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Diaphragm Valve Type 15 Pneumatic Model Type AV

1. Double action Air to open Notpushed OF Shut Opn Diaphragm Valve Type 15 Pneumatic Model Type AV 13 ASAHI AV VALVES Installation Operation and Maintenance Manual lt Adjustment of opening closing speed procedure gt Double action type oo N COSSALY HES res Spanner wrench 2 1 Tum to the right the adjustment knob of the solenoid For Double action type with solenoid valve Peer errr e er rrrre er rrrer rr rrrre rr rrrrr rr rrrr rrr rrr rrr rr reer irri errr rrr errr rir errr rere r rrr rrr rrr rrr rrr valve fully A Caution Avoid excessive tightening The speed controller can be damaged Close side one Speed down Speedup _ Speed down hi Re ee 2 Supply the air to the solenoid valve 3 Apply regular rated voltage to solenoid valve and turn to the left the open side adjustment knob little by little _ Adjustment knob N Locking nut 4 Turm off the solenoid valve and turn to the left the shut side adjustment knob little by little 5 Repeat item 3 4 to adjust the opening closing speed required 6 When the adjustment is finished while holding the knob with a finger fix the adjustment knob by turning the locking nut nght with a spanner wrench A Caution Avoid excessive tightening The locking nut can be damaged Diaphragm Valve Type 15 Pneumatic Model Type AV 14 ASAHI AV VALVES Installation Operation and Maintenance M
2. O Keep the valve away from excessive heat or fire It can be deformed or destroyed Set valve support on the valve Refer to page7 O Keep the valve away from places of direct sunlight water and dust Use cover to shield the valve The valve will not operate properly O Do not use AV valves in a place where they may become submerged in water Submergence will make AV valve fail 2 General instructions for transportation unpacking and storage O Keep the valve packed in the carton or box as delivered until installation Keep the valve away from any coal tar creosote antiseptic for wood termite insecticide vermicides and paint This could cause swelling and damage the valve Do not impact or drop the valve It can be damaged Avoid scratching the valve with any sharp object Diaphragm Valve Type 15 Pneumatic Model Type AV 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 Name of parts Nominal size 125 150mm 5 6 21 Double acting i In case of body material is PVDF se Rubber s ATIN D oF AK Cushion cover SA ONS yA OS baue a ATT e e g amp Diaphragm Boltmut Actuator airtoopen ee fAcoreirosd sei G8 Ney a a a Spring washer Use with the PVDF body Diaphragm Valve Type 15 Pneumatic Model Type AV 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Comparis
3. Procedure nn tn Fig 2 1 Shape the diaphragm G into fig 2 2 Tum the diaphragm right clockwise to set Tighten it up ene completely and turn it left so that the center rib of diaphragm accords with the longer rib of compressor eae tatiana osetia tate 3 Shape the diaphragm into fig3 O y ljll 4 Supply the air to the actuator 60 61 and fully open the valve Fig 3 5 Put the actuator 60 G1 on the body Q 3 C GP A 6 Set the Blot nut and tighten the body Q and actuator 60 G1 a As to the body tightening torque refer to Table 1 Table 1 Body tightening torque value Unit N m kgf cm 125mm 150mm Diaphragm 5 gt 6 gt material Diaphragm Valve Type 15 Pneumatic Model Type AV 17 ASAHI AV VALVES Installation Operation and Maintenance Manual O Air to shut eee BNC SAB YMC eee ees geese Spanner wrench Allen wrench Protective gloves Safety goggles A Caution Wear protective gloves and safety goggles as some fluid remains in the valve Injure may occur lt Disassemble gt Procedure 1 Completely discharge fluid from line Pees 2 Remove the gauge cover QD Fully close the valve by air Fig 1 Operation 3 Shut the main air valve and open the bypass valve to discharge we a the air from the actuator 60 G1 2 f Z ir 4 Remove the air piping eee aid F 5 Loosen the bolt nut 4 between the body Q and the actuator 62 fy 6 Remove act
4. fix it The cover can be set with the wire extraction opening turned upward or downward fig 3 9 Tighten the cable by connector Diaphragm Valve Type 15 Pneumatic Model Type AV inal A DO O j P Faston terminal Or Orol ne WAT WS A re 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 12 Operating Procedure Procedure A Caution When AV valve is equipped with a solenoid valve do not leave solenoid valve terminal cover off Contact with the terminal will cause an electric shock Check that the supply pressure of the pressure reducing valve with a filter is 0 4MPa 4 lkgf em or more AV valve may not function Procedure Fig 1 1 Supply air to the air supply opening 2 Check that the air supplying side and the stopper Pom position are matching A Caution When AV valve is equipped with a fully opened adjustment switch they do not have stoppers Check iN S if the valve is open or close by the direction of the fluid oe 3 Stop supplying air lt For the solenoid valve gt Fig 2 Procedure 1 Supply the air to the solenoid valve 2 Push the button with a finger and confirm the action p i f mode shown in the following table fig 2 f L 3 Apply regular rated voltage to the solenoid valve and w 4 confirm the action mode shown in the following B Push table 4 Tum offthe solenoid valve
