AsahiAV 14 User manual

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 0
Serial No. H – V028 E – 8
Diaphragm Valves Type 14
True Union Diaphragm Valves Type14
User’s Manual
Contents
(1) General operating instructions
(2) General instructions for transportation,
unpacking and storage
(3) Name of parts
(4) Comparison between working
temperature and pressure
(5) Installation procedure
(6) Operating procedure
(7) Adjustment procedure for stopper
(8) Diaphragm replacement procedure
(9) Mounting an inserted and a base (panel)
(10) Inspection items
(11) Troubleshooting
(12) Handling of residual and
wastematerials
(13) Inquiries
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ASAHI AV VALVES

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 1
(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
VA LV E ” .
（Some chemicals may damage incompatible valve materials.）
○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 & flange bolt torque should be made part of preventative
maintenance program properly re-tightening the bolts as necessary. It is especially important to re-tighten all
bolts during the first shutdown.
(Refer to page 5.)
○The travel stop may have to be adjusted if media leakage is detected between the upstream & downstream sides
of the valve.
○Do not step on the valve or apply excessive weight on valve. (It can be damaged.)
○ Do not exert excessive force in closing or opening the valve.
○ 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.
○Keep the valve away from excessive heat or fire. (It can be deformed, or destroyed.)
○The valve should be operated by hand.
(2) General instructions for transportation, unpacking and strange
○Keep the valve packed in the carton or box as delivered until installation.
○Keep the valve away from coal tar, creosote (antiseptic for wood ), termite insecticide, vermicides, and paint.
（The could cause swelling and damage the valve.）
○Do not impact or drop the valve. (It can be damaged.)
○Avoid scratching the valve with any sharp object.

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 2
(3) Name of parts
No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION
◯
1Body ◯ 11 Gauge cover ◯
20 Stopper
◯
2Bonnet ◯ 12 Name Plate ◯
21 Screw
◯
3b Diaphragm ◯ 13 Retaining ring c-type ◯ 24 Metal insert (Ensat)
◯
3a Inserted metal of DIA ◯ 14 O-ring (A) 25b End connector (Socket end)
◯
4Cushion ◯ 15 O-ring (B) 25c End connector (Threaded end)
◯
6Compressor ◯ 16 Thrust ring (A) 25e End connector(Spigot end)
◯
7Joint ◯ 17 Thrust ring (B) ◯
26 Union nut
◯
8Stem ◯ 18 Bolt, Nut (A) ◯
27 O-ring (C)
◯
9Sleeve 18a Washer
◯
10 Handle wheel ◯ 19 Conical spring washer
Diaphragm ◯
4is available only when diaphragm ◯ 3a is PTFE .

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 3
No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION
◯
1Body ◯ 9Sleeve ◯ 17 Thrust ring(B)
◯
2Bonnet ◯ 10 Handwheel ◯ 18 Bolt, Nut (A)
◯
3Diaphragm ◯ 11 Gauge cover 18a Washer (A)
◯
3a Inserted metal of DIA ◯ 12 Name plate ◯ 20 Stopper
◯
4Cushion ◯ 13 Retaining ring-c type ◯ 89 Compressor pin
◯
6Compressor ◯ 14 O-ring(A) ◯ 90 Inserted nut
◯
7Joint ◯ 15 O-ring(B) ◯ 98 Spring washer
◯
8Stem ◯ 16 Thrust ring(A) ◯ 99 Va l v e s h e e t
Diaphragm ◯
4is available only when diaphragm ◯ 3a is PTFE .

