AsahiAV AV Series User manual

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV
Serial No.
H-A010-E-11
Contents
(1) Be sure to read the following warranty
clauses of our product 1
(2) General operating instructions 2
(3) General instructions for transportation,
unpacking and storage 3
(4) Name of parts 4
(5) Maximum working pressure vs. temperature 7
(6) Specifications of valve 8
(7) Specifications of positioner 9
(8) Specifications of pressure reducing valve with filter 9
(9) Specifications of tools for
disassembling and assembling valve 10
(10) Installation procedure 11
(11) Support setting procedure 12
(12) Air piping procedure 13
(13) Connecting of E-A positioner procedure 14
(14) Operation procedure 15
(15) Method of adjustment positioner 16
(16) Disassembling method for replacing parts 17
(17) Countermeasures to avoid leakage 21
(18) Inspection items 21
(19) Troubleshooting 22
(20) Handling of residual and waste materials 22
Control Valves
Pneumatic Actuated
Type AV
Electro- Pneumatic
POSITIONER
Nominal Size: 15, 25mm
Body Material: U-PVC, PVDF
Nominal Size: 50, 80, 100mm
Body Material: U-PVC

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 1
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.
<Warning & Caution Signs>
This symbol reminds the user to take caution due to the potential for serious injury or death.
This symbol reminds the user to take caution due to the potential for damage to the valve if used in
such a manner.
<Prohibited & Mandatory Action Signs>
Prohibited: When operating the valve, this symbol indicates an action that should not be taken.
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 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 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) 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.
Warning
Caution

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 2
(2) General operating instructions
- Do not disassemble or modify the actuator.
(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 hazard 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.
- Do not step on or apply excessive weight on valve. (It can be damaged.)
- Do not use AV valves in a place where they may become 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.
(The valve will not operate properly.)
- Products with positioners are adjusted for opening with minimum operating pressure.
Please note that readjustment is required when using at other than the minimum operating pressure.
- 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 regular maintenance. (Leakage may develop due to temperature changes or periods of
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.
Warning
Caution

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 3
(3) General instructions for transportation, unpacking and storage
- When suspending and supporting a valve, take care and do not stand under a suspended valve.
- This valve is not designed to handle impacts of any kind. Avoid throwing or dropping the valve.
- 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.
(These chemicals may cause damage to the valve.)
- 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.
Caution
Warning

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 4
(4) Name of parts
Nominal size: 15, 25mm (1/2”, 1”) / Body material: U-PVC
*Drawing shows E-A positioner of “Air to open” type.
No.
Description
No.
Description
No.
Description
[1]
Body
[10]
Seat
[25]
Stem
[3]
Orifice
[11]
O ring(A)
[31a]
Positioner
[4]
Plug
[12]
O ring(B)
[41]
Bolt･Nut (A)
[5]
Piston (A)
[16]
Name plate
[42]
Bolt･Nut (B)
[7]
Bush
[19]
Stand
[54]
Screw (B)
[9]
Stop ring
[20]
Actuator
Electro-Pneumatic
POSITIONER

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 5
Nominal size: 15, 25mm (1/2”, 1”) / Body material: PVDF
*Drawing shows E-A positioner of “Air to open” type.
No.
Description
No.
Description
No.
Description
[1]
Body
[16]
Name plate
[42]
Bolt･Nut (B)
[3]
Orifice
[19]
Stand
[54]
Screw (B)
[5]
Piston (A)
[20]
Actuator
[57]
V-Packing
[10]
Seat
[25]
Stem
[58]
Packing holder
[11]
O ring(A)
[31a]
Positioner
[59]
Stopper
[12]
O ring(B)
[41]
Bolt･Nut (A)
[60]
Piston guide
Electro-Pneumatic
POSITIONER

