Constant Flow Valves
Contents
1. 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 Constant Flow Valves 3 ASAHI AV VALVES 4 Name of parts Nominal Size 15mm 1 2 20mm 3 4 j A da pag E de TENE Pe a ZO 22 PR DER uf Pd De S CS bari c SU ohms i7J f ilm A a ela 20 4 ll po E TH miras a i ur Ig E mE t pec UR TE TE 11 7 5 ee I Flow Nominal Size 25mm 1 Aer d j By A A N Ke Yn VK Y A ET x J va 24 L Is E oy WU LAE L eas Jf g J fl A 7 4 2 p Vi Le Vy VA F EA lt F D NN My We 94 x Z X 7 J OK DIC A qug ug F d d NAP A d d MU d s P a V A JY EN Beim is ius Constant Flow Valves Installation Operation and Maintenance Manual DESCRIPTION DESCRIPTION 14 15 Thrust ring Spring A Spring B 23 Washer B Handle base 252. Handle cover Screw mm Type A Type B C ASAHI AV VALVES Installation Operation and Maintenance Manual Nominal Size 50mm 2 80mm 3 1 14 Sleeve 2 Bonnet 15 ap 4 19 20 21 22 Orifice 23 Type A LI Ce Flow Type B C D Nominal Size 100mm 4 DESCRIPTION DESCRIPTION 1 Body 14 Sleeve 5 Plug 20 Spring A RT ls EE Flow Type C D Constant Flow Valves 5 ASAHI AV VALVES Installation Operation and Maintenance Manual 5 Specifications Q Working Temperature PVC 0 50 C 30 120 F C PVC 0 70 C 30 160 F Q Upstream Working Pressure 0 25MPa 2 6kgf cm or less 0 25 to 0 5 MPa 2 6 to 5 1kgf cm 0 5 to 0 75 MPa 5 1 to 7 7kgf cm 0 75 to 1 0 MPa 7 7 to 10 2kgf cm Nom size 100mm 4 is 0 5 MPa 5 1kgf cm or less only 0 1MPa 14 286PSI A Type 25mm 17 80mm 3 Fluid flows through the valve inside Suitable for semi conductor industry Ultra pure water line B Type 15mm 1 2 80mm 3 Flow rate setting range 1s large Covers small flow rate to large rate C Type 15mm 1 2 100mm 4 Range of working differential pressure is large For lines with large pressure differential between u
3. product specifications after removing the valve from the packing case AX Do not step on or apply excessive weight on valve It can be damaged Do not use the valve for the fluid having a viscosity of more than 35cp Do not use the valve in conditions where the fluid may have crystallized The valve will not operate properly a5 Keep the valve away from excessive heat or fire It can be damaged or destroyed The flow rate scale of the opening indicator has already been adjusted before the products shipped so that the differences between reading and actual values meet the standard accuracy within 6 of full scale 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 Regardless of horizontal installation or vertical installation the strainer with the 60 Mesh should be installed in the upper stream line of th
4. 4 in nominal size have alignment pins 5 Insert the bonnet into the body Note The valve 15mm 1 2 and 20mm 3 4 in nominal size have alignment pins that fit internal grooves to set normal position Note 1 The valve 15mm 1 2 and 20mm 3 4 in nominal size don t have alignment marks Note 2 Avoid excessive tightening The valve can be damaged Run fluid 1 Set the flow indicator to the preset flow rate 2 Run fluid Operate the hand wheel slowly 12 Handling of residual and waste materials A 5 Make sure to consult a waste treatment dealer for recommendations on the proper disposal Warning of plastic valves Poisonous gas is generated when the valve is burned improperly Constant Flow Valves 14 ASAHI AV VALVES Installation Operation and Maintenance Manual Constant flow valve ASAHI AV VALVES Distributor Asahi Organic Chemicals Industry s homepage http wwvw asahi yukizai co jp en Information in this manual is subject to change without notice 2011 5 Constant Flow Valves
5. ASAHI AV VALVES Installation Operation and Maintenance Manual Constant Flow Valves User s Manual Contents 1 Be sure to read the following warranty clauses of our product MM 1 2 General operating Instructions 2 3 General instructions for transportation unpacking and storage 3 4 Names of parts ee 4 5 Specifications 6 6 Principle amp operation 7 7 Installation procedure enn g 8 Operating procedure e 10 9 Inspection items nnne 10 10 Troubleshooting 11 11 Disassembly procedure for cleaning ile incu ol valvas ipm 11 12 Handling of residual and waste materials 14 ASAHI AV VALVES Constant Flow Valves ASAHI AV VALVES Installation Operation and Maintenance Manual This User s Guide contains information important to the proper installation maintenance and safe use of the ASAHI AV product store in an easily accessible location lt Warning amp Caution Signs gt Ay This symbol reminds the user to take caution due to the potential for serious Warning injury or death A This symbol reminds the user to take caution due to the potential for damage to Caution the valve if used in such a manner lt Prohibited amp Mandatory Action Signs gt 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 Al
