Assured Automation 38 Series Instruction manual

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Doc. AA-38-IOM-2023.05.15
38 Series
Stainless Steel 2-way Ball Valves
Installation, Operation, & Maintenance Manual

TABLE OF CONTENTS
1. General Precaution
1.1. Material Section ........................................................................................1
1.2. Pressure-Temperature Rating ....................................................................1
1.3. Fluid Thermal Expansion ..........................................................................1
1.4. Static Electric Effect..................................................................................1
1.5. Liquids with High Fluid Velocity .............................................................1
1.6. Throttling Service......................................................................................1
1.7. Disassembling Valve.................................................................................1
1.8. Skin Contact with the Valve Surface ........................................................1
1.9. Fluid Contact with the Valve.....................................................................1
1.10. Locking Device .........................................................................................1
2. Product Description
2.1. Feature .......................................................................................................1
2.2. Product Specification ................................................................................2
2.3. Dimensions................................................................................................2
3. Design Specification..........................................................................................3
4. Pressure Temperature Rating .........................................................................4
5. Delivery Condition and Storage ......................................................................4
6. Valve Installation
6.1. Handling ....................................................................................................4
6.2. Cleaning.....................................................................................................4
6.3. Flow Direction...........................................................................................4
6.4. Position and Weight Support.....................................................................4
6.5. Installation of Threaded End Valve...........................................................5
6.6. Installation of Weld End Valve .................................................................5
6.7. Systems Hydrostatic Test ..........................................................................5
7. Valve Operation
7.1. Manual Operation......................................................................................5
7.2. Automatic Operation .................................................................................5
8. Maintenance
8.1. Maintenance Frequency ............................................................................6
8.2. Disassembling and Cleaning the Valve.....................................................6
8.3. Replacing Seats and Joint Gaskets ............................................................6
8.4. Replacing Stem Sealing Components .......................................................6
9. Torque Data
9.1. Valve Assembly Torque Table..................................................................7
10. Assembly Diagram............................................................................................8

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1. General Precaution
1.1. Material Section
Material deterioration is determined by the contained fluid. The need for period inspection
must be determined by user based on the contained fluid. Among possible cases of
deterioration are carbide phase conversion to graphite, oxidation of ferrite materials,
decrease in ductility of carbon steels at low temperature (even in applications above -
29°C). Although information about corrosion data is provided in this user‘s manual, the
user should pay special attention to determine the suitability of material in his own specific
application
1.2. Pressure-Temperature Rating
Stated rating is considered for static pressure only. Please refer to P & T rating section
on page 3 for working precaution. The allowable temperature range is between ambient
temperature and 200°C. DO NOT exceed the temperature range. Exceeding the
temperature range could result in serious accidents
1.3. Fluid Thermal Expansion
When the valve is subjected to extreme variation in ambient temperature, fluid thermal
expansion might cause the ball valve to exceed intended operating pressure. This
condition tends to be more severe when the ball valve is left in closed position for a long
period of time during extreme temperature variation. While our valve is designed to
equalize the pressure within the ball valve cavities, the user must take measures to
ensure that the valve does not exceed it rated pressure due to fluid thermal expansion
1.4. Static Electric Effect
The ball valve has an internal anti-static design. It is designed to provided electric
continuity between ball, stem, and body. When service conditions require electrical
continuity to prevent static discharge, the user is responsible for providing static
grounding
1.5. Liquids with High Fluid Velocity
When your application calls for frequent high fluid velocity, please contact our distributor
for advise on minimizing the possibility of seat deformation, especially when ball valves
are subjected to high pressure and high temperature lines
1.6. Throttling Service
Ball valves are generally not recommended for throttling service. The fluid flow and the
leading edge of the ball can damage or deform the resilient ball seats. High fluid velocity
or the presence of solid particles in the pipeline will further reduce the seat life in throttling
applications
1.7. Disassembling Valve
Do not disassemble or loosen any part of valve while it is under pressure. When the
valve is not equipped with pressure sensing device, user should check the line pressure
by other method through the piping system
1.8. Skin Contact with the Valve Surface
When the valve is in service, do not touch the valve surface until you can be sure that it is
within the safe temperature range for touching
1.9. Fluid contact with the Valve
Do not use the valve on fluids that are corrosive or inappropriate to any part of the valve.
Please review the corrosion data on page 8 for more information
1.10. Locking Device
To guard against valve being operated by unauthorized personnel, lockable ball valve is
available as an option. However, the pad lock must be provided by the customer.
2. Product Description
2.1. Feature
a. Full bore ball valve with ISO5211 mounting pad for direct mounting to actuator with
DIN3337 standard
b. Easily retrofitted with manual handle, double acting actuator, or single acting actuator

