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Contents
1. Jator Fix the installation jig under the valve and stand with jibe O a bolts Refer to page 24 sheet a 4 pe ae H eee Spread the rubber sheet on the pipe and secure pipe with o ao imo i HH micas U type clamp q an typ p ame ind II Ball Valve Type 21 210 Pneumatic Actuated Type AA ASAHI AV VALVES Installation Operation and Maintenance Manual 14 Air piping procedure lt 1 gt For a standard type and an attached speed controller type Do not remove a dust proof cap provided to piping port before piping work starts Caution Avoid excessive tightening The threaded area of a pipe can be damaged Do not apply a sealant excessively lest it fall off in the pipeline when an actuator is piped Check the connection locations air pipe sizes and screw types with the approved drawings and other documents for the product Then lay the air piping The operating fluid must be clean air filtered through a pertinent air filter If the actuator is used in an environment below 5 C temperature its operating fluid must be free from the water and moisture contained in it because of possible problems due to the freeze Steel pipes must always be of the plated Before installing an actuator in pipeline flash the inside of pipeline completely2. 2 Check that the valve indicating direction and the operating direction agree with each other 3 Stop supplying air lt For the solenoid valve gt Thi Procedure 1 Supply the air to the solenoid valve Fig 5 2 Push the button fig 5 with a finger and confirm the AX action mode shown in the following table E 3 Apply regular rated voltage to the solenoid valve and i confirm the action mode shown in the following table A pede 4 Tum offthe solenoid valve Push button Current Pak wos Air to shut Air to open Pushed On Open Shut Not pushed Off Shut Open Adjustment of opening closing speed procedure A Solenoid valve A speed controller adjusts and fastens a lock nut by open ended spanners Warning ODouble action type cmeesy Necessary items Bui eues eee tedecess eee keehece estes AAAG EEDA ye eso ed A Ve AAA E EEA AEEA ee ee eee E eee Sele eo eG eR ane daa i l Spanner wrench i Ball Valve Type 21 21a Pneumatic Actuated Type AA 23 ASAHI AV VALVES Procedure 1 Release the adjustment knob of the solenoid valve by 2 3 4 5 6 7 turning the locking nut left with a spanner holding the two adjustment knobs open side and close side of the speed controller with fingers Turn right the adjustment knob ofthe solenoid valve fully Avoid excessive tightening The speed controller can be damaged
3. Type 21 and 21a have not all same parts to male one complete As for details please consult your nearest service station beforehand Ball Valve Type 21 21a Pneumatic Actuated Type AA 1 Body 6 Stem 23 Actuator 2 Ball 7 Seat 24 Stand 3 Carrier 8 O ring A 25 Joint 4b End connector Flanged end type 9 O ring B 26 Bolt A 4c End connector Socket end type 10 O ring C 27 Bolt nut B 4d End connector Threaded end type 11 O ring D 28 Screw B 4e End connector Spigot end type 12 O ring E 5 Union nut 13 Stop ring ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Working pressure vs temperature Ball Valve Type 21 21a Pneumatic Actuated Type AA 5 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Specifications of valve body Specification of Type 21 amp Type 21a Nominal si Body material ee PVC CPVC PP PVDF 15 50mm 1 2 2 Type2la Type21 7 Specifications of actuator Angle aoad E 3 Nominal Actuator operating Actuation Size e aes pices NI yi open Air supply bore 2 and Close MES kerem
4. Supply the air to the solenoid valve Apply regular rated voltage to solenoid valve and turn left the open side adjustment knob little by little Tum off the solenoid valve and turn left the close side adjustment knob little by little Repeat item 4 5 to adjust the opening closing speed required When the adjustment is finished fix the adjustment knob by tuming locking nuts right with a spanner holding the adjustment knobs with fingers Avoid excessive tightening The locking nut can be damaged O Single action type Necessary items Spanner wrench Installation Operation and Maintenance Manual For Double action type with solenoid valve Close side g S a D Open side Seeed down Speed up Speed down fesh h J Speed uP ea Nash fs Adjustment knob Locking knob _ A For Double action type with speed controller The actuation type changes the speed adjustable direction Single action Opening speed Closing speed Air to open type Not adjustable Adjustable Air to shut type Adjustable Not adjustable Ball Valve Type 21 210 Pneumatic Actuated Type AA 24 ASAHI AV VALVES Installation Operation and Maintenance Manual Procedure For Single action type with solenoid valve 1 Release the adjustment knob of the solenoid valve by Oo turning the locking nut left with a spanner holding the i adjustment of the speed controller wit
