Diaphragm Valve Type 72
Contents
1. Fully shut Diaphragm Valve Type 72 12 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Adjustment procedure for stopper A Ifa stopper is loose adjust it To learn how to adjust it see the operation manual 1 Caution Tighten the stoppers securely Too weak a torque on a stopper may cause it to loosen i Necessary items e ee eS Two spanner wrenches Protective gloves Safety goggles Procedure 1 Remove the gauge cover 2 Fix the stopper and loosen the set nut Vasher 7 3 Loosen the stopper PPT j 4 Re tighten the handle gradually until the fluid stops leaking 5 Fix the stopper so that the bottom of it is touched with the top of seat l slightly and tighten the set nut up to fix ES 6 Tum the handle back to the original position and apply grease on the bottom and top of seat 7 Install the gauge cover without allowing the gasket to come off 11 Disassembling method for replacing parts A B Be sure to conduct a safety check on all hand and power tools to be used before beginning work Caution Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty i You may be injured i i Do not change or replace valve parts under line pressure i Necessary items Torque wrench Spanner wrenches Protective gloves Safety goggles Diaphragm Valve Type 72 13 ASAHI AV VALVE2. 19 20 17 18 15135 3 PTFE diaphragm 2 AS 2I Se av F 24a 29 l k I i 12 10 MN Nominal size 200 250mm No DESCRIPTION No DESCRIPTION No DESCRIPTION 1 Body 11 O ring A 23 Stud bolt nut 2 Bonnet 12 Grease nipple 24 Bolt nut 3 Diaphragm 13 Handle 24a Washer 3a Inserted metal of diaphragm A 14 Name plate 25 Bonnet upper liner 4 Cushion 15 Cap 26 Body liner 4a Cushion cover 17 Valve sheet 27 Rib liner 5 Compressor 18 Stopper 28 U bolt nut 8 Stem 19 Spring washer 29 Conical spring washer 9 Sleeve A 20 Set nut 10 Thrust bearing A 21 Gauge cover Diaphragm Valve Type 72 ASAHI AV VALVES Installation Operation and Maintenance Manual Nominal Size 200 250mm 8 10 with Limit Switch Option 36 oP 37 Tr o i El eh eh H EN J TL In case of body material PVC 36 38 Bracket A 40 Diaphragm Valve Type 72 5 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Working pressure vs temperature 1
3. wash the even when the valve is closed 07080 matter 1s n the valve foreign matter away The valve sheet or the diaphragm is scratched Repair or replace Lack of the inserted metal of diaphragm Replace the inserted metal The valve can not be opened fully y Compressor pin is broken Disassemble and replace The valve does not operate Compressor pin is broken Disassemble and replace even when the handle is turned Stem is broken Disassemble and replace Tightening bolt is loose Re tighten the bolt Toe ae Lea pen Dady The fluid is crystallized Disassemble and clean the valve and bonnet The seal is worn Replace The fluid leaks from the stem Diaphragm is broken Replace 14 Handling of residual and waste materials A Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic Warning valves Poisonous gas is generated when the valve is bumed improperly Diaphragm Valve Type 72 15 ASAHI AV VALVES Installation Operation and Maintenance Manual Diaphragm Valve Type 72 ASAHI ORGANIC CHEMICALS INDUSTRY CO LTD Distributor Asahi Organic Chemicals Industry s homepage http Avww asahi yukizai co jp en en Feet esha Urner Bees FEST Bt cancun ate acer hth nan tear TA ct delle dna dra tiled FCT Diaphragm Valve Type 72
4. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V001 E 7 Diaphragm Valve Type 72 Contents 1 Be sure to read the following warranty CLAUSES OF CLIT POLL Aisit 1 2 General operating instructions PPIE O PEE SORE PEA E A EAAS ATE 2 3 General instructions for transportation unpacking and storage H 3 4 Name of parts nnn 4 5 Working pressure vs temperature eeen 6 6 Specification of limit switch procedure 10 7 Installation procedure 10 8 Connection of limit switch procedure 11 9 Operating procedure r nnnnnennnmnennnenennnenennnen 12 10 Adjustment procedure for stopper 13 11 Disassembling method for replacing parts 13 12 Inspection items nnn 14 13 Troubleshooting u 15 14 Handling of residual and waste materials 15 ASAHI AV VALVES Diaphragm Valve Type 72 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 Warming This symbol reminds the user to take caution due to the potential for serious injury or death Caution lt Prohibited amp Mandatory Action Signs gt This symbol reminds the user to take caution due to the potential for damage to the valve if used in such a manner Prohibited When ope
5. AV Diaphragm Type 72 Specification of the connection A specification In case of Rubber or PTFE Diaphragm with the material PVC In case of Rubber or PTFE Diaphragm with the material PP C PVC PVDF conical spring was Sonnet upper liner SUS Conical spring washer is only used with PVDE Diaphragm Valve Type 72 6 ASAHI AV VALVES Diaphragm Valve Type 72 Installation Operation and Maintenance Manual ASAHI AV VALVES Installation Operation and Maintenance Manual 1 AV Diaphragm Type 72 Specification of the connection B specification In case of Rubber or PTFE Diaphragm of the material PVC Conical spring washe In
6. S Installation Operation and Maintenance Manual lt Disassembly gt Procedure 1 Completely discharge fluid from pipes 2 Fully close the valve 3 Remove the bolt nuts of coupled flange and valve body and remove the valve 4 To disassemble the product refer to the figure on page 4 to 5 Name of parts lt Assembly gt Procedure Carry out the assembly work in the reverse procedure of its disassembly Bonnet torque value Bonnet tightening Nom Size torque value mm inch N m kef cm LTb inch 200 8 250 10 12 Inspection items A ai Perform periodic maintenance Leakage may develop due to temperature changes or over periods of Caution prolonged storage rest or operation Inspect the following items 1 Check for any flaw crack or deformation on the outside 2 Check whether fluid leaks to the outside 6 Check the tightness of coupled bolt nut between the body and the bonnet and that of the gauge cover loose or not 4 _ Check whether the operation of the handle is smooth gt lt Re tighten the bonnet diagonally referring to the bonnet tightening torque value as above Diaphragm Valve Type 72 14 ASAHI AV VALVES Installation Operation and Maintenance Manual 13 Troubleshooting Problem Cause Treatment Adjustment stopper is working Adjuster the stopper The fluid can not be sealed Forei tter is in the val Fully open the valve and
