Spears LXT-3A-0107 User manual

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SPEARS®LXT™ TRUE UNION

BALL VALVES & DIAPHRAGM VALVES

Installation Instructions

LXT-3A-0107

These instructions cover general installation

for all Spears®LXT™ True Union Ball, Ball

Check & True Union Diaphragm Valves. All

applicable instructions & procedures should be

read thoroughly before starting. Suitability of the

intended service application should be determined

prior to installation. Plastic piping systems should

be engineered, installed, operated & maintained in

accordance with accepted standards & procedures

for plastic piping systems.

SPECIAL INSTALLATION INFORMATION

True Union type ball valves use removable end

connectors. To avoid problems, NEVER ASSEMBLE

THE JOINT TO THE END CONNECTORS

WHILE THEY ARE ATTACHED TO THE VALVE

CARTRIDGE.

Check Valves may be installed in either horizontal or

vertical position with a minimum of 10 pipe diameters from

any pump or other source of turbulence. Check valves

MUST be installed with the valve’s “FLOW” arrow pointing

in the direction of ﬂow.

IMPORTANT: Read Precautions & Warnings for all Valve Installations at the end of

these instructions. It is absolutely necessary that all design, installation, operation and

maintenance personnel be trained in proper handling, installation requirements and

precautions for installation and use of plastic piping systems before starting.

LUBRICATION WARNING: Some Lubricants, including vegetable oils, are known to

cause stress cracking in thermoplastic materials. Formulation changes by lubricant

manufacturers may alter compatibility of previously acceptable materials and are beyond

our control. Lubricants are not required for installation of Spears®Valves.

1. Union Nut

3. Ball Check Valve Body

2. End Connector

4. Ball Valve Body

5. Diaphragm Valve Body

6. Typical Valve Support

INSTALLATION INSTRUCTIONS FOR SOLVENT WELDING APPLICATIONS

Remove Union Nuts (1) and End Connectors (2) from the Valve Body (3)

- (instructions apply to spigot and ﬂanged valves). All components should

be removed from packaging & exposed to the installation environment for a

minimum of 1 hour to thermally balance the components. Wipe clean and match

all components to their assigned identiﬁcation numbers.

STEP 1 Prepare connecting

pipes as required. Pipe ends must

be cut square at 90° using a wheel-

type cutter or a saw and miter box.

Regardless of the cutting method

used, burrs will be created, which

must be removed. All pipe ends

should be beveled at 10° to 15°.

A deburring tool is recommended,

however a ﬁle may be used in its

place as shown.

STEP 2 Remove Union Nuts (1) and End

Connectors (2) from the Valve Body (3). Wipe

away all loose dirt & moisture from the pipes &

components with a clean dry cloth. Slide Union

Nuts (1) over pipe ends where each End Connector

Socket is to be installed, being sure that the Union

Nut threads will be facing the Valve body.

STEP 3 Check the Joint Interference ﬁt

between the pipe and the End Connector Socket

(or ﬁtting socket for spigot end). An Interference

Fit is necessary for proper fusion of the joint. To

check, lightly insert the End Connector Socket

over the prepared pipe ends.

DO NOT FORCE

THE SOCKET ONTO THE PIPE.

Interference must occur between 1/2 the Socket

depth (FULL INTERFERENCE) and the Socket

bottom (NET FIT).

Do not use components

which do not properly mate

Make sure that the face of each End

Connector Socket is at a square 90° angle

with the pipe end.

True Union End Connector Socket O-rings must

be free of any signs of dirt & debris. Clean as

necessary. If O-rings must be removed, clean all surfaces and re-install by pressing the

O-ring evenly into its retaining groove, being sure to avoid any wrinkles or creation of an

uneven sealing surface.

Note: Steps 4 through 6 apply to spigot end valves with spigot end being “pipe” and

mating ﬁtting being “end connector.”

STEP 4 Primer is necessary to penetrate & soften both pipe and End

Connector Socket surfaces in order for the solvent cement to properly bond.

Using a brush or applicator size no less

than 1/2 the pipe diameter, apply a liberal

coat of primer with a circular, scrubbing

90°

Deburr Bevel

Socket

Depth

NET FIT

End

Connector

(or Valve

Socket )

Socket

Depth

Socket

Depth

End

Connector

FULL INTERFERENCE FIT

(or Valve

Socket )

PIPE DIAMETER CEMENT OR PRIMER APPLICATOR

PIPE

ONE-WAY

MOTION

UNION NUT

Valve

Body

Slide Union Nut onto pipe FIRST

PIPE

Union Nut threads face Valve Body

motion to the inside socket of the End Connector until the surface is softened and

semi-ﬂuid. This will occur in 5 to 15 seconds, depending on size and temperature.

Apply primer to the outside of pipe ends in the same manner extending application

area to slightly beyond the insertion depth of the End Connector Socket. Apply a

second coat to both pipe and socket.

Check the penetration and softening by scraping the

primed surfaces. A few thousandths of the semi-ﬂuid

surface should easily be removed.

REPEAT PRIMER APPLICATION IF NECESSARY.

THE MOST FREQUENT CAUSE OF JOINT FAILURE IS INADEQUATE PRIMER

PENETRATION AND SOFTENINGOF BONDING SURFACES DURING THE WELDING

OPERATION. TAKE EXTRA CARE THAT NO SOLVENTS ARE ALLOWED TO COME

IN CONTACT WITH THE BALL OR OTHER INTERNAL VALVE COMPONENTS.