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 Ball Valve Type 21 210 Pneumatic Actuated Type AA 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General operating instructions A Do not disassemble or modify the actuator Warning If disassembled forcible internal parts may jump out and this is very dangerous Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the 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 H202 NaClO etc may be prone to vaporization OffGassing 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 to fluid containing slurry The valve will not operate properly Do not use AV valves in a place where they may be
6. AA 30 ASAHI AV VALVES Installation Operation and Maintenance Manual Ball Valves Type 21 21a Pneumatic Actuated Type AA Automatic Valve ASAHI AV VALVES Asahi Organic Chemicals Industry s homepage http wwwaasahi yukizai co jp en Information in this manual is subject to change without notice 2014 3 Ball Valve Type 21 21a Pneumatic Actuated Type AA
7. Rc 1 4 11 8 3 8 turns amp Air to shut JIS sign Ball Valve Type 21 21a Pneumatic Actuated Type AA 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 12 Installation procedure A S 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 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 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 a piece of equipment at the end of the piping line nior be sure to keep the secondary Downstream End Connector and Union Nut installed on the valve SE When installing valve at the end note the direction of flow l Find the mark lt 4 molded on the Carrier side body On the secondary Downstream side the Carrier is integral with e i ration the valve body This is the preferred method if installation when con installing the equipment at the end of the line for safety purposes When loosening the union nut on the union side fix
8. cover or housing Contact of a crimping terminal with the cover may disable the cover from being closed or may cause a ground fault Ifyou use the limit switch at 1ImA 100mA or 5 30V consult near Asahi dealer Be sure that the terminal cover and body cover are put on during the operation riei Necessary items eee ee Soret Siete eee eee Sheena eee ee Se eee eee eee eee ieee ere EO Screw driver Crimp style terminal Terminal crimping tool connector G1 2 Wire stripper Procedure 1 Loosen three screws used to attach the limit switch cover with a Phillips head screwdriver and remove the cover from limit switch The screw is made so that it will not detach from the cover 2 Pull and remove protective cap made of resin from the cover 2 Sey J 3 Draw a cable through the connector 4 Strip cable with wire stripper 5 Install a crimp style terminal on the lead wire with a terminal crimping tool 6 Connect terminal screw with a Phillips head screwdriver according to the internal circuit diagram shown in pages Tighten up the screw If not electric leaks or shocks may occur Ere reer EEE E N E EA tere creer eet rere 7 Tighten the above three screws with a Phillips head screwdriver to install cover on the limit switch Ball Valve Type 21 21 Pneumatic Actuated Type AA 19 ASAHI AV VALVES lt CFC 6301 CFC 6302 gt Shut down the power on the equipment before connecting wires There are risks o
9. reeeree Ne cessary items sop a ae a ar ke ee i ra a a ra a Torque wrench AV gasket Bolt Nut Washer For many flanges specification Spanner wrench Procedure 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 AQ 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 A failure to observe them can cause destruction due to stress application to the pipe Axial Parallelism Axial misalignment Parallelism Nene Misalignment a b i 15 32mm p F i 1 1 1 0 04 gt 0 5mm 0 02 eo hee 1 0mm 0 04 0 8mm 0 03 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to Fig 1 EREE hod a E NENE E OE ta a a cna aN ea sl at et Sh me atv ae a es Caution poe manner Recommended torque value Unit N m kgf cm lb inch i Nom Siz 15 20mm 25 40mm 50 mm alee 1 2 3 4 1 1 1 2 2 1 PIFE PVDF 17 541793 155 20 0 204 177 22 5 230 230 coated Rubber 8 0 823 71 20 0 204 177 22 54230 230 Ball Valve Type 21 21a Pneumatic Actuated Type AA 11 ASAHI AV VALVES Installation Operation and Maintenance Manual Be sur
