172-65254M-03 (A-COS-10) 27 October 2008
ISO 9001/ ISO 14001
Manufacturer
Kakogawa, Japan
is approved by LRQA LTD. to ISO 9001/14001
Pressure Reducing Valve for Air
COSPECT
A-COS-10
Copyright © 2008 by TLV CO., LTD.
All rights reserved
1
Contents
Introduction .......................................................................... 1
Safety Considerations.......................................................... 2
Specifications....................................................................... 4
Acceptable Operating Range............................................... 4
Correct Usage of the
COSPECT
Pressure Reducing Valve 5
Configuration........................................................................ 7
Installation............................................................................ 8
Adjustment ......................................................................... 11
Maintenance ......................................................................12
Disassembly....................................................................... 13
Reassembly ....................................................................... 17
Troubleshooting ................................................................. 18
Product Warranty ............................................................... 21
Introduction
Thank you for purchasing the COSPECT pressure reducing valve for
air.
This product has been thoroughly inspected before being shipped from the
factory. When the product is delivered, before doing anything else, check the
specifications and external appearance to make sure nothing is out of the
ordinary. Also be sure to read this manual carefully before use and follow the
instructions to be sure of using the product properly.
Air-using equipment can achieve its intended efficiency only if the air being
used is very dry. Using air in which matter such as condensate, scale or types
of oil is entrained can not only result in problems with the air-using equipment
and in lowered productivity, but can also lead to shortened service life for and
malfunction of the reducing valves.
The COSPECT pressure reducing valve for air, model A-COS, is a new
reducing valve that eliminates these problems and makes possible the supply
of very dry air at a constant pressure.
If detailed instructions for special order specifications or options not contained
in this manual are required, please contact for full details.
This instruction manual is intended for use with the model(s) listed on the front
cover. It is needed not only for installation, but also for subsequent
maintenance, disassembly/reassembly and troubleshooting. Please keep it in
a safe place for future reference.
172-65254M-03 (A-COS-10) 27 Oct 2008
2
Safety Considerations
• Read this section carefully before use and be sure to follow the instructions.
• Installation, inspection, maintenance, repairs, disassembly, adjustment and valve
opening/closing should be carried out only by trained maintenance personnel.
• The precautions listed in this manual are designed to ensure safety and prevent
equipment damage and personal injury. For situations that may occur as a result
of erroneous handling, three different types of cautionary items are used to
indicate the degree of urgency and the scale of potential damage and danger:
DANGER, WARNING and CAUTION.
• The three types of cautionary items above are very important for safety: be sure
to observe all of them as they relate to installation, use, maintenance and repair.
Furthermore, TLV accepts no responsibility for any accidents or damage
occurring as a result of failure to observe these precautions.
Symbols
Indicates a DANGER, WARNING or CAUTION item.
DANGER
Indicates an urgent situation which poses a threat of death or
serious injury
WARNING
CAUTION
WARNING
CAUTION
Indicates that there is a potential threat of death or serious injury
Indicates that there is a possibility of injury or equipment / product
damage
NEVER apply direct heat to the float.
The float may explode due to increased internal pressure, causing
accidents leading to serious injury or damage to property and
equipment.
Install properly and DO NOT use this product outside the
recommended operating pressure, temperature and other
specification ranges.
Improper use may result in such hazards as damage to the product or
malfunctions that may lead to serious accidents. Local regulations
may restrict the use of this product to below the conditions quoted.
DO NOT use the product in excess of the maximum operating
pressure differential.
Such use could make discharge through the air trap impossible
(blocked).
Use hoisting equipment for heavy objects (weighing
approximately 20 kg or more).
Failure to do so may result in back strain or other injury if the object
should fall.
Take measures to prevent people from coming into direct
contact with product outlets.
Failure to do so may result in burns or other injury from the discharge
of fluids.
Safety considerations are continued on the next page.
172-65254M-03 (A-COS-10) 27 Oct 2008
3
CAUTION
When disassembling or removing the product, wait until the
internal pressure equals atmospheric pressure and the surface
of the product has cooled to room temperature.
