Butterfly Valves
Contents
1. Nomina 31 T 167 Nominal 167 Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation Procedure T In suspending and supporting a valve take enough care and do not stand under a suspended valve Warning 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 AG Caution much 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 install2. s Protective Gloves Vise Q Circular Stick Plastic or Wood i 6 Goggles Q Grease Silicone Pressing Machine Q Screw Driver i Spanner Wrench Q Square Lumber Hammer Q Screw Driver Stabilization Ring 157 lt lt Disassembly gt gt grev Seat 3 Procedure 3 1 Drain fluid completely from the pipeline 2 Leavethe valve slightly opened 3 Loosen the connecting bolts and nuts 4 Remove the valve from the pipeline Lever Type 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 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 Nominal size 40mm 350mm 1 1 27 14 Itadvances 400mm 16 as follows To take off stem holder 8 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
3. ASAHI AV VALVES Installation Operation and Maintenance Manual ANSI Standard Body Material PVC PP PVDF Dimension of Insert Bolt A Bolt ren Nom Size 11 2 gena 50mm 125mm 4 92 J sg 130mm 5 12 oe See Pw 130mm 5 127 145mm 5 717 Dimm 5 165mm 6 50 ves Imm 6 3 4 10 175mm 6 89 3 4 10 0 79 190mm 7 48 40mm m 9657 per 7 8 Flat 26mmQ65 0 87 Dimension of Insert Bolt B Bolt Minimum Li Si S2 99 39 v ANSI Standard Body Material PDCPD Dimension of Insert Bolt A Bolt Mimum MM ee Dimension of Insert Bolt B Nom Size Nut Washer Bolt Minimum BoltA Bolt B EE i 5 z Butterfly Valves 40 400mm 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating Procedure A S Donot use the valve to fluid containing slurry Caution The valve will not operate properly Caution pipeline A 6 The installed valve must never be opened or closed when foreign matter such as sand is present in the i Do not exert excessive force in closing the valve i 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
4. 1 12 350mm A F Body material PVC PP PVDF 22 a Cap Bolt Screw Gasket D Cus maw 3 Sew o Butterfly Valves 40 400mm 4 ASAHI AV VALVES Installation Operation and Maintenance Manual Type56 Gear Type 400mm 16 Body material PP PVDF PDCPD pou d f R je N S NA aN w NM vice ECY A A m Po Ac f aA L Z Y E L E mE PA L SAN A d 4 e a Zan 2 PA NOE J gt Og Se a 2 Gasket A Bol Reference figure Butterfly Valves 40 400mm ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Comparison between working temperature and pressure ominal size ominal size a tZam k g e M ominal ominal si N D
5. 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 ne enced boli an motion m Adjust and retighten proper torque or evenly Foreign materials have adhered Clean it up The handle does not work Vioserboxisdamaset 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 Butterfly Valves 40 400mm 18 ASAHI AV VALVES Installation Operation and Maintenance Manual 13 Handling of Residual and Waste Materials A o Make sure to consult a waste treatment dealer to dispose of the valves CRUDO Poisonous gas is generated when the valve is burned improperly Butterfly Valves 40mm 350mm 1 1 2 16 Type 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 1s subject to change without notice 2008 8 Butterfly Valves 40 400mm
6. 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 d 4 Fig 7 1 3 Incase of gear type 40 400 mm 11 1 2 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 o 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 Installation Operation and Maintenance Manual Technical Data for
7. install a locking device The locking device will prevent the possibility of the valve drifting in severe condition form it is original intermediate setting Handle lock Butterfly Valves 40 400mm 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General Instructions for Transportation Unpacking and Storage A S In suspending 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 Q5 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
8. 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 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 Assembly 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 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 Nominal size 40mm 3
9. to the pipe Unit mm inch Axial Misalignment Parallelism a b Axial Misalignment i 40 80mm 1 0 0 8 1 1 2 3 0 04 0 03 i 1 0 iar ae ae 4 6 0 04 0 04 e 8 16 0 06 0 04 A Q5 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 12 50 65mm 272 12 80 100 mm 3 4 Torque value 20 0 204 177 22 5 230 200 30 0 306 266 125 150 mm 5 6 200 250 mm 8 10 300 350 mm 12 14 400 mm 16 40 0 4408 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 Bolt nn enn Nom LO o Noms EE xxu n 125mm 4 92 O 125mm 4 92 125mm 4 92 92 35mm lcm MI6 BoomGB as 0 63 80mm el n O mem an IT 5 _ a a M20 E Nu 79 20mm 866 20mmG8 9 M2 250mmQ8 Dimension Ka Insert E B Body Material PDCPD JIS Standard Dimension of Insert Bolt A Minimum Dimension of Insert Bolt B Nom Size Butterfly Valves 40 400mm 10
10. 50mm 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 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 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 Maintenance Manual 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 prope
