3-Way Ball Valve
Contents
1. Nominal size 15 5Omm 1 2 2 POP Sem S Nominal size 80 100mm 3 4 3 Way Ball Valve CE 2 Installation Operation and Maintenance Manual ASAHI AV VALVES 4 Comparison between working temperature and pressure Nominal size 15mm 50mm 1 2 2 A l 2 2 99 VU L D 310 28 150 a LE TO 2 L Q SE i i c 70 I O i l I Nominal size 80mm 100mm 3 4 A Caution Do not operate the valve beyond the range of working temperature and pressure The valve can be damaged 3 Way Ball Valve CE ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Installation procedure Flanged type Material PVC C PVC PP PVDF AE Necessary items EEEE E Torque wrench Spanner wrench AV gasket Bolt Nut Washer For many flanges specification When a non AV gasket is used a different tightening torque specification should be followed 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 tempo2. C PVC PP PVDF h Necessary items AA EEA AE Sealing tape A non sealing tape can cause leakage Strap wrench Do not use Pipe wrench Spanner wrench A Caution Make sure that the threaded connections are plastic x plastic Metallic thread can cause damage Procedure 1 Winda sealing tape around the extemal thread of jomt leaving the end about 3mm free 2 Loosen the union nut S witha strap wrench 3 Remove the union nut 5 and the end connector Ga 4 Lead the union nut G through the pipe 5 Tighten the external thread of the joint and the end connector d hardly with hand 6 Using a spanner wrench screw in the end connector d by tuming 180 360 carefully without damaging it A Caution Avoid excessive tightening The valve can be damaged 7 Make sure that the O ring A 8 is mounted 8 Set the end connector Gd and union nut G directly on the body without allowing the O ring A 8 to come off 9 Tighten union nut G hardly with hand 10 Using a strap wrench tighten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 turns A Caution Avoid excessive tightening The valve can be damaged 3 Way Ball Valve CE 5 ASAHI AV VALVES Installation Operation and Maintenance Manual Socket type Material PVC C PVC ee Necessary items Geese eee ceases sass assesses E aEG EEE EEEEE E A E E E AAAA AAE Adhesive for hard vinyl chloride pipes Strap wrench Do not us
3. ASAHI AV VALVES 3 Way Ball Valve User s Manual 3 Way Ball Valve CE Installation Operation and Maintenance Manual _ Contents 1 General operating instructions Aaa spadiesessasdetarecesecssdeesaseuesesscestossscrecessacieceseseaets 1 2 General instructions for transportation unpacking and storage EE O O cobs E E OO AA 1 3 Name of parts doacacardaddccavsedsesusdedadevdansvaescaccuvadcccdseesccscdbnecessestasesabssesebaseesedeneesssbeyancanteacnten 2 4 Comparison between working temperature and pressure 1s 3 5 Installation procedure apis ENE EENE OETA EE EE EES 4 6 Operating procedure A A E E SE 8 7 Adjustment face pressure between ball and geat rr rrrrrrereeeeeeeeeseseetseeessssssssssee 9 8 Disassembling method for parts replacement ne 10 9 Mounting actuator eee 11 10 Inspection items ons riiinnnnnnnnnnnnnnnnnnnnnnnnninnnnnnnntn 11 il Hrowbleshootitio seniwsnaninenesaamancipacenemnnnnnmereimmenssa 12 12 Handling of residual and waste materials 12 13 Marking einn 13 GCS Mii icc ee ee ee eee 14 ASAHI AV VALVES ASAHI AV VALVES Installation Operation and Maintenance Manual 1 General operating instructions Operate the valve within the pressure Vs temperature range The valve can be damaged by operating beyond the allowable range Select a valve material that is compatible with the media refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE Some chemicals may
4. damage incompatible valve materials O Donotuse the valve to fluid containing slurry The valve will not operate properly O Donotuse the valve on condition that fluid has crystallized The valve will not operate properly Do not step on the valve or apply excessive weight on valve It can be damaged O Do not exert excessive force in closing the valve O Make sure to consult a waste treatment dealer to dispose of the valves Poisonous gas is generated when the valve is burned improperly Allow sufficient space for maintenance and inspection O Keep the valve away from excessive heat or fire It can be deformed or destroyed 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 Certain liquid such as H202 NaClO 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 packed in the carton or box as delivered until installation Keep the valve away from any coal tar creosote antiseptic for wood termite insecticide vermicides and paint This could cause swelling damage the valve Do not impact or drop the valve It can be damaged O Avoid scratching the valve with any sharp object 3 Way Ball Valve CE 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 Name of parts