c. Options of threaded end, socket weld end, or butt weld end with face to face
dimensions according to DIN3202-M3
d. Three-Piece design enables in-line maintenance
e. Special pyramidal stem design for exceptional stem sealing during high cycle
operation
f. Blowout proof stem
g. Anti-static design with electric continuity for ball, stem, and body
h. Self pressure relief seat to prevent pressure built up
i. Optional handle or lockable handle available to prevent unauthorized valve operation
2.2. Product Specification
Connection Type
2.3. Dimensions (mm)
A=1/4"
B=3/8"
C=1/2"
D=3/4"
E=1"
F=1 1/4"
G=1 1/2"
H=2"
J=3"
K=4"
Size Seat & Seal Material
R=RPTFE
P=PTFE
38N=NPT Female
38S=Socket Weld
38C=Tri-clamp w/ cavity filler
38E=Ext. Butt Weld w/ cav. filler
Seat & Seal Material
X=None
F=Same as Seats
Size ØA B C D G H ØF ØK ISO
5211 J1 K1 J2 K2 SW
1/2 0.63 2.95 2.79 4.33 0.99 1.67 0.86 0.88 F03/F04 1.42 0.24 1.65 0.24 0.35
3/4 0.79 3.15 2.89 4.33 1.09 1.76 1.07 1.11 F03/F04 1.42 0.24 1.65 0.24 0.35
10.96 3.54 3.31 5.31 1.30 2.13 1.34 1.33 F04/F05 1.65 0.24 1.97 0.28 0.43
1 1/4 1.26 4.33 3.52 5.31 1.62 2.33 1.68 1.73 F04/F05 1.65 0.24 1.97 0.28 0.43
1 1/2 1.50 4.72 4.31 6.50 1.94 2.89 1.92 2.00 F05/F07 1.97 0.28 2.76 0.35 0.55
21.97 5.51 4.68 6.50 2.50 3.26 2.41 2.46 F05/F07 1.97 0.28 2.76 0.35 0.55
2 1/2 2.50 7.48 6.10 11.81 3.23 4.21 3.03 3.00 F07/F10 2.76 0.35 4.02 0.43 0.67
33.00 8.66 6.50 13.19 3.77 4.62 3.54 3.50 F07/F10 2.76 0.35 4.02 0.43 0.67
44.00 10.63 7.00 13.19 4.64 5.21 4.55 4.50 F07/F10 2.76 0.35 4.02 0.43 0.67
ØA
H
ØF
C
D
View A-A NPT
Socket
Weld
G
B
Top
A A
SW
ØJ2
ØJ1 ØK1
ØK2
DIMENSIONS - NPT Threaded & Socket Weld Connections
-2-