5. parts valve does not open or close broken Refer to page 17 18 17 Handling of residual and waste materials A Caution In discarding remaining or waste materials be sure to ask waste service company Poisonous gas is generated Diaphragm Valve Type 15 Pneumatic Model Type AV 20 ASAHI AV VALVES Installation Operation and Maintenance Manual 18 Inquiries ASAHI ORGANIC CHEMICALS INDUSTRY CO LTD Nobeoka Head Office 2 5955 Nakanose Cho Nobeoka City Miyazaki Pref Japan Tel 81 982 35 0880 Fax 81 982 35 9350 Tokyo Head Office Furukawachtyoda Bldg 15 9 Uchikanda 2 Chome Chiyoda Ku Tokyo Japan Tel 81 3 3254 8177 Fax 81 3 3254 3474 Singapore Branch Office 16 Raffles Quay 40 03 Hong Leong Building Singapore 048581 Tel 65 220 4022 Fax 65 324 6151 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 Room 1301 P Shanghai Kerry Center 1515 Nanjing Xi Road Shanghai China Tel 21 5298 6900 Fax 21 5298 6556 ASAHI AMERICA Ine 35 Green Street PO Box 653 Malden Massachusetts 02148 U S A Tel 1 781 321 5409 Fax 1 781 321 4421 Distributor Diaphragm Valve Type 15 Pneumatic Model Type AV 21 ASAHI AV VALVES Installation Operation and Maintenance Manual Diaphragm Valve Type 15 Pneumatic Model Type AV Automatic Valve Information
6. ALVES Installation Operation and Maintenance Manual 9 Support Setting Procedure arar Necessary poteeeeeeeeeeeeeee Spanner wrench U type clamp with bolt Rubber sheet A Caution Set the valve support The valve may be damaged because the actuator is heavy Do not subject valve pump vibrations The valve may be damaged Level installation Fix the valve stand and the support stand with bolts Spread the rubber sheet on the pipe and secure pipe with U type clamp Perpendicular installation Fix the valve stand and the support stand with bolts Spread the rubber sheet under the actuator and support it with the stand Diaphragm Valve Type 15 Pneumatic Model Type AV 10 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Connection of limit switch procedure 3 a Necessary items nnn Screw driver 4 Connector G1 2 Crimp style terminal Wire stripper Terminal crimping tool Procedure 1 Loosen the three screws used to attach the limit switch cover with a screwdriver and remove the cover from the limit switch These screws are captive Shut limit switch 2 Pull and remove the protective cap made of resin from the cover 3 Draw the cable through the connector mn K 4 Strip the cable with a wire stripper ee a 5 Install a crimp style terminal on the lead wire nnn with a terminal crimping tool 6 C
7. ASAHI AV VALVES Installation Operation and Maintenance Manual Contents 1 General operating instructions Babee EEEE RERESET ALEE EREEREER EEEE EEE ETENEE l Diap hragm Valve Type 1 5 2 General instructions for transportation unpacking and storage E EE E EE dseeaen l Pneumatic Model Type AV 3 Name of parts rrr renncensinsestennnennernnennarniennninnennnin 2 4 Comparison between working temperature and pressure SAAR AA a A A Ln nan on AF Bas 3 5 Specifications of actuator Vis bahed chwdlea Use cussvasiehsaessabsavs SETIER 5 User s Manual 6 Specifications OF Option aginduetan ai 5 Specifications of solenoid valve eee eee 5 Specifications of limit switch eeeeeeeeeseeereeeeesssrreresssssseeeeesssssereeeesssseeee 6 Specifications of pressure reducing valve with filter soetbustoietoaedteetietent 6 Specifications of speed controller eeeeeeeeeeeeesserrerssssssrerresssssereeeesssss 6 7 Installation procedure AEEA TEESE ENE AL vet NE ATEEN EASE EE E Co 7 8 Air piping procedure AAA E EAE A 8 By S rae 10 10 Connection of limit switch procedure sereen 11 1 1 Connection of solenoid valve procedure T 12 12 Operating procedure S A AEA AAA AAA AAAA RER AAAA T ESS l 3 Adjustment of opening closing speed procedure TARARE TARE 14 13 Adjustment procedure for stopeer ge Stes E oeist ceed odes otee eset l 6 14 Disassembling method for replacing parts vee 17 15 Inspection items EE diate dda Shin iedes cals socaawete