5. e the pipe wrench A Caution 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 Gc 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 amp and the pipe spigot A Caution Do not apply more adhesives than necessary The valve can be damaged due to solvent cracking Adhesive quantity guideline Nomai 15mm 20mm 40 50 80 100 ES E S Ko 1 ae ES ES EJ Quantity g 10 130 0 6 After applying adhesive insert the pipe quickly to the end connector Ge 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 Set the end connector Gc and union nut 5 directly on the body without allowing the O ring A 8 to come off 10 Tighten the union nut G hardly with hand 11 Using a strap wrench tighten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 tums A Caution Avoid excessive tightening The valve can be damaged 3 Way Ball Valve CE 6 ASAHI AV VALVES Installation Operation and Maintenance Manual Socket type _ Material PPPVDF 3 a Necessary items E E A A E Strap wrench Do not use the pipe wrench Sleeve weld
6. er or automatic welding machine User s manual for sleeve welder or 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 1s mounted 6 Set the end connector Gc and the union nut 5 directly without allowing the O ring A 8 to come off 7 Tighten the union nut G 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 A Caution Avoid excessive tightening The valve can be damaged Spigottype Material PVDF Necessary igis OMNMNGCCCiMNtN OOO TTT 3 Strap wrench Do not use the pipe wrench Automatic welding machine User s manual for 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 Ge and the union nut 5 directly without allowing the O ring A 8 to come off 7 Tighten the union nut G hardly with hand 8 Using a strap wrench tigh
7. esentative Office Shanghai Branch Office ASAHI AMERICA INC Distributor 3 Way Ball Valve CE 2 5955 Nakanose Cho Nobeoka City Miyazaki Pref Japan Tel 81 982 35 0880 Fax 81 982 35 9350 Furukawachiyoda Bldg 15 9 Uchikanda 2 Chome Chiyoda Ku Tokyo Japan Tel 81 3 3254 8177 Fax 81 3 3254 3474 16 Raffles Quay 40 03 Hong Leong Building Singapore 048581 Tel 65 6220 4022 Fax 65 6324 6151 Kaiser Friedrich Promenade 61 D 61348 Bad Homburg v d H Germany Tel 49 6172 9175 0 Fax 49 6172 9175 25 Room 1301 P Shanghai Kerry Center 1515 Nanjing Xi Road Shanghai China Tel 21 5298 6900 Fax 21 5298 6556 35 Green Street P O Box 653 Malden Massachusetts 02148 U S A Tel 1 781 321 5409 Fax 1 781 321 4421 14 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 Way Ball Valves ASAHI AV VALVES Information in this manual is subject to change without notice 2003 1 3 Way Ball Valve CE
8. h screw B 8 4 Engage the joint 5 with actuator 5 Fix the stand 4 to the top flange with bolt nut B 6 Make sure that the valve works smoothly by operating actuator 3 by hand 10 Inspection items Olnspect the following items Existence of scratches cracks deformation and discoloring Existence of leakage from the valve to the outside 3 Existence of leakage when the valve is opened fully at right or left 3 Way Ball Valve CE 11 ASAHI AV VALVES Installation Operation and Maintenance Manual 11 Troubleshooting Adjust the face pressure between the The carrier 1s loosened ball and the seat Refer to page 9 Fluid leaks from the valve The seat is scratched or wom Replace the seat with a new one even when the valve is closed fully Foreign matter is in the valve Clean up The ball is scratched or wom ea the scratched ball with a new Adjust the face pressure between the Fluid leaks from the valve The carrier 1s loosened ball and the seat Refer to page 9 The O ring is scratched or worn Replace the O ring with a new one Foreign matter is in the valve Clean up The handle can not be turned smoothly l Deformation By heat etc Replace the parts The stem is broken Replace the stem with a new one The handle fails to engage I The engagement between the stem and the ball Replace the stem and ball with new is broken ones 12 Handling of residual and wa
9. harge fluid from pipes 3 ef 2 Turn the handle to full close _ D 3 Loosen the right union nut and the left one G with a strap wrench 4 Remove the body part from piping system 5 Pull the handle off the body part A Caution As for nominal size 80 100mm 2 1 2 4 loosen the screw 45 properly with a screwdriver before pulling it off 6 Engage the upper convex part of the handle with the concave part of the union A Caution Adjust the unions on both sides 7 Inthe engaged state turn the handle 4 counter clockwise to loosen it and remove the union 3 Cani 8 Remove the seat 7 carefully by hand without damaging it Ball n 9 Push out the ball Q by hand E A 10 Push out the stem from the top flange side to the body side per L o lt Assembly gt mas TTT Carry out the assembly work in the reverse procedure from item 10 A Caution With regard to item 8 before installing seat 7 on the valve check the seat for its face and back 3 Way Ball Valve CE 10 ASAHI AV VALVES Installation Operation and Maintenance Manual 9 Mounting actuator Attach actuator to the top flange Procedure 1 Remove the handle 44 A Caution As for nominal 80mm 100mm tighten the screw 45 properly before removing it 2 Fix the stand to actuator 3 with bolt A Cr 3 Fix the stem to the joint 5 wit
