic maintenance Leakage may develop due to temperature changes or over periods of Caution prolonged storage rest or operation Inspect the following items Check for flaw crack or deformation on the valve Check for leaks to the outside Check for
15. olt Length L2 Thickness of Washer a Body Insertion Part c Thickness of Flange Jmm XMake sure to check whether both upstream and downstream side bolt does not interfere with each other Butterfly Valve Type 57L Lug Style PDCPD g ASAHI AV VALVES Installation Operation and Maintenance Manual Procedure Seat Disc 1 Install the valve between flanges and open the valve slightly P VA L Tubing with the piping of upstream LIE 2 Lug Insert le is inserted in the body 1 Body 3 Ensure that the direction of fluid and the flow direction marked on the valve body are the same 1 4 Insert bolts set nuts and washer and tighten the bolts and nuts temporarily by hand 5 Tighten the bolts and nuts gradually with torque wrench to the specified torque in a diagonal manner Fig 6 1 Q Be certain when installing the valve that the directional Warning arrow on the valve body and the direction of fluid flow are the same Failure to do so will result in a very dangerous condition Tubing with the piping of downstream 6 The flange on the downstream side is set 7 Insert bolts set nuts and washer and tighten the bolts and nuts temporarily by hand 8 Tighten the bolts and nuts gradually with torque wrench to the specified torque in a diagonal manner Fig 6 1 Before p
16. r side Stem hole is small size Concave part of seat bush Make certain tabs are properly aligned Convex part of seat bush Butterfly Valve Type 57L Lug Style PDCPD 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Insert the stem 7 of the body 1 7 Install stem holder A 8 onto valve body 1 with countersunk holes facing up using 4 screws 157 8 To install lever or gear operator reverse disassembly procedure 5 Make certain line scribed on top of stem 7 indicates disc 2 position while installing stem 7 After assembly make sure that the valve can be fully opened and closed smoothly 9 Installation procedure for handle i Q5 Do not give any unjust force to cap in installing or removing the cap It can be damaged Ce ee NNNM Ne cessary items Q Plastic Hammer Q Socket Wrench Q Screw Driver Goggles Q Protective Gloves lt lt Installation gt gt 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 by using a plastic hamrer Indicator Nominal Size 80 100
17. symbol indicates an action that should not be taken Mandatory action When operating the valve this symbol indicates mandatory actions that must be adhered to 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 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 c
18. talling a pipe support by means of a U band or something similar take care not to over tighten Caution Excessive force may damage the pipe When installing pipes and valves ensure that they are not subjected to tension compression bending impact or other excessive stress 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 Do not use AV valves in a place where they may become submerged in water Submergence will make AV valve fail Care must be used during piping installation to ensure that J the pipes or flanges are properly aligned so that the valve disc does not constant them in any setting Misalignment as in Figure below will result in damage to the valve Use flat faced flanges for connection to AV Valves Ensure that the mating flanges are of the same standards The gasket is unnecessary INTERFERENCE OF THE DISK The seat carries out the role of the gasket e l TP e NOT RECOMMENDED The valve disc is sent in the position indicated by solid lines in Gent M Figure prior to shipment from the factory If the valve is m Fd f opened or closed after unpacking it must be reset in this 7 SS AL G position before installation Failure to do so will result in z A T
19. ur nearest service station beforehand While removal of valves from pipeline or during maintenance pras a pnm to protect worker Before removal of valves from pipeline make sure to empty the line so no liquid A Direction of the Arrow l is remaining Then take off bolts at the mu a c downstream side first It is dangerous rms NVE FA LL taking off bolts at the upstream side first EN re Gp a It causes the valve drop out from NC 008b pipeline Lug Butterfly Valve 1s designed for being able to maintam SHUT OFF POSITION at the disconnected downstream side pipeline while connected to upstream side pipeline This valve has flow direction Therefore do not take away the upstream side bolts Caution If you take off the upstream side with out stopping and emptying at upstream side there will be leakage on both side While removal of a flange on downstream side draw out fluids from removing side pipeline completely 7 Maintaining low pressure on upstream side will ensure safety Q Do not step on or apply excessive weight on valve It can be damaged Caution Do not use AV valves in a place where they may become submerged in water Submergence will make AV valve fail Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly ab Keep the valve away from excessive heat or fire It can be da
20. ustomer 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 or which is reported to us will be investigated immediately to identify its cause Should our product be deemed Butterfly Valve Type 57L Lug Style PDCPD 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General operating instructions A o 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 as covering the piping with protective material For inquiries please contact us 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 yo
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