Kitz XJ User manual

Document No.：KE-2010-04
Operation Manual
For
XJ TYPE BUTTERFLY VALVE
(WAFER TYPE)
Thank you for having chosen KITZ products.
For safe and trouble-free function and performance of the
product, make sure to read and understand all items of this
manual before valve mounting and operation.
Keep this manual in a convenient place for your valve operators’
easy access.

Document No.：KE-2010-04
This manual applies to the KITZ manual XJ type butterfly valve of wafer type.
For electric or pneumatic valve operation, refer to the operation manual of relevant valve actuators
prepared by the manufacturers.
CAUTION AND WARNING
To ensure safe and trouble-free function and performance of the product, please read all items of
this manual before handling, mounting and operation of the units.
The items listed here are indicated to prevent personal injury and product damages.
Please follow the cautions described here.
The signal words “WARNING”and “CAUTION”are defined as follows:
Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury and product damages.
Indicate prohibition of an action.
Indicate mandatory implementation of an action.
NOTES TO USERS
This manual is designed to show an appropriate usage of products for transportation, storage,
installation, operation and maintenance.
Ensure to read the manual before starting any of transportation, storage, installation, operation,
maintenance, and handling valves. Also ensure to read the operation manual (No. D36) enclosed
with the product in the package.
This manual does not cover the whole scope of conceivable usage of products for transportation,
storage, installation, operation and maintenance. If technical assistance beyond the scope of this
manual is required, contact KITZ Corporation or its distributors.
The specifications for transportation, storage, installation, operation and maintenance described in
this manual have been determined with valve maintenance taken into consideration. DO NOT use
products beyond the specifications.
The illustrations given in this manual do not introduce all details. If more detailed data are required,
refer to our relevant valve assembly drawings.
* Any information provided in this operation manual is subject to revision at any time without
notice. This edition cancels all previous issues.

Document No.：KE-2010-04
C O N T E N T S
Sheet
ⅠConstruction and Design Features ················································· 1
ⅡValve Operation Device······································································ 6
ⅢTransportation and Storage of Valves·········································· 9
ⅣValve Installation··················································································· 12
ⅤValve Operation····················································································· 16
ⅥPeriodic Inspection··············································································· 20
ⅦDisassembly and Reassembly of Valves ······································ 24

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CHAPTER Ⅰ
Construction and Design Features

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ⅠConstruction and Design Features
XJ Butterfly Valves
1. Construction and Function
1.1 The valve design and the name of the parts are shown below.
1.2 90rotation of the stem opens and closes the valve.
1.3 Butterfly valve is serviceable in fully open, closed and intermediate position for volume control.
1.4 XJ type butterfly valve has center drive mechanism.
1.5 The bi-directional flow is available for butterfly valve.
Long-Neck Short-Neck
Stem
Rubber Seat
Disc
Disc
Bottom Stem
Stem
Rubber Seat
Stem
Disc
Bottom Stem
Rubber Seat

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ⅠConstruction and Design Features
2. General Feature
2.1 Selectable Neck Design
Neck design can be selected from 2 types of long and short as required.
2.2 Interchangeability to JIS Products
It complies with JIS B 2032 standardized for butterfly valve. It should be interchangeable to the
JIS standard existing butterfly valve. And gear-operated valve complies with public building
operation, too. (nominal diameter 50～300A)
2.3 Improved Operability
Light body of aluminum alloy die-casting is made alignment easy.
2.4 Supportable to Various Fluid
Stainless-steel (SCS14A) disc and EPDM seat are provided as standard items which are applicable
to various fluids. （But EPDM seat can’t be used for oil.）
2.5 Stable Operating Torque
Application of bearing prevents the stem galling and realizes stable operating torque.
2.6 Easy Mounting of Various Actuators
Actuator mounting flange complies with ISO 5211, so actuators can be mounted directly to the
valve body.
2.7 High Performance of Condensation Prevention
The longneck type is provided with condensation preventive system. Heat insulation work at gear
will be unnecessary and condensation will be prevented at chilled water line. (as for gear-operated
valve.)
[Rubber Seat]
Improved stability by rib-reinforced spherical surface seat
①Wide seal valve seat: High-performance wide seal structure
is adopted.
②Rib-reinforced seat: Providing rib in rubber seat prevents
misalignment from the position and separation caused by
friction to the disc or load of fluid.
③Stem seal: Stabilized sealing performance by thrusting into
bearing..
④Flange seal surface (no need for gasket)

