Ball Check Valve True Union Ball Check Valve Ball Foot Valve
Contents
1. ASAHI AV VALVES 5 Working pressure vs temperature Nominal size 15 50mm 1 2 2 Installation Operation and Maintenance Manual Nominal size 80 100mm 3 The measurement of the minimum pressure for opening amp closing the valve Unit MPa kgf cm PSI Test Items Vertical Piping Horizontal Piping Nominal Size Min Air Pressure to Min Air Pressure to Min Air Pressure to Min Air Pressure to mm inch open the valve shut the Disc perfectly open the valve shut the Disc perfectly 15 1 2 0 005 0 05 0 73 0 02 0 2 2 90 0 001 0 01 0 15 0 02 0 2 2 90 20 3 4 0 005 0 05 0 73 0 03 0 3 4 35 0 001 0 01 0 15 0 03 0 3 4 35 25 1 0 005 0 05 0 73 0 03 0 3 4 35 0 001 0 01 0 15 0 03 0 3 4 35 40 11 2 0 01 0 1 1 45 0 03 0 3 4 35 0 002 0 02 0 29 0 03 0 3 4 35 50 2 0 01 0 1 1 45 0 03 0 3 4 35 0 002 0 02 0 29 0 03 0 3 4 35 80 3 0 01 0 1 1 45 0 02 0 2 2 90 0 002 0 02 0 29 0 02 0 2 2 90 100 4 0 01 0 1 1 45 0 02 0 2 2 90 0 002 0 02 0 29 0 02 0 2 2 90 Data mentioned in the tab2. 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 ball 2 stop ring A 5 and seat 9 are set 6 Set the end connector 3 and the union nut 4 directly on the valve 7 Tighten the union nut 4 hardly with hand 8 Using a strap wrench tighten union nuts 4 approx from 90 to 180 tums 1 4 to 1 2 turns 7 Disassembling Method for Replacing Parts A Be sure to conduct a safety check on all hand and power tools to be used before beginning work Wear protective gloves and safety goggles as fluid remain in the valve even if the pipeline is empty You may be injured A S Do not change or replace valve parts under line pressure Caution Do not use the pipe wrench The valve can be damaged Warning Be aware of over tightening the Union Nut The valve can be damaged When installing disassembling or reassembling the piping fix the End Connector Before a water test be sure that the Union Nut is tightly fastened Fasten the Union Nut while avoiding the parallelism and axial misalignment of the flange surface When connecting an ASAHI AV Valve to metal piping take care not to let the pipe stress on the ASAHI AV Valve 85 Strap wrench Safety goggles Protective gloves lt Disassembly gt Procedure 1 Completely discharge fluid from pipes 2 Loosen the union nut 4 on the seat 9 side
3. AHI AV VALVES Installation Operation and Maintenance Manual 3 General instructions for transportation unpacking and storage A S 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 These chemicals may cause damage to the valve d 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 se b m h ey Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 3 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Name of parts BALL CHECK VALVE Nominal Size 15 100mm 1 2 4 Body Material U PVC C PVC PP PVDF End Connector Socket End Threaded End Flange End 1 Body material PP is only available for Socket End and Threaded End Connection 2 Body material PVDF is only available for Threaded End and Flange End Connection Refer to the following page f
4. ASAHI AV VALVES Installation Operation and Maintenance Manual Serial No H V014 E 12 Ball Check Valve True Union Ball Check Valve 1 Be sure to read the following warranty Contents 2 General operating instructions ENNEN AEI NE PEIEE AE 2 3 General instructions for transportation unpacking and storage EEEIEE ETAETA AE EET 3 EE EE r 6 Installati on procedure E EET PENE EAE E ANTEE E E EEPE E E ETE 7 7 Disassembling meth od for replacing parts RO NRO 10 8 Inspection items a YY 9 Troubleshooting PPAS A E EE PEI IAE P EAE O 1 1 10 Handling of residual and waste materials rene 11 ASAHI AV VALVES Ball Check Valve True Union Ball Check Valve and Ball Foot Valve ASAHI AV VALVES Installation Operation and Maintenance Manual 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 lt Warning amp Caution Signs gt This symbol reminds the user to take caution due to the potential for serious injury or Waming 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 amp Mandatory action When operating the valve this sym
5. and A d The parallelism and axial misalignment of the flange surface should be under the values shown in Caution 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 Axial Parallelism Axial misalignment Parallelism Nam Size Miem ab 15 25mm 1 0 05 yo 0 04 0 02 40 50mm 1 0 0 8 l 1 1 2 2 0 04 0 03 80 100mm 1 0 1 0 i 34 0 04 0 04 3 Using a torque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 7 ASAHI AV VALVES Caution Recommended torque value Installation Operation and Maintenance Manual A S Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner Ne Unit N m kef cm Ib inch Nom Size 15 20mm 25 40mm 50 mm 80 100 mm 1 2 3 4 1 1 1 2 2 3 4 pie 17 5 179 155 20 0 204 177 22 5 230 230 30 0 306 266 Rubber 8 0 82 71 20 0 204 177 22 5 230 230 30 0 306 266 Be sure to set the union nut 4 when it was removed or loosen from body 1 1 Attach ball 2 stop ring A 5 and seat 9 in order and tighten the union nut 4 by hand 2 Using a strap wrench screw union nut 4 in b
