Instruction manual
Contents
1. oe i 10 20 eee Sere 20 res SS A 19 sls ees Wy Pe 16 9 J i 17 B Jo i a r fe A pt PT cl PT Ty 4 E eee Port size 6mm i ia Port size 15mm No DESCRIPTION No DESCRIPTION No DESCRIPTION 1 Body 8 O ring B 16 Nut 2 Bonnet 9 O ring C 17 Thrust ring 3 Cylinder 10 O ring D 18 Handle Base 4 Plug 12 Sleeve 19 Handle Wheel 5 Orifice 13 Cap 20 Screw 6 Seat 14 Key 7 O ring A 15 Cap nut 25mm 1 5 Port size 6mm Port size 15mm No DESCRIPTION No DESCRIPTION No DESCRIPTION 1 Body 7 O ring A 17 Thrust ring 2 Bonnet 9 O ring C 19 Hand wheel 3 Cylinder 11 O ring E 20 Machine screw 4 Plug 12 Sleeve 21 Lift indicator 5 Orifice 13 Cap 6 Seat 14 Key Needle valve ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Working pressure vs temperature 6 Installation procedure A as Be sure to conduct a safety check on all hand and power tools to be used before beginning work Waming Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured A SO Avoid excessive tightening The valve can be damaged Caution When installing pipes and valves ensure that they are not subjected to tension compression Use flat faced flanges for connection to AV Valves Ensure that the mating flan2. 3 Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner Refer to fig 1 Caution manner Recommended torque value Unit N m kgf cm Ib inch Nom Size 15 20mm 25mm 1 3 gt a PTFE PVDF ceid 17 5 179 155 20 0 204 177 Rubber 8 0 82 71 20 0 204 177 A g Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal Needle valve ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating Procedure A S Do not use the valve to fluid containing slurry The valve will not operate properly Warning Do not exert excessive force in closing the valve Don t take the indicator apart GS Tum right the handle when the divide is set a ae te mc a ho ac kak at yd na la a a E ENE EAE E EE O E E i eee Open and close the valve by rotating hand wheel slowly Right turn Clockwise Flow quantity is decreased Left turn Counterclockwise Flow quantity is increased O Tum the handle to set the direction needle to the mark of expected open degree Turn right the handle when the divide is set O Set the direction needle to the mark of zero when the valve is closed 8 Disassembly and assembly procedure for parts replacement A S Don t take the indicator apart Caution i Wear protective gloves and safety goggles as fluid remain
3. 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 2 Failure to observe our defined precautions or instructions regarding the construction installation handling maintenance 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 Needle valve 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A us Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the repellent Waming 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 A SO Do not s
4. ASAHI AV VALVES Needle valve Needle valve User s Manual Installation Operation and Maintenance Manual Serial No H V024 E 6 Contents 1 Be sure to read the following warranty clauses of our product RADE R 1 2 General operating instructions PERETE PE TEE 2 3 General instructions for transportation unpacking and storage lt nn 3 4 Name of parts sirsie 4 5 Working pressure vs temperature 5 6 Installation procedure nnn 5 8 Disassembly and assembly procedure for parts replacement oos55isa5head8yscdidaeteasieesdsessastassseeeesaaiesaies 7 9 Inspection items sees 8 10 Troubleshooting asesanti 8 11 Handling of residual and Waste Materials ieee 9 ASAHI AV VALVES ASAHI AV VALVES Installation Operation and Maintenance Manual This user s guide contains information important to the proper installation maintenance and safe use of an ASAHI AV Product Please store this manual in an easily accessible location lt Warning amp Caution Signs gt A This symbol reminds the user to take caution due to the potential for serious injury or death Waming A This symbol reminds the user to take caution due to the potential for damage to the valve if used in such a Caution manner lt Prohibited amp Mandatory Action Signs gt S Prohibited When operating the valve this symbol indicates an action that should not be taken as Mandatory action When operating the v
5. alve this symbol indicates mandatory actions that must be adhered to 1 Be sure to read the following warranty clauses of our product Always observe the specifications of and the precautions and instructions on using our product 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 problems 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 constructing 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 assume the responsibility to repair or replace it free of charge