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ⅠConstruction and Design Features
[S Shape Valve Disc]
Spherical disc and it contacts the seat internal evenly
3. Valve Specification and Pressure-Temperature Rating
3.1 Valve Specification
3.1.1 Maximum allowable pressure: 1.0 MPa
3.1.2 Service temperature range: from 20C to +120C
(See PT chart for more details)
3.1.3 Continuous operation fluid temperature range: from 0C to +100C
3.1.4 Face to face dimension: JIS B 2032 (46 series)
3.1.5 Shell test pressure (hydrostatic): 1.5 MPa
3.1.6 Seat test pressure (hydrostatic): 1.1 MPa
3.2 Pressure-Temperature Rating. (P-T Rating)
Operational Pressure
Temperature
1.0
0.7
0.5

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ⅠConstruction and Design Features
4. Size and Number of Mounting Bolt and Nut
JIS 10K
Valve Size
No.
Nominal Size
Length (L)
mm
inch
mm
40
11/2
4
M16
85
50
2
4
M16
95
65
21/2
4
M16
105
80
3
8
M16
105
100
4
8
M16
110
125
5
8
M20
120
150
6
8
M20
125
200
8
12
M20
130
250
10
16
M22
150
300
12
16
M22
160
5. Minimum Inside Diameter of Applicable Pipes
Never apply the pipes with smaller inside diameter than the figures shown in the following table. That
will cause unwanted contact of the valve disc with the pipe ends.
Valve Size
Pipe Inside Dia.
mm
inch
mm
40
11/2
28
50
2
30
65
21/2
50
80
3
70
100
4
90
125
5
116
150
6
144
200
8
194
250
10
244
300
12
292
Hexagonal Bolt and Nut (L=mm)

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CHAPTER Ⅱ
Valve Operation Device

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ⅡValve Operation Device
1. Lever Handle Type
1.1 The lever handle is directly mounted on the valve.
1.2 Turning the lever handle 90clockwise will close the valve, and turning the lever handle 90
counterclockwise will open the valve.
Fluid Flow Direction
Fluid Flow Direction
OPEN
CLOSE

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ⅡValve Operation Device
2. Worm Gear Type
2. 1 The worm gear operation device is mounted on the valve.
2. 2 According to the letter or arrow on the hand wheel, turning the hand wheel clockwise will close the
valve, and turning the hand wheel counterclockwise will open the valve.
2. 3 Hand wheel operating torque depends on the size and opening position.
2. 4 Worm gear operator is to transmit a large torque to valve stem, converting a torque from drive shaft
by means of reduction gearing unit using worm gears.
Open Close

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CHAPTER Ⅲ
Transportation and Storage of Valves

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ⅢTransportation and Storage of Valves
1. Transportation of Valves
1.1 Caution for safety
●Keep off the valve lifting area to prevent personal injury caused by unsecured
valves when transporting the valve by lifting.
●Take care not to damage the valve painting surfaces during transportation,
which may subsequently cause corrosion and get the valve rusty.
The damaged surfaces should be touched up adequately.
●Take care the handling and storage of the carton packed product.
The high humidity may damage the cartons.
1.2 Transportation of Valves
1.2.1 Keep the packages as they are delivered just before installation.
1.2.2 Handle valves carefully so that they should not fall or drop on the ground. Avoid any
extraordinary mechanical impact.

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ⅢTransportation and Storage of Valves
2. Storage
2.1 Caution for safety
●DO NOT store valves in the corrosive environment; otherwise, it may cause
corrosion on threaded portions of valves.
●DO NOT drop or shake the valves during storage and DO NOT apply any heavy
load; otherwise, valves may damage.
●DO NOT carelessly pile up products to avoid risk of product damage and
personal injury caused by unstable piling.
2.2 Storage
2.2.1 Store the valve indoors under a dust-free, least humid and well-ventilated condition.
2.2.2 Do not place the valves directly on the ground or concrete floor.
Place packed valves on racks for storage.
2.2.3 In case the valve is stored for a long period of time, keep the valve open by 10for the protection
of the rubber seat from deformation.

