Type57 TL Butterfly Valves (Isolator Lug Style/ PVC)
Contents
1. 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 Messosocesosososesesecccosececesesooceocesecesocessossoceoscescososcescoceoceocosecesocesecosocceecesececesesceceeovececeseccoccovocesceceeoseccee 1 i TAPA 2 adjuster Ne Remove the rubber cap of Full closing Full opening 4 hi P 2 Loosen the first stopper hex bolt completely by Allen v J Wrench 05 5 3 Adjustthedisc of valve to required position nis _ 4 Tighten the stopper hex bolts 5 Put the rubber cap of Full closing Full opening adjuster back on gearbox Adjuster for Full Shut Position Adiuster for Full Opened Position AN 5 Perform periodic maintenance Leakage may develop due to temperature changes or over periods of i Caution prolonged storage rest or operation i Inspect the following items Check for the existence of flaw crack or deformation on the valve Check for the existence of leakage from the valve to the outside of the pipeline 3 Check for the deformation of seat due to improper installation of valve 4 Check for the smoothness of handle operation Butterfly Valves Type 57TL Isolator Lug style PVC 16 ASAHI AV VALVES Installation Operation and Maintenance Manual 12 Troubleshooting The stopper is not2. 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 TS Hg 7 1 3 Incase of gear type 3 12 80 300mm 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 For the full opened position the indication shows Open O Full Shut Close Position Full Opened Position Butterfly Valves Type 57TL Isolator Lug style PV
3. 2 12 Remove the retaining 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 Butterfly Valves Type 57TL Isolator Lug style PVC 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 Insert the retaining 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 Q5 Make certain tabs are properly aligned Both upper and lower retaining rings 156 are identical Caution 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 Install the retaining 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 1s reset into body of valve 6 Remove the stem 7 7 Resetthe seat 3 into the body 1 o ee eB Ee eB ee Be Be Ee BB BM BM ooo ooo ooo EB BE eB EB EB EB EB eB eB eB BE
4. BE EK KK KF Make certain retaining rings 156 sit flush inside of seat 3 with tabs properly aligned If retaining rings Caution 156 are not installed correctly the seat 3 will not sit in the body 1 properly This is indicated by a i 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 i A Q Look into valve body 1 to be certain full square in disc 2 is centered with upper valve 1 stem hole i Caution If not repeat step 8 9 and 10 Make certain line scribed on top of stem 7 indicates dise 2 position while installing sem 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 repeat from step 8 to properly align the disc 2 in the valve body 1 12 Install stem holder A 8 onto valve body 1 with countersunk holes facing up using 4 screws F 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 Type 57TL Isolator Lug style PVC
5. 14 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Installation procedure for handle nuu Necessary items u H H P Plastic Hammer Socket Wrench Q Screw Driver Goggles Protective Gloves A S Do not give any unjust force to cap 1n installing or removing the cap It can be damaged Caution 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 ix 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 hammer 3 4 80 100mm 6 8 150 200mm M6 x 15L M8 x 15L Remove Procedure cidade a 1 To remove the cap push up the side of the cap by using screw driver FJ l 2 Loose the bolts and washer by using socket wrench then remove A ERN the handle EC aM ty Butterfly Valves Type 57TL Isolator Lug style PVC 15 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Adjustment procedure for stopper gear type j SN Necessary Items m cc U n
6. ASAHI AV VALVES Type57 TL Butterfly Valves Isolator Lug Style PVC 3 12 80 300mm UJser s Manual Butterfly Valves Type 57TL Isolator Lug style PVC Installation Operation and Maintenance Manual Contents 1 Be sureto read the following warranty clauses of Our product TUNIS 1 2 General operating instructions AE J 3 General instructions for transportation MAU eee ee 4 6 A EAE eevee eee ee ee Ui T E E 8 Disassembly and assembly procedure for parts replacement M 12 9 Installation procedure for handle EE E E 1 5 10 Adjustment procedure for E e Fain sia ors ene heme cee ee 16 ETO E E N A N E T ted T 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 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 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 observ
