OM Manual - Gate Valves
Contents
1. Z WEY OO GE Gasket A 2 2 Bolt Length Flanges Except for AV TS Flange iy AN b i Fi ange Valve Body 4 g L Bolt Length L Three threads beyond Thickness of Nut b Thicknessof Body d Thicknessof Thickness of Nut of Bolt a Washer X 2 c Gasket e Flange f Nom Size bando a b C d e f 40mm 1 22mm 0 87 50mm 2 23mm 0 917 65mm 2 24mm 094 80mm 2 25mm 0 98 100mm 4 Three 27mm 1 067 7 threads Thickness of Thickness of Washer or Thickness of Thickness of Pamm beyond Nut x2 ame Gasket Flange 150mm 6 Nut 27mm 1 06 _200mm 8 28mm 1 10 250mm 10 30mm 1 187 350mm 14 32mm 126 GATE VALVES 21 ASAHI AV VALVES Installation Operation and Maintenance Manual Threaded type A Q Avoid excessive tightening The valve can be damaged Caution Do not use the pipe wrench The valve can be damaged Make sure that the threaded connections are plastic x plastic Metallic thread can cause damage Wrap the threaded joints on our plastic piping with sealing tape Using a liquid sealing agent or liquid gasket may cause stress cracks Environmental Stress Cracking Our product warranty shall not apply in case of said use even when said u2. 66 O ring H ASAHI AV VALVES AV Gate Valve Type S 65mm 2 1 2 125mm 5 Cap Metal Stem 6 9 16 7 1 ZW i TUS 7 A 5 K 8 SES 2 pe 1 eC D o 7 7 W Gp ep gt GATE VALVES Installation Operation and Maintenance Manual ie D 7 4 9 5 5 No DESCRIPTION 1 Body 2 Gate 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 7 Bolt nut A 8 O ring B 9 O ring 16 O ring D 18 Dust seal 19 Cap 20 Set screw B 10 ASAHI AV VALVES AV Gate Valve Type S 200mm 8 Cap Metal Stem UI AJ Ka ka I 2 t l i a C1 Ld CODN E CS L7 7 GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION 1 Body 2c Gate A 2e Gate B 2g Bolt A 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 6a Thrust bearing 7 Bolt nut A 8 O ring B 9 O ring C 10 Bush A 11 Bush B 14 O ring E 15 O ring 16 O ring D 17 Set screw A 18 Dust screw 19 Cap 20 Set screw B 85 O ring M 11 ASAHI AV VALVES AV Gate Valve Type S 40 1 1 2 150mm
3. 32 Pin A 33 Sleeve 34 Nut GATE VALVES 15 ASAHI AV VALVES AV Gate Valve Type S 65mm 2 1 2 125mm 5 External Threaded Type Round Handle Metal Stem 6 3 3 2 x rel Y tr r A i t 6 V T i 8 Wy i 5 2 52 1 7 E gt GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION 1 Body 2 Gate 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 7 Bolt nut A 8 O ring B 9 O ring 16 O ring D 18 Dust seal 22 Handle 32 Pin A 33 Sleeve 34 Nut 16 ASAHI AV VALVES AV Gate Valve Type S 200mm 8 250mm 10 External Threaded Type Round Handle Metal Stem MS Bx A d B H SAR VA x Y gt 1 CDA 3 its 3 SS l l 7 GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION 1 Body 2c Gate A 2e Gate B 2g Bolt A 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 7 Bolt nut A 8 O ring B 9 O ring 16 O ring D 18 Dustseal 22 Handle 32 Pin A 33 Sleeve 34 Nut 17 Installation Operation and Maintenance Manual ASAHI AV VALVES 5 Working pressure vs temperatur
4. Number of Bolt d NominalSize L Length S Length of Threaded i D Dimension of Bolt Minimum Nom Size JIS 10K unit mm ANSI Class150 unit inch DINPNIO unit mm mm inch n D L S n D L S n D L S 40mm 1 4 M16 65mm 38mm 4 WS8 11 256 1 50 4 M16 65mm 38mm 50mm 27 4 M16 70mm 38mm 4 WS 8 11 276 1 50 4 M16 70mm 38mm 65mm 2 4 M16 75mm 38mm 4 WS8 11 295 1 50 4 M16 75mm 38mm 80mm 3 8 MI6 75mm 38mm 4 WS 8 10 2 95 150 8 MI6 75mm 38mm 100mm 4 8 M16 80mm 38mm 8 WS 8 10 3 15 150 8 MI6 80mm 38mm 125mm 5 8 M20 85mm 46mm 8 W3 10 335 181 8 MI6 85mm 46mm 150mm 6 8 M20 80mm 46mm 8 W34 10 3 15 181 8 M20 80mm 46mm 200mm 8 10 M20 85mm 46mm 6 W3 4 10 335 1 81 6 M20 85mm 46mm 250mm 10 12 M22 95mm 50mm 12 W7 8 9 3 74 1 97 12 M20 95mm 50mm 300mm 12 14 M22 95mm 50mm 10 W7 8 9 3 74 197 10 M20 95mm 50mm 350mm 14 12 M22 100mm 50mm 8 WT 8 3 94 197 12 M20 100mm 50mm lt Inserted metal of Body Dimension of Bolt Minimum Nom Size JIS 10K unit mm ANSI Class150 unit inch DIN PN1O unit mm mm inch n D L S n D L S n D L S 200mm 8 2 M20 55mm 46mm 2 W3 10 2 17 1 81 2 M20 55mm 46mm 300mm 12 2 M22 60mm 50mm 2 W7 8 9 2 36 197 2 M20 60mm 50mm 350mm 14 4 M22 60mm 50mm 4 WI 8 2 36 197 4 M20 60mm 50mm