6. d valve 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 1f the pipeline is empty You may be injured A 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 Every type of valve has its one flow direction across the valve Make sure therefore that the flow direction is consistent with the arrow mark indicated on the valve body when installed 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 specification should be followed Warning Caution pe Necess ary IGNIS erent vee nnn ner mic ect SUei EDI S ee eee Spanner wrench Torque wrench Q Bolt Nut Washer Vary per flange type Q V 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 Constant Flow Valves 8 ASAHI AV VALVES 4J Installation Operation and Maintenance Manual A 5 The parallelism and axial misalignment of the flange surface should be under the
7. e valve in order to avoid the malfunction possibility caused by clogging of the valve by foreign matters Do not set the configuration as shown in the drawing because it may malfunction Other than ultra pure water lines Warning Caution Regarding Specific Gravity it should be less than 1 4 at the size of 15mm 1 2 to 80mm 3 and less than 1 1 at 100mm 4 Constant Flow Valves 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 SO 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 When transporting a valve do not carry it by the handle T 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
8. eceuesae O To operate the valve for opening closing turn the hand wheel slowly To get the flow rate decreased turn the hand wheel clockwise A G5 To set new flow rate turn the hand wheel counterclockwise to let the indicator of i opening degree reach beyond the required level and then the hand wheel clockwise to i obtain proper flow rate i This is the recommendable procedure to get exact flow rate L ee ee ee ee ee ee ee i X ee ee eK KG I I I I Caution I I O To shut the valve turn the hand wheel clockwise and adjust the indicator to the 0 position of the flow rate scale Application of rubber material for shut off seat gives the valve perfect closing with little tightening torque A Do not operate the valve out of scale especially at lower level than the minimum indicated scale The function of valve could be deteriorated Caution A ap Perform periodic maintenance Leakage may develop due to temperature changes or over Canion periods of prolonged storage rest or operation O Inspect the following items Existence of scratches cracks deformation and discoloring Existence of leakage from the valve to the outside Existence of leakage when the valve is opened fully at right or left Constant Flow Valves 10 ASAHI AV VALVES Installation Operation and Maintenance Manual 10 Troubleshooting 4 Insufficient Working differential pressure The flo
9. eos 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 Parallelism Asia misalisuiment Parallelism Misalignment a b a E 15 25mm 27 1 1 0 0 04 0 5 0 02 40 50mm 1 19 3 1 0 0 04 0 8 0 03 jw 1 0 0 04 1 0 0 04 3 Usingatorque wrench tighten the bolts and nuts gradually to the specified torque in a diagonal manner Refer to Fig 1 Caution a diagonal manner AX S Tighten the bolts and nuts gradually with a torque wrench to the species torque level in Recommended torque value Unit N m kgf cm Ib inch Nom Size 15 20 mm 25 mm 50 mm 80 100 mm 1 2 3 4 17 2 7 3 4 PTFE PVDF coated 17 5 179 155 20 0 204 177 22 5 230 230 30 0 306 266 acmon E EB RR Constant Flow Valves ASAHI AV VALVES Installation Operation and Maintenance Manual 8 Operating procedure A S Do not exert excessive force in closing the valve Caution Q8 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 etel liis Bee tne procedure qn seving he Now Tale od aede cup onecaeaandbeuedacedem
10. ned first then remove the bonnet Avoid scratching the inside parts and surface of the valve with any sharp objects Do not change or replace valve parts under line pressure Warning Caution pm Necessary o censsumeUuiuiem dicium A SU ELA DM t ide Q Strap Wrench Removal of the bonnet Q Snap Ring Plier Removal of the bonnet Q Nylon Brush Wash The Parts Q Grease Silicon Grease Constant Flow Valves 1l ASAHI AV VALVES Installation Operation and Maintenance Manual Dissassembly 1 Open the valve fully 2 Check for marking between the body and bonnet If there is no marking please make alignment marks with a marker as follows Note No need for marking on 15mm 1 2 and 20mm 3 4 in nominal size Marking Using a marker Snap ring Constant Flow Valves 12 ASAHI AV VALVES Installation Operation and Maintenance Manual Washing 1 Check the valve parts for damages 2 Wash the valve parts with a nylon brush Assembly 1 Insert the piston into the cylinder smoothly then insert the snap ring tightly 2 If there is no grease around the o ring of the cylinder apply a sufficient amount of grease to the surface of the o ring Constant Flow Valves 13 ASAHI AV VALVES Installation Operation and Maintenance Manual 4 Cycle the piston assembly to 1 2 open position to keep alignment pins from falling into the bonnet cavity Note The valve 15mm 1 2 and 20mm 3