10. wrench lt Disassembly gt Procedure 1 Completely discharge fluid from pipes Pag 2 Shut the main air valve and open the bypass valve to discharge air cf from the actuator l Ekoa 3 Tum off the power source of solenoid valve Only solenoid valve N 4 Loosen the union nuts 5 at right and left with a strap wrench 5 Remove the body from the piping system 6 Loosen nut and bolt B 27 with a spanner wrench and remove stand 24 from the top flange 7 Loosen the bolt A 26 between the actuator 23 and the stand and remove the actuator 23 ATU U sree Ca 8 Loosen set screw 28 with an allen wrench and remove joint 25 from stem 6 9 Engage the upper convex part of the handle with the concave part of the union 3 10 Inthe engaged state turn the handle to loosen it and remove the union 3 Loosen the union Ball valve type 21 Counter clockwise Ball valve type21 Clockwise 11 Remove the seat 7 carefully by hand without damaging it 12 Operate the valve to full close 13 Push out the ball 2 by hand 14 Push out the stem 6 from the top flange side to the body side ail lt Assembly gt Procedure Carry out the assembly work in the reverse procedure from item 14 A a With regard to item 11 before installing seat 7 on the v
11. 0 59 Fixation of bottom stand with panel Ball Valve Type 21 210 Pneumatic Actuated Type AA After fixation 26 ASAHI AV VALVES Installation Operation and Maintenance Manual 19 Method of adjusting face pressure between ball and seat A Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty Warning You may be injured A S Take care not to over tighten the Union Nut The valve can be damaged i Caution Do not use the pipe wrench The valve can be damaged r iiia Necessary items E ER E E E A E E A E EE A S ie E A ed a E N E N E EA 5 Strap wrench Allen wrench Handle For manual operating Option 14 Safety goggles AES a e ee OR ae Procedure 1 Completely discharge fluid from pipes 2 Shut the main air valve and open the bypass valve to discharge air from the actuator gt I f TE 3 Turn off the power source of solenoid valve In the case of solenoid valve mounted 4 Loosen the two unions nuts 5 at night and left with an strap wrench 5 Remove the body part from piping system OCT La 4 i SL 6 Loosen bolt B 27 with a spanner wrench and remove the body part Memorize both opening degree of boll 2 and actuator 23 Ball va
12. 1a0 Pneumatic Actuated Type AA 7 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Specifications of limit switch option lt ILSI J gt Actuation Nom size Type sign Protection grade Double actuation Type ILS1 J IP67 IEC529 15 50mm Air to open 1 2 2 amp ILS1 J IP67 IEC529 Air to shut Limit switch rating Connection diagram At intermediate opening Rea Sai ae ae ee A a a a a V A A AC125 10 6 AC250 10 6 DC115 0 8 0 2 2 T eS NC2 DC230 0 4 0 1 lt CFC 6301 CFC 6302 gt Actuation Nom size Type sign Switch contact Protection grade i i CFC 6301 Silver contacts Double ee IP67 IEC529 actuation Type 1 2 2 a Gold contacts i Minute load specification i CFC 6301 Silver contacts ALD Op 15 50mm amp 1 2 2 IP67 IEC529 Airto shut CFC 6302 race Minute load specification Connection diagram Limit switch rating Type sign Rate voltage V AC250 CFC 6301 DC24 AC250 CFC 6302 DC24 Ball Valve Type 21 21a Pneumatic Actuated Type AA 8 ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Specification of speed controller option Effective cross section area eis 2 Actuation Nom size Type sign Pipe bore mm mee ee Free flow Control flow Double actuation Type 15 50mm Traces 2 SC7 08A
13. ASAHI AV VALVES Ball Valve Type 21 21a Pneumatic Actuated Type AA User s Manual Ball Valve Type 21 21 Pneumatic Actuated Type AA Installation Operation and Maintenance Manual Serial No H A003 E 11 Contents 1 Be sure to read the following warranty clauses of our product incunnanacpeticanacsbannssesbonanccsbaacncesoanancesbe 1 2 General operating instructions rr 2 3 General instructions for transportation unpacking and storages eta 3 4 Name of parts eeeeeeeereresererereererereririsrerereeisresresresrtnrisreertertertereerrarran 4 5 Working pressure vs temperature 1 5 6 Specifications of valve body 6 7 Specifications of actuator 8 Specifications of pressure reducing valve with filter 6 9 Specifications of solenoid valve E EEEE EEEE 7 10 Specifications of limit switch ad 1 Specifications of speed controller MEENE EEPE AEAT E EE A 9 12 Installation procedure PEPER E EERE EEEIEE TA SEE PI E N 10 13 Support setting procedure 15 Connection of limit switch procedure ee 19 16 Connection of solenoid valve procedure 21 17 Operating procedure vr rennet Manual operating procedure Automatic operating procedure 22 Adjustment of opening closing speed procedure 23 18 Mounting inserted metal and base Panel er 26 19 Method of adjustment face pressure between ball and seat sesssessonsanteonssseceosorecceseesrseeoeesntesesoonte 27 20 Disas
