Users Guide - Type-21 Ball Valve
Contents
1. 2 Failure to observe our defined precautions or instructions regarding the construction installation handling mainte nance or servicing of our product 3 Any inconvenience caused by any product other than ours 4 Remodeling or otherwise modifying our product by anyone other than us 5 Using any part of our product for anything other than the intended use of the product 6 Any abnormality that occurs due to a natural disaster accident or other incident not stemming from something inside our product Inquiries As for details refer to the User s manual No H V027 ASAHI ORGANIC CHEMICALS INDUSTRY CO LTD http www easahi yukizal cojp en Valves and Piping System Administration Overseas Department World Trade Center Bldg 20F 4 1 Hamamatsu cho 2 Chome Minatoku Tokyo Japan Tel 81 3 3578 6015 Fax 81 3 3578 6025 Bangkok Representative Office 50 GMM Grammy Place Tower 15th Floor Sukhumvit 21 Road Asoke North Klongtoey Wattana Bangkok 10110 Thailand Tel 66 2 665 9938 Fax 66 2 665 9939 Europe Representative Office Kaiser Friedrich Promenade 61 D 61348 Bad Homburg v d H Germany Tel 49 6172 9175 0 Fax 49 6172 9175 25 Shanghai Branch Office RM 1305 Orient International Plaza Part C No 85 Lou Shan Guan Road Shanghai China 200336 Tel 21 6278 7862 Fax 21 6278 7892 ASAHI AMERICA Inc 35 Green Street P O Box 653 Malden Massachusetts 02148 U S A Tel 1 781 321 5409 Fax2. We always strive to improve product quality and reliability but cannot guarantee perfection Therefore should you intend to use this product with any equipment or machinery that may pose the risk of serious or even fatal injury or property damage ensure an appropriate safety design or take other measures with sufficient consideration given to possible prob lems We shall assume no responsibility for any inconvenience stemming from any action on your part without our written consent in the form of specifications or other documented approval The related technical documents operation manuals and other documentation prescribe precautions on selecting con structing installing operating maintaining and servicing our products For details consult with our nearest distributor or agent Our product warranty extends for one and a half years after the product is shipped from our factory or one year after the product is installed whichever comes first Any product abnormality that occurs during the warranty period or which is reported to us will be investigated immediately to identify its cause Should our product be deemed defective we shall as sume the responsibility to repair or replace it free of charge Any repair or replacement needed after the warranty period ends shall be charged to the customer The warranty does not cover the following cases 1 Using our product under any condition not covered by our defined scope of warranty
3. 1 781 321 4421 Information in this manual is subject to change without notice 201107 9 A rrr Err
4. For the Owner and the Installing Contractor BALL VALVE TYPE21 21 ASAHI AV User s Guide Serial No UA 001E Read and use the information contained within these documents This User s Guide contains information important to the proper installation maintenance and safe use of the BALL VALVE TYPE21 21a store in an easily accessable location Warning amp Caution Signs A This symbol reminds the user to take caution due to the potential for serious injury or death arning This symbol reminds the user to take caution due to the potential for damage to the valve if used in such a manner Caution Prohibited amp Mandatory Action Signs OQ Prohibited When operating the valve this symbol indicates an action that should not be taken Q Mandatory action When operating the valve this symbol indicates mandatory actions that must be adhered to General Information for Transportation Unpacking and Storage A This valve is not designed to handle impacts of any kind Avoid throwing or dropping the valve Caution Avoid scratching the valve with any sharp object Do not over stack cardboard shipping boxes Excessively stacked packages may collapse Avoid contact with any coal tar creosote insecticides vermicides or paint These chemicals may cause damage to the valve Store products in their corrugated cardboard boxes Avoid exposing products to direct sunlight and store them indoors at room temperature Als
5. body cap hold it with your hand and perform installation accordingly If the DESIGNATION Carrier side body cap turns the union will turn together resulting in the union and ball separating from the body If the union is loosened retighten the union Installation Procedure The connection method of the BALL VALVE TYPE21 and 21a there are Flanged End Socket End Threaded End and Spigot End Install according to the preferred method of joining for the particular application As for details refer to the User s manual separately Flanged End The parallelism and axial misalignment of the flange surface should Caution be under the values shown in the following table to prevent damage to the valve A failure to observe them can cause destruction due to stress application to the pipe Use flat faced flanges for connection to AV Valves Ensure that the mating flanges are of the same standards Be sure to use sealing gaskets AV Gasket bolts nuts and washers and tighten them to specified torques 1 Cleaning Confirm the flange face area is clean and free of dirt or foreign materials Axial Misalignment Parallelism 2 Set the AV gasket between the flanges Insert washers and bolts from the pipe side insert washers and nuts from the valve side then temporarily tighten them by hand Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner lt Axial Misal