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 6
Nominal size: 50, 80, 100mm (2”, 3”, 4”) / Body material: U-PVC
*Drawing shows E-A positioner of “Air to open” type.
No.
Description
No.
Description
No.
Description
[1]
Body
[9]
Stop ring
[19]
Stand
[4]
Plug
[10]
Seat
[20]
Actuator
[5]
Piston (A)
[11]
O ring (A)
[31a]
Positioner
[7]
Bush
[12]
O ring (B)
[41]
Bolt･Nut (A)
[8]
Bush guide
[14]
O ring (D)
[54]
Screw (B)
Electro-Pneumatic
POSITIONER

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 7
(5) Maximum working pressure vs. temperature

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 8
(6) Specifications of valve
Nom. Size
15mm(1/2”)
25mm(1”)
50mm(2”)
80mm(3”)
100mm(4”)
Type
Double acting
Air to open
Single seated control valve Air cylinder type
Type of Nom. size
Double acting
Air to open
- Standard control
type
- Minute control
type
- Standard
control type
- Large size control type
Rated pressure
(MPa{kgf/cm2})
Double acting
Air to open
1.0{10.2}
1.0{10.2}
1.0{10.2}
0.75{7.6}
0.75{7.6}
Shut off pressure
(MPa{kgf/cm2})
Double acting
0.7{7.1}
0.7{7.1}
0.7{7.1}
0.65{6.6}
0.65{6.6}
Air to open
0.7{7.1}
0.7{7.1}
0.7{7.1}
0.7{7.1}
0.7{7.1}
Flow characteristic
Double acting
Air to open
Equal %
or linear
Equal %
or linear
Equal %
Equal %
Equal %
Inherent
rangeability
Double acting
Air to open
-Standard 50:1
-Minute 20:1
50:1
50:1
50:1
50:1
Operating pressure
(MPa{kgf/cm2})
Double acting
Air to open
0.4-0.7
{4.1-7.1}
0.4-0.7
{4.1-7.1}
0.4-0.7
{4.1-7.1}
0.4-0.7
{4.1-7.1}
0.4-0.7
{4.1-7.1}
Air consumption
Nl per 1 open and
close
(MPa{kgf/cm2})
Double acting
0.6
0.7
2.1
2.1
6.3
Air to open
1.3
1.5
2.7
5.5
7.9
Air supply bore
Double acting
Air to open
Rc 1/4

Installation, Operation and Maintenance Manual
Control Valves Pneumatic Actuated Type AV 9
(7) Specification of positioner
E-A positioner
Actuation
Nom. Size
Type Sign
Input signal
electric current
/resistance
Air pipe bore
Electrical
connection bore
Protection
grade
Double
action
15mm (1/2”),
25mm(1”)
YT-1000L-SJ111S
DC4-20mA
/250Ω
Rc1/4
G1/2
ExdⅡBT5
50mm(2”),
80mm(3”),
100mm(4”)
YT-1000L-SJ131S
Air to
open
15mm (1/2”),
25mm(1”)
YT-1000L-SJ111S
50mm(2”),
80mm(3”),
100mm(4”)
YT-1000L-SJ131S
A-A positioner
Actuation
Nom. Size
Type Sign
Input signal air
pressure
(MPa {kgf/cm2})
Air pipe bore
Protection grade
Double
action
15mm (1/2”),
25mm(1”)
YT-1200L-S111S
0.02(0.2)-0.10(1.0)
Rc1/4
IP66
50mm(2”),
80mm(3”),
100mm(4”)
YT-1200L-S131S
Air to
open
15mm (1/2”),
25mm(1”)
YT-1200L-S111S
50mm(2”),
80mm(3”),
100mm(4”)
YT-1200L-S131S
(8) Specification of pressure reducing valve with filter
Action
Nom. size
Type sign
Pipe bore
Element
degree of
filtration
Double
action
Air to open
15mm (1/2”)
25mm(1”)
50mm(2”)
80mm(3”)
100mm(4”)
AUR2-
02-8A-G
Rc1/4
5μm