10. rarily tighten them by hand A Caution 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 failure to observe them can cause destruction due to stress application to the pipe Unit mm inch Nom Size Axial Parallelism Misalignment a b 15 25mm 2 1 1 0 0 04 0 5 0 02 Axial misalignment Parallelism q pen 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to fig 1 A Caution Avoid excessive tightening The valve can be damaged Recommended torque value Unit N m kgf cm Ib inch 15mm 20mm 25mm 40mm 50mm 80mm 100mm Nom Size 2 GA aq di2 3 20 0 20 0 204 204 177 177 Be sure to set the union nut 5 when it was removed or loosen from body Q 1 Theo ring A 8 should be set on surface of the end connector 2 The end connector 4 must be put onto the carrier then ensure that the o ring A 8 is being between the end connector 4 and the carrier 3 Tighten the union nut G hardly with hand 4 Screw the union nut G on the body Q by quarter or half turn using a strap wrench without damaging it A Caution Avoid excessive tightening The valve can be damaged 3 Way Ball Valve CE 4 ASAHI AV VALVES Installation Operation and Maintenance Manual Threaded type Material PVC
11. re ie 7 E I TC _ ll 1 Completely discharge fluid from pipes ys pe 2 Turn the handle to full close 3 Loosen the right union nut and the left one G with a strap wrench 4 Remove the body part from piping system IES rt A Caution 5 7 8 9 Wear protective gloves and safety goggles as some fluid remains in the valve As for nominal size 80 100mm 3 4 loosen the screw 45 properly with a screwdriver before pulling it off Adjust the unions on both sides You may be injured Pull the handle off the body part Caution Engage the upper convex part of the handle with the concave part of the union G f A Caution l Direction where carrier 1s loosened Make an adjustment by turning the union clockwise to tighten it or counter clockwise to loosen it Make sure that the handle can be operated smoothly Assemble the valve by following the above procedure in the reverse order starting at 6 3 Way Ball Valve CE 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Disassembling Method for Replacing Parts se NCCC CIS E Strap wrench Safety goggles Protective gloves A Caution Wear protective gloves and safety goggles as some fluid remains in the valve You may be injured De offic o Procedure am T 1 Completely disc
12. ste materials A Caution In discarding remaining or waste materials be sure to ask waste service company Poisonous gas is generated 3 Way Ball Valve CE 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 13 Marking l i E Pa i AH gt BALL VALVE ASA y SE _ 25 N NH D r Y i Be H NS ka JO m o X IN ca NAN va im AN E Sa DS EN markin Io vel DN lominal jZ 1 COO N Nominal pt 19 a Za B Max allowable workin g temp NAN Sy AOO PB Max allowable working press ene i ee 2 Month ex A Jan B Feb L D O A Or IO Body Noa Nominal Max allowable Max allowable Material e press working temp working press DN15 DN20 DN25 DN40 A U PVC DN50 DNS0 DN100 PN 10 50 C 10 BAR DN15 DN20 DN25 DN40 DN50 PN 10 4 BAR C PVC JAR iman oar RAR sar Note Label of CE0035 are applied to valves DV40 and over If the nameplate is damaged or become dirty let our Sales Division know the Manufacturing number We will send a new nameplate 3 Way Ball Valve CE 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 13 Inquiries ASAHI ORGANIC CHEMICALS INDUSTRY CO LTD Nobeoka Head Office Tokyo Head Office Singapore Branch Office Europe Repr
13. ten union nuts uniformly on each side approx 90 180 turns 1 4 to 1 2 turns A Caution Avoid excessive tightening The valve can be damaged 3 Way Ball Valve CE 7 ASAHI AV VALVES Installation Operation and Maintenance Manual A Caution 15mm 50mm 1 2 2 It is recommended to install the valve with the threaded carrier to the upstream side of the system This allows for an increase safety factor and eliminating a threaded connection when used as a blocking valve This also allows the down stream union nut and end connector to be removed safely under pressure It increases the safety where there is no chance of thread leakage or accidentally removing the carrier The designation of the up stream side non threaded carrier is marked as shown on the body 6 Operating Procedure A Caution Avoid excessive tightening The valve can be damaged O Tum the handle gently to open or close Fully closed The position of the handle should be perpendicular to the pipe Open to left Fully closed Open to right 3 Way Ball Valve CE Q ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Method of Adjusting Face Pressure between Ball and Seat Necessary items Safety goggles Screwdriver only with nominal size 80 100mm Strap wrench Protective gloves Procedu
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