7. C 11 ASAHI AV VALVES Installation Operation and Maintenance Manual Fig 7 2 Technical data for operation Stem Torque Required Operating Force Nom N m N Size Note Data mentioned in the table above is reference only These data are measured in standard condition and it slightly differs depending on conditions 8 Disassembly and assembly procedure for parts replacement Ay S 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 Do not change or replace valve parts under line pressure Q5 Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured A Q5 When installing pipes and valves ensure that they are not subjected to tension compression bending Caution impact or other excessive stress Butterfly Valves Type 57TL Isolator Lug style PVC 12 ASAHI AV VALVES Installation Operation and Maintenance Manual pr ANG Cessalty EMIS i Rem Sag AA ER Ee onpisi ctetu Fl rere rE A eo Q Protective Gloves Q Vise Q Circular Stick Plastic or Wood i Goggles Grease Pressing Machine Screw Driver i Spanner Wrench Square Lumber Hammer Screw
8. Driver i 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 5 To remove handle A 16 first take off the cap A 24 by using screw driver 2 and release bolt B 21 by using socket wrench then pull up the handle A 16 ae while holding handle lever 17 6 To take off locking plate 22 release 4 self tapping screws B 23 by using 2 i a Inrust beari screw driver and take off stem holder A 8 lat Gear Type 7 Loosen set bolt C 28 for gear box 25 and pull off the gear box upward with v gasket L 158 8 To take off stem holder A 8 Release 4 tapping screws F 157 by using screw driver Lever amp Gear Type 9 Hold flat surface of Stem 7 with vise and pull off valve body 1 10 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 11 Set the disc 2 parallel to the working desk to half opened position Push the seat 3 and remove the disc
9. Size 3 4 6 8 10 l 80 100mm 150mm 200 250mm 40 0 Torque value 408 355 Butterfly Valves Type 57TL Isolator Lug style PVC 8 ASAHI AV VALVES Installation Operation and Maintenance Manual Necessary items A Q Torque Wrench Spanner Wrench Q Bolt Washer 2 P s y N EJ b l 1 Bolt length Flanges AV TS Flange ANSI Unit inch Nonin nina Thickness Thickness Body Face to Face up Recommended pra Washer of pa Part 5 Bolt Internal Thread Thread 5 8 11 UNC SED 11 UN S amp ILUNC 5 8 11 UN The body insertion part c above shows the minimum value 2 Bolt length Flanges Except for AV TS Flange ANSI Bolt length L Thickness of Washer a Body Insertion Part c Thickness of Flange inch 7 Make sure to check whether both upstream and downstream side bolt does not interfere with each other Butterfly Valves Type 57TL Isolator Lug style PVC iU ASAHI AV VALVES Installation Operation and Maintenance Manual Procedure 1 Install the valve between flanges and open the valve slightly Tubing with the piping of upstream 2 Lug Insert 1e is factory molded in the body 1 3 There is no flow directional requirement for the 57TL 1 4 In
10. as fluid remain in the valve even if the pipeline is empty You may be injured Av S When installing 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 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 ab 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 E Ensure that the mating flanges are of the same standards ud nu The gasket 1s unnecessary The seat carries out the role of the gasket Additional gaskets will increase stem torque and may make valve fail or become inoperable 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 INTERFERENCE OF THE DISK in Figure below will result in damage NOT RECOMMENDED The valve disc is sent in the position indicated by solid lines oeat DISC in figure prior to shipment from the factory If the valve is Zh uL 7 Lig opened or closed after unpacking it must be reset in this Z N i E rA S 7 m posit
11. e 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 factory or one year after the product is installed whichever comes first Any product abnormality that occurs during the warranty 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
12. emperature 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 ee ee ee ee ee ee ee ee ee ee ee eee eee eee eee Ss After unpacking the products check that they are defect free and meet the specifications Butterfly Valves Type 57TL Isolator Lug style PVC 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Names of parts Lever Type 3 8 80 200mm D 21 Bolt B 22 Locking Plate 3 Seat 23 Screw B 156 Retaining Ring p E 7 Pal x p Gu Ge P d W AE J p N e A S Reese N 181 B 4 eo LL WL gl d Ll Handle A 182 jt xe 17 Handle Lever 186 Rubber Washer WARE 18 Wm e me 6 Butterfly Valves Type 57TL Isolator Lug style PVC 4 ASAHI AV VALVES Installation Operation and Maintenance Manual Gear Type 3 12 80 300mm Butterfly Valves Type 57TL Isola