7. case of Rubber or PTFE Diaphragm with the material PP C PVC PVDE with high pressure when the temperature is 80 Cor more 100 Cor more with PVDF on special request SUS Conical spring wash onnet upper liner SUS Conical spring washer is only used with PVDE Diaphragm Valve Type 72 8 ASAHI AV VALVES Installation Operation and Maintenance Manual Diaphragm Valve Type 72 9 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Specification of limit switch option Nominal Size Type Code Protection Grade 200 250mm 8 10 ILS1 J IP67 Limit Switch Rating Connection Diagram AC125 10 6 y 2O AC250 10 6 No4 N93 DC115 0 8 0 2 _ l DC230 0 4 0 1 NG a A 7 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 beginn
8. cause destruction due to stress application to the pipe Axial misalignment Parallelism Nom Si Axial Parallelism OL LS Misalignment a b 200 250mm 1 5 1 0 8 10 0 06 0 0 Unit mm inch 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to fig 1 A S Tighten the bolts and nuts gradually with a torque wrench to the ma i Caution specified torque level in a diagonal manner A N f M N Y J i N Z 1 Recommended torque value Unit N m kgf cm Ib inch 200 250mm Nominal Size 8 10 55 Torque value 561 488 8 Connection of limit switch procedure option A Shut down the power on the equipment before connecting wires There are risks of electrical Warning shock depending on the level of operating voltage Ay Be sure that the terminal cover and body cover are put on during the operation If you use the limit switch at ImA 100mA or 5 30V consult near Asahi dealer Ii oe a I ae ily CAIN ESSIEN eR Oe ev Necessary items eeennnnnne emenn neeem Screw driver Connector G1 2 Crmp style terminal Wire stripper Terminal crimping tool Diaphragm Valve Type 72 11 ASAHI AV VALVES Installation Operation and Maintenance Manual Procedure 1 Loosen the three screws used to attach the limit switch cover with a screwdriver and remove the cover from th
9. e limit switch ay These screws are captive 2 Pull and remove the protective cap made of resin from the cover 3 Draw the cable through the connector 4 Strip the cable with a wire stripper 5 Install a crimp style terminal on the lead wire with a terminal crimping tool 6 Connect the terminal screw with a screwdriver according to the internal circuit diagram show in page 10 Tighten the screws If not electric leaks or shocks may occur 7 Tighten the above three screws with a screw driver to install the cover on the limit switch 8 Tighten the cable by connector 9 Operating procedure A S Do not exert excessive force in closing the valve Caution Do not use the valve to fluid containing slurry The valve will not operate properly The installed valve must never be opened or closed when foreign matter such as sand is present in the pipeline When operating the handle be sure to do so with your hand Using a tool may damage the handle If a stopper is loose adjust it To learn how to adjust it see the operation manual OTurn the handle gently to open or close Turn the handle clockwise to close the handle indicates S and counter clockwise to open the handle indicates O Fully shut The bottom of stopper clings to the top of cap Fully opened The blue line on the top of gauge cover accords with the red line of stopper
10. ify 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 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 Diaphragm Valve Type 72 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General operating instructions A BG Using a positive pressure gas with our plastic piping may pose a dangerous condition due to the repellent Warning 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
11. ing work Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured 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 impact or other excessive stress When connecting an ASAHI AV Valve to metal piping take care not to let the pipe stress on the ASAHI AV Valve Use flat faced flanges for connection to ASAHI 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 tighten them to specified torques ay When installing pipes and valves ensure that they are not subjected to tension compression bending When a non AV gasket is used a different tightening torque specification should be followed Necessary items Torque wrench Spanner wrench Bolt Nut Washer For many flanges specification AV gasket 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 Diaphragm Valve Type 72 10 ASAHI AV VALVES Installation Operation and Maintenance Manual A a The parallelism and axial misalignment of the flange surface should be under the values shown Caution in the following table to prevent damage the valve A failure to observe them can
12. operly re tightening the bolts as necessary It is especially important to re tighten all bolts during the first shutdown Diaphragm Valve Type 72 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 Waming 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 When transporting a valve do not carry it by the handle iy 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 These chemicals may cause damage to the valve Diaphragm Valve Type 72 3 ASAHI AV VALVES 4 Name of parts Nominal Size 200 250mm 8 10 Installation Operation and Maintenance Manual
13. rating 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 adhered to 1 Be sure to read the following warranty clauses of our product approval 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 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 ident
14. under water pressure If absolutely 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 Q 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 The travel stop may have to be adjusted if media leakage is detected between the upstream amp downstream sides of the valve Bonnet bolt torque should be checked before installation as they may become loose after long term storage A periodic check of the valve condition as well as bonnet amp flange bolt torque should be made part of preventative maintenance program pr
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