Size ØA B C D G H ISO
5211 J1 K1 J2 K2 T SW
1/2 0.37 4.50 2.79 4.33 0.99 1.67 F03/F04 1.42 0.24 1.65 0.24 0.07 0.35
3/4 0.63 5.50 2.89 4.33 1.09 1.76 F03/F04 1.42 0.24 1.65 0.24 0.07 0.35
10.87 6.25 3.31 5.32 1.30 2.13 F04/F05 1.65 0.24 1.97 0.28 0.07 0.43
1 1/2 1.37 9.00 4.31 6.50 1.94 2.89 F05/F07 1.97 0.28 2.76 0.35 0.07 0.55
21.87 9.50 4.68 6.50 2.50 3.26 F05/F07 1.97 0.28 2.76 0.35 0.07 0.55
2 1/2 2.37 6.52 5.25 9.06 2.76 4.21 F07/F10 2.76 0.35 4.02 0.43 0.07 0.67
32.88 8.98 5.91 11.81 4.02 4.62 F07/F10 2.76 0.35 4.02 0.43 0.07 0.67
43.84 8.87 6.90 11.81 4.02 5.21 F07/F10 2.76 0.35 4.02 0.43 0.08 0.67
ØA
H
T
C
D
A A
SW
ØJ2
ØJ1
View A-A
Top
ØK1
ØK2
G
B
-3-
3. Design Specification
Items Standards and Codes
Pressure and Temperature Rating Designed to PrEN12516-1
Testing According to PrEN 1226-1
Material of Casting (Body, Cap, Ball)
EN10213-4 for 1.4408
EN10213-4 for 1.4308
EN 10213-2 for 1.0619
Bolt and Nut ISO-3506 (A2-70)
Size ØA B C D ØE G H ISO
5211 J1 K1 J2 K2 SW
1/2 0.37 3.50 2.79 4.33 1.00 0.99 1.67 F03/F04 1.42 0.24 1.65 0.24 0.35
3/4 0.63 4.00 2.89 4.33 1.00 1.09 1.76 F03/F04 1.42 0.24 1.65 0.24 0.35
10.87 4.50 3.31 5.32 1.98 1.30 2.13 F04/F05 1.65 0.24 1.97 0.28 0.43
1 1/2 1.37 5.50 4.31 6.50 1.98 1.94 2.89 F05/F07 1.97 0.28 2.76 0.35 0.55
21.87 6.25 4.68 6.50 2.52 2.50 3.26 F05/F07 1.97 0.28 2.76 0.35 0.55
2 1/2 2.37 7.00 5.25 9.06 3.05 2.76 4.21 F07/F10 2.76 0.35 4.02 0.43 0.67
32.88 9.00 6.30 11.81 3.58 4.02 4.62 F07/F10 2.76 0.35 4.02 0.43 0.67
43.84 9.50 6.90 11.81 8.90 4.02 5.21 F07/F10 2.76 0.35 4.02 0.43 0.67
65.78 15.50 8.51 19.68 6.57 7.42 8.50 F10/F12 4.02 0.47 4.92 0.55 1.06
ØE
ØA
H
C
D
A A
SW
ØJ2
ØJ1
View A-A
Top
ØK1
ØK2
G
B
DIMENSIONS - Extended Butt Weld Connections
DIMENSIONS - Tri-Clamp Connections

-4-
4. Pressure Temperature Rating
The pressure temperature rating of the ball valve is determined, not only by the valve
shell material, but also by the sealing material of ball seat, stem packing, and body seal.
Choice of sealing materials should be based on, all the factors including but not limited to,
the service media, service temperature, service pressure, media velocity within the line,
frequency of valve operation and size of the ball valve. The following chart shows
pressure vs. temperature rating for non-shock fluid service for different seat material.
Please refer to general precautions section on page 1for more information
5. Delivery Condition and Storage
a. Valves are set to open position and individually bagged prior to shipment
b. Upon delivery, customer’s quality control must check the package to make sure that
the valves are not damaged during the shipping process
c. Valves must also be checked for loosening of bolts due to shipment
d. Valves should be stored indoors and in its original package
6. Valve Installation
6.1. Handling
To ensure safety, user must handle the valve with both hands so that the weight of the
valve is equally distributed at both ends. If a hoist is used to lift large valve, user must
make sure the hoist is strong enough to support the weight of the valve
6.2. Cleaning
To prevent damage to the seats and ball surface, the user must inspect the valve for dirt,
burrs and welding residues prior to installation. Although all valves were cleaned and
bagged prior to delivery, if for some unforeseen circumstances that the valves were
soiled during transportation, the user must clean the valve prior to installation. The user
may clean the valve by water, steam or pressurized air
6.3. Flow Direction
Our valves are bi-directional, meaning upstream or downstream could be at either end of
the valve
6.4. Position and Weight Support
The weight of the valve must be properly supported by means other than the connected
pipelines. The valve end connection and the pipeline forms an integral sealing zone. If

