3-WAY TRUE UNION BALL VALVES
Contents
1. Fl T MA Necessary items E Torque wrench Spanner wrench AV gasket Bolt Nut Washer For many flanges specification When a non AV gasket is used a different tightening torgue specification should be followed 1 Setthe 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 Remark The parallelism and axial misalignment of the flange surface should be below the values in the following The three ways are all as following A failure to observe then can cause destruction due to stress application to the pipe Unit mm inch Axial misalignment Paralldism Axial Parallelism a Misalignment a b 1 0 0 04 0 5 0 02 Nom Size 15 25mm 2 1 40 80mm 1 43 100mm 4 1 0 0 04 0 8 0 03 1 0 0 04 1 0 0 04 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to fig 1 Specified torque value Unit N m kef cm lb inch Nom Size 15mm 20mm 25mm 40mm 50mm 80mm 100mm 4 2 3 4 a a 1 2 2 3 4 17 5 17 5 20 0 20 0 22 5 30 0 30 0 Torque value 179 179 204 204 230 306 306 155 177 200 200 200 266 266 Remark Avoid excessive tightening The valve can be damaged Threaded type ed Necessary2. Tel 8173 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 Am Wehrhahn 33 40211 Duesseldorf Germany Tel 49 6172 9175 0 Fax 49 6172 9175 25 ASAHI AMERICA Inc 35 Green Street Malden Massachusetts U S A 02148 Tel 1 781 321 5409 Fax 1 781 321 4421 3 WAY TRUE UNION BALL VALVE ASAHI ORGANIC CHEMICALS INDUSTRY CO LTD Information in this manual is subject to change without notice 2000 11
3. ASAHI AV Valves Serial No H V003E 0 Contents 3 WAY TRUE UNION BALL VALVES 1 General operating instructions wo 2 General instructions for transportation unpacking and storage evo 3 Name of parts a91 4 Comparison between working temperature and pressure setan ngan anise 5 Installation procedure ss 6 Operation procedure oo 7 Disassembling method for replacing parts 8 Tnspectiontiemd eee tee oh aa E 10 Handling of residual and LL Inquiries www sam ORGANIC CHEMICALS INDUSTRY CO LTD General operating instruction Operate the valve within the range of the published working temperature and pressure The valve can be damaged by operation beyond the maximum allowable range of temperature vs pressure Toselect a valve in appropriate materials refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE Some chemicals give heavy damage to valve materials O The valve is not designed to bear any kind of external load Never stand on or place anything heavy on the valve at anytime O When the valve is disposed of contact waste disposal specialist The valve generates toxic gas O The valve should be installed at place where space for periodic inspection amp maintenance is sufficient Do not store or install the valve near any heat source or hot surface O Do notuse the valve for fluid containing slurry The valve will not operate properly Do notuse t
4. ON BALL VALVES the direction of flow left and right is shown above 7 Disassembling Method for Replacing Parts Necessary items Strap wrench Safety goggles Protective gloves Screwdriver Wrench or vice Caution Wear protective gloves and safety goggles as some fluid remains in the valve You may be injured lt Disassembly gt Procedure 1 Completely discharge fluid from pipes 2 Turn the handle to full close 3 Loosen the union nuts 5 on both sides with a strap wrench With 3 WAY TRUE UNION BALL VALVES loosen the three union nuts 4 Disconnect three joints and remove the body part only As for the flanged type remove the bolt With 3 WAY TRUE UNION BALL VALVES the body part can be pulled up just with loosening the union nut O 5 Loosen the screw of the handle with a screwdriver and pull the handle 4 off the body part 6 Using a wrench or vice engage the carrier 3 7 Turn the carrier G counter clockwise to loosen 8 Follow 6 and 7 for the other side With 3 WAY TRUE UNION BALL VALVES loosen the carrier in the same way 9 Push out the ball 2 by hand 10 Push out the stem 6 from the top flange side to the body side lt Assembly gt Procedure Carry out the assembly work in the reverse procedure 8 Inspection items Inspect the following items 1 Check for any flaw crack or deformation on the outside 2 Check whether fluid leaks to