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CHAPTER Ⅳ
Valve Installation

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ⅣValve Installation
1. Cautions for Installation
●Check the valve specifications with the catalogs and/or attached nameplate. The
substantial part and seat materials determine the characteristic of service fluid
and service range of pressure and temperature. Services beyond the valve
specifications will cause the leakage problem or other accidents.
●Keep the firm footing for valve installation and operation.
●Prepare sufficient lighting for valve installation and operation.
●Use supports for firmly holding pipes as required so that the large amount of load
will not be applied on the pipes by mass or operation of valve.
●DO NOT connect the butterfly valve directly with check valve or pumps, which
may damage the valve disc by unwanted contact.
1.1 Provide sufficient room for operation, installation and subsequent maintenance of valves.
1.2 Take appropriate measures for smooth operation, inspection and maintenance of valves if they
are forced to be installed in small spaces.
1.3 Try not to install valves in the places where valve functions may be hampered by such outer
forces as vibrations and others.

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ⅣValve Installation
2 Cautions for Piping
●NEVER use the flange gasket for piping, which may cause the leakage.
●DO NOT forcibly tuck the valve into too narrow space between pipes when
piping, which may cause the deformation of the rubber seat and the leakage.
●After flanges are welded with pipes, wait until the welding heat cools down
enough before installing the valves.
●Chamfer or round edge of welded flanges appropriately to prevent the rubber
surface from damages.
●Before installation of valves, clean the connecting pipes to remove any foreign
object such as sand, dust or welding spatters.
●Make sure that the flange surfaces have no damage and defection. Remove
any foreign object from the flange surfaces. (Make sure that EPDM seats must
be free from oil.)
●Align the primary side and secondary side piping accurately. The leakage from
the flange connection is caused by the inaccurate alignment.
●Install or dismantle the valve with the valve open by approx. 10to the full close.
Support the valve and pipes for tube axis
be in straight line for correct alignment.

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ⅣValve Installation
3Valve Mounting
3. 1 Set jack bolts to adjust the dimension between pipe flanges as required. The dimension between
pipe flanges must be 6 to 10mm wider than the dimension between the valve faces for installation.
3. 2 After setting 2 bolts temporary at the lower part of the
valve, insert the valve between piping flanges. Take care
not to damage the rubber seat. Then, set 2 bolts shown
above. Rubber seats will seal the connections between
the flanges of pipes and valve, so do not use any gaskets.
3. 3 Tighten upper and bottom four bolts temporary. Align the
pipes and valve accurately.
3. 4 Before tightening piping bolts, make sure that the disc does
not get any contacts with the pipe inside in fully open
position.
3. 5 Thread other bolts through the holes of pipe flanges.
3. 6 Take care not to tighten certain bolts completely before
tightening all the bolts evenly. Tighten bolts evenly and
alternately in a star pattern.
3. 7 Tighten bolts and nuts so that the piping flanges get
enough contacts with the metal of the body.
※Excessive tightening torque causes serious damages for
the valve body.
※DO NOT use an impact wrench to tighten.
※Tightening torque is following table.
Valve size
Torque
(N・m) Bolt size
DN40 to 100 49 M16
DN125 to 200 88 M20
DN250 to 300 118 M22

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CHAPTER Ⅴ
Valve Operation

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ⅤValve Operation
1. Cautions for Safety
●DO NOT loosen bolts or nuts of flange area on pressuring.
●DO NOT remove the operator on pressurizing, which makes the stem blow-off
from the upper hole.
●DO NOT use the valve as a blank flange by fully closing. when the pipeline is
tested for exceeding the design pressure.
●DO NOT touch the stopper bolts in the gear operator. It may change the
stopper position, which may result in internal leakage.
●The stopper in the gear operation device functions at the full admission and
totally enclosed position of the indicator.
DO NOT apply excessive control force from this position.
The gear is destroyed.
●When the pipeline is tested for exceeding the design pressure, fully open the
valve.
●To operate the valve, avoid the use of special tools such as pipes or wrenches,
which may damage the valves.
●When the valve is to be used with an opening position less than 30°, contact
KITZ or its distributor for technical advises.
2. Operation
2. 1 Lever Handle Type
Turning the lever handle 90°clockwise will close the valve and 90°counterclockwise will open the
valve.
2. 2 Worm Gear Type
According to the arrow or letter on the hand wheel, turning the hand wheel clockwise will close the
valve, and turning the hand wheel counterclockwise will open the valve.