8. Air consumption Double action type N per 1 open and close at 0 4MPa Air to close type 38 4 60 5 Air supply bore Re 1 4 6 Specifications of Option Specifications of Solenoid valve Pipe Effective Power p cross section i Additional function consumption bore area 125 150 4N3S102K nor OBypass valve built in ieee OSilencer with needle valve All type 5 6 WO C3 il 193 Rc 1 4 orot rane to be used as speed controller 4N3S102K WO G31193 AC100V 50 60Hz Actuation Nom size Type sign Jis special order DC125V 9 _ connection diagram _ TSsion qi gt i S J Diaphragm Valve Type 15 Pneumatic Model Type AV 5 ASAHI AV VALVES Installation Operation and Maintenance Manual Specifications of Limit switch Double actuation 125 150mm Sie eaan y 5 6 Equivalent to IP55 Limit switch rating connection diagram 125 150mm G 6 125 150mm 5 6 SC7 08A Rc 1 4 Effective cross section area mm Actuation aa ce Needle No of revolution Free Freeflow Control flow flow Diaphragm Valve Type 15 Pneumatic Model Type AV 6 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Installation procedure P EE T Necessary items e EE E ES OES EESE ae 3 Torque wrench AV gasket When a non AV gasket is used a different tightening torque specification should be followe
9. S Installation Operation and Maintenance Manual 13 Adjustment procedure for stopper NN Spanner wrench Allen wrench Procedure A eee a Cee rerernrenegepenererossenerewny 2 Fully open the valve 3 Loosen the upper part of the locking nut about 1 2 turn 4 Tighten the lower part of the locking nut by turning it ae wl left little by little Lower locking nut wer i 7 5 Fix the lower part of the locking nut not to move with a spanner wrench and tighten the upper part of that s titi OO eee leaks or not Ifthe valve leaks repeat the item 2 to 6 until it stops 7 Install the gauge cover 1 Diaphragm Valve Type 15 Pneumatic Model Type AV 16 ASAHI AV VALVES Installation Operation and Maintenance Manual 14 Disassembling Method for Replacing Parts O Double action and air to open pee ECESSATY IN ae Protective gloves Safety goggles Spanner wrench A Caution Wear protective gloves and safety goggles as some fluid remains in the valve Injury may occur lt Disassembly gt Procedure 1 Completely discharge fluid from pipes 2 Shut the main air valve and open the bypass valve to discharge the air from the actuator 60 G1 3 Remove the air piping 4 Loosen the bolt nut between the body Q and the actuator G0 Gi 5 Remove actuators 60 G1 6 Remove the diaphragm G by turning it left counter clockwise lt Assembly gt
10. anual lt Adjustment of opening closing speed procedure gt O Single action type See Necessary items AAR Spanner wrench 2 POU ttre r rrr rrr rrr errr rrrrrrr rrr rrr rrr irri r rrr rrr iii r tir rrrr rrr iri rt iti ttr rrr irs Single action Opening speed Closing speed Air to shut Notadjasabie Adjsuble ial eee ia ha Not adjustable ee j Sy Not used Procedure ee C Speed down ia eo Speed up amp Ut J I Adjustment knob A gi i 1 Tum right the adjustment knob of the solenoid valve Locking nt lt a fully A Caution Avoid excessive tightening The speed controller can be damaged Air to open 2 Supply the air to the solenoid valve Close side 3 Apply regular rated voltage to solenoid valve and turn e off the solenoid valve then turn left the adjustment Not used knob little by little to adjust the opening closing speed IKN 2 ba Adjustment knob required Locking nut 4 When the adjustment is finished while holding the knob with a finger fix the adjustment knob by turning the locking nut nght with a spanner wrench A Caution Avoid excessive tightening The locking nut can be damaged Pererrreeerrrererrrrrrrrrrrrrr rr rrrrr errr tree rrr terri rrr rrr rrr errr reer rrr rer rrr rrr rrr errr trier rrr irr r rrr tii r rir i irri rrr rir rr Diaphragm Valve Type 15 Pneumatic Model Type AV 15 ASAHI AV VALVE
11. d Procedure 1 Set the AV gasket between the flanges 2 Insert washers and bolts from the pipe side insert washers and nuts from the valve side then temporarily tighten them by hand A Caution The parallelism and axial misalignment of the flange surface should be under the values shown in the following table to prevent damage the valve A failure to observe them can cause destruction due to stress application to the pipe Unit mm inch Nominal size Axial Parallelism Misalignment a b Axial misalignment Parallelism q 125 150mm 1 0mm 1 0mm 5 6 0 04 0 04 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque level in a diagonal manner Refer to fig 1 _ Recommended torque value Unit N m kgf cm Ib inch Figli o Torque value A Caution Avoid excessive tightening The valve can be damaged Diaphragm Valve Type 15 Pneumatic Model Type AV fi ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Air piping procedure lt 1 gt For a standard type and an attached speed controller type eee Necessary items Seacoast A eee eee AAA AEEA Spanner wrench Seal tape If seal tape isn t used leakage may be caused Steel pipe or tube for piping Joint for steel pipe or tube A Caution Use compressed air as operating fluid Don t use oil pressure and water pressure Actuator may be damaged Use clean filtered compresse
