Type57L Butterfly Valves Type57L-IS Butterfly Valves (Lug Style/ PVC)
Contents
1. Fig 7 1 3 Incase of gear type 80 300 mm 3 12 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 Type57L Type57L IS Lug style PVC 9 ASAHI AV VALVES Installation Operation and Maintenance Manual Fig 7 2 Technical Data for Operation Stem Torque Required Operating Force N m Note Data mentioned in the table above 1s reference only These data are measured in standard condition and it slightly differs depending on conditions 8 Disassembly and Assembly Procedure for Parts Replacement Q The handle part can be removed with line pressure present The stem retainer can t be Warning removed with line pressure present If stem retainer needs to be removed there can not be line pressure present Q 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 eee es ml Butterfly Valves Type57L Type57L IS Lug style PVC 10 ASAHI AV VALVES Installation Operation and Maintenan2. Berk 2 Lug Insert le is inserted in the body 1 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 Be certain when installing the valve that the directional 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 Arrow 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 A Pa N ae i p N 4 os i I Bolt Washer Flange Bolt Washer bonennnnnenennnenenennnenneneneennenennennenennernennennennennenenneneenennenneneenn ene eee eee eee ree ere rere eer ere reer eee reer ere errr reer Socoseooooooooooooooocosooosooosocosoocoococococooocooosocosooooooooocosooocoococoooooosooooooooooosoosococcscosococososoccoosococosocosooosocooooososoooo Bu
3. Type57L IS Lug style PVC 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Installation Procedure for Handle poe Necessary items E Plastic Hammer Socket Wrench Screw Driver Goggles Protective Gloves Do not give any unjust force to cap in installing or removing the cap er It can be damaged 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 hammer NE 80 100mm 150 200mm 3 4 6 8 M6xI5L M8 15L Remove Procedure 1 Toremove the cap push up the side of the cap by using screw driver EEE 2 Loose the bolts and washer by using socket wrench then remove the handle i Butterfly Valves Type57L Type57L IS Lug style PVC 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Adjustment Procedure for Stopper Gear Type po Necessary em EEE een eens cect ee ne ete crete EN e 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 1 Remove the
4. 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 dise 2 12 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 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 rings 156 are identical Butterfly Valves Type57L Type57L IS Lug style PVC 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 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 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 th
5. 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 Do not use AV valves in a place where they may become submerged tn water Submergence will make AV valve fail Butterfly Valves Type57L Type57L IS Lug style PVC 5 ASAHI AV VALVES Installation Operation and Maintenance Manual A Q Care must be used during piping installation to ensure i NT ME tiange or pi Caon that the pipes or flanges are properly aligned so EE iy that the valve disc does not contact them in any setting TN go E Misalignment as in Figure below will result VRE Jy in damage oo ee ES Sn pS LJ Wy The valve disc is sent in the position indicated by solid lines in Figure prior to shipment from the factory If the valve is opened or closed after unpacking it must be reset NOT RECOMMENDED in this position before installation Failure to do so will Sed p Disc result in damage to the surface of the valve seat during a yp 7 Yo handling and installation S In case of the thick
6. ASAHI AV VALVES Type57L Butterfly Valves Type57L IS Butterfly Valves Lug Style PVC 80mm 3 100mm 4 150mm 6 200mmd 8 250mm 10 300mm 12 User s Manual Butterfly Valves Type57L Type57L IS Lug style PVC 1 Installation Operation and Maintenance Manual Contents Be sure to read the following description Of our product watranty EE EET 1 2 General Operating Instructions sees 2 3 General Instructions for Transportation Unpacking and Storage v 3 4 Names of Parts ssssseseeeesssseeeeesesssassnssssssssssssssssssssseeeeeeeessessssssssssssssssss 4 5 Comparison between Working Temperature and Pressure stem 5 6 Installation Procedure EEE EE EE ENERSEN 5 7 Operating re sa eae 9 8 Disassembly and Assembly Procedure for Parts Replacement ETE 10 9 Installation Procedure for Handle seses 13 10 Adjustment Procedure for Stopper on Gear Type u 14 1 1 Inspection EN 45 14 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 This remark expresses the user to take caution due to the potential for serious injury or death arning This remark expresses the user to take caution due to the potential for damage to the valve if used in such Caution a man