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 4
Flange
True Union（Socket, Threaded, Spigot）
(4) Comparison between operating temperature and pressure
Do not operate valve beyond the range of working temperature and pressure.
(The valve can be damaged.)
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 5
(5) Installation procedure
Flanged type (Material : PVC, C-PVC, PP, PVDF)
●Torque wrench ●Spanner wrench
●AV g a s k e t （When a non-AV gasket is used ,a different tightening torque specification should be followed.)
●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.
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
misalignment
Parallelism
(a-b)
15-32mm
(1/2”-1 1/4”) 1.0 (0.04) 0.5 (0.02)
40, 50mm
(1 1/2”-2”) 1.0 (0.04) 0.8 (0.03)
65-100mm
(2 1/2”-4”) 1.0 (0.04) (0.04)
3) Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner.
(Refer to Fig.1.)
Recommendedtorquevalue Unit
：N-m ｛kgf-cm｝[lb-inch]
Nom. Size 15-20mm
(1/2”-3/4”)
25-40mm
(1”-1 1/2”)
50, 65mm
(2”-2 1/2”)
80, 100mm
(3”, 4”)
Torque value
17.5
{179}
[155]
20.0
{204}
[177]
22.5
{230}
[200]
30.0
{306}
[266]
N
ecessar
y
items
Avoid excessive tightening. (The valve can be damaged.)
(Axial misalignment) (Parallelism)
Fig. 1
Caution
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 6
Threaded type
(Material : PVC, C-PVC, PP, PVDF)
● Sealing tape（A non-sealing tape can cause leakage.）
●Strap wrench（Do not use Pipe wrench.）
●Spanner wrench
Procedure
1) Wind a sealing tape around the external thread of joint, leaving the end (about 3mm) free.
2) Loosen the union nut ◯
26 with a strap wrench..
3) Remove the union nut ◯
26 and the end connector 25b .
4) Lead the union nut ◯
26 through the pipe.
5) Tighten the external thread of the joint and the end connector 25b hardly with hand.
6) Using a spanner wrench, screw in the end connector 25b by turning 180°- 360°carefully without damaging it.
7) Make sure that the O-ring (C) ◯
27 is mounted.
8) Set the end connector 25b and union nut
◯
26 directly on the body without allowing the O-ring (C) ◯ 27 to
come off.
9) Tighten union nut ◯
26 on each valve until hand tight.
10) Using a strap wrench tighten union nuts uniformly on each side approx 90°- 180°turns, 1/4 to 1/2 turns.
N
ecessar
y
items
Make sure that the threaded connections are plastic x plastic.
（Metallic thread can destroy the body cap）
Avoid excessive tightening. (The valve can be damaged.)
Avoid excessive tightening. （The valve can be damaged.）
Caution
Caution
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 7
Socket type
(Material : PVC,C-PVC)
● Adhesive for hard vinyl chloride pipes
●Strap wrench
Procedure
1) Loosen the union nut ◯
26 with a strap wrench.
2) Remove the union nut ◯
26 and end connector 25b .
3) Lead the union nut through the pipe.
4) Clean the hub part of the end connector 25b by wiping with a waste cloth.
5) Apply adhesive evenly to the hub part of the end connector 25b and the pipe spigot.
Adhesive quantity （guideline）
Nom. Size 15mm
(1/2”)
20mm
(3/4”)
25mm
(1”)
32mm
(1 1/4”)
40mm
(1 1/2”)
50mm
(2”)
65mm
(2 1/2”)
80mm
(3”)
100mm
(4”)
Quantity（ｇ） 1.0 1.3 2.0 2.4 3.5 4.8 6.9 9.0 13.0