-5-
OPEN CLOSE
the weight of the valve is entirely distributed to the joint area, the valve will deform and
cause leakage
6.5. Installation of Threaded End Valve
a. Use conventional sealant, such as hemp core, PFA-lined, etc
b. Use wrench and apply force on the hexagon end of the valve only. Apply force to
other area of valve may seriously damage the valve
c. For applications where threaded end valves are back-welded on site, the valves must
be dismantled according to instructions for weld end valves
6.6. Installation of Weld End Valve
a. Tack-weld the valve on the pipe in four points on both end caps.
b. With the valve in open position (see valve position diagram on page 4), loosen all the
nuts on the body bolts
c. Remove all the bolts except one
d. Swing the body outside the pipe
e. Turn the handle to the half open position to assist in the removal of the seats and
body gaskets
f. Turn the handle to the closed position and remove the ball
g. Place all removed parts in a clean and secure place
h. Replace the body and the removed bolt. Tighten all nuts slightly. To prevent any
leakage to the body joints after welding, make sure that the body and the end caps
remain perfectly parallel
i. Finish welding both end caps onto the pipe
j. After the pipeline and valve cool, clean end caps then remove the previous replace
bolt. Swing out the body. Turn the valve to the closed position, then replace the ball.
Turn valve in open position and replace seats and body gaskets
k. After seats, body gaskets and ball are replaced, swing the body into position, replace
the removed bolts and nuts, and tighten the nuts according to the valve assembly
torque table on page 6
6.7. Systems Hydrostatic Test
Before delivery, our valves are tested to 1.5 times the allowable pressure at ambient
temperature in the open position. After installation, the pipeline may be subjected to
system test pressure of no more than 1.5 times the rated pressure
7. Valve Operation
7.1. Manual Operation
Handle is offered as an option
a. Valve in Open Position is indicated by handle in parallel (in-line) with the valve or
pipeline
b. Valve in Closed Position is indicated by handle in perpendicular (crossed with the
valve or pipeline
7.2. Automatic Operation
a. Prior to actuator installation the position of the valve is indicated as shown in the
illustrations below with a line indicator on top of the valve stem

-6-
b. After Actuator installation, valve should be check for valve stem alignment. Angular
or linear misalignment will result in high operational torque and unnecessary wear on
the stem seal
8. Maintenance
8.1. Maintenance Frequency
User should determine the maintenance frequency depending on specific application. If
there is sign of leakage from the stem, it is time to replace the stem sealing components.
If there is sign of internal leakage, it is time to replace the seats and gasket components.
Life of the valve can be maximized if the valve is used within the rated range, in
accordance with pressure, temperature, and corrosion data
8.2. Disassembling and Cleaning the Valve
Ball valve can trap fluids in ball cavity when it is in the closed position. If the valve has
been used in hazardous media, it must be decontaminated before disassembly.
a. Relieve the line pressure
b. Place valve in half-open position and flush the line to remove any hazardous material
from valve
c. All persons involved in the removal and disassembly of the valve should wear proper
protective clothing, such as face shield, glove, apron, etc
8.3. Replacing Seats and Joint Gaskets
Seat and joint gaskets should be replaced at the same time. Once the valve is
disassembly for seat service, the gasket should also be replaced to ensure proper body
sealing
a. Follow the direction on Disassembling & Cleaning the valve. Make sure the pipeline
is de-pressurized
b. With the valve in open position (see valve position diagram on page 4), loosen all the
nuts on the body bolting. Remove all the bolts except one. Swing the body outside
the pipe.
c. Turn the handle to the half open position to assist in the removal of the seats
d. Replace with a new set of seats and body gaskets
e. Swing the body back into position. Replace the removed bolts, and tighten the bolts
according the valve assembly torque table on page 6
8.4. Replacing Stem Sealing Components
a. Follow the direction for replacing the seats and joint gaskets from a. to c.
b. To assist in loosening of the disc plate, place a rod of diameter smaller than the ball
orifice into the ball orifice. Loosen and remove the disc plate with two-prone tool.
Remove the set of Belleville washers and the gland. Place all removed parts in a
clean and secure place
c. Remove the rod. Turn the valve to the closed position (see valve position diagram
on page 4). Remove the seats and body gaskets. The ball should slide out with a
gentle push. Place all removed parts in a clean and secure place
d. Push the stem downward. It should come out through the center body. Remove the
stem then remove the pyramidal stem seal. Thoroughly clean the stem. Replace
with a new pyramidal stem seal.
e. Remove the v-ring stem packing from the center body cavity. Thoroughly clean the
center body. Replace with a new v-ring stem packing.
f. Replace the stem, the Belleville washers and the gland. Replace the disc plate. To
tighten the disc plate, hold the stem in place and tighten the disc plate with two-prone
tool. Refer to the stem disc torque in the valve assembly torque table on page 6 for
the correct torque value.
g. Turn the valve to the closed position (see valve position diagram on page 4)..
Replace the ball. Turn the valve to the open position. Replace the seats and joint
gaskets.
h. Swing the center body back into position. Replace the removed bolts and nuts.
Tighten the nuts according to valve assembly torque table on page 6.