Disassembling or removing the product when it is hot or under
pressure may lead to discharge of fluids, causing burns, other injuries
or damage.
Be sure to use only the recommended components when
repairing the product, and NEVER attempt to modify the product
in any way.
Failure to observe these precautions may result in damage to the
product and burns or other injury due to malfunction or the discharge
of fluids.
Do not use excessive force when connecting threaded pipes to
the product.
Over-tightening may cause breakage leading to fluid discharge, which
may cause burns or other injury.
Use only under conditions in which no freeze-up will occur.
Freezing may damage the product, leading to fluid discharge, which
may cause burns or other injury.
Use only under conditions in which no water hammer will occur.
The impact of water hammer may damage the product, leading to
fluid discharge, which may cause burns or other injury.
172-65254M-03 (A-COS-10) 27 Oct 2008
Specifications
CAUTION
CAUTION
Install properly and DO NOT use this product outside the recommended
operating pressure, temperature and other specification ranges.
Improper use may result in such hazards as damage to the product or
malfunctions which ma y lea d to serio us a cc id e nts. Lo ca l regulations
may restrict the use of this product to below the conditions quoted.
DO NOT use the trap in excess of the maximum operating pressure
differential; such use could make discharge imp o ssib le (block e d ).
4
CAUTION
Use only under conditions in which no freeze -up will occur. Freezing
may damage the product, leading to fluid discharge, which may cause
burns or other injury.
Refer to the product nameplate for detailed specifications.
Serial Number
Valve No.*
Nominal Diameter
* Valve No. is displayed for products with options. This item is omitted from the nameplate when
there are no options.
Model
Maximum Operating
Temperature
Primary Pressure Range
Secondary Pressure
Adjustable Range
Acceptable Operating Range
Maximum
Operating
Temperature (°C)
Adjustable Flow
Use Model
Primary
Pressure
Range
(MPaG)
Secondary
Pressure
Adjustable Range
(MPaG)
Minimum
Differencial
Pressure
(MPa)
Minimum
Rate
For Air A-COS-10
0.1 - 0.9 0.05 - 0.7 0.05 100
172-65254M-03 (A-COS-10) 27 Oct 2008
10% of rated flow
rate
5
T
T
Correct Usage of the
CAUTION
Install properly and DO NOT use this product outside the recommended
operating pressure, temperature and other specification ranges.
Improper use may result in such hazards as damage to the product or
malfunctions which may lea d to serious accidents. Local regulations
may restrict the use of this product to below the conditions quoted.
COSPECT
Pressure Reducing Valve
1. The COSPECT should be operated only within its specifications.
2. Installing an ON / OFF Valve (Solenoid Valve or Motorized Valve)
Motorized
Valve
電動弁
COSPECT
入口側
Inlet Side
減圧弁
COSPECT
減圧弁
出口側
Outlet Side
Solenoid
Valve
電磁弁
If an on-off valve, such as a motorized valve, is required, install it at the inlet side
of the COSPECT. If a solenoid valve is installed at the outlet of the reducing
valve, its opening and closing will cause heavy chattering and may lead to
damage of the piston and main valve. (When the on-off valve opens, the
secondary pressure of the reducing valve changes from zero to the set pressure.
Passing through an area of the reducing ratio of less than 10:1, where
adjustment is impossible, chattering occurs momentarily.)
3. Installing a Safety Valve
Control
Valve
制御弁
Safety
減圧弁
COSPEC
安全弁
Valve
エア使用装置
Equipment
減圧弁
COSPEC
Control
制御弁
Valve
Equipment
When installing a safety valve to protect the air equipment, be sure to install it on
the air equipment or directly before the inlet of the air equipment. If the safety
valve is installed on the outlet side of the COSPECT between the COSPECT and
a control valve, an eventual pressure rise could activate the safety valve.
Safety
Valve
安全弁
エア使用装置
172-65254M-03 (A-COS-10) 27 Oct 2008
6
4. Precautions for the Installation of Additional Fittings Before or After the Reducing
Valve
In order to ensure stable air flow, the piping upstream and downstream of the
reducing valve must be straight runs. If a pressure reducing valve is installed
either directly before or after an elbow or control valve, unevenness in air flow
may result in chattering and unstable pressure.
