Butterfly Valves - ASAHI/America,Inc.
Contents
1. 5 Put the rubber cap nut of Full shut Full opening adjuster back Adjuster for Full Open Position on gearbox Butterfly Valve Type 775 Butterfly Valves Type 56 75 56D 75D 15 ASAHI AV VALVES 12 Inspection items Installation Operation and Maintenance Manual Sas a is a a a a ia A EE Perform periodic maintenance Leakage may develop due to temperature changes or over periods Caution of prolonged storage rest or operation 1 Check for flaw crack or deformation on the valve 2 Check for leaks to the outside 3 Check for the deformation of seat due to improper installation of valve 4 Check for the smoothness of handle operation 13 Troubleshooting Phenomenon Cause Treatment Fluid is not stopped in the full closed position at the seat Fluid leaks to the outside 1 The stopper is not set correctly 2 The seat is damaged or worn 3 Foreign materials are caught 4 The disc is damaged or worn 5 The connecting bolts are over tightened or tightened unevenly 1 The seat is damaged or worn 2 The connecting bolts are not tightened in proper torque or evenly Adjust the stopper Replace the seat Clean up Replace the disc Adjust and retighten Replace the seat Adjust and retighten The handle does not work smoothly 1 Foreign materials have adhered 2 The gearbox is damaged 32. More than More than OU 320mm 12 6 110mm 4 3 600mm More than 70mm More than 30mm 24 M30 350mm 13 8 OS we 120mm 4 7 M30 1 2 Butterfly Valves Type 56 75 56D 75D ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Connection of limit switch procedure option A O Shut down the power on the equipment before connecting wires There are risks of electrical Warning shock depending on the level of operating voltage A de Be sure that the terminal cover and body cover are put on during the operation If you use the limit switch at ImA 100mA or 5 30V consult near Asahi dealer a RR EE pai Necessary items SEENEN O Screw driver O Connector G1 2 O Crimp style terminal O Wire stripper O Terminal crimping tool Procedure TA 200 SB2 1 Remove the indicator 2 Remove the fixed screws from casing using screw driver Don t be missing the o ring of case end ES 3 Tum to counter clockwise and remove the piping port protective cap 4 Draw the cable through the connector 5 Strip the cable with wire stripper 6 Connect the cable to terminal board with a screw driver in accordance page 9 gt Tighten the screws Short circuit or shocks may occur 7 Tighten up the connector to fix the cable 8 The screws must be tightened in turn after set the casing with screws driver XBe sure to set the o ring when the casi
3. Se ES 8 Dei os N do E ef E eo Neca S 2 sew ge ee oe H Dal H 0 0 40 20 0 20 40 60 80 100 120 40 Lei 30 70 Dol 140 175 210 250 Temperature C P F 40 20 0 20 40 60 80 100 120 40 al 30 70 105 140 175 210 250 ee 4 gt EM is gt E gt E cee ee et ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Specification of limit switch option Nominal Size Type Type Code Protection Grade 400mm 16 Gear Type TA 200 SB2 IP55 Limit Switch Rating Connection Diagram Type Code Rate Voltage Resistive Load Inductive Load TA 200 SB2 V A A 1 AC125 11 7 AC250 11 7 A ee DC125 0 5 0 1 NO O Gees DC250 0 25 0 04 pk 7 Installation procedure A O When suspending and supporting a valve take care and do not stand under a suspended valve Warnina 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 A O 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 When installing pipes and valves ensure that they are not subjected to tension compression bending impact or other excessive
4. The connecting bolt is over tightened Adjust and retighten Replace the gearbox Adjust and retighten Valve doe not operated 1 The gearbox is damaged 2 The stem is damaged 14 Handling of residual and waste materials Repair or replace Replace the stem A ab 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 bumed improperly Butterfly Valves Type 56 75 56D 75D 16 ASAHI AV VALVES Installation Operation and Maintenance Manual Butterfly Valves Type 56 400mm 16 Type 75 450 600mm 18 24 Type 56D 400mm 16 Type 75D 450 600mm 18 24 ASAHI AV VALVES Distributor Asahi Organic Chemicals Industry s homepage http Avww asahi yukizai co jp en Information in this manual is subject to change without notice 2012 01 Butterfly Valves Type 56 75 56D 75D