11. on moves downward to narrow the area of the orifice opening and automatically adjusts the orifice to the preset flow rate value With the type of B C and D the plug has no inlet hole for fluid as the pressure differential P P2 exerts directly on the surface of the plug The reverse is also true when the pressure differential decreases the piston moves upward increasing the orifice opening area and allowing the fluid flow rate to increase to the preset value Preset flow rate range for use Design flow rate ranges TYPE Flow rate m hr D UM Working differential pressure 15mm 0 04 0 8 20 1 0 02 0 IMPa um 2 1 Okgf cm J 7 1 2 0 08 0 8 0 03 0 2 MPa 2 0 kgf cm 3 4 0 12 1 2 l l 3 20kgf cm lOkgffem lOkgffem 2 0 kgf cm 1 0 kgticm 1 0 kgticm 2 0 kgf cm 50 200 4 1 002 0 1 MPa 0 2 LOkgf cm 80mm 10 200 20 1 002 01MPa 02 1 0 Kg cm 37 2 0 20 0 10 1 003 90 2 MPa 0 3 2 0 kgf cm _ 15 0 30 0 0 03 0 15 MPa 0 3 1 5 kgf cm 100mm 10 0 60 0 6 1 0 03 0 2 MPa 0 3 20 kgf cm _ 30 0 60 0 0 02 0 2MPa 0 2 2 0 kgf cm 1m hr 4 4033gal min 0 1MPa 14 286PSI 25mm 1 50mm 2 Constant Flow Valves 7 ASAHI AV VALVES Installation Operation and Maintenance Manual 7 Installation procedure A S When suspending and supporting a valve take care and do not stand under a suspende
12. pstream amp downstream Q D Type 80mm 3 100mm 4 A large flow rate can be set Constant Flow Valves 6 ASAHI AV VALVES Installation Operation and Maintenance Manual 6 Principle amp Operation Refer to Figure 1 for design and operation of ASAHI AV Flow Control Valve When the upstream fluid pressure P is introduced at the flow control orifice it exerts a corresponding pressure on the upper surface of the flange on the piston type valve plug Likewise the downstream pressure P exerts a corresponding pressure to the lower surface of the valve plug flange Thus when a differential pressure exists visto between the fluid upstream and downstream of the orifice NO I the corresponding pressure differential acting on the oressure introducinc surfaces of the flange moves the valve plug piston either E downward against the force of the spring cartridge or upward by the force the spring depending upon the direction of the force induced by the existing pressure differential This upward or downward movement of the valve plug piston causes the flow orifice to be widened or narrowed accordingly thus the flow rate of the fluid passing across the orifice is automatically adjusted For example if the pressure differential P P2 created between the upstream and downstream side of the orifice increases the valve plug pist
13. r the following cases i 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 i 3 Any inconvenience caused by any product other than ours i 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 Constant Flow Valves 1 ASAHI AV VALVES Installation Operation and Maintenance Manual 2 General Operating Instructions A Q5 Using a positive pressure gas with our plastic piping may pose a dangerous condition 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 Since the Asahi AV constant flow valve has four types of A D according to piping and fluid conditions make sure of the
14. w rate is Foreign materials are caught extraordinarily small Appearance of algae or seaweed on Clean donean surface of valve inside Sand is Sand is caught in the valve in the valve Clean 00000 dheincdc Dunaeed OE WO For further detail and assistance consult pug 8 l your nearest AOC agents branches M For further detail and assistance consult The orifice is damaged or worn The flow rate is larger your nearest AOC agents branches than the range of Ithas exceeded beyond the range of l l recommended flow rate Working differential pressure FROUSCNVOPEIIENOUITERUSIDTESSHLOS Appearance of algae or seaweed on a Clean the surface of valve inside Sand is caught in the valve m Appearance of algae or seaweed on Clean Fluid is not stopped in RE surface of valve inside the full shut tion cM ARM Sand is Sand is caught in the valve in the valve Clean Adjust Working differential pressure 11 Disassembly procedure for cleaning the inside of valve A S Do not disassemble the parts not mentioned above Do not try to disassemble any part that is hard to disassemble parts stuck together Consult our office nearest to you VAN The flow rate scale of the opening indicator has already been adjusted before the products shipped so that the differences between reading and actual values meet the standard accuracy within 6 of full scale n case of removing the bonnet the valve should be fully ope
15. ways 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 i 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 i 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 i cause Should our product be deemed defective we shall assume the responsibility to repair or replace it free of charge i Any repair or replacement needed after the warranty period ends shall be charged to the customer The warranty does not cove
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