6. bol indicates mandatory actions that must be adhered to 1 Be sure to read the following warranty clauses of our product Always confirm 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 i 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 i 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 An
7. ck back pressure Foreign matter is in the valve Clean the valve Fluid leaks from the valve even when the valve is closed fully The seat or ball is scratched or worn Replace the seat or ball with a new one The seat is scratched or worn Replace seat with a new one Fluid leaks from the valve The O ring is scratched True Union Ball Check Valve only The union nut is loosened Tighten up the union nut Replace O ring a new one 10 Handling of residual and waste materials A Make sure to consult a waste treatment dealer for recommendations on the proper disposal of plastic Waring valves Poisonous gas is generated when the valve is bumed improperly eas a a a a seme eae a cee a a Ge la a gm a a a a i a ee Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 11 ASAHI AV VALVES Installation Operation and Maintenance Manual Ball Check Valve True Union Ball Check Valve Ball Foot Valve ASAHI AV VALVES Information in this manual is subject to change without notice 2012 9 Ball Check Valve True Union Ball Check Valve and Ball Foot Valve
8. d excessive tightening The valve can be damaged ASAHI AV VALVES Installation Operation and Maintenance Manual Socket type Body Material U PVC C PVC A S When using an adhesive ventilate the space sufficiently prohibit the use of a fire in the vicinity Warning and do not inhale adhesive vapors directly If an adhesive gets into contact with your skin wash it off immediately If you feel sick or find any anomaly receive a physician s diagnosis and take appropriate measures promptly Caution remain Solvent cracks may occur damaging the equipment After assembling the piping system open both ends of the piping and use a fan of the Low Voltage Type or something similar to ventilate the space thus removing the solvent vapors d Use the appropriate Asahi AV cement A S Take care in doing work at low temperatures Solvent vapors are hard to evaporate and are likely to i Conduct a water test at least 24 hours after joining the pipes with an adhesive cement e Necessary items rrr Adhesive for hard vinyl chloride pipes Strap wrench Example Installation procedure of the end connector on the seat side of ball check valve Procedure 1 Loosen the union nut 4 with a strap wrench 2 Remove the union nut 4 and end connector 3 3 Lead the union nut 4 through the pipe 4 Clean the hub part of the end connector 3 by wiping the waste cloth 5 Apply adhesive evenly to the hub part of the end connector 3 an
9. d the pipe spigot A S Do not apply more adhesive than necessary The valve can be damaged due to solvent cracking Caution Adhesive quantity guideline 15mm 20mm 25mm 40 50 80 100 aZ GA C a 2 e a Quantity g 1 0 13 2 0 3 5 4 8 9 0 13 0 Nom Size 6 After applying adhesive insert the pipe quickly to the end connector 3 and leave it alone for at least 60 seconds A D Do not try to insert a pipe into another fitting or valve by striking it under any circumstances which Caution may break the piping 7 Wipe away overflowing adhesive 8 Make sure that the ball 2 stop ring A 5 and seat 9 are set 9 Set the end connector 3 and union nut 4 directly on the body 10 Tighten the union nut 4 hardly with hand 11 Using a strap wrench tighten union nut 4 approx from 90 to 180 turns 1 4 to 1 2 turns Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 9 ASAHI AV VALVES Installation Operation and Maintenance Manual Socket type Body Material PP Necessary items Strap wrench Sleeve welder or automatic welding machine User s manual for sleeve welder or automatic welding machine Example Installation procedure of the end connector on the seat side of ball check valve Procedure 1 Loosen the union nut 4 with a strap wrench 2 Remove the union nut 4 and the end connector 3 3 Lead the union nut 4 through the pipe
10. e station beforehand A S Do not step on or apply excessive weight on valve It can be damaged Caution Avoid using the valve in a line where the fluid flow is turbulent The ball may excessively bounce around resulting in damage Do not use the valve to fluid containing slurry The valve will not operate properly Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly 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 away from places 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 Use the valve at a pressure exceeding the minimum operating differential pressure Check the effective head 4 Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 2 AS