14. Threaded area ofa pipe must be free from the sharp edges and burr Bhs Necessary Tem a P50 Eee eee Sa etme oe at i ete eis a Spanner wrench Seal tape Steel pipe or tube for piping Joint for steel pipe or tube edin opens a ie See te tees ee ath tee cee teeth Renee enat hat 1 Wind a seal tape onto the male screw of the joint with a 7 shy A blank about 3mm about 2 threads left at the end 2 Screw the joint in the piping female screw of the 2 actuator by hand to the full C 3 Serew the joint one tri with 3 spanner wrench Novels vo vtisi tovani dodini V oori Svo V OVES VNV EEEEV SONEK V EOE VOOREN VENE VOEE VOEE SVEEN OE NVO Avoid excessive tightening The valve can be damaged All 4 Mounta steel pipe or a tube PI Ball Valve Type 21 21a Pneumatic Actuated Type AA 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 Do not remove a dust proof cap provided to piping port before piping work starts Caution Avoid excessive tightening The threaded area of a pipe can be damaged Do not apply a sealant excessively lest it fall off in the pipeline when an actuator is piped Steel pipes must always be of the plated Before installing an actuator in pipeline flash the inside of pipeline completely Threaded area of a pipe must be free f
15. all Valve Type 21 210 Pneumatic Actuated Type AA 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General instructions for transportation unpacking and storage SG ee Ah a a eg ce a a e a tc a A aa a a i a a ena a a gl eh a es A S When suspending and supporting a valve take care and do not stand under a suspended valve Warning A 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 Avoid contact with any coal tar creosote insecticides vermicides or paint The force of swelling may damage the valve When transporting a valve do not carry it by the handle as 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 Ball Valve Type 21 21 Pneumatic Actuated Type AA 3 ASAHI AV VALVES 4 Name of parts Nominal size 15 50mm 1 2 2 Installation Operation and Maintenance Manual
16. alve check the seat for its face and back Caution depression side engagement with ball Refer to page 4 5 il Ill Va 5 En AD i iI side T Union sid ill side iN Union sid il 0 Type 21 Pa Ball Valve Type 21 21a Pneumatic Actuated Type AA 28 ASAHI AV VALVES 21 Inspection items Installation Operation and Maintenance Manual A Caution Perform periodic maintenance Leakage may develop due to temperature changes or over periods of prolonged storage rest or operation Sea Sass Sane Bs gp wap a en E as gan vn ae ca aia a ae E es ae esp fan Se Scere ace eas pcre Sse OPeriodically inspect and maintain the AV valve in accordance with the decided schedule Portion to be inspected Inspection item Actuator travel indicator internal disconnection 1 Existence of rust peeling of paint and dirt of inspection hole of valve 2 Tightening condition of respective threaded portions Loose or not 3 Existence of rust and corrosion around the limit switch and existence of 4 Existence of abnormality in opening and closing operating sounds Tt is unnecessary to supply oil to this actuator 22 Troubleshooting Cause 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 closed fully at right or left Treatment The han
17. at 0 AMPa Deible a PPW Dee T0414 06 Re 1 8 ree 1 2 1 1 4 adjust 40 50mm Unable to T 2 ype 1 1 2 2 PPOO adjust 0 4 4 1 1 2 Rc 1 4 Single ee PPOOS Unanet 04 4 1 0 7 Rc 1 4 pr 1 2 1 1 4 adjust 40 50mm Unable to T gt ype 1 1 2 2 PP10S adit 04 4 1 1 7 Rc 1 4 8 Specification of pressure reducing valve with filter option Actuation Nominal size Type sign Pipe bore ee ee 15 50mm Double actuation Type 1 2 2 ARU2 0208A B Rc 1 4 Sum Air to open Type 15 50mm amp 1 2 Air to shut Type aS SPM n Re Ee N UT a l aoe Ball Valve Type 21 21a Pneumatic Actuated Type AA 6 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Specification of solenoid valve option Nom Effective Power Actuation Sye f Type sign Pipe bore cross section Gohin Additional function area ia aT OBypass valve built in 15 50mm 4N3S102K W 4 amo See es 12 2 G31193 or more OSil ith needle val Air to open DC 55W S needle valve amp to be used as speed controller Air to shut 4N3S102K WL G31193 ae Specification sign AC100V 50 60Hz 1 AC110V 50 60Hz 2 X is special order AC200V 50 60Hz 3 AC220V 50 60Hz 4 DC24V 5 DC48V 6 DC100V 7 DC125V 8 DC110V 9 connection diagram __ JISsign _ Ball Valve Type 21 2