6) After applying adhesive, insert the pipe quickly to the end connector 25b and leave it alone for at least 60
seconds.
7) Wipe away overflowing adhesive.
8) Make sure that O-ring(C) ◯
27 is mounted
9) Tighten union nut ◯
26 on each valve until hand tight.
10) Using a strap wrench tighten union nuts uniformly on each side approx. 90°- 180°turns, 1/4 to 1/2 turns.
11) Using a strap wrench, screw it in by turning 90°- 180°carefully without damaging it.
N
ecessar
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items
Do not install a socket type valve where the atmospheric temperature is 5℃or lower.
（The valve can be dama
g
ed.）
Do not apply more adhesives than necessary.
（The valve can be damaged due to solvent cracking.）
Avoid excessive tightening. (The valve can be damaged.)
Caution
Caution
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 8
Socket type
(Material : PP,PVDF )
Spigot type
(Material : PP,PVDF)
●Strap wrench （Do not use the pipe wrench.）
●Sleeve welder 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 ◯
26 and the end connector 25b .
3) Lead the union nut ◯
26 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 (C) ◯
27 is mounted.
6) Set the end connector 25b and the union nut ◯
26 directly without allowing the O-ring (C) ◯ 27 to come off.
7) Tighten union nut ◯
26 on each valve until hand tight.
8) Using a strap wrench tighten union nuts uniformly on each side approx. 90°- 180°turns, 1/4 to 1/2 turns.
N
ecessar
y
items
Avoid excessive tightening. (The valve can be damaged.)
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 9
(6) Operating Procedure
○Open and shut the valve by rotating handle wheel.
○The top of the travel stop will be flush with the top of the handle wheel when the valve is fully closed.
< Nominal size : 15-50mm (1/2”-2”)>
< Nominal size : 65-100mm (2 1/2”-4”)>
(7) Adjustment procedure for stopper
●Spanner wrench ●Allen wrench
●Screw driver(-) ●Protective Gloves ●Goggles
＜15-50mm＞＜65-100mm＞
N
ecessar
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items
The valve is designed for manual operation only.
（The use of assist device may damage the valve.）
Full open Half open Full shut
Full open Half open Full shut
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 10
Travel stop adjustment
＜Nominal size : 15-50mm ＞
Turn valve handle clockwise to the full closed position. Remove the
gauge cover, being careful not to damage the gauge cover O-ring.
Remove the travel stop / position indicator with a spanner wrench
and loosen the axial set screw counterclockwise with an Allen wrench.
Theaxialsetscrewislocatedwithin
thebrasstravelstoplookingdown..
Loosen the travel stop counter-clockwise.
Tighten the travel stop clockwise until it stop
and the turn it back (counter-clockwise)180°.
Re-attach the gauge cover.
Tightening torque of the screw
Unit : N-m {kgf-cm} [lb-inch]
Nom. Size 15-32mm
(1/2”-1 1/4”)
40, 50mm
(1 1/2”, 2”)
Torque value
8.0
{81}
[71]
12.0
{122}
[106]
①
②
③
Slowly tighten the handwheel clock wise until the leak-by stops.
④
⑦
⑥Secure the travel stop/position indicator with wrench and tighten the axial
setscrewclockwise
withanAllenwrench.
⑤

