Asahi/America 56 User manual

3/15/02 Rev B T56Install
Butterfly Valve Type 56
No. DESCRIPTION No. DESCRIPTION
1Body 17 Handle lever
2Disc 18 Pin
3Seat 19 Spring
4O-ring (A) 20 Washer (A)
5O-ring (B) 21 Bolt (B)
6O-ring (C) 22 Locking plate
7Stem 23 Screw (B)
8Stem holder (A) 24 Cap (A)
16 Handle (A) 25 Gear box
16a Inserted metal of handle 28 Bolt (C)
Installation Procedure
Caution
To avoid interference the piping ID must be equal to or larger than the D dimension
shown in the following chart. If pipe interference is evident spacers or chamfering of
the pipe or fitting is required.
Nominal Diameter D Nominal Diameter D Nominal Diameter D
Size (inch) Size (inch) Size (inch)
1-1/2" 1.34 4" 3.66 10" 9.33
2" 1.77 5" 4.65 12" 11.38
2-1/2" 2.36 6" 5.47 14" 13.39
3" 2.80 8" 7.48 16" 14.57
1)The valve disc is set in the position indicated by the solid lines in Fig. 5-1 prior to
shipment from the factory. If the 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.
2)The valve must not be dropped or come in contact with other objects, as the sealing
surface of the disc and the sealing surface of the valve seat may be damaged.
3)Care must be used during piping installation to ensure that the pipes or flanges are
properly aligned so that the valve disc does not come in contact with them.
Misalignment as shown in Fig. 5-2 will result in damage to the valve.
4)The installed valve should not be opened or closed when foreign matter such as
shavings, etc. are present from system installation. System should be flushed prior
to operating valves.
RECOMMENDED
NOT RECOMMENDED
Interferrence of the Disc
NOT RECOMMENDED
Parts Identification
Fig. 5-1
Fig. 5-2

3/15/02 Rev B T56Install
The parallelism and axial misalignment of the flange surface should be under the values
shown in the following table to prevent damage to the valve.
Procedure
1) Install the valve between flanges with the valve slightly open. (Refer to Fig. 5-3)
2) Insert bolts, nuts and washers and tighten the bolts and nuts temporarily by hand.
3) Open the valve fully to check for pipe interference before fully tightening the bolts.
Unit: inch
Nominal Size Axial misalignment Parallelism (a – b)
1 1/2" – 3" 0.04 0.03
4" – 6" 0.04 0.04
8" – 16" 0.06 0.04
(Refer to Fig. 5-4)
4) Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a
diagonal manner. (Refer to Table 5-1 and Figure 5-5)
Table 5-1 Recommended torque value Unit: foot-lbs
Nominal Size Torque value Nominal Size Torque value
1 1/2" 14 8" - 10" 40
2" - 2 1/2" 16 12" - 14" 43
3" - 4" 22 16" 58
5" - 6" 32
Installation Procedure for Handle
Install the handle on the stem. Set the direction of handle to correspond with the indication
line at the top of stem.
1) Secure the handle at the top of stem with the enclosed bolt and washer by using a socket
wrench.
2) Set the cap on top of the handle and gently strike it with a rubber or plastic hammer, until it
is seated.
Nominal Size 1 1/2" – 4" 5" – 8"
Bolt Size M6 x 15L M8 x 15L
Socket Size 10 MM 13 MM
Removal Procedure
1) To remove the cap, insert a screwdriver into the indentation, then push down and pry out.
2) Remove the bolt and washer by using a socket wrench, then remove the handle.
1) Remove the gearbox from the valve according to the disassembly and assembly procedure for parts replacement.
2) Remove the drive bushing from the gearbox.
3) Set the gearbox to a full opened position.
4) Insert a tool from the bottom of the gearbox, then remove the indicator by pushing it out. Do not remove the indicator
cap from the top of the gearbox as the indicator and gearbox can be damaged.
5) Align the highest convex part of four convex parts of the indicator with the deepest concave part of the gearbox as
shown in Fig. 1 & 2. (If not properly aligned the indicator cap can be damaged.)
Adjustment Procedure for the Indicator on Gear Type
Drive
Bushing
The deepest concave part of gearbox as
shown in the full close position.
Fig. 1 Indicator Bottom View Fig. 2 Gear Box Top View
Fig. 5-3
Fig. 5-4
Fig. 5-5