6. e away overflowing adhesive Threaded End End connector material PVC C PVC PP PVDF Make sure that the threaded connections are plastic x plastic Caution Metallic thread can cause damage Wrap the threaded joints on our plastic piping with sealing tape Sealing Tape Using a liquid sealing agent or liquid gasket may cause stress cracks a Environmental Stress Cracking Our product warranty shall not apply in case of said use even when said use is unavoidable Avoid excessive tightening The valve can be damaged 4 Preparation The seal tape is wound to the Male threaded adapter 2 to 3 complete wraps around the male threads are sufficient 5 Connection Tighten the external thread of the joint and the end connector hand tight Using the spanner wrench screw in the end connector by turning 180 360 carefully without damaging it 6 Advance to step 9 Socket End Spigot End End connector material PP PVDF As for details refer to the User s manual for automatic welding machine 4 Preparation Clean the hub part of the end connector by wiping with a waste cloth Turn on the welding machine Socket End The bench mark indicates the maximum penetration depth of the pipe into the end connector 5 Heating Welding The temperature of the heater must be confirmed with a thermometer before welding Socket and pipe are inserted and heated for a specified time 6 Heater removal Connection After the heater is r
7. emoved connect the pipe quickly to the end connector and leave it alone for a specified time Socket End Insertion to the bench mark XThis figure is Spigot End 7 Cooling Allow appropriate time for cooling 8 Cleaning Clean the surface of the heating elements with a clean cloth T Socket End B Threaded End J Eng 9 Make sure that O ring A is mounted 10 11 10 Tighten union nut by hand 11 Using a strap wrench tighten union nuts USS ae O Ring A uniformly on each side approx 90 180 1 4 D to 1 2 turns lt A ASAHI AV VALVES For the Owner and the Installing Contractor BALL VALVE TYPE21 21 ASAHI AW x 5 User s Guide Serial No UA 001E LS 2112 ae ene ee eae ae en eT eee en lt Panel Mounting gt lt Locking Device Option gt Refer to the User s manual for Metal Insert Ensat by Maker The handle lock can be done by full open close Refer to the User s manual for Locking Device Option 15 50mm 1 2 2 65 100mm 2 1 2 4 Schematic Metal Insert Ensat Handling of Residual and Waste Materials A Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic valves Warming Poisonous gas is generated when the valve is burned improperly Product Warranty Be sure to read the following description of our product warranty Always observe the specifications of and the precautions and instructions on using our product
8. ignment and Parallelism of Flanged face gt Unit mm inch Nom Size Axial Misalignment Parallelism a b 15 32 1 2 1 1 4 1 0 0 04 0 5 0 02 40 80 1 1 2 3 1 0 0 04 0 8 0 03 100 4 1 0 0 04 1 0 0 04 lt Recommended Torque Value gt Unit Nem kgf cm Ib inch O SK O Nom Size 15 20 1 2 3 4 25 40 1 1 1 2 50 65 2 2 1 2 80 100 3 4 O O PTFE PVDF coated 17 5 179 155 20 0 204 177 22 5 230 200 30 0 306 266 ojo Rubber 8 0 82 71 20 0 204 177 22 5 230 200 30 0 306 266 Socket End Threaded End 1 Loosen the union nut and remove the union nut and the end connector 2 Lead the union nut through the pipe 3 The end connector is joined according to each joining method Body ae 1 Union MS End Connector FFE vie Nut Union Nut ASAHI AV VALVES WZ For the Owner and the Installing Contractor BALL VALVE TYPE21 21 ASAHI AV User s Guide Serial No UA 001E Socket End End connector material PVC C PVC OQ When using an adhesive ventilate the space sufficiently prohibit the use of fire in the vicinity and do not inhale Warning adhesive vapors directly D lf an adhesive gets into contact with your skin wash it off immediately If you feel sick or find any anomaly receive a physician s diagnosis and take appropriate measures promptly A Take care in doing work at low temperatures Solvent vapors are hard to evaporate and are l