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 11
Travel stop adjustment
＜Nominal size 65-100mm ＞
1) Loosen the gauge cover ◯
11 with hand.
2) Loosen the upper nut ◯
20 from the lower nut ◯ 20 with spanner wrench.
3) Loosen the lower nut ◯
20 .
4) Operate the handle wheel to tighten gradually until the leakage of fluid stops.
5) Tighten the lower nut ◯
20 until it stop, and then turn it back (counter-clockwise) 180°.
6) Tighten the upper nut ◯
20 to the lower nut ◯ 20 with spanner wrench.
7) Tighten the gauge cover ◯
11 .
Tightening torque of the screw
Unit : N-m {kgf-cm} [lb-inch]
Nom. Size 65-100mm
(2 1/2”-4”)
Torque valve 15.0 {153} [133]

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 12
(8) Diaphragm replacement procedure
1) Drain fluid completely from the pipe line.
2) Remove valve bonnet from the body.
3) Turn handle of valve clockwise until it stops.（Do not force it）.The
compressor should be fully extended out of the bonnet.
4) Bayonet connection type (standard)
Remove the diaphragm from the compressor by turning it 90°and
mount the new diaphragm by reversing step.
Make sure that the pin of inserted metal of diaphragm connects joint
completely.
Threaded connection type
Turn the diaphragm clockwise to remove the diaphragm and
mount the new diaphragm by reversing step.
5) Mount the bonnet to the valve by reversing step 2. Tighten bonnet bolts
by hand only.
6) Rotate the handle 360°counter-clockwise.
7) Using a torque wrench, tighten the bonnet bolts in a diagonal, cross-
cross pattern.
Bonnet torque value Unit : N-m{kgf-cm}[ib-inch]
Nom. Size 15, 20mm
(1/2”, 3/4”)
25, 32mm
(1”, 1 1/4”)
40mm
(1 1/2”)
50mm
(2”)
65mmm
(2 1/2”)
80mm
(3”)
100mm
(4”)
Rubber
3.0
{31}
[27]
5 .0
{51}
[44]
12.0
{122}
[106]
15.0
{153}
[133]
13.0
{133}
[115]
18.0
{184}
[160]
35.0
{357}
310
PTFE
5.0
{51}
[44]
8.0
{82}
[71]
15.0
{153}
[133]
20.0
{204}
[177]
15.0
{153}
[133]
20.0
{204}
[177]
40.0
{408}
[355]
8) Re-adjust the stopper if necessary.
Necessary items
Wear protective gloves and goggles because some fluid is left in the body.
（You can be injured by working without then.）
Bayonet connection
Threaded connection
Inserted metal of diaphragm
Joint
Diaphragm
●Torque wrench ●Spanner wrench
●Protective gloves ●Goggles
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 13
(9) Mounting an inserted metal, and a base (panel)
Procedure
Refer to the user’s manual for the Inserted metal (Ensat)
(Commercially available).
Bottom stand dimension
Unit ；mm (inch)
Nom. Size S1 S2 S3
15-32mm (1/2”-1 1/4”) 25 (0.98) 7 (0.28) 13 (0.51)
40, 50mm (1 1/2”, 2”) 45 (1.77) 9 (0.35) 15 (0.59)
65mm (2 1/2”) 85 (3.35) 11 (0.43) 20 (0.79)
80mm (3”) 100 (3.94) 15 (0.59) 28 (1.10)
100mm (4”) 120 (4.72) 15 (0.59) 28 (1.10)
Fixation of bottom stand with panel
(10) Inspection items
○Inspect the following items.
(1) Check for any flaw, crack, or deformation on the outside.
(2) Check whether fluid leaks to the outside.
(3) Check whether the cap nut has been loosened.
(4) Check whether the handle can be operated smoothly.

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 14
(11) Troubleshooting
Problem Cause Treatment
The travel stop is not set correctly. Adjust the travel stop.
Solid particles have lodged in the
valve.
Clear the solid particles from the
valve.
Fluid is leaking past the fully closed
position.
Media has worn diaphragm and / or
weir. Replace.
The diaphragm has pulled off the
stem.
Replace diaphragm. If the valve is in
vacuum service, special vacuum
valves may be required.
Consult factory.
Valve can not be fully open.
The metal joint failed.
Remove
Diaphragm & compressor and replace
joint.
The stem is broken. Disassemble bonnet and replace the
stem.
The handle spins freely.
The metal joint failed. Remove diaphragm & compressor
and replace joint.
Bonnet bolts have loosened. Re-tighten.
Media has crystallized on the
diaphragm.
Disassemble and clean on a regular
basis. Replace failed diaphragm, if
necessary.
Valve leaks between body and bonnet.
The diaphragm has failed due to
fatigue. Replace.
Valve leaks from stem. The diaphragm has failed. Replace.
(12) Handling of residual and waste materials
In discarding remaining or waste materials, be sure to ask a waste service company.
（Poisonous gas is generated.）
Caution

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 15
(13) Inquiries
ASAHI ORGANIC CHEMICALS INDUSTRY CO., LTD.
Nobeoka Head Office : 2-5955, Nakanose- Cho, Nobeoka –City, Miyazaki- Pref. , Japan.
Tel : [phone] Fax : [phone]
Tokyo Head Office : (Furukawachiyoda Bldg.) 15-9, Uchikanda 2- Chome, Chiyoda-Ku, Tokyo, Japan.
Tel : [phone] Fax : [phone]
Singapore Branch Office : 16 Raffles Quay, #40-03 Hong Leong Building, Singapore 048581.
Tel : [phone] Fax : [phone]
Europe Representative Office : Kaiser-Friedrich-Promenade 61 D-61348 Bad Homburg v. d. H. Germany.
Tel : [phone] Fax : [phone]
Shanghai Branch Office : Room 1301-P Shanghai Kerry Center, 1515 Nanjing Xi Road, Shanghai China
Tel : [phone] Fax : [phone]
ASAHI /AMERICA Inc. :35 Green Street P.O.Box 653 , Malden, Massachusetts 02148 U.S.A.
Tel : [phone] Fax : [phone]
Distributor

ASAHIAVVALVES Installation,OperationandMaintenanceManual
Diaphragm Valves Type 14 True Union Diaphragm Valves Type14 16
Diaphragm Valve Type 14
True Union Diaphragm Valve Type 14
Information in this manual is subject to change without notice. 2003. 5
ASAHI AV VALVES