18. come submerged in water Do not remove a dust proof cap provided to piping port before piping work starts Do not use the valve in conditions where the fluid may have crystallized 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 changes with time during prolonged storage rest or operation Set valve support on the valve The AV valves must be used within the specifications specifically applicable to the Product If the actuator is used in an environment below 5 C temperature its operating fluid must be free from the water and moisture contained in it because of possible problems due to the freeze The operating fluid must be clean air filtered through a pertinent air filter er a a a ee a a ag ca a pm mg gc wep E ee es gg a ae ee The valve will not operate properly B
19. dle is not can t be turned when the valve is operated manually The valve has already been opened fully The air is supplied to actuator Turn the direction handle in the reverse Shut the main air valve and open the bypass valve Foreign matter is in the valve Disassemble the valve to remove foreign matter Refer to page 28 The torque of the valve is increased by the piping stress Remove the piping stress The torque is increased by the influence temperature components pressure of fluid on the valve Check service condition Refer to page 6 The valve does not operate by air operations The power source of the control panel is turned off Turn on the power source The solenoid valve is disconnected Check the connection again Refer to page 7 21 The supply voltage to the solenoid valve is wrong The voltage to the solenoid valve is low The bypass valve is opened Check voltage with a tester and set specified voltage Close the bypass valve The speed controller is turned right excessively Ball Valve Type 21 210 Pneumatic Actuated Type AA Tum the adjuster know left 29 ASAHI AV VALVES The valve does not operate by air operations Installation Operation and Maintenance Manual Foreign matter is in the valve Treatment Disassemble the valve to remove foreign matter Refer to page 28 The torque of the valve i
20. e 1 Loosen the union nut 5 with a strap wrench 2 Remove the union nut 5 and end connector 4c 3 Lead the union nut through the pipe 4 Clean the hub part of the end connector 4c by wiping the waste cloth 5 Apply adhesive evenly to the hub part of the end connector 4c and the pipe spigot A j Do not apply more adhesive than necessary The valve can be damaged due to solvent cracking Caution BRRR Ball Valve Type 21 21a Pneumatic Actuated Type AA 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 7 8 9 Adhesive quantity guideline N Si 15mm 20mm 25mm 32mm 40mm 50mm ue 172 6A a aml a2 Quantity g 1 0 13 2 0 24 3 5 48 After applying adhesive insert the pipe quickly to the end connector 4c and leave it alone for at least 60 seconds Wipe away overflowing adhesive Make sure that O ring A 8 is mounted Set the end connector 4c and union nut 5 directly on the body without allowing the O ring A 8 to come off 10 Tighten the union nut 5 on each valve until hard tight 11 Using a strap wrench tighten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 turns Socket End Material PP PVDF ase Necessary items hones Saco canoer Sank cept oan a Bled Chain eae ewe sb Senet ne Re ees See ee wee ee A ee nt Strap wrench Sleeve welder or automatic welding machine User s manual for sle
21. e 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 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
22. e 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 up 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 Threaded End Material PVC C PVC PP PVDF A S Avoid excessive tightening The valve can be damaged Caution Make sure that the threaded connections are plastic x plastic Metallic thread can cause damage SASRA R FAAA AN in case of said use even when said use is unavoidable SERE Necessary items See oe De E E ee ee ee eter EENE ee Sherer es Sree Sealing tape Strap wrench Spanner wrench 1 Wind a sealing tape around the external thread of joint leaving the end about 3mm free Sealing Tape lt 2 Loosen the union nut 5 with a strap wrench EERDE gai 3 Remove the union nut 5 and the end connector 4d 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 PE EE E E dene waarmee ES a 5 Using a spanner wrench screw in the end connector 4d by turning 180 360 carefully without dama