STEP 5 Solvent Cement

must be applied IMMEDIATELY

to the primed surfaces before the

primer dries, in an alternating 3-coat

application. Using a brush or applicator

no less than 1/2 the pipe diameter,

apply a liberal coat of solvent cement

to the primed pipe surfaces. Next,

apply a light to medium coat to the End

Connector Socket primed surface. If a

“NET FIT” was experienced during

the dry ﬁt check (See Step 3) then

apply an additional liberal coat again

to the pipe surface.

STEP 6 Immediately following the application of solvent cement, and before

it begins to set, insert the End Connector Socket over the pipe end, push with a 1/4

twisting motion to evenly distribute the solvent cement within the joint. A full bead of

solvent cement should form around the circumference of the joint. Hold joint together for

approximately 30 seconds to make sure that the End Connector Socket does not back off

of pipe. Use a cloth to remove any excess cement from the exterior juncture of the pipe

and End Connector.

Repeat STEP 6 to attach opposite end connector to pipe.

Allow joint to cure according to solvent

cement manufacturer’s instructions.

PIPE

ONE-WAY

MOTION

UNION NUT

Hold 30 Seconds

STEP 7

Attach Valve Body to End Connector

Socket and begin to tighten Union

Nut.

DO NOT USEANY TYPE OF THREAD

SEALANTS. “HAND TIGHTEN

ONLY.”

BE SURE THAT THE FACE OF THE END CONNECTOR SOCKET IS

SQUARELY ALIGNED (FLUSH) WITH THE VALVE BODY AND IS FLUSH

AGAINST THE O-RING.

DO NOT USE THE REMAINING UNION NUT TO DRAW TOGETHER ANY

GAPS BETWEEN THE END CONNECTOR AND THE VALVE BODY.

STEP 8 Pressure test the system only after all solvent cement joints have

fully cured. If any leaks are found at End Connectors during pressure check, use a strap

wrench to tighten Union Nut 1/4 turn to stop the leak.

DO NOT OVER TIGHTEN AS DAMAGE MAY OCCUR

THREADED CONNECTIONS

WARNING: SOME PIPE JOINT COMPOUNDS OR TEFLON PASTES MAY CONTAIN

SUBSTANCES THAT COULD CAUSE STRESS CRACKING TO PLASTIC.

TRANSITIONS TO METAL PIPE REQUIRE THOROUGH CLEANING AND

DEGREASING TO REMOVE ANY PIPE THREAD CUTTING OIL.

RECOMMENDED SEALANT:

Spears®Manufacturing Company highly recommends the use of Spears®BLUE 75™

thread sealant, which has been tested for compatibility with Spears®products. Please

follow the sealant Manufacturers’ Application/Installation instructions. Choice of another

appropriate thread sealant is at the discretion of the installer.

Attach ﬁnal Union Nut to Valve Body.

SPEARS®MANUFACTURING COMPANY

CORPORATE OFFICE

15853 Olden Street, Sylmar, CA 91342

PO Box 9203, Sylmar, CA 91392

(818) 364-1611 • www.spearsmfg.com

Printed in the United States of America 10/09. LXT-3A-0107

IF A TAPE SEALANT IS USED:

1. Use TFE tape no less than 25

mil thick.

2. Initial wrap must fully cover the

thread end.

3. Wrap clockwise with standard

pipe threads.

4. Use only 2-3 wraps of tape.

STEP 1 Apply Joint Sealant -

Threaded connections require application of a quality grade thread sealant to seal and

lubricate the joint assembly. Sealants must only be applied to male pipe threads.

STEP 2 Assemble Joint - 1 to 2 turns beyond “FINGER TIGHT” are generally

all that is required to make a sound plastic threaded connection.

Unnecessary OVERTIGHTENING will cause damage to both pipe and valve.

Follow Step 7 and Step 8 from Solvent Welding Instructions.

STEP 3 Wrench Make Up - Threaded pipe and valve components must

always be installed using commercially available strap wrenches. Do not

use conventional pipe wrenches, which can cause damage to plastic piping

materials. Apply wrench make-up of no more than 1 to 2 turns beyond finger-

tight thread engagement. Care must be taken in final positioning so as to avoid

the need to “Back-up” the wrench assembly.

PRECAUTIONS AND WARNINGS

CAUTION: The system must be designed and installed so as not to pull the components

in any direction. Pipe system must be cut and installed in such a manner as to avoid

all stress loads associated with bending, pulling, or shifting. All piping systems must be

supported.

CAUTION: BEFORE THE VALVE IS CYCLED, all dirt, sand grit or other material shall

be ﬂushed from the system. This is to prevent scarring of internal components; e.g. ball,

cup, wedge, seats, etc.

WARNING: System should not be operated or ﬂushed out at ﬂow velocities greater than

5 feet per second.

NOT FOR USE WITH COMPRESSED AIR OR GAS

WARNING: Do not use compressed air or gas to test any PVC or CPVC thermoplastic

piping product or system, and do not use devices propelled by compressed air or gas

to clear the systems. These practices may result in explosive fragmentation of system

piping and components causing bodily injury or death.

All air must be bled from the system during the initial ﬂuid ﬁll. Pressure testing of the

system must not be made until all solvent cement joints have properly cured. Initial

pressure testing must be made at approximately 10% of the system hydrostatic pressure

rating to identify potential problems prior to testing at higher pressures.

APPLY THREAD

SEALANT

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