5. Type 56 75 56D 75D 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts Type 56 56D Gear Type 400mm 16 Body Material PP PVDF PDCPD 25 26 6 m1 S 1 Ka a SSAC KS A 2 L dE ll No DESCRIPTION No DESCRIPTION No DESCRIPTION 1 Body 5 O Ring B 26 Gasket A 2 Disc 6 O Ring C 28 Bolt C 3 Seat 7 Stem 4 O Ring A 25 Gear Box Reference figure Butterfly Valves Type 56 75 56D 75D ASAHI AV VALVES Type 75 75D Gear Type 450 600mm 18 24 Body Material PP PVDF PDCPD Installation Operation and Maintenance Manual DESCRIPTION Gear Box Bolt C Bolt D Stand Reference figure 1 only for Body material PP PVDF Type 56 56D Gear Type 400mm 16 with Handle Lock Option Body Material PP PVDF PDCPD pa A 61 tail of part e lt aL E EY i No DESCRIPTION 161 Lock Plate A 162 Lock Plate B Ll e Reference figure TH CH Butterfly Valves Type 56 75 56D 75D ASAHI AV VALVES Installation Operation and Ma
6. as covering the piping with protective material For inguiries 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 A O Do not step on or apply excessive weight on valve It can be damaged Caution Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly Si 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 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 applicati
7. manner Avoid excessive tightening The valve can be damaged Specified torque value Unit Nem kgf cm Ib inch 400 450mm 16 18 500 600mm 20 24 Torque value 80 816 710 100 1020 887 E Axial Butterfly Valves Type 56 75 56D 75D 10 ASAHI AV VALVES Installation Operation and Maintenance Manual Body Material PP PVDF E H KE l TH HS i TH Unit mm inch f Bolt A Bolt B Nominal Size q L S al L SI e Nut Washer 400mm More than 16 300mm 11 81 More than 450mm More than 45mm 120mm 4 8 45mm 27mm 24mm 18 paz 315mm 12 4 1 8 Me 1 8 1 1 SE 0 94 500mm More than More than 20 330mm 13 0 125mm 49 600mm More than 50mm More than 50mm 33mm 30mm 24 NBO 375mm 14 8 OU NO 145mm 5 7 20 1 3 Mog 1 2 Body Material PDCPD It A d Lg L y LC Li Unit mm inch l BoltA Bolt B Nom Size A Nut Washer d L S dl L1 400mm More than More than 16 290mm 11 43 100mm 4 450mm More than 60mm More than 24mm 18 M24 310mm 12 2 ogy MA 110mm 4 3 MA 094 500mm
8. shaving is not necessary E E Nominal size Diameter D FE Bia 400mm 16 366mm 14 41 L 450mm OS 419mm 165 d LIL 500mm OU 469mm 18 5 Eq A 600mm 24 569mm 22 4 L ala EE L Necessary items iy O Torque wrench O Spanner wrench O Bolt Nut Washer For many flanges specification I Procedure 1 Leave the disc 2 slightly opened by the handle Do not make the disc protrude from the seat The disc may be damaged 2 Set the valve to the coupled flange 3 Insert the connecting bolt washer nuts and temporarily tighten them by hand 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 tumed over and suffer a crack The parallelism and axial misalignment of the flange surface should be under the values shown in the 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 Parallelism Axial misalignment Nom S Parallelism oiae Misalignment a b 400 600mm 1 5 1 0 16 24 0 06 0 04 Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal
9. such a Caution manner lt Prohibited 8 Mandatory Action Signs gt O Prohibited When operating the valve this symbol indicates an action that should not be taken s Mandatory action When operating the valve this symbol indicates mandatory actions that must be adhered to 1 Be sure to read the following warranty clauses of our product 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 i the product is installed whichever comes first Any product abnormality that oc