23. eve welder or automatic welding machine Procedure 1 2 3 4 5 6 7 8 Loosen the union nut 5 with a strap wrench Remove the union nut 5 and the end connector 4c Lead the union nut 5 through the pipe For the next step refer to the user s manual for the sleeve welder or the automatic welding machine After welding make sure that the O ring A 8 is mounted Set the end connector 4c and the union nut 5 directly without allowing the O ring A 8 to come off Tighten union nuts 5 on each valve until hand tight Using a strap wrench tighten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 turn Ball Valve Type 21 21a Pneumatic Actuated Type AA 14 ASAHI AV VALVES Installation Operation and Maintenance Manual Spigot End Material PP PVDF ie cee Necessary items ETEEN AREA ay eat AEE a Ta el A EBE at mtn tt eta eta NA eR SO RS nl ne Rie nek at tata OE at A a eS Cre et al a i Strap wrench Sleeve welder or automatic welding machine User s manual for sleeve welder or automatic welding machine 1 Loosen the union nut 5 with a strap wrench 2 Remove the union nut 5 and the end connector 4c 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 directl
24. f electrical shock Warning depending on the level of operating voltage A S Be sure that the cover are put on during the operation Installation Operation and Maintenance Manual Caution ee Necessary items IERE TEPE A EIEEE PO a AE E S OL hat oa Sl Se eh Oe aia Screw driver Screw driver connector G1 2 Wire stripper IE 1 Loosen four screws used to attach the limit switch cover with a 2 3 4 5 6 Phillips head screwdriver and remove the cover from limit switch The screw is made so that it will not detach from the cover Remove a protective cover made of resin Draw a cable through the connector Strip cable with wire stripper Connect terminal screw with a flat head screwdriver according to the internal circuit diagram shown in page8 Tighten up the screw If not electric leaks or shocks may occur Tighten the above four screws with a Phillips head screwdriver to install cover on the limit switch Ball Valve Type 21 210 Pneumatic Actuated Type AA 20 ASAHI AV VALVES Installation Operation and Maintenance Manual 16 Connection of solenoid valve procedure A Go after you surely interrupt a power supply when you do the installation of the terminal base line Caution is combined Solenoid valve A speed controller adjusts and fasten a lock nut by open ended spanners a Tease beans lt a eee meee gee eee ea epee ere ee Terminal crimping tool Scre
25. ging 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 screw it in by turning 90 180 carefiilly without damaging it Ball Valve Type 21 210 Pneumatic Actuated Type AA ASAHI AV VALVES Installation Operation and Maintenance Manual Socket End Material PVC C PVC A S When using an adhesive ventilate the space sufficiently prohibit the use of a fire in the vicinity and do not Warning inhale adhesive vapors directly Ifan adhesive gets into contact with your skin wash it off immediately If you feel sick or find any anomaly receive a physician s diagnosis and take appropriate measures promptly Caution remain Solvent cracks may occur damaging the equipment After assembling the piping system open both ends of the piping and use a fan of the Low Voltage Type or something similar to ventilate the space thus removing the solvent vapors A S Take care in doing work at low temperatures Solvent vapors are hard to evaporate and are likely to Use the appropriate Asahi AV cement Conduct a water test at least 24 hours after joining the pipes with an adhesive cement es Necessary items lt 0 isiceei sie er ercie rei ciersice E E E ic dire seid ecu a ea i Adhesive for hard vinyl chloride pipes Strap wrench Procedur
26. h fingers Close side 6 A lt 2 Turmright the adjustment knob of the solenoid valve fully Not used sed dumn gt 5 z z peed up gt Avoid excessive tightening al The speed controller can be damaged NC ee gt i Adjustment knob i Locking nut K 3 Supply the air to the solenoid valve 4 Apply regular rated voltage to solenoid valve turn left the open side adjustment knob little by little 5 Turn off the solenoid valve and turn left the close side adjustment knob little by little 6 Repeat item 4 5 to adjust the opening closing speed required 7 When the adjustment is finished fix the adjustment knob with locking nuts y gt Avoid excessive tightening N Ja The locking nut can be damaged i heed n bani IAG NU peed uf Adjustment knol Ball Valve Type 21 21 Pneumatic Actuated Type AA 25 ASAHI AV VALVES Installation Operation and Maintenance Manual 18 Mounting inserted metal ensat and base panel Warning When screwing in a Metal Insert Ensat install it vertically Refer to the User s Manual for Metal Insert Ensat by the Maker Fixation of bottom stand with panel Procedure Refer to the user s manual for the Ensat metal insert Commercially available Bottom stand dimension Unit mm inch Nom Size S S S3 15 25mm 19 7 3 11 1 2 1 0 75 0 29 0 43 32 50mm 30 9 15 1 1 4 2 1 18 0 35