11. le above is reference only Ball Check Valve True Union Ball Check Valve and Ball Foot Valve ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Installation procedure A S Take care not to over tighten the Union Nut The valve can be damaged Caution Do not use the pipe wrench The valve can be damaged The valve is applicable to both types vertical and horizontal piping In the case of vertical piping use the valve in applications where the fluid travels upwards Install the piping while matching the arrow on the valve body with the flow direction of the fluid Horizontal Pipir rtical Piping Flanged Type __ Body Material U PVC C PVC PP PVDF A Use flat faced flanges for connection to AV Valves Caution 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 When a non AV gasket is used a different tightening torque specification should be followed Necessary items Spanner wrench Bolt Nut Washer For many flanges specification Strap wrench Torque wrench 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 h
12. or Flange End Connection i UE No DESCRIPTION POD ASX 2 Ball 3 End connector 4 Union nut For instance 5 Stop ring A drawing shows Socket End Connector 9 Seat BALL FOOT VALVE Nominal Size 15 100mm 1 2 4 Body Material U PVC C PVC PP PVDF End Connector Socket End Threaded End Flange End 3 Body material PP is only available for Socket End and Threaded End Connection 4 Body material PVDF is only available for Threaded End Connection only No DESCRIPTION 1 Body 2 Ball 4 Union Nut 5 Stop Ring A 8 Screen 9 Seat For instance drawing shows Socket End Connector Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 4 ASAHI AV VALVES Installation Operation and Maintenance Manual TRUE UNION BALL CHECK VALVE Nominal Size 15 50mm 1 2 2 Body Material U PVC C PVC PP PVDF End Connector Socket End Threaded End Flange End No DESCRIPTION 1 Body 2 Ball 3 End connector Flanged end type 3c End connector Socket end type 3d End connector Threaded end type 3e End connector Spigot end type 4 Union nut 5 Stop ring A 8 Stop ring B 9 Seat 10 O ring Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 5
13. with a strap wrench 3 Remove the seat 9 stop ring A 5 and ball 2 4 Only for True Union Ball Check Valve Loosen the union nut 4 on another side with a strap wrench and remove it Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 10 ASAHI AV VALVES Installation Operation and Maintenance Manual lt Assembly gt Procedure 1 Attach the ball 2 stop ring A 5 and seat 9 in order and tighten the union nut 4 hardly by hand A a Check the seat and the stop ring A for their faces and backs and ensure they are St p Rit Caution installed properly they will not work properly if installed backwards a eee They can not be sealed aa 2 Only for True Union Ball Check Valve Set the end connector 3 directly on the body 1 without allowing the O ring A 10 to come off and tighten the union nut 4 hardly by hand 3 Using a strap wrench screw them in by turning from 90 to 180 carefully without damaging them 8 Inspection items A g Perform periodic maintenance Leakage may develop due to temperature changes or over periods Caution of prolonged storage rest or operation OtInspect the follow items Check for any flaw cracks or deformation on the outside Check whether fluid leaks to the outside Check whether the cap nut has been loosened 9 Troubleshooting Problem Cause Treatment Insufficient back pressure Che
14. y 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 i 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 Ball Check Valve True Union Ball Check Valve and Ball Foot Valve 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A ap Using a positive pressure gas with our plastic piping may pose a hazard due to the repellent force Waming 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 servic
15. y turning from 90 Threaded type Body Material U PVC C PVC PP PVDF Caution Sealing tape Strap wrench Spanner wrench apply in case of said use even when said use is unavoidable to 180 carefully without damaging it Make sure that the threaded connections are plastic x plastic Metallic thread can cause damage Wrap the threaded joints on our plastic piping with sealing tape Using a liquid sealing agent or liquid gasket may cause stress cracks Environmental Stress Cracking Our product warranty shall not Example Installation procedure of the end connector on the seat side of ball check valve Procedure 1 Wind a sealing tape around the external thread of joint leaving the end about 3mm free 2 Loosen the union nut 4 with a strap wrench 3 Remove the union nut 4 and the end connector 3 4 Tighten the external thread of the joint and the end connector 3 hardly with hand 5 Using a spanner wrench screw in the end connector 3 by turning 180 360 carefully without damaging it 6 Make sure that the ball 2 stop ring A 5 and seat 9 are set 7 Set the end connector 3 and union nut 4 directly on the body 8 Tighten the union nut 4 hardly with hand 9 Using a strap wrench tighten union nut 4 approx from 90 Ball Check Valve True Union Ball Check Valve and Ball Foot Valve Sealing Tape Dig to 180 turns 1 4 to 1 2 turns A S Avoi
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