3/15/02 Rev B T56Install
Adjustment Procedure for Travel Stop Gear Type
The adjustments for full-opened and full-closed position are preset at the factory. If adjustment is required refer
to the following procedure:
Adjustment for Full-Closed (Full-Opened) Position
1) Remove the protective rubber caps
2) Loosen the stop hex-bolt with an allen wrench.
3) Adjust the disc of valve to the required position.
4) Tighten the stop hex-bolts.
5) Replace the protective rubber caps.
<< Disassembly >>
1) Drain the fluid completely from the pipeline.
2) Leave the valve slightly opened.
3) Loosen the flange bolts and nuts.
4) Remove the valve from the pipeline.
5) Lever type:
To remove the handle [16], first remove the cap [24] by using a flat head screw driver and
bolt [21] by using a socket wrench, then pull up the lever [17] and remove the handle[16].
To take off the locking plate [22], remove the four self tapping screws [23] by using a
philips screw driver and remove the stem holder [8].
Gear type:
Remove bolts [28] from gear box and pull upward to remove gear box [25].
6) Secure the flat surface of Stem [7] with a vise and pull or press away valve body [1].
7) For sizes up to 12", set the valve body [1] on supports at edges of the valve body. Press out the disc and seat as one piece
using a press or non metallic object to prevent damage.
For further details consult O&M User’s manual.
<< Assembly >>
1) Before starting the assembly, silicone grease (equivalent to Troy Silicone HVG) should be spread on the disc O-rings [4][5]
and stem O-ring [6].
2) The procedure of the assembly is the almost reverse of its disassembly. However, to insert the seat [3] with the disc [2] into
the body [1], set the disc [2] in the half – opened position. Press outer rim of seat [3] into inside of the body [1], keeping
stem holes aligned.
(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 valve can be fully opened and closed smoothly.
For further details consult O&M User’s manual.
(PSI, WATER, NON-SHOCK)
Body PVC PP PVDF
Disc PP PP PVDF
Nominal
Size 30˚F 121˚F 141˚F-5˚F 141˚F-5˚F 141˚F 176˚F211˚F
(inches) 120˚F 140˚F 175˚F 140˚F 175˚F 140˚F 175˚F 210˚F 250˚F
1 1/2” - 3” 150 70 30 150 100 150 100 85 75
4” - 6” 150 45 30 150 100 150 100 85 75
8” - 10” 150 40 20 150 85 150 85 75 60
12” 100 30 15 100 60 100 60 45 30
14” 100 30 7 100 45 100 45 30 15
16” NA NA NA 85 45 85 45 30 15
Note: Consult factory for pressure ratings for lug style.
Working Pressure Vs. Temperature
Adjustment for full-open position
Adjustment for full-close position
1) Wear protective gloves and goggles in case some dangerous fluid remains in the valve body.
(You could be injured by working without them.)
2) The handle part [16] can be removed with line pressure present. The locking plate [22] can not be removed with line
pressure present. If locking plate [22] needs to be removed, there can not be line pressure present.
3) The gear operator [25] can not be removed with line pressure present. If the gear box parts [25] need to be removed, there
can not be line pressure present.
Disassembly and Assembly Procedure for Parts Replacement
Caution

3/15/02 Rev B T56Install
Visual Maintenance Inspection
(1) Check for flaws, cracks, or deformation on the valve.
(2) Check for leaks to the outside.
(3) Check for the deformation of seat or disc due to improper installation of valve.
(4) Check for the smoothness of handle operation.
Troubleshooting
Problem Cause Treatment
Fluid leaks by in the 1) The gear travel stop or handle is not set Adjust the stop or handle.
full closed position. correctly.
2) The seat is damaged or worn. Replace the seat.
3) Foreign materials are trapped. Remove the material.
4) The disc is damaged or worn. Replace the disc.
5) The flange bolts are over tightened Adjust and retighten.
or tightened unevenly.
Fluid leaks to the outside. 1) The seat is damaged or worn. Replace the seat.
2) The connecting bolts are not tightened Adjust and retighten the bolts.
properly or torqued unevenly.
The handle does not 1) Foreign materials have collected on the Remove the material.
operate smoothly. disc or seat. Repair or replace.
2) The gearbox is damaged. Adjust and retighten the flange
3) The flange bolts are over tightened. bolts.
Valve does not operate. 1) The gear box is damaged. Repair or replace.
2) The stem is damaged. Replace the stem.
If you would like more details about this valve, please request the O & M User’s Manual.
35 Green Street, P.O. Box 653, Malden, MA 02148 • Tel: [phone] • Fax: [phone]
Operating procedure
√Open and close the valve by turning handle slowly. Turn clockwise to close and counterclockwise to open.
√Lever type, the direction of handle is same as the disc.
For the full-closed position, the handle is perpendicular to the piping system.
For the full-opened position, the handle is parallel to the piping system.
√Gear type, the indicator shows the position of the disc on the top of gear box.
For the full-closed position, the indication shows Shut.
For the full-opened position, the indication shows Open.
General Operating Instructions
√Operate the valve within the Pressure Vs Temperature range.
(The valve can be damaged by operating beyond the allowable range.)
√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 step on the valve or apply excessive weight on the valve. (It can be damaged.)
√Allow sufficient space for maintenance and inspection.
√Keep the valve away from excessive heat or fire. (It can be deformed or destroyed.)
√Make sure to consult a waste treatment dealer to dispose of the valves.
(Poisonous gas is generated when the valve is burned improperly.)
Caution: Do not change or replace valve parts under line pressure.
Refer to O&M User’s manual for further details.
General Instructions for Transportation, Unpacking and Storage
√Keep the valve packed in the carton or box as delivered until installation.
√Keep the valve away from any coal tar, creosote (antiseptic for wood), termite insecticide, vermicides, and paint.
(This could cause swelling and damage the valve.)
√Do not impact or drop the valve. (It can be damaged.)
ASAHI/AMERICA
®