27. lve type 21 Tighten 7 Operate the valve to full close igh Except for spring single action type alli 8 Engage the upper convex part of the handle with the concave part of the union 9 Make an adjustment by tuming the union clockwise or counter clockwise Tighten the union Ball valve type 21 Clockwise i Ball valve type21 Counter clockwise Ball valve type 21a Loosen the union Loosen Ball valve type 21 Counter clockwise Ball valve type21 Clockwise alli 10 Assemble the valve by following the above procedure in the reverse order starting at 6 Tighten Ball Valve Type 21 21 Pneumatic Actuated Type AA 27 ASAHI AV VALVES Installation Operation and Maintenance Manual 20 Disassembling method for replacing parts A amp Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty Warning You may be injured A S Take care not to over tighten the Union Nut The valve can be damaged Caution Do not use the pipe wrench The valve can be damaged i Type 21 amp Type 21 Alpha has not all same parts to make one complete Please check and specify the i model from the valve overview r ies Necessary items ieadloeiieee eet Sy ese ve tees etek A ot peisv whet sun ae E net eee ee AAR arate cates betewec aber emia ay as a Strap wrench Allenwrench Handle For manual operating Option 14 Safety goggles Protective gloves Spanner
28. rom the sharp edges and burr Avoid excessive tightening The threaded area of a pipe can be damaged Solenoid valve A speed controller adjusts and fasten a lock nut by open ended spanners Open the drain periodically in order to exhaust the deposit The equipment must be used at a pressure below the maximum operating pressure specified for the product r wis Necessary items P TI a cS al A a a eh E E Ste Tat I an a ae Se E i Spanner wrench Seal tape Steel pipe or tube for piping Joint for steel pipe or tube 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 tum with a spanner wrench Avoid excessive tightening The valve can be damaged 4 Mounta steel pipe or a tube Ball Valve Type 21 210 Pneumatic Actuated Type AA ASAHI AV VALVES Installation Operation and Maintenance Manual 15 Connection of limit switch procedure lt ILS1 J gt Shut down the power on the equipment before comnecting wires There are risks of electrical shock i Warning depending on the level of operating voltage AY S Be sure that the cover are put on during the operation Caution Connect the cables by using insulated sheathed crimping terminals in such a way as not to contact the
29. s increased by the piping siess Remove the piping stress peraire p gt P Refer to page 5 on the valve Fluid leaks from the valve even when the valve is closed fully Adjust the face pressure between the The carrier is loosened ball and the seat Refer to page 27 The seat is worn Replace the seat with a new one The seat and ball are scratched Replace the scratched seat and ball with new ones Foreign matter is in the valve Discharge the foreign matter from the valve by opening and closing the valve several times Fluid leaks from the valve The union nut is loosened Tighten up the union nut The O ring is scratched or worm The O ring is projected from the groove Replace the O ring with a new one The sliding face or the fixed face of the O ring is scratched or worm Replace the sliding face or the fixed face with a new one The actuator operates but the valve is not open or close The stem or the joint is broken Replace the stem or the joint with a new one The engagement between the stem and the ball is broken 23 Handling of residual and waste materials Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic AO Warning Replace the engagement with a new one valves Poisonous gas is generated when the valve is bumed improperly Ball Valve Type 21 210 Pneumatic Actuated Type
30. sembling method for replacing parts ve 28 2 1 Inspection items PEE NEEE IPAE E EEIE EEEN OE A NAAA AANE 29 22 Troubleshooting esisi 29 23 Handling of residual and waste materials vee 30 ASAHI AV VALVES 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 ya This symbol reminds the user to take caution due to the potential for serious injury or death I A This symbol reminds the user to take caution due to the potential for damage to the valve if used in Caution such a manner lt Prohibited amp Mandatory Action Signs gt S Prohibited When operating the valve this symbol indicates an action that should not be taken g Mandatory action When operating the valve 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 tak