6. ges are of the same standards Be sure to use sealing gaskets AV Gasket bolts nuts and washers and tighten them to specified torques When a non AV gasket is used a different tightening torque specification should be followed This valve can be installed horizontally and vertically But install the valve so that the upstream and downstream line which across the valve may be full with the fluid 1 I 1 I I 1 1 I 1 L 1 1 1 I 1 I 1 I I l I 1 1 i 1 I 1 1 I 1 1 1 l bending impact or other excessive stress 1 1 1 I 1 1 1 I 1 I I 1 1 i 1 I I 1 I 1 1 1 1 I 1 I 1 1 Needle valve 5 ASAHI AV VALVES Necessary items Torque wrench K AV gasket Procedure Spanner wrench 1 Set the AV gasket between the flanges Installation Operation and Maintenance Manual Bolt Nut Washer For many flanges specification 2 Insert washers and bolts from the pipe side insert washers and nuts from the valve side then temporarily tighten them by hand Caution A failure to observe them can cause destruction due to stress application to the pipe Unit mm inch Nom Size onl sarees misalignment a b 15 25mm 1 0 0 5 1 2 1 0 04 0 02 A aD The parallelism and axial misalignment of the flange surface should be under the values shown in the following table to prevent damage the valve Axial misalignment Parallelism
7. in the valve even if the pipeline is empty You may be injured When installing pipes and valves ensure that they are not subjected to tension compression i bending impact or other excessive stress i Do not change or replace valve parts under line pressure i In case of removing the bonnet fully open the valve first then remove the bonnet i fg EA im a a eE M E a Di DE a FEAA EAn a Fant a EA OE A ec PE PA ha i eA a PA le a aa ca PEA ER Pae a E t ea e A e lt Disassembly gt 1 Drain fluid completely from the pipeline 2 Tum the handle of valve counterclockwise to full open Do not force it 3 Remove the bonnet 2 from the body 1 4 Incase of 15mm and 20mm Cap 13 can be removed Needle valve ASAHI AV VALVES lt Assembly gt Installation Operation and Maintenance Manual The procedure of assembly is the almost reverse of its disassembly 1 Before fix the bonnet 2 turn handle clockwise to full open 2 lt Nominal size 15mm 20mm 1 2 3 4 gt Fit the rugged part of body 1 and bonnet 2 and tighten the cap nut 15 Body and bonnet of 15mm 20mm have rugged part lt Nominal size 25mm 1 gt Fit the line mark of body 1 and bonnet 2 Body and bonnet have line mark 3 After assembly turn the handle clockwise to full shut and make sure that the direction needle is set to the mark of zero 9 Inspection items Perform periodic maintenance Leakage may deve
8. lop due to temperature changes or over periods of AO Caution prolonged storage rest or operation O Inspect the follow items Existence of scratches cracks deformation and discoloring Existence of leakage from the valve to the outside 10 Troubleshooting Problem The valve can t be operated Foreign matter is in the valve Existence of leakage when the valve is opened fully at right or left Treatment Disassemble the valve to remove foreign matter The Fluid is leaking past the fully closed position Media has worn diaphragm and or weir Replacement Solid particles have lodged in the valve Clear the solid particles from the valve Fluid leaks from the valve Needle valve O ring is worn Replacement ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Handling of residual and waste materials A o Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic Warning valves Poisonous gas is generated when the valve is burned improperly Needle valve N ASAHI AV VALVES Distributor Asahi Organic Chemicals Industry s homepage http www asahi yukizai co jp en Information in this manual is subject to change without notice 2011 6 Needle valve 9
9. t 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 When transporting a valve do not carry it by the handle Store products in their corrugated cardboard boxes Avoid exposing products to direct sunlight and store them indoors at room temperature Also 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 4 After unpacking the products check that they are defect free and meet the specifications a a a E me i yee a ma cee ma ma a a a a a a Sa fee A Needle valve 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts 15 20mm 1 2 3 4
10. tep on or apply excessive weight on valve It can be damaged Caution Do not use the valve for the fluid having a viscosity of more than 35cp Don t take the indicator apart Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly ey Keep the valve away from excessive heat or fire It can be damaged or destroyed 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 Regardless of horizontal installation or vertical installation the strainer with the 60 Mesh should be installed in the upper stream line of the valve in order to avoid the malfunction possibly caused by clogging of the foreign matters Needle valve 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General Instructions for Transportation Unpacking and Storage A S This valve is no
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