5. a level HI om 1 vis 4 Sa Gs A 2g pu L 1 H 7 z 7 SD o GATE VALVES Installation Operation and Maintenance Manual EI cer c0 espe pre No DESCRIPTION 1 Body 2c Gate A 2e Gate B 2g Bolt A 3 Stem 4 Bonnet A 5 Bonnet B 6a Thrust bearing 7 Bolt nut A 8 O ring B 9 O ring 10 Bush A 11 Bush B 14 O ring B 15 Oring 16 O ring D 17 Set screw A 18 Dustseal 21 Packing 22 Handle 23 Indicating cover 24 Indicating ring 24 Guide pin 26 Guide pin holder 27 O ring G 28 Washer 29 Box nut 30 Handle bush 85 O ring W 14 ASAHI AV VALVES Installation Operation and Maintenance Manual AV Gate Valve Type S 40 1 1 2 150mm 6 External Threaded Type Round Handle Metal Stem dc yit Em it 2c M 8 uL NP e iy b 3 3 Y l j 2 7 nd E 5 No DESCRIPTION gt o I Body 2c Gate A ale lt 2j Female screw metal lt 2k Female screw holder e oe i 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrustring 7 Boltnut A 8 O ring B 9 O ring C 18a Dust seal A 22 Handle
6. the pipe stress on the Caution ASAHI AV Valve Necessary items Allen wrench Spanner wrench lt Disassembly gt Procedure 1 Remove the cap with a hexagon wrench Ask the nearest blanch about the round handle type Other types except from the round handle and any parts related to the valve travel indicate are the same procedure as the cap type 2 Bonnet A and bonnet B can be removed with the stem by loosening the bolt not lt Assembly gt Procedure Carry out the assembly work in the reverse procedure of its disassembly 9 Inspection items A ep Perform periodic maintenance Leakage may develop due to temperature changes or over periods of Caution prolonged storage rest or operation UE LE at a aE ILL T N a UE EID SE el a A an a a meee Ao ra een aE cane E MID ears Olnspect the follow items Check for flaws cracks or deformation on the valve Check for leaks to the outside Check for the deformation of seat or disc due to improper installation of valve Check for the smoothness of handle operation GATE VALVES 23 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Troubleshooting Problem Cause Treatment The seat is scratched or worn Replace the body or the gate Fluid leaks from by in the full closed position Foreign matter is in the valve Clean the valve The gate is scratched or worn Replace the body or th
7. 6 Round Handle PVC Stem 6 5 fc 1 l 4 es g j p zu ry ql 7 UL 1 id 4 amp GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION 1 Body Dd Ga A 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrustring 7 Bolt nut A 8 O ring B 9 O ring 21 Packing 22 Handle Q3 Indicaingcovr 24 Indicating ring 25 Guide pin 26 Guide pin holder 7 O ring 28 Washer 29 Boxnut 12 ASAHI AV VALVES AV Gate Valve Type S 65mm 2 1 2 125mm 5 Round Handle PVC Stem fr d d 6 i 9 y 16 S rj er i A di 5 iia 3 25 2 ic 2 1 s Q D 7 M GATE VALVES Installation Operation and Maintenance Manual Box nut Handle bush No DESCRIPTION 1 Body 2 Gate 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 7 Bolt nut A 8 O ring B 9 O ring 16 O ring D 21 Packing 22 Handle 23 Indicating cover 24 Indicating ring 25 Guide pin 26 Guide pin holder 27 O ring G 28 Washer 13 ASAHI AV VALVES AV Gate Valve Type S 200mm 8 Round Handle PVC Stem d h En amp i i ii l
8. ASAHI AV VALVES GATE VALVES Type P Standard Plug Type S Soft Seal GATE VALVES Installation Operation and Maintenance Manual Serial No H VO11 E 11 Contents 1 Be sure to read the following warranty clauses of our product r 1 Q General operating instructions 2 3 General instructions for transportation unpacking and storage 2 4 Name of parts nnn 3 5 Working pressure vs temperature 7e 18 6 Installation procedure e i ics ae geen deat aca ts 19 8 Disassembling method for replacing parts 23 9 Inspection eigenaar 23 10 Troubleshooting nnn 24 11 Handling of residual and waste materials IA 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 Waming amp Caution Signs A This symbol reminds the user to take caution due to the potential for serious injury or death laming 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 e Mandatory action When operating the valve this symbo