10. 05 261 27 317 32 Butterfly Valves Type 56 75 56D 75D Note Data mentioned in the table above is reference only These data are measured in standard condition and it slightly differs depending on conditions 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Disassembly and assembly procedure for pats replacement A as Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty 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 Lnn ee Protective gloves O Safety goggles Spanner wrench Plate O Thrust bearing O Silicone grease Screwdriver E SOM O Ei Sa Procedure at 1 Drain fluid completely from the pipeline and leave the valve slightly H 227 LL opened 2 Loosen the connecting bolts and nuts with a spanner wrench 3 Remove the valve fromthe pipeline O enema 4 To take off the gearbox 25 loosen the bolt C 28 and pull up the 9 gearbox C l 5 Attach jack thrust bearing plate and pipe to the valve and thread the 7 jack into the stem 7 U 6 Remove the stem 7 from the jack 7 Remove the O ring C 6 ot ee Scenes RR ES Jacl 9 Pull out the b
11. 5 56D 75D ASAHI AV VALVES 5 Working pressure vs temperature BUTTERFLY VALVE TYPE56 Nominal Size 400mm o a 150 1 0 a A gt o a S o 5 AA N 70 05 N a E 2 E Ei S Dien O Sa w N LI 0 0 40 20 0 20 40 60 80 100 120 40 Lal 30 70 105 140 175 210 250 Temperature C E 40 20 0 20 40 60 80 100 120 40 Lal 30 70 105 140 175 210 250 BS bd gt gt Oe Ro x gt Z a a gt al O AE S BUTTERFLY VALVE TYPE75 Nominal Size 500 600mm E a 150 10 a a ES o a s o 2 5 N Dei os a A 2 A ok e ei amp E P e e Z o SER L K i Li 0 0 40 20 0 20 40 60 80 100 120 Gan La 30 70 105 140 175 210 250 Temperature C E 40 20 0 20 40 60 80 100 120 40 Lal 30 70 105 140 175 210 250 E ot gt LINA lt Cs gt RSS aee MC lt gt Butterfly Valves Type 56 75 56D 75D Installation Operation and Maintenance Manual BUTTERFLY VALVE TYPE75 Working pressure MPa PSI 150 1 0 70 0 5 i 0 0 40 20 0 40 ai 30 40 20 0 Nominal Size 450mm 20 40 60 80 100 op 70 105 140 175 210 250 Temperature C OI F 20 40 60 80 100 120 40 al 30 70 105 140 175 210 250 amp KI PE gt ee 4 gt OCE E BUTTERFLY VALVE TYPE56D 75D Nominal Size 400 600mm SG 50 1 0 a e a
12. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V030 E 8 Butterfly Valves Type 56 400mm 16 Body PP PVDF Type 75 450 600mm 18 24 Body PP PVDF ae Type 56D 400mm 16 Body PDCPD 1 Be sure to read the following warranty Type 75D 450 600 mm 18 24 clauses of our product mmm l Body PDCPD 2 General operating instructions ee 2 3 General instructions for transportation unpacking and storage SE 3 A User s Manual 5 Working pressure VS temperature si 8 6 Specification of limit switch 9 7 Installation procedure e 9 8 Connection of limit switch procedure mm 12 9 Operating procedure O 13 10 Disassembly and assembly procedure for parts replacement ELENE EEE EA PIEP EEEE EEE 14 11 Adjustment procedure for stopper s 15 13 Troubleshooting amas 16 14 Handling of residual and waste materials SEELEN 16 ASAHI AVVALVES Butterfly Valves Type 56 75 56D 75D 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 lt Warning 8 Caution Signs gt A This symbol reminds the user to take caution due to the potential for serious injury or death aming A This symbol reminds the user to take caution due to the potential for damage to the valve if used in
13. curs 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 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 ay dd A a a Sims nd aqui Sa a a o a a EA Butterfly Valves Type 56 75 56D 75D 1 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A dy 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
14. intenance Manual Type 56 56D Chain Type 400mm 16 tion Type 75 75D Chain Type 450 600mm 18 24 tion Body Material PDCPD PDCPD el H A Al le No DESCRIPTION aL 62 Sprocket Wheel Y NN 63 Chain A CaN 3 64 Chain Cover Nal A S i Reference figure L p Je Type 56 56D Long Stem Type 400mm Oe Option Type 75 75D Long Stem Type 450 600mm 18 24 Option Body Material PP PVDF PDCPD al ei SCH Er Pe all ole lle No DESCRIPTION or Jm 66 Bolt Nut B OO 681 yr 70 Gasket C 74 Pipe 75 Shaft 77 Bolt H 158 Gasket L Reference figure Butterfly Valves Type 56 75 56D 75D ASAHI AV VALVES Installation Operation and Maintenance Manual Type 56 56D Gear Type 400mm 16 with Limit Switch Box TA 200 SB2 Option 5 E E oo y 7 Et N T T Li No DESCRIPTION 38 Bracket A 45 Limit Switch Box Reference figure Butterfly Valves Type 56 7