-7-
9. Torque Data
9.1. Valve Assembly Torque Table
This torque table shows the required torque that is needed to tighten the valve stem and
valve body bolt. It is very important that these torque values are applied with tolerance
of no more or no less than 10%. Incorrect torque values might result in improper sealing
of the valve or deformation of the bolts.
Size Stem Disc Torque (NM) Body Bolt Torque (NM)
1/4" DN8 12 8
3/8" DN10 12 8
1/2" DN15 12 18
3/4" DN20 12 18
1" DN25 17 18
1 1/4" DN32 17 34
1 1/2" DN40 24 34
2" DN50 24 59
2 1/2" DN65 35 113
3" DN80 35 113
4" DN100 40 113
9.2. Valve Operation Torque Table
The table below lists break torque values for PTFE seat in clear non-viscous fluid.
Torque value can vary depending on temperature, pressure, line medium, and seat
material
75 PSI 150 PSI 300 PSI 700 PSI 1000 PSI
Differential
Pressure 5 BAR 10 BAR 20 BAR 50 BAR 63 BAR
Valve Size IN-LB NM IN-LB NM IN-LB NM IN-LB NM IN-LB NM
1/4", 3/8" DN8/10 45 5.1 45 5.1 45 5.1 45 5.1 45 5.1
1/2" DN15 60 6.8 60 6.8 60 6.8 60 6.8 60 6.8
3/4" DN20 80 9.0 80 9.0 80 9.0 80 9.0 80 9.0
1" DN25 130 14.7 130 14.7 130 14.7 130 14.7 130 14.7
1 1/4" DN32 160 18.1 160 18.1 160 18.1 180 20.3 190 21.5
1 1/2" DN40 200 22.6 200 22.6 260 29.4 300 33.9 350 39.5
2" DN50 280 31.6 375 42.4 400 45.2 450 50.8 480 54.2
2 1/2" DN65 500 56.5 600 67.8 620 70.1 800 90.4 - -
3" DN80 650 73.4 800 90.4 900 101.7 1300 146.9 - -
4" DN100 1100 124.3 1500 169.5 1900 214.7 2400 271.2 - -
a. For dry gas, increase the above torque value by 15%
b. For viscous fluid or fluids with solid or abrasive contents, increase the above torque
value by 35%
c. For 15% glass fiber filled PTFE (RPTFE) seats, increase the above torque value by
15%
d. For 25% carbon fiber filled PTFE (CTFE) seats, increase the above torque value by
25%
e. For 50% stainless steel powder filled PTFE seats, increase the above torque value
by 25%
f. A safety factory of 20% is recommended for actuator sizing

-8-
10. Assembly Diagram