12. d air Actuator may not work normally When a steel pipe is used for piping use the pipe the inside of which is treated to be rust preventive The intrusion of rust into the actuator the electromagnetic valve may cause a malfunction Don t forget to remove flash in the screw part of the joint A creak and air leakage may be caused Don t remove the protective plug until piping The intrusion of contaminants and water may cause the malfunction of the actuator Clean the pipe by brushing before piping to prevent the malfunction of the actuator Procedure 1 Wind a seal tape onto the male screw of the joint with a blank about 3mm about 2 threads left at the end 2 Screw the joint in the piping female screw of the actuator by hand fully 3 Screw the joint one turn with a spanner wrench A Caution Avoid excessive tightening The valve can be damaged 4 Mounta steel pipe or a tube Double acting Airto open Air to shut Airsupply Arsy L o of Air supply nl o E J Tr gt Cn I TT J 7 coo to LL tw Pictures above have no speed controller but the piping procedure is the same as above Diaphragm Valve Type 15 Pneumatic Model Type AV ASAHI AV VALVES Installation Operation and Maintenance Manual lt 2 gt For a pressure reducing valve with a solenoid valve and a pressure reducing valve with a filter er Nece
13. dedeseeseacuaesecsu A ieee tess sestoneessestos l 9 1 6 Troubleshooting EE EE E E EE EE E EE E EROE R AEE ET 1 9 17 Handling of residual and waste materials 1 20 18 Inquiries ver eeeeeeneenenenentnnananananenesnnnananananananennninin 2 ASAHI AV VALVES Diaphragm Valve Type 15 Pneumatic Model Type AV ASAHI AV VALVES Installation Operation and Maintenance Manual 1 General operating instructions O Operate the valve within the pressure Vs temperature range The valve can be damaged by operating beyond the allowable range Select a valve material that is compatible with the media refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE Some chemicals may damage incompatible valve materials Diaphragm part may become loose after long term storage or unused period or by the change of temperature during operation Check it and re tighten the bolt between the actuator and the body diagonally refer to the torque value on page 17 The valve may leak O Donotuse the valve to fluid containing slurry The valve will not operate properly O Do not disassemble the actuator Injury may occur Do not step on the valve or apply excessive weight on valve It can be damaged Donot exert excessive force in closing the valve Make sure to consult a waste treatment dealer to dispose of the valves Poisonous gas is generated when the valve is burned improperly Allow sufficient space for maintenance and inspection
14. in this manual is subject to change without notice 2003 5 Diaphragm Valve Type 15 Pneumatic Model Type AV
15. nel is a Tae eee ee turned off P l The solenoid valve is disconnected ee Comme on gedit Refer to page 5 Air is not supplied to the solenoid valve Supply air to solenoid valve The supply voltage to the solenoid valve is wrong Check voltage with a tester and set specified voltage The voltage to the solenoid valve 1s low The valve does not operate by Closed bypass valve by turning the The bypass valve opens bypass valve knob in a clockwise direction The speed controller s knob is fully turned ina Turn speed controller s knob in a clockwise direction counterclockwise direction The operation pressure is low Check the operating pressure l Replace the diaphragm with a new The diaphiragr 1S WON one Refer to page 17 18 Replace scratched parts with new The diaphragm or the body is scratched ones Refer to page 17 18 air operations Diaphragm Valve Type 15 Pneumatic Model Type AV 19 ASAHI AV VALVES Installation Operation and Maintenance Manual Problem Cause Treatment The bolt between the body and actuator is Tighten the bolt to the specified torque loose Refer to page 17 Fluid leaks from the valve The diaphragm or the body is scratched Replace scratched parts with new one There is foreign matter between the diaphragm Disassemble valve to remove foreign and the body matter Refer to page 17 18 9 The actuator operates but the The diaphragm or the joint metal fitting is Replace broken