7. ce Manual NN SEES Protective Gloves Vise Circular Stick Plastic or Wood Goggles Grease Silicone Pressing Machine 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 5 To remove handle 16 first take off the cap 24 by using 3 screw driver and release bolt 21 by using socket wrench es then pull up the handle 16 while holding handle lever 17 i 6 To take off locking plate 22 release 4 self tapping screws 23 by using screw j driver and take off stem holder 8 2 Plate 7 Loosen set bolt 28 for gear box 25 and pull off the gear box upward with l ay gasket 158 Po 8 To take off stem holder 8 Release 4 tapping screws 157 by using screw driver ponent 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
8. e take enough care and do not stand under a suspended valve Warning Q 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 Keep the piping in the corrugated cardboard boxes avoid direct sunlight and store it indoors at Room 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 Type57L Type57L IS Lug style PVC 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Names of Parts Nominal Size 80mm 3 200mm 8 Nominal Size 80mm 3 300mm 12 2 Disc 18 28 Bolt ON Butterfly Valves Type57L Type57L IS Lug style PVC 4 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Comparison between Working Temperature and Pressure LUG BUTTERFLY VALVE TYPE57L Wafer Nominal Si
9. e stem 7 7 Reset the seat 3 into the body 1 A Caution 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 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 repeat from step 8 to properly align the disc 2 in the valve body 1 12 Install stem holder 8 onto valve body 1 with countersunk holes facing up using 4 screws 157 13 To install lever or gear operator reverse disassembly procedure 5 14 After assembly make sure that the valve can be fully opened and closed smoothly Butterfly Valves Type57L
10. e to the end of the piping we recommend to aoa ees use the Blind Flange at the opposite side ol the valve 1 prevent accidental A Direction of the Arrow opening of the valve Wear protective gloves and safety goggles as fluid remains in the valve You may be Upstream side SK KO If you remove a valve from the pipeline draw out fluids completely and confirm the pressure will be zero level at first Then take away bolts at the downstream side first If you remove a valve from the pipeline take caution to not leave a dangerous condition for So other workers Butterfly Valves Type57L Type57L IS 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 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 locking device will prevent the possibility of the valve drifting in severe condition from it is original intermediate setting Handle lock Q Insuspending and supporting a valv
11. lve 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 L eee ee el hl 0 el el el el ee ee ee ee ee 1 Open and close the valve by turning handle smoothly Turn clockwise to close and counterclockwise to open 2 Incase of lever type 80 200 mm 3 8 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 For the full opened position the handle is parallel to the piping axis direction Full Opened Position a cy __
12. ner lt Prohibition amp Mandatory Action Signs gt SE Prohibition When operating the valve this remark indicates an action that should not be taken o 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 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 pe
13. riod 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 Type57L Type57L IS Lug style PVC 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the 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
14. rubber cap of Full closing Full opening adjuster NN ga TT X At ous 2 Loosen the first stopper hex bolt completely by Allen KI 5 a i J Wrench tt Vy a 3 Adjust the disc of valve to required position oa 4 Tighten the stopper hex bolts By F 5 Put the rubber cap of Full closing Full opening adjuster back on gearbox Adjuster for Full Shut Position Adjuster for Full Opened Position ce 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 Check for flaw crack or deformation on the valve Check for leaks to the outside d Check for the deformation of seat due to improper installation of valve Check for the smoothness of handle operation Butterfly Valves Type57L Type57L IS Lug style PVC 14 ASAHI AV VALVES Installation Operation and Maintenance Manual 12 Troubleshooting The stopper is not set correctly Adjust the stopper The seat is damaged or worn Replace the seat Fluid is not stopped in the full Foreign materials are caught Clean it up closed position at the seat The disc is damaged or worn Replace the disc The connecting bolts are over tightened or Adjust and retighten tightened unevenly Replace th The seat is damaged or worn eplace the seat Fluid leaks to the outside Fjerne bolis are sed Adju