9. Cap Metal Stem Arte e lI Ii as Hj RZ 8 a m g SS z 4 zu GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION 1 Body 2 Gate 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust nng 6a Thrust bearing 7 Bolt nut A 8 O ring B 9 O ring C 10 Bush A 11 Bush B 15 O ring F 16 O ring D 17 Set screw A 18 Dustseal 19 Cap A 20 Set screw B 85 O ring M ASAHI AV VALVES AV Gate Valve Type P 40 1 1 2 150mm 6 Round Handle Metal Stem GO i a 9 C 16 7 9 TV E fe j ee 7 l 8 sla P 2 1 cm D 7 hy yd GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION 1 Body 2 Gate 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 7 Bolt nut A 8 O ring B 9 O ring O 16 O ring D 21 Packing 22 Handle 23 Indicating cover 24 Indicating ring 25 Guide pin 26 Guide pin holder 27 O ring G 28 Washer 29 Box nut 30 Handle bush ASAHI AV VALVES Installation Operation and Maintenance Manual AV Gate Valve Type P 200 8 350mm 14 Round Handle Metal Ste
10. d 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 After unpacking the products check that they are defect free and meet the specifications GATE VALVES 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts AV Gate Valve Type P 40 1 1 2 150mm 6 Cap Metal Stem 6 9 d 19 9 s z 7 a e g 3 l 8 e 4 9 SER A 6 J C ll l No DESCRIPTION oe 1 Body 2 Gate 7 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring b L7 7 Bolt nut A AE 8 O ring B sje 9 Oring 16 O ring D 18 Dustseal 19 Cap A 20 Setscrew B GATE VALVES 3 ASAHI AV VALVES AV Gate Valve Type P 200 8 350mm 14
11. e buio 18 GATE VALVES ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation procedure Flanged type A Q When suspending and supporting a valve take care and do not stand under a suspended valve Warning Be sure to conduct a safety check on all hand and power tools to be used before beginning work Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty i You may be injured A Q When installing a pipe support by means of a U band or something similar take care not to over tighten Caution Excessive force may damage the pipe When installing pipes and valves ensure that they are not subjected to tension compression bending impact or other excessive stress 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 When a non AV gasket is used a different tightening torque specification should be followed Necessary items Torque wrench Spanner wrench Bolt nut washer For many flanges specification ij Q AV gasket Procedure 1 1 Set the AV gasket between the flanges 1 2 Insert washers and bolts from the pipe side insert washers and nuts from the valve side then temporarily tighten them by hand A The parallelism and axial misalignment of the flange
12. e gate The O ring is scratched or worn Replace the o ring Hluid leaks to the valve The bolt nut is loose Retighten the bolt nut The handle does not operate Foreign materials have adhered Clean the valve smoothly Deformation Due to heat etc Replace parts The stem is broken Replace the stem The valve does not operate The engagement between the stem and the Replace the stem and the gate gate is broken 11 Handling of residual and waste materials A 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 bumed improperly ek a ee E E neun e uon s ao ty eae sil nut E i a yf an a a ees Nt a Ri em dien ime me p omm GATE VALVES 24 ASAHI AV VALVES Installation Operation and Maintenance Manual Gate Valves Type P Standard Plug Type S Soft Seal 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 10 GATE VALVES
13. e weight on valve It can be damaged Caution Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly av 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 Use an external screw type Rising Stem for fluids containing slurry or crystal like substance Using an internal screw type Non Rising Stem may disable opening and closing When the GATE VALVE is laid underground or it exposes with concrete Fig 1 Bury the GATE VALVE after putting the hand wheel into the state of shut close position A A Q When suspending and supporting a valve take care and do not stand under a suspended valve Warning A Q This valve is not designed to handle impacts of any kin
14. l 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 technicaldocuments 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 Any repair or rep
15. lacement 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 GATE VALVES ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General operating instructions A g Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the Warming 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 A S Do not step on or apply excessiv