16. on between working temperature and pressure O Double acting g Pressur Norkir A Caution Do not operate the valve beyond the range of working temperature and pressure The valve can be damaged Diaphragm Valve Type 15 Pneumatic Model Type AV 3 ASAHI AV VALVES O Single acting Installation Operation and Maintenance Manual A Caution Do not operate the valve beyond the range of working temperature and pressure The valve can be damaged Diaphragm Valve Type 15 Pneumatic Model Type AV ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Specifications of Actuator 125mm 5 150mm 6 Standard operating pressure Mata aoan
17. onnect the terminal screw with a screwdriver according to the internal circuit diagram show in page 6 Caution Tighten the screws If not electric leaks or shocks may occur 7 Tighten the above three screws with a screw driver to install the cover on the limit switch 8 Tighten the cable by connector Diaphragm Valve Type 15 Pneumatic Model Type AV 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Connection of solenoid valve procedure pe N COSSATY EMS nnn Terminal crimping tool Screw driver Connector G1 2 Wire stripper A Caution Make sure of the agreement between the power voltage indicated on the solenoid valve and the voltage wiring to be done Wiring with wrong voltage may cause failure in the solenoid unit Procedure 1 Loosen the hexagon socket head cap screws and remove the cover A Caution Don t loose O ring Short circuit or shocks may occur 2 Remove the Faston terminal inserted into coil side and the insulating sleeve A Caution Insulating sleeve isn t attached in Faston terminal 3 Draw the cable through the connector to the cover 4 Strip the cable with wire stripper 5 Draw the lead wire through the cover 6 Install the Faston terminal on the lead wire with a terminal crimping tool 7 Insert the Faston terminal into the coil side And fit the cover 8 Tighten the cover setting screws to
18. ssary items E A naan minnumcenAnEEReenaannas B Spanner wrench Seal tape If seal tape isn t used leakage may be caused Steel pipe or tube for piping Joint for steel pipe or tube A Caution Use compressed air as operating fluid Don t use oil pressure and water pressure Actuator may be damaged Use clean filtered compressed air Actuator may not work normally When a steel pipe is used for piping use the pipe the inside of which is treated to be rust preventive The intrusion of rust into the actuator the electromagnetic valve may cause a malfunction Don t forget to remove flash in the screw part of the joint A creak and air leakage may be caused Don t remove the protective plug until piping The intrusion of contaminants and water may cause the malfunction of the actuator Clean the pipe by brushing before piping to prevent the malfunction of the actuator Procedare pa 1 Wind a seal tape onto the male screw of the Air supply bore joint with a blank about 3mm about 2 threads left at the end 2 Screw the joint in the piping female screw of the actuator by hand to the full fig 2 3 3 Screw the joint one turn with a spanner wrench o ees A Caution Avoid excessive tightening The valve can be damaged Fig 2 4 Mounta steel pipe or a tube Air supply bore Diaphragm Valve Type 15 Pneumatic Model Type AV 9 ASAHI AV V
19. uators 60 G1 7 Remove the diaphragm Q by turning it left counter clockwise lt Assembly gt Procedure en tinny 1 Shape the diaphragm G into fig 2 2 Tum the diaphragm G right clockwise to set Tighten it up completely and turn it left so that the center rib of diaphragm accords with the longer rib of compressor 3 Shape the diaphragm Q into fig 3 4 Put the actuator 60 6 on the body Q Fig 3 5 Set the Blot nut and tighten the body Q and actuator 60 G1 As to the body tightening torque refer to table 1 on page 17 Diaphragm Valve Type 15 Pneumatic Model Type AV 18 ASAHI AV VALVES Installation Operation and Maintenance Manual 15 Inspection items O Periodically inspect and maintain the AV valve in accordance with the decided schedule Portion to be inspected Inspection item 1 Existence of rust peeling of paint and dirt of inspection hole of valve travel indicator 2 Tightening condition of respective threaded portions Loose or not 3 Existence of abnormality in opening and closing operating sounds Actuator Tt is unnecessary to supply oil to this actuator 1 Existence of scratches cracks deformation and discoloring 2 Existence of leakage from the valve to the outside 3 Existence of leakage when the valve is opened fully at right or left 4 Tightening condition of bolt B loose or not 16 Troubleshooting The power source of the control pa

Diaphragm Valve Type 15 Pneumatic Model Type AV

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