Instruction manual
Contents
1. 3 Way Ball Valve Type 23H 10 ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Method of adjusting face pressure between ball and seat Caution Do not use the pipe wrench The valve can be damaged A G Take care not to over tighten the Union Nut The valve can be damaged Strap wrench Safety goggles Protective gloves Procedure __ 8 a Ba e D oken TA 0S lnain ie A 1 Completely discharge fluid from pipes E i 4 coe i ranch piy W y ke Ta 2 Tum the handle to 0 degree 3 Loosen the union nut 5 for branch pipe with a strap wrench 4 Turn the handle to 90 degree 5 Loosen the union nut 5 for main pipe with a strap wrench 6 Remove the body part from piping system A Wear protective gloves and safety goggles as some fluid remains in the valve You may be injured Caution 7 Pull the handle off the body part 8 Engage the upper convex part of the handle with the concave part of the union 3 Adjust the unions on both sides 9 Make an adjustment by turning the union clockwise to loosen it or counter clockwise to tighten it 10 Make sure that the handle can2. 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 3 Way Ball Valve Type 23H 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts No DESCRIPTION No DESCRIPTION 1 Body 7 Seat 2 Ball 8 Oring A 3 Camer 9 Oring B 4c End connector Socket End 10 Oring 4d End connector Threaded End 11 Oring D 4e End connector Spigot End 12 O ring 5 Union nut 14 Handle 6 Stem 3 Way Ball Valve Type 23H 4 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Working pressure vs temperature Nominal Size 15 50mm 150 1 0 70 0 5 Working pressure MPa PSI 0 0 20 0 20 40 60 80 100 120 5 30 7
3. 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 Any repair or replacement needed after the warranty period
4. 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 3 Way Ball Valve Type 23H 1 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 Warning 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 Certain liquid such as H20 NaClO etc may be prone to vaporiz
5. handle to 0 degree i L ae ee ee 3 Loosen the union nut 5 for branch pipe with a strap wrench 4 Turn the handle to 90 degree 5 Loosen the union nut 5 for main pipe with a strap wrench 6 Remove the body part from piping system 7 Pull the handle off the body part 8 Engage the upper convex part of the handle with the concave part i of the union Adjust the unions on both sides 9 In the engaged state turn the handle 14 clockwise to loosen it and remove the union 3 lt Direction where carrier is loosened 10 Remove the seat 7 carefully by hand without damaging it sis 11 Push out the ball 2 by hand MA 12 Push out the stem 6 from the top flange side to the body side Se lt Assembly gt Procedure Direction where cameristightened Carry out the assembly work in the reverse procedure from iten 12 bc n A g Before installing the Teflon seat on the valve check the seat Caution for its front and back Bal Seat H 3 Way Ball Valve Type 23H 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Inspection items A es Perform periodic maintenance Leakage may develop due to temperature changes or over periods of Caution prolonged storage rest or operation Inspect the following items Check for flaw crack or deformation on the valve Check for leaks to the outside or inside C
6. 0 105 140 175 210 250 Temperature C F 20 0 20 40 60 80 100 120 5 30 70 105 140 175 210 250 3 Way Ball Valve Type 23H 5 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation procedure A es 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 A S 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 Take care not to over tighten the Union Nut The valve can be damaged Do not use the pipe wrench The valve can be damaged 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 Before a water test be sure that the Union Nut is tightly fastened 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 the pipe stress on the ASAHI AV Valve A B Use flat faced flanges for connection to AV Valves Caution Ensure that the mating flanges are of the sam
7. 0mm OSEE 1 1 1 4 1 1 2 BEEN DE 300 204 177 20 0 204 177 20 0 204 177 coated Rubber 20 0 204 177 20 0 204 177 20 0 204 177 Be sure to set the union nut 5 when it was removed or loosen from body 1 1 The O ring A 8 should be set on surface of the end connector 4b 2 The end connector 4b must be put onto the carrier then ensure that the O ring A 8 is being between the end connector 4b and the carrier 3 Tighten the union nut 5 hardly with hand 4 Screw the union nut 5 on the body 1 by quarter or half turn using a strap wrench without damaging it 3 Way Ball Valve Type 23H Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner ASAHI AV VALVES Installation Operation and Maintenance Manual AY S Make sure that the threaded connections are plastic x plastic Metallic thread can cause damage Caution Make sure that the threaded connections are plastic x plastic 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 use is unavoidable Sealing tape Strap wrench Spanner wrench Procedure 1 Wind a sealing tape around the external thread of joint leaving the end about 3mm free 2 Loosen
8. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V062 E 2 contents 3 Way Ball Valve Type 23H 1 Be sure to read following warranty User s Manual 3 General instruction for transportation 4 Name of parts rns A 5 Working pressure vs temperature eee 5 6 Installation procedure rrr 6 7 Operating procedure O 8 Method of adjusting face pressure between ball and seat OAI EAE 11 9 Disassembling method for replacing parts 12 10 Inspection items lt 13 11 Troubleshooting eerie 13 12 Handling of residual and waste materials 1771711111 13 ASAHI AV VALVES 3 Way Ball Valve Type 23H ASAHI AV VALVES Installation Operation and Maintenance Manual This user s guide contains very important information for 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 Waming A Caution This symbol reminds the user to take caution due to the potential for serious injury or death This symbol reminds the user to take caution due to the potential for damage to the valve if used in such a manner lt Prohibited amp Mandatory Action Signs gt Prohibited When operating the valve this symbol indicates an action that should not be taken B Mandatory action When operating the valve this symbol indicates mandatory actions that must be
9. ation Off Gassing which may cause irregular pressure increases which may destroy the valve A S Do not step on or apply excessive 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 ay 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 3 Way Ball Valve Type 23H 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General instructions for transportation unpacking and storage A S 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
