®
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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 fl ow.
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
INSTALLATION INSTRUCTIONS FOR SOLVENT WELDING APPLICATIONS
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1. Union Nut
2. End Connector
3. Ball Check Valve Body
1
2
5
3
4
2
1
®
Valves.
4. Ball Valve Body
5. Diaphragm Valve Body
Remove Union Nuts (1) and End Connectors (2) from the Valve Body (3)
- (instructions apply to spigot and fl anged 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 identifi cation numbers.
90°
90°
Deburr Bevel
STEP 1 Prepare connecting
pipes as required. Pipe ends must
be cut square at 90° using a wheeltype 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 fi le may be used in its
place as shown.
Slide Union Nut onto pipe FIRST
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.
FULL INTERFERENCE FIT
End
Connector
(or Valve
Socket )
End
Connector
(or Valve
Socket )
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 fi tting being “end connector.”
Socket
Depth
Socket
Depth
NET FIT
Socket
Depth
½
STEP 3 Check the Joint Interference fi t
between the pipe and the End Connector Socket
(or fi tting 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.
THE SOCKET ONTO THE PIPE.
Interference must occur between 1/2 the Socket
depth (FULL INTERFERENCE) and the Socket
bottom (NET FIT).
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
PIPE
Valve
Body
Union Nut threads face Valve Body
DO NOT FORCE
Do not use components
.
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
PIPE
UNION NUT
6. Typical Valve Support
1 2
6
ONE-WAY
MOTION
PIPE DIAMETER
CEMENT OR PRIMER APPLICATOR
motion to the inside socket of the End Connector until the surface is softened and
Hold
30 Seconds
semi-fl uid. 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-fl uid
surface should easily be removed.
STEP 7
Attach Valve Body to End Connector
Socket and begin to tighten Union
Nut.
DO NOT USE ANY TYPE OF THREAD
SEALANTS. “HAND TIGHTEN
ONLY.”
REPEAT PRIMER APPLICATION IF NECESSARY.
THE MOST FREQUENT CAUSE OF JOINT FAILURE IS INADEQUATE PRIMER
PENETRATION AND SOFTENING OF 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 fi t check (See Step 3) then
apply an additional liberal coat again
to the pipe surface.
PIPE
ONE-WAY
MOTION
UNION NUT
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.
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.
Attach fi nal Union Nut to 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
Repeat STEP 6 to attach opposite end connector to pipe.
Allow joint to cure according to solvent
cement manufacturer’s instructions.
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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
follow the sealant Manufacturers’ Application/Installation instructions. Choice of another
appropriate thread sealant is at the discretion of the installer.
®
products. Please
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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.
APPLY THREAD
SEALANT
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 fl ushed from the system. This is to prevent scarring of internal components; e.g. ball,
cup, wedge, seats, etc.
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 fingertight thread engagement. Care must be taken in final positioning so as to avoid
the need to “Back-up” the wrench assembly.
WARNING: System should not be operated or fl ushed out at fl ow 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 fl uid fi ll. 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.
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SPEARS® MANUFACTURING COMPANY
CORPORATE OFFICE
15853 Olden Street, Sylmar, CA 91342
PO Box 9203, Sylmar, CA 91392
(818) 364-1611 • www.spearsmfg.com
© Copyright 2007 Spears® Manufacturing Company. All Rights Reserved.
Printed in the United States of America 10/09. LXT-3A-0107
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