11. ASAHI AV VALVES Installation Operation and Maintenance Manual Butterfly Valves Type 57 40 mm 1 4 350 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 etenn 1 Type 56D 400 mm 16 Body PDCPD 2 General Operating Instructions 2 3 General Instructions for Transportation Unpacking and Storage E GED ab assent 3 E een mains ii 5 Comparison between Working Temperature and Pressure Se acute eee E TUN e eae 6 6 Installation Procedure TM NUNC E ee eee NC ME A NES 7 7 Operating Procedure de n l l 8 Disassembly and Assembly Procedure for Parts Replacement ponk adv 1 4 10 Adjustment Procedure for Stopper on Gear Type l 7 11 Inspection Items nnne 18 12 Troubleshooting nn 18 13 Handling of Residual and Waste Materials eee 19 ASAHI AVVALVES 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 Warning amp Caution Signs gt This remark expresses the user to take caution due to the potential for serious injury or death aming A This remark expresses the user to take caution due to the potential for damage to the valve if used in Caution such
12. Operation Required Hand Length of Lever and d Wheel Torque Diameter of Handle Requires aki Body Material N m moun m us T 40mm PVC PP 112 PVDF 50mm PVC PP Ser oe ee ee 65mm PVC PP em mb 5 2 ws 80mm PVC PP for ome o9 HW qo we 100mm PVC PP w me 9 om omo wm 125mm PVC PP for wor 9 3 om oe oes oe 150mm PVC PP e ee 91 9 e eo PVC PP LIE ow o RON e PVC PP 107 PVDF p PVC PP Fle RERUM E PVC PP 14 PVDF PP PVDF e e an Note Data mentioned in the table above 1s reference only 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 8 Disassembly and Assembly Procedure for Parts Replacement A 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 A G Wear protective gloves and safety goggles as fluid remains in the valve Caution You may be injured 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 r Necessary items 2 2 2 22 22 22 2 22 22
13. a leak test on newly installed piping 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 a 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 1s present and an intermediate setting 1s required It is recommended to
14. a manner lt Prohibition amp Mandatory Action Signs gt EM Prohibition When operating the valve this remark indicates an action that should not be taken EM 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 Always observe the specifications of and the precautions and instructions on using our product Wealways 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 warranty
15. he contact of pipe and disc If inside diameter of the connection part is larger than size D shaving is not necessity poto pi id L 40mm 1 1 2 30mm 1 18 50mm 2 44mm 1 737 L 7 j 65mm 212 67mm 2 64 JAEN l 30mm 3 Timm 2 80 L lt S LX 250mm 10 234mm 9 21 300mm 12 284mm 11 18 d 350mm 14 336mm 13237 UL 400mm 16 370mm 14 58 N A kis Butterfly Valves 40 400mm 8 ASAHI AV VALVES Installation Operation and Maintenance Manual n Necessary MONIS ee eee e OO Torque Wrench Q Spanner Wrench Procedure A Caution anil en The disk 2 1s prevented from overflowing The disk 2 is damaged a p ZA I 1 Install the valve between flanges and open the valve slightly Ta 2 Insert bolts set nuts and washer and tighten the bolts and nuts temporarily by Bodi A hand o 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 A 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
16. ing 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 i Excessive tension may damage it The seat carries out the role of the gasket A The valve disc is sent in the position indicated by solid lines in Figure prior to shipment from 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 iNEREREERERERRAHERRREHRERRRRRRHRRERRERHRERRRRRERRRRRRHRERRRRRRHRRERRERHRERRRRRRRRRRRHRERRRRRRERRERRERHRRSRRRRRERRERRERHRERRERRRRHRRERRERHRRHRRRRRRHRRRRRRRRRR NOT RECOMMENDED Seat DISC AZI D ZZ AD RECOMMENDED Body Butterfly Valves 40 400mm 7 ASAHI AV VALVES Installation Operation and Maintenance Manual A Q5 Care must be used during piping installation to ensure that the pipes or flanges are properly aligned so Caution that the valve disc does not contact them in any setting Misalignment as in Figure below will result in damage to the valve In case of the thick wall of the connection part flange and pipe 1s too thick shave the flange or the pipe inside in order to avoid t
17. ose the bolts and washer by using socket wrench then remove the T handle Dy E n i A SO 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 p INGGOSSHEV IOT Sse a nO RTT l e Allen Wrench The adjustments for full opened and full shut position are step less and it can be done with the stopper adjuster UU 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 allen wrench 3 Adjust the disc of valve to required position 4 Tighten the stopper hex bolts 5 Putthe 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 tems A Q5 Perform periodic maintenance Caution Leakage may develop due to temperature changes or changes with time during prolonged storage rest i or operation Inspect the following items Check for flaw crack or deformation on the valve Check for leaks to the outside l 12 Troubleshooting The stopper 1s 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
18. 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 Butterfly Valves 40 400mm 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A GD 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 1s 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
19. rly 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 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 pee Necessary Items meme sn n Hse Y 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 by using a plastic hammer Noman 40 100mm 125 200mm 1 1 2 4 5 8 M6X15L M8X1SL Butterfly Valves 40 400mm 16 ASAHI AV VALVES Installation Operation and Maintenance Manual Remove Procedure D Toremove the cap push up the side of the cap by using screw driver 777mm _ 2 Lo
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