9. ikely to remain Caution Solvent cracks may occur damaging the equipment After assembling the piping system open both ends of the piping and use a fan of the Low Voltage Type or something similar to ventilate the space thus removing the solvent vapors Do not apply more cement than necessary Avoid getting cement in the internals of the valve This can cause damage to the seals and moving parts Solvent and fumes can chemically attack the valve materials if allowed to enter the internals of the valve Cementing with the valve in a vertical position should be avoided Do not under any circumstances try to insert a pipe into another fitting or valve by striking it which may break the piping Use Asahi AV cement Number 32 Number 52 or Number 62 for PVC and Number 88 for C PVC in case of JIS Pipe amp Fittings The other standard Pipe amp Fittings shall be used industrial proper PVC or C PVC cement Allow 24 hours for solvent cement to dry before performing a water leak test 4 Entry of the Bench Mark The bench mark indicates the maximum penetration depth of the pipe into the end connector 5 Cleaning Clean the hub part of the end connector by wiping with a waste cloth 6 Application of adhesive Apply adhesive evenly to the hub part of the end connector and the pipe spigot 7 Insertion After applying adhesive insert the pipe quickly into the end connector and leave it alone for at least 60 seconds 8 Insertion completion Wip
10. o avoid storing products in areas with excessive temperatures Corrugated cardboard packages become weaker as they become wet with water or other liquid Take care in storage and handling After unpacking the products check that they are defect free and meet the specifications Inspection Items A Q C Check for flaw crack or deformation on the valve C Check for leaks to the outside or inside Caution OJ Check for the smoothness of handle operation O Inspect the cap nut and be sure it is not loose General Operating Instructions A S Certain liquid such as H O NaClO etc may be prone to vaporization Off Gassing which may cause irregular Warning pressure increases which may destroy the valve Do not change or replace valve parts under line pressure Q Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the repellent force particular to compressible fluids even when the gas is under similar pressures used for liquids Therefore be sure to take the necessary safety precautions such as covering the piping with protective material For inquiries please contact us For conducting a leak test on newly installed piping be sure to check for leaks under water pressure If absolutely necessary to use a gas in testing please consult your nearest service station beforehand Do not step on or apply excessive weight on valve It can be damaged Caution Do not use the valve to fluid containing slu
11. rry The valve will not operate properly Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly Q Keep the valve away from excessive heat or fire It can be damaged or destroyed Before opening or closing a lubricant free product be sure to apply water Always operate the valve within the pressure vs temperature range The valve can be damaged or deformed by operating beyond the allowable range Allow sufficient space for maintenance and inspection Select a valve material that is compatible with the media For chemical resistance information refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE Some chemicals may damage incompatible valve materials Keep the valve out of direct sunlight water and dust Use cover to shield the valve The valve will not operate properly Perform periodic maintenance Leakage may develop due to temperature changes or periods of prolonged storage rest or operation do ASAHI AV VALVES For the Owner and the Installing Contractor BALL VALVE TYPE21 21 ASAHI AW User s Guide Serial No UA 001E General Operating Instructions Be sure to conduct a safety check on all hand and power tools to be used before beginning work Warning Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured When installing a pipe support by means of a U band or something similar
12. take care not to over tighten Caution Excessive force may damage the pipe Take care not to over tighten the Union Nut The valve can be damaged The installed valve must never be opened or closed when foreign matter such as sand is present in the pipeline Do not use the pipe wrench The valve can be damaged Q When installing pipes and valves ensure that they are not subjected to tension compression bending impact or other excessive stress When installing disassembling or reassembling the piping fix the End Connector Fasten the Union Nut while avoiding the parallelism and axial misalignment of the flange surface When connecting an ASAHI AV Valve to metal piping take care not to let pipe stress to ASAHI AV Valve When installing a piece of equipment at the end of the piping line be sure to keep the secondary Downstream End Connector and Union Nut installed on the valve When installing Ball Valve Type 21 and 21a 15 to 50 mm 1 2 to 2 in end of line service note the direction of flow UNION NUT Find the mark 4 molded on the Carrier side body On the secondary i r Downstream side the Carrier is integral with the valve body This is the L END CONNECTOR preferred method of installation when installing the equipment at the end of the line for safety purposes Before a water test be sure that the Union Nut is tightly fastened Ball Valve Type21 When loosening the cap nut on the union side install the
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