Instruction manual
Contents
1. Gauge Valve 6 ASAHI AV VALVES Glass pipe Procedure 1 Loosen the gland nut 3 by hand 2 Remove the gland nut 3 gland 4 and O ring A 7 from the body 1 3 Set the gland nut 3 gland 4 and O ring A 7 through the glass pipe 4 Insert the glass pipe into the body 1 5 Tighten the gland nut 3 with hand Recommended O D of glass pipe Unit mm inch Nom Size O D 20mm 3 4 18mm 0 72 24mm 1 26mm 1 04 7 Operating Procedure Caution Installation Operation and Maintenance Manual glass pipe A S Do not use the valve to fluid containing slurry The valve will not operate properly No DESCRIPTION 1 Body 3 Gland nut 4 Gland 7 O ring A The installed valve must never be opened or closed when foreign matter such as sand is present in the pipeline Do not exert excessive force in closing the valve When operating the handle be sure to do so with your hand Using a tool may damage the handle O Hand wheel operating should be done by hand Open and close the valve by rotating the hand wheel Right turn Clockwise Shut Left turn Counterclockwise Open Check the opening degree When the valve shuts operation torque of the valve is high Gauge Valve ah a ae ee ge ga ag ae a Sst ce ee ae meme fg ce E me a eat a nen ee eee een ASA2. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V016 E 8 Gauge Valve User s Manual Contents 1 Besureto read the following warranty clauses of our product A EA TA 1 2 General operating instructions Seaitedt sets silent aitsdiiciiee Galen E p 3 General instructions for transportation unpacking and storage 3 4 Name of parts nnn 4 5 Working pressure vs temperature renee 5 6 Installation procedure PE LET OE E TA E SE teen 6 C Openline prncedare Git a 7 8 Disassembly and assembly produce for parts replacement e 8 9 Inspection items nnn 8 10 Troubleshooting wr rrr rere enna 9 11 Handling of residual and waste materials 9 ASAHI AV VALVES Gauge Valve 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 lt Warning amp Caution Signs gt This symbol reminds the user to take caution due to the potential for serious injury or Waring death This symbol reminds the user to take caution due to the potential for damage to the valve Caution if used in 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 ey Mandatory action When operating th
3. HI AV VALVES Installation Operation and Maintenance Manual 8 Disassembly and assembly procedure for parts replacement A 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 A S Take care not to over tighten the Gland Nut The valve can be damaged Caution 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 Necessary items nnn Torque wrench Spanner wrench Screwdriver Monkey wrench Strap wrench Protective gloves Safety goggles lt Disassembly gt 1 Drain fluid completely from the pipeline 2 Loosen the gland nut 3 and remove the glass pipe 3 Loosen bolts from the pipe side and nuts from the valve side 4 Loosen the nut 15 of the upper hand wheel side 5 Remove the hand wheel 14 6 Loosen the bonnet 2 with the spanner wrench 7 Remove the stem part from the bonnet 2 8 Loosen the compressor pin 10 that fixed compressor 9 with the screwdriver 9 Remove compressor part from the stem 11 lt Assembly gt The produce of assembly is the reverse of its disassembly 9 Inspection items A h Perform peri
4. e 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 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 cha
5. ghten them to specified torques When a non AV gasket is used a different tightening torque specification should be followed pee Necessary items nso ii it it ttm ee Torque wrench Spanner Wrench Bolt Nut Washer For many flanges specification _ AV gasket Flanged end 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 The parallelism and axial misalignment of the flange 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 Axial misalignment Parallelism Unit mm inch Nom Size Axial Parallelism misalignment a b 20 25mm 1 0 0 5 l 3 4 1 0 04 0 02 ai je J e a ee ee E E R ee a G A E E S ee ee 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to fig 1 A Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner Caution Fig 1 Recommended torque value Unit N m kgf cm Ib inch we BN Nom Size 20mm 3 4 25mm 1 eat N 7 Pcs PTFE PVDF l Cc coated 17 5 179 155 20 0 204 177 Y 3 Rubber 8 0 82 71 20 0 204 177
6. odic maintenance Leakage may develop due to temperature changes or over periods of Caution prolonged storage rest or operation O Inspect the follow items Check for any flaw crack or deformation on the outside Check whether fluid leaks to the outside Check for tightness of body and bonnet Check for tightness of gland nut and glass pipe Check whether the handle can be operated smoothly Gauge Valve ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Troubleshooting Problem Cause Treatment tis loose Retight fad ee E A T E A a e bonnet Media has crystallized Clean Media has worn diaphragm and or Repl t The Fluid is leaking past the fully wer eplacemen closed position Solid particles have lodged in the Clear the solid particles from the valve valve The gland nut is loose Retighten Solid particles have lodged Clean O ring is worn Replacement Glass pipe is damaged Replacement Fluid leaks from the glass pipe Fluid leaks from stem part Diaphragm is worn Replacement 11 Handling of residual and waste materials A Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic valves Warming Poisonous gas is generated when the valve is burned improperly as ase sc ga E E E EE E E PE EE a a AEE E Gauge Valve 9 ASAHI AV VALVES Installation Operation and Maintenance Manual Ga
7. rge 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 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 ese eg a a ae my age ce es gc cyan ek an Se fae gaat E a ag a A a ga ae a a gas es mc eg a E h Gauge Valve 1 x ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A Gb 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 absolutel
8. rial 4 Gland 9 Compressor 14 Hand wheel 5 Drain plug 10 Compressor pin 15 Nut Gauge Valve ASAHI AV VALVES Flanged elbow 25mm 1 Installation Operation and Maintenance Manual S JL417 S I A e y S L_ No DESCRIPTION No DESCRIPTION 1 Body 4 Gland 3 Gland nut 7 O ring A 5 Working pressure vs temperature Gauge Valve ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation procedure A 4o 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 When installing a pipe support by means ofa U band or something similar take care not to over tighten Gaution 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 ti
9. t 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 Gauge Valve 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts 20mm 3 4 4 Pas 11 13 12 A xX E 2 PA o i E CAA i U 1 25mm 1 e 14 NI 1 7 10 III 3 12 4 gt 2 ae 9 s j No DESCRIPTION No DESCRIPTION No DESCRIPTION 1 Body 6 Diaphragm 11 Stem 2 Bonnet 7 O ring A 12 Inserted metal of bonnet B Gland nut 8 O ring B 13 Indication of mate
10. uge valve 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 5 Gauge Valve
11. y necessary to use a gas in testing please consult your nearest service station beforehand 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 g 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 Gauge Valve 2 ASAHI AV VALVES Installation Operation and Maintenance Manual 3 General Instructions for Transportation Unpacking and Storage A S When suspending and supporting a valve take care and do not stand under a suspended valve Warning A S This valve is not designed to handle impacts ofany kind Avoid throwing or dropping the valve Caution Avoid scratching the valve with any sharp objec
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