15. ng is re set Short circuit or shocks may occur 9 Inset the indicator to the upper camshaft which must be set same direction of the seal s arrow Butterfly Valves Type 56 75 56D 75D 12 ASAHI AV VALVES 9 Operating Procedure Installation Operation and Maintenance Manual A O 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 When operating the handle be sure to do so with your hand Using a tool may damage the handle O The indicator shows the position of the disc on the top of gear box For the full shut position the indication shows Shut S For the full opened position the indication shows Open O Type 56 400mm 16 Full shut position Type 75 450 600mm 18 24 Full shut position Technical Data for Operation S Full open position Nominal Size Stem Torque Diameter of Required Operating Force N Body Material PP PVDF PDCPD Handie Gum PP PVDF PDCPD mm inch Nm kef cm Nem kgf cm N kgf N kgf 400 16 760 7500 1300 13300 150 170 17 290 30 450 18 820 8000 1500 15300 205 135 14 244 25 500 20 1150 11300 1800 18400 205 188 20 293 30 600 24 1600 15700 1900 19400 2
16. ons 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 form it is original intermediate setting Butterfly Valves Type 56 75 56D 75D 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General Instructions for Transportation Unpacking and Storage A O When suspending and supporting a valve take care and do not stand under a suspended valve Warning A 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 Butterfly Valves
17. oth edges of seat 7 and remove the seat 3 and disc 2 i 10 Take the disc 2 out of the seat 3 11 Remove the O ring A 4 and the O ring B 5 Butterfly Valves Type 56 75 56D 75D 14 ASAHI AV VALVES Installation Operation and Maintenance Manual lt lt Assembly gt gt Procedure dt e eto a de 1 Before starting assembly silicone grease equivalent to Toray Silicone HVG should be spread on the disc O rings A 4 B 5 and stem O ring Col 2 The procedure of the assembly is the almost reverse of its disassembly However to insert seat 3 with the disc 2 into the body 1 set the disc 2 with half opened position E Press outer rim of seat 3 into inside ofthe body 1 keeping tem holes stralght Make sure that stem holes of the seat 3 are in alignment with the stem holes of the body 1 3 After assembly make sure that the disc 2 fits seat 3 well 11 Adjustment procedure for stopper Necessary items Se a O Protective gloves Allen wrench Spanner wrench e The adjustments for full opened and full shut position are step less and it can be done with the stopper adjuster Butterfly Valve Type 56 1 Remove the rubber cap nut of Full shut Full opening adjuster E Rubber Cap 2 Loosen the stopper hex bolt completely by Allen wrench 3 Adjust the disk of valve to required position 4 Tighten the stopper hex bolt Adjuster for Full Shut Position
18. 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 Use flat faced flanges for connection to AV Valves EE Ensure that the mating flanges are of the same standards No good The gasket is unnecessary The seat carries out the role of the gasket E seat JISC L The valve disc is in the position indicated by solid lines in figureto ia TN the right prior to shipment from the factory If the valve is APS 1 7 4 a ERR opened or closed after unpacking it must be reset in this position AN before installation Failure to do so will result in damage to the i Good md surface of the valve seat during handling and installation 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 in figure below will result in damage to the valve Butterfly Valves Type 56 75 56D 75D 9 ASAHI AV VALVES Installation Operation and Maintenance Manual In case of an abutting thick walled flange and pipe shave the flange or the pipe inner diameter in order to avoid contact of pipe and disc If the inside diameter of the connecting pipe is larger than dimension D below
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