10. be operated smoothly 11 Assemble the valve by following the above procedure in the reverse order starting at 8 3 Way Ball Valve Type 23H 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Disassembling method for replacing parts See eee eee eee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee a A amp 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 Do not change or replace valve parts under line pressure Caution Take care not to over tighten the Union Nut The valve can be damaged i Do not use the pipe wrench The valve can be damaged When installing disassembling or reassembling the piping fix the End Connector Before a water test be sure that the Union Nut is tightly fastened Fasten the Union Nut while avoiding the parallelism and axial misalignment of the flange surface When connecting a ASAHI AV Valve to metal piping take care not to let the pipe stress on the ASAHI 4 AV Valve Strap wrench Safety goggles Protective gloves or gue aes Bees i e a seeeeel ees Procedure Okan i main pipe ULE SL 1 Completely discharge fluid from pipes T ge 2 Turn the
11. e standards Be sure to use sealing gaskets AV Gasket bolts nuts and washers and tighten them to specified torques i When a non AV gasket is used a different tightening torque specification should be followed Torque wrench Spanner wrench Strap wrench AV gasket Bolt Nut Washer For many flanges specification 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 3 Way Ball Valve Type 23H 6 ASAHI AV VALVES Installation Operation and Maintenance Manual Caution following table to prevent damage the valve Unit mm inch A failure to observe them can cause destruction due to stress application to the pipe Nom Size Axial Parallelism j Misalignment a b 25 32mm 1 1 1 4 1 0 0 04 0 5 0 02 40mm 1 2 1 0 0 04 0 8 0 03 Axial misalignment g The parallelism and axial misalignment of the flange surface should be under the values shown in the Parallelism es i an i cat E SAA DA SEAE A en A FA de PE PEE SA a ee E A A PAR SA S e yah EA D E hen e A allt i lic a Ra al 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to Fig 1 Caution 5 Recommended torque value Unit N m kgf cm Ib inch N Si 25mm 32mm 4
12. ed improperly 3 Way Ball Valve Type 23H 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 Way Ball Valves Type 23 ASAHI AV VALVES Asahi Organic Chemicals Industry s homepage http www asahi yukizai cojp en Information in this manual is subject to change without notice 2012 9 3 Way Ball Valve Type 23H
13. h side approx 90 180 turns 1 4 to 1 2 turns Spigot type Strap wrench Sleeve welder or Automatic welding machine User s manual for the sleeve welder or the automatic welding machine 1 Loosen the union nut 5 with a strap wrench 2 Remove the union nut 5 and the end connector 4 3 Lead the union nut 5 through the pipe 4 For the next step refer to the user s manual for the sleeve welder or the automatic welding machine 5 After welding make sure that the O ring A 8 is mounted 6 Set the end connector 4 and the union nut 5 directly without allowing the O ring A 8 to come off 7 Tighten the union nut 5 hardly with hand 8 Using a strap wrench tighten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 turns 3 Way Ball Valve Type 23H 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Operating procedure A 6 Do not use the valve to fluid containing slurry Caution The valve will not operate properly The installed valve must never be opened or closed when foreign matter such as sand is present When operating the handle be sure to do so with your hand Using a tool may damage the handle Before opening or closing a lubricant free product be sure to apply water in the pipeline
14. heck for the smoothness of handle operation Inspect the Union nut and be sure it is not loose 11 Troubleshooting Problem Cause Treatment Adjust the face pressure between the The carrier is loosened ball and the seat Refer to page 11 Fluid leaks from the valve even when the valve is closed fully The seat is scratched or worn Replace the seat with a new one Foreign matter is in the valve Clean up Replace the scratched ball with a new one The ball is scratched or worn The union nut is loosened Tighten the union nut Adjust the face pressure between the Fluid leaks from the valve The carrier is loosened ball and the seat Refer to page 11 The O ring is scratched or wom Replace the O ring with a new one Foreign matter is in the valve Clean up The handle can not be turned smoothly Deformation By heat etc Replace the parts Adjust the face pressure between the Ae Cann S Mepiea me Oo THEN ball and the seat Refer to page 11 The stem is broken Replace the stem with a new one The handle fails to engage The engagement between the stem and the ball Replace the stem and ball with new is broken ones 12 Handling of residual and waste materials Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic gt Warning valves Poisonous gas is generated when the valve is bum
15. the union nut 5 with a strap wrench 3 Remove the union nut 5 and the end connector 4d A EE E lS Stand E A iu ath a ee ee ee eee ee 5 Using a spanner wrench screw in the end connector 4d by turning 180 360 carefully without damaging it 6 Make sure that the O ring A 8 is mounted 7 Set the end connector 4d and union nut 5 directly on the body without allowing the O ring A 8 to come off 8 Tighten the union nut 5 hardly with hand 9 Using a strap wrench tighten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 turns 3 Way Ball Valve Type 23H 8 ASAHI AV VALVES Installation Operation and Maintenance Manual Socket type sepa Necessary items Sessa AE O EE TE E A eS EG aE tele a Ent an adnan Gn Sane Aah SG eal emt let cure bt Strap wrench Sleeve welder or automatic welding machine User s manual for the sleeve welder or the automatic welding machine Procedure 1 Loosen the union nut with a strap wrench 2 Remove the union nut 5 and the end connector 3 Lead the union nut 5 through the pipe 4 For the next step refer to the user s manual for the sleeve welder or the automatic welding machine 5 After welding make sure that the O ring A 8 is mounted 6 Set the end connector 4c and the union nut 5 directly without allowing the O ring A 8 to come off 7 Tighten the union nut 5 hardly with hand 8 Using a strap wrench tighten union nuts uniformly on eac
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