16. m fe il Ur 6 egal gt E BN p Ne DESCRIPTION wee Sea I Body i i 2 Gate yo 1 3 Stem EX Mj Bont A 4 I e ca B Bonnet B wA 8 6 Thrustring p zs 6a Thrust bearing O2 3 7 Bolt nut A D 8 O ring B exp 2 5 9 O ring C ou E 10 Bush A l 11 Bush B L 1 ta Oring amp Gf E s5 H5 O ing CEP PN e 16 Oing D ed 20 Set screw A P 21 Packing l 22 Handle n 23 Indicating cover 24 Indicating ring ec 7 25 Guide pin oy ee 26 Guide pin holder eee 27 O ring G 28 Washer 29 Box nut 30 Handle bush 85 O ring M GATE VALVES ASAHI AV VALVES AV Gate Valve Type P 40 1 1 2 150mm 6 Round Handle PVC Stem K pa p SS W Jo 7 j 7 GATE VALVES Installation Operation and Maintenance Manual No DESCRIPTION Body Gate Stem Bonnet A Thrust ring Bolt nut A Bonnet B O ring B 9 O ring C 21 Packing 22 Handle 23 Indicating cover 24 Indicating ring 25 Guide pin 26 Guide pin holder 27 Oring G 28 Washer Box nut ASAHI AV VALVES AV Gate Valve Type P 200 8 350
17. mm 14 Round Handle PVC Stem 4 a A EM 7i SON q I N i A e pos li e e e ew e e GATE VALVES 14 1 6a 3 6a 10 15 85 Installation Operation and Maintenance Manual No DESCRIPTION 1 Body 2 Gate 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 6a Thrust bearing 7 Bolt nut A 8 O ring B 9 O ring 10 Bush A 11 Bush B I4 O ring E 15 O ring 16 O ring D 17 Set screw A 21 Packing 22 Handle 23 Indicating cover 24 Indicating ring 25 Guide pin 26 Guide pin holder 27 O ring G 28 Washer 29 Box nut 85 O ring M ASAHI AV VALVES AV Gate Valve Type S Type 66 40 1 1 2 150mm 6 Cap Metal Stem 2k 2j 531 e ze S Pug 8 K J EI J y i Wi GATE VALVES Installation Operation and Maintenance Manual 19 20 18 7 No DISCRIPTION 1 Body 65 2c Gate A 2j Female screw metal 3 2k Female screw holder 3 Stem 4 Bonnet A 5 Bonnet B 6 Thrust ring 7 Bolt nut A 8 O ring B 9 O ring C 16 O ring D 18 Dust screw 19 Cap 20 Set screw B 31 Stopper A 32 Pin A
18. se is unavoidable Sealing tape 09 Strap wrench Procedure 1 Winda sealing tape around the external thread of joint leaving the end about 3mm free 2 Tighten the external thread of joint and the body lightly by hand 3 Using a spanner wrench screw them in by turning 90 180 degrees carefully without damaging them 7 Operating procedure A Q Do not exert excessive force in closing the valve Caution Do not use the valve to fluid containing slurry The valve will not operate properly amp b When operating the handle be sure to do so with your hand Using a tool may damage the handle co eee Turn the handle gently to open or close For the left open valve turn the handle clockwise to close and counter clockwise to open For the right open valve turn the handle to the reverse side of left open valve O The cap type should not be forced to operate as it dose not have any travel indicators GATE VALVES 22 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 8 Disassembling method for replacing parts A Be sure to conduct a safety check on all hand and power tools to be used before beginning work Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured Do not change or replace valve parts under line pressure Warning amp When connecting a ASAHI AV Valve to metal piping take care not to let
19. surface should be under the values shown in the following Caution table to prevent damage the valve A failure to observe them can cause destruction due to stress application to the pipe Unit mm inch Axial misalignment Parallelism Nom Size i Axial Parallelism i l Misalignment a b 40 150mm 1 5 1 5 1127 67 0 06 0 06 200 350mm 2 0 2 0mm 8 147 0 08 0 08 GATE VALVES 19 ASAHI AV VALVES Installation Operation and Maintenance Manual 1 3 Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner Refer to Fig 1 A amp b Tighten the bolts and nuts gradually with a torque wrench to the specified Caution torque level in a diagonal manner Recommended torque value Unit N m kgf cm Ib inch Nom Size Torque value Nom Size Torque value 40 1 7 20 0 204 177 150 6 40 0 408 355 50 2 22 5 230 200 200 8 55 0 561 488 65 2 22 5 230 200 250 107 55 0 561 488 80 3 30 0 306 266 300 12 60 0 612 532 100 4 30 0 306 266 350 14 60 0 612 532 125 5 40 0 408 355 GATE VALVES 20 ASAHI AV VALVES 2 1 Bolt Length Flanges AV TS Flange Installation Operation and Maintenance Manual L n
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