13. ion before installation Failure to do so will result in m Se i 1 jJ damage to the surface of the valve seat during handling and RECOMMENDED E 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 d ju cea lcd pem FJ uw Ly Butterfly Valves Type 57TL Isolator Lug style PVC 7 ASAHI AV VALVES Installation Operation and Maintenance Manual 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 inch mm Nom Size Axial Misalignment Parallelism a b 3 004 Axial Misalignment a 4 6 0 04 m 8 12 0 06 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 Tighten the bolts and nuts gradually with torque wrench to the specified torque in a diagonal manner Avoid excessive tightening The valve can be damaged Recommended torque value Unit N m kgf cm Ib inch Nom
14. ipeline make sure to empty the line so no liquid 1s remaining While removal of a flange on upstream side or downstream side draw out fluids from removing side pipeline completely and confirm the other side will be on low pressure to ensure safety A S 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 ob 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 operation Before opening or closing a lubricant free product be sure to apply water If you install this valve to the end of the piping we rec
15. ommend to use the Blind Flange at the opposite side of the valve to prevent accidental opening of the valve Bling Flange Upstream site Butterfly Valves Type 57TL Isolator Lug style PVC 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 allows Handle lock 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 1s recommended to install a locking device The locking device will prevent the possibility of the valve drifting in severe condition from it is original intermediate setting A SO 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 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 t
16. 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 Valves Type 57TL Isolator Lug style PVC 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General operating instructions A aD 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 your nearest service station beforehand While removal of valves from pipeline or during maintenance please take precautions to protect worker Before removal of valves from p
17. sert 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 i A Q5 Be certain the valve type is the Type 57TL Isolator Lug i Caution Butterfly Valve This is denoted by a factory molded T i on valve body i ISOLATOR LUG 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 Before Bolt Washer Flange Butterfly Valves Type 57TL Isolator Lug style PVC 10 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating procedure A S Do not use the valve to fluid containing slurry The valve will not operate properly Caution 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 T 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 3 8 80 200mm the direction of handle is same as the disc as shown in Fig 7 1 For the full shut Close position
18. 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 Ra Fluid leaks to the outside Thie contedine bole are not taimed in Adjust and retighten proper torque or evenly Foreign materials have adhered Clean it up The handle does not work ieee E 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 is damaged Replace the stem 13 Handling of residual and waste materials l 9 A i5 Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic Warning valves Poisonous gas is generated when the valve is burned improperly Butterfly Valves Type 57TL Isolator Lug style PVC 17 ASAHI AV VALVES Installation Operation and Maintenance Manual Butterfly Valves Type 57TL 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 2012 2 Butterfly Valves Type 57TL Isolator Lug style PVC
19. tor Lug style PVC 5 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Working pressure vs temperature LUG BUTTERFLY VALVE TYPE57TL Wafer Nominal Size 3 10 80 250mm 150 1 0 P g al oO 0 70 05 i Q o0 E AX i o 0 0 40 20 0 20 40 60 80 100 120 40 5 30 70 105 140 175 210 250 Temperature C C F 40 20 0 20 40 60 80 100 120 40 5 30 70 105 140 175 210 250 COME M a Na eU 8h qe qe Nominal Size 12 300mm 150 1 0 70 0 5 Working pressure MPa PSI 0 0 0 20 40 60 80 100 120 30 70 105 140 175 210 250 Temperature C C F 0 20 40 60 80 100 120 30 70 105 140 175 210 250 Butterfly Valves Type 57TL Isolator Lug style PVC 6 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation procedure A S When suspending and supporting a valve take care and do not stand under a suspended valve Warning 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
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