15. st and retighten proper torque or evenly Foreign materials have adhered Clean it up The handle does not work EE Repair or replace smoothly The connecting bolt is over tightened Adjust and retighten The gear box is damaged Repair or replace Valve does not operate The stem 1s damaged Replace the stem 13 Handling of Residual and Waste Materials Ay amp Make sure to consult a waste treatment dealer to dispose of the valves Warning Poisonous gas is generated when the valve is burned improperly Butterfly Valves Type57L Type57L IS Lug style PVC 15 ASAHI AV VALVES Installation Operation and Maintenance Manual Type57L Butterfly Valves Type57L IS Butterfly Valves ASAHI AV VALVES Asahi Organic Chemicals Industry s homepage http www asahi yuk1zai co jp en Information in this manual is subject to change without notice 2009 11 Butterfly Valves Type57L Type57L IS Lug style PVC
16. tterfly Valves Type57L Type57L IS Lug style PVC 7 ASAHI AV VALVES Installation Operation and Maintenance Manual ao 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 i Axial Misalignment Parallelism a b Axial Misalignment Parallelism I q I 100 150mm 200 300mm 8 AR l px a When you insert a valve between flanges Caution 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 dg Tighten the bolts and nuts gradually with torque wrench to the specified torque in a diagonal manner Caution Recommended torque value Unit N m kgfm Ib inch 80 100mm 150mm 200 250mm Nom Size 374 6 8 10 30 0 40 0 Torque value 306 408 266 355 Caution Avoid excessive tightening The valve can be damaged ee ee eT A Butterfly Valves Type57L Type57L IS Lug style PVC g ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating Procedure Donotuse the valve to fluid containing slurry Caution The valve will not operate properly ay The installed va
17. us For conducting 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 Do not step on the valve or apply excessive weight on valve It can be damaged AQ Caution Keep the valve away from excessive heat or fire It can be damaged or destroyed 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 on condition that fluid has crystallized The valve will not operate properly ap 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 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 Blind Flange lt Before opening or closing a lubricant free product be sure to apply water ian 7 If you install this valv
18. 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 Hr o EE ee 250mm 10 23imm 6 0 T 30mm 12 280mm 1102 Hede Necessary items EEE EEE EE EEE REE EEE EN EE ER E EE EN Torque Wrench Spanner Wrench Type57L ANSI150Lb Nominal Size T L A or so svnune as oar e 0 saiounc 200 og 20 saiounc 225 os Internal Thread T pr Lug Insert as Installed L _invavebody O La 127 300 78 9UNC 250 217 Lug insert Cross Section of Valve Body Nominal size 3 4 are type S7LAS 805752 short Butterfly Valves Type57L Type57L IS Lug style PVC 6 SB SB SB BB BB BB SB SB BP BP BM BP BP BP BM BM BM BM BM BM BP BM BP BP BB BP BB BP BP BM BM BM BM BP BM BM BP BB BP BM BB BP BM BM BM BP BP BM BP BP V eB BE KL ASAHI AV VALVES Installation Operation and Maintenance Manual 0 o s IS05752 short ae bar a sene ar or 3 4 10 UNC IDUN Procedure den 1 Install the valve between flanges and open the valve slightly z Tubing with the piping of upstream
19. ze 80mm 150mm 37 107 Nominal Size 300mm 12 150 1 0 150 1 0 70 0 5 70 0 5 Working pressure MPa PSI Working pressure MPa PSI 0 0 0 20 40 60 80 100 120 30 70 105 140 175 210 250 Temperature C F 20 0 20 40 60 80 100 120 40 5 30 70 105 140 175 210 250 Temperature C F 100 120 210 250 20 100 120 0 0 30 30 210 250 20 40 60 80 20 40 60 80 70 105 140 175 70 105 140 175 6 Installation Procedure Q In suspending and supporting a valve take enough care and do not stand under a suspended valve Warning ae 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 Q When installing a pipe support by means of a U band or something similar take care not to fasten it too Caution much Excessive tension may damage it When installing pipes and valves ensure that they are not subjected to tension compression bending impact
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