31. ted open the bypass valve to make atmospheric pressure in the actuator Caution It can t do Manual operation poss Necessary items 141ta Spanner wrench Procedure 1 Attach the spanner wrench to the output shaft in the upper part of the actuator and turn the handle 1 2 times between full open and full close Right turn clock wise Close direction Left turn counter clock wise Open direction i f Bypass valve knob_ Do not tum the handle forcibly at the right and left fall Sf Tie operating positions Open If not a trouble will develop 2 Set the valve in the fully opened of fully closed position Shut and remove the spanner wrench from the output shaft in va the upper part of the actuator f In case of solenoid valve mounted shut the bypass valve If not a trouble will develop Automatic Air Operating Procedure A Make sure that the spanner is not attached to the output shaft in the upper part of the actuator securely Warning If not the spanner will be flown by the rotation of the output shaft and the spanner may injure you A amp Keep air supply pressure from a compressor at least 0 4 MPa 4 1 kgf cm2 and at the maximum 0 8MPa Caution 8 2kgf cm2 Ball Valve Type 21 210 Pneumatic Actuated Type AA 22 ASAHI AV VALVES Installation Operation and Maintenance Manual Procedure Opening indicator 1 Supply the air to the air supply opening
32. the body cap hold it with your hand and do work Ifthe body cap turns the union will turn together resulting in the union and ball separating from the body Ifthe union is loosened retighten the union 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 When screwing in a Metal Insert Ensat install it vertically Refer to the User s Manual for Metal Insert Ensat by the Maker Take care not to over tighten the Union Nut The valve can be damaged rr Ball Valve Type 21 21 Pneumatic Actuated Type AA 10 ASAHI AV VALVES Installation Operation and Maintenance Manual Flanged End Material PVC C PVC PP PVDF ck gh lt n emt E E E i an cae wee A a ae eas cats ay wae mea yp a ace a fa ms es eng cena E Sam gah ge Snel N E Pay epee fad Cec acta A Use flat faced flanges for connection to AV Valves Caution Ensure that the mating flanges are of the same standards i 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
33. w driver Connector G1 2 Wire stripper Procedure 1 Loosen the hexagon socket head cap screws and eee eee ce neeene eee neeeeeee eee ce neeeeeeeeneeee eee ceeeeen ce nee nee ecenee cee neeeennn nee neeceaeneeneneeeeeennenes remove the cover etl Don t loose O ring i x fnot electric leaks or shocks may occur 2 Remove the Faston terminal inserted into coil side and the insulating sleeve 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 fix it The cover can be set with the wire extraction opening l turned upward or downward l 9 Tighten the cable by connector Sdda vee sounsensacsuinendaesiensensusoen sensgueescensevscesessdaneusevsseaessenssnniesesusetees veneaued soentysasansney SAANEEN ANENE Ball Valve Type 21 210 Pneumatic Actuated Type AA 21 ASAHI AV VALVES Installation Operation and Maintenance Manual 17 Operating procedure Manual Operating Procedure ODouble action type Don t supply air during manual operation Warning When air is supplied during the manual operation you may be injured A go Incase of solenoid valve moun
34. y without allowing the O ring A 8 to come off 7 Tighten the union nut 5 hardly with hand 8 Using a spanner wrench screw in the end connector 4d by turning 180 360 carefully without damaging it Ball Valve Type 21 21a Pneumatic Actuated Type AA 15 ASAHI AV VALVES Installation Operation and Maintenance Manual 13 Support setting procedure A Set valve support on the valve O E E PEEN Necessary items KARRERA PECE AR R AAA EEA E REEERE ARARA EEA EE ENA RA AEL EA ANRA RAAE AAS AA EE EEE E RAA EAA RA ENAA Spanner wrench U type clamp with bolt Level installation ee eee eee eee eee eee eee eee eee eee eee eee eee eee eee eeee eee eeee eeee eee eaee cece eee cece eee eens eeee eee eaee cece eaeeeeeneaeeeeeeeeee een f i U Ty lam OUsing metal insert Ensat amp U type clamp ibbel A Fix the installation jig under the valve and stand with NN Se ane i CE bolts Refer to page 24 FX ery 7 N p t i mam Spread the rubber sheet on the pipe and secure pipe with E PARN U type clamp FOR tand It OUsing U type clamp Only Flanged type Spread the rubber sheet on the flanged part of pipe and secure pipe with U type clamp Perpendicular installation
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