5. e hub part of the end connector 4d by wiping with waste cloth 5 Apply adhesive evenly to the hub part of the end connector and the pipe spigot Remark Do not apply more adhesive than necessary The valve can be destroyed due to solvent cracking Adhesive quantity guideline Mon Sia 15mm 20mm 25mm 40mm 50mm 65mm 80mm 100mm 1 2 3 4 qd ad 1 2 2 212 8 47 Quantity g 1 0 13 2 0 3 5 48 6 9 9 0 13 0 6 After applying adhesive insert the pipe quickly to the end connector Gc and leave it alone for at least 60 seconds 7 Wipe away overflowing adhesive 8 Make sure that O ring A 8 is mounted 9 Tighten the union nut lightly by hand 10 Using a strap wrench screw it in by tuming 90 180 carefully without damaging it Remark Avoid excessive tightening The valve can be damaged 6 Operating Procedure O Tum the handle gently to open or close The handle can be turned 360 Turn the handle clockwise to close and counter clockwise to open The arrow on top of the handle indicates the flow direction ay Open to the left Fully closed Open to the right The handle is parallel to the The handle is parallel to the pipe The handle is perpendicular to the pipe The direction of the arrow is pipe The direction of the arrow is left right O With AV 3 WAY TRUE UNI
6. he valve on condition that fluid has crystallized The valve will not operate properly Caution Certain liquid such as H202 NaC 10 etc may be prone to vaporization which may cause irregular pressure increases which may destroy the valve 2 General instructions for transportation unpacking and storage O Keep the valve in its original packaging until needed for installation Avoid contact with any coal tar creosote insecticides vermicides or paint The force of swelling may damage the valve The valve is not designed to handle any kind of impact Avoid throwing or dropping the valve O Avoid scratching the valve with any sharp object 3 Name of parts Nominal size 15mm 100mm 1 2 2 DESCRIPTION Body Ball Carrier End connector Flanged end type End connector Socket end type End connector Threaded end type Union nut Stem Seat O ring A O ring B Cushion O ring D O ring Stop ring Handle 3 Use only with Flanged type Only with C PVC 15 25mm 1 2 1 No W Comparison between working temperature and pressure Nominal size 15mm 50mm 1 2 2 4 ieee Nominal size 80mm 100mm 3 E ee ee Do not operate the valve beyond the range of working temperature and pressure 3 2 8 3 5 Installation procedure
7. items ss ss ss ss ss EEEE AEEA ATE NT 0 Sealing tape A non sealing tape can cause leakage Strap wrench Do not use Pipe wrench Spanner wrench Make sure that the threaded connections are plastic x plastic Metallic thread can damage the body cap Procedure 1 Winda sealing tape around the extemal thread of joint leaving the end about 3mm free 2 Loosen the union nut G witha strap wrench 3 Remove the union nut G and the end connector 4d 4 Lead the union nut G through the pipe Nn Tighten the extemal thread of the joint and the end connector Gd lightly by hand 6 Using a spanner wrench screw in the end connector by tuming 180 360 carefully without damaging it Remark Avoid excessive tightening The valve can be damaged 7 Make sure that the O ring A 8 is mounted oo Tighten the union nut lightly by hand 9 Using a strap wrench screw it in by tuming 90 180 carefully without damaging it Remark Avoid excessive tightening The valve can be damaged Socket type ees Necessary itens Na an Adhesive for hard vinyl chloride pipes Strap wrench Do not use the pipe wrench Do not install a socket type valve where the atmospheric temperature is 5 C or lower The valve can be damaged Procedure 1 Loosen the union nut G with a strap wrench 2 Remove the union nut G and end connector 4 3 Lead the union nut 5 through the pipe 4 Clean th
8. the outside 3 Check whether tightness of bolt nut 4 Check whether the handle operates smoothly 9 Troubleshooting and action Problem Cause Action Fluid leaks from the valve even when the valve is closed fully The carrier is loosened Adjust the face pressure between the ball and the seat Refer to page 8 The seat is scratched or worn Replace the seat with a new one Foreign matter is in the valve Clean the valve The ball is scratched or worn Replace the scratched ball with a new one Fluid leaks from the valve The O ring is scratched or worn Replace the O ring with a new one The handle is not can not be turned smoothly Foreign matter is in the valve Clean the valve Deformation By heat etc Replace the parts The handle fails to engage The stem is broken Replace the stem with a new one The engagement between the stem and the ball is broken 10 Handling of residual and waste materials Replace the stem and ball with new ones Remark In discarding remaining or waste materials be sure to ask waste service company Poisonous gas is generated 11 Inquiries Head Office No 2 5955 Nakanose Cho Nobeoka City Miyazaki Pref Japan Tel 81 982 35 0880 Fax 81 982 35 9350 Tokyo Office Furukawachiyoda Bldg No 15 9 Uchikanda 2 Chome Chiyoda Ku Tokyo Japan
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