To ensure stable air flow, it is recommended that the pressure reducing valve be
installed on straight runs of piping, as illustrated below.
① Inlet (primary side) of the pressure reducing valve NOTE: d = pipe diameter
Maintain a straight piping
run of 10 d or more
when a
Valve, strainer,
elbow, etc.
manual valve, a strainer or
an elbow, etc. is installed.
(Example: if nominal size is 25
mm, have 250 mm or more)
Maintain a straight piping
run of 30 d or more
when
Automatic
Valve
an automated valve (on-off
valve) is installed.
(Example: if nominal size is 25
mm, have 750 mm or more)
② Outlet (secondary side) of the pressure reducing valve
Maintain a straight piping
run of 15 d or more
when
COSPECT
a manual valve, a strainer
or an elbow, etc. is
installed.
(Example: if nominal size is 25
mm, have 375 mm or more)
Maintain a straight piping
run of 30 d or more
safety valve is installed.
(Example: if nominal size is 25
mm, have 750 mm or more)
when a
COSPECT
Maintain a straight piping
run of 30 d or more
when
another pressure reducing
valve is installed.
pressure reduction)
(Example: if nominal size is 25
mm, have 750 mm or more)
(Two-stage
Maintain a straight piping
run of 30 d or more
when a
control valve or an
automated valve (on-off
valve) is installed.
(Example: if nominal size is 25
mm, have 750 mm or more)
COSPECT
COSPECT
10 d or
more
30 d or more
15 d or more
30 d or more
Second
Reducing
Valve
30 d or more
Control or
Automated
Valve
30 d or more
COSPECT
COSPECT
Valve, strainer,
elbow, etc.
Automatic
Valve
COSPECT
Less
than
10 d
Less than
30 d
Less than
15 d
Safety
Valve
COSPECT
Safety
Valve
Less than
30 d
COSPECT
COSPECT
Second
Reducing
Valve
Less than
30 d
Automated Valve
Less than
30 d
172-65254M-03 (A-COS-10) 27 Oct 2008
COSPECT
COSPECT
Control or
Configuration
Plug (option)
No. Name
1 Main Body
2 Trap Body
3 Trap Cover
4 Separator
5 Float
6 Float Cover
7 Trap Valve Seat
8 Separator Screen
9 Main Valve Seat
10 Main Valve
11 Piston
12 Cylinder
13 Pilot Screen
14 Pilot Screen Holder
15 Pilot Valve Body
16 Pilot Valve
17 Pilot Valve Seat
18 Diaphragm
19 Diaphragm Support
20 Spring Housing
21 Coil Spring
22 Adjustment Screw
23 Spanner Cap
24 Plug – Sensing Line Port
7
172-65254M-03 (A-COS-10) 27 Oct 2008
Installation
C
S
CAUTION
CAUTION
Install properly and DO NOT use this product outside the recommended
operating pressure, temperature and other specification ranges.
Improper use may result in such hazards as damage to the product or
malfunctions which may lea d to serious accidents. Local regulations
may restrict the use of this product to below the conditions quoted.
Use hoisting equipment for heavy objects (weighing approximately
20 kg or more). Failure to do so may result in back strain or other injury if
the object should fall.
8
CAUTION
Take measures to prevent people from coming into direct contact with
product outlets. Failure to do so may result in burns or other injury from
the discharge of fluids.
Installation, inspection, maintenance, repairs, disassembly, adjustment and valve
opening/closing should be carried out only by trained maintenance personnel.
1. Blowdown
Before installing the COSPECT unit, be
sure to blow down all piping thoroughly. If
this is not possible, perform a blowdown
using the bypass valve.
Blowdown is especially important for
newly installed piping or after the system
Blowdown
Piping Before
Installation
Blowdown Using
Bypass Valve
has been shut down for a long period of
time.
2. Removing Seal and Cap
Before installation, be sure to remove all protective seals and caps.
(Found in 3 locations, on the product inlet and outlets.)
3. Installation Angle
Install the COSPECT vertically, so that the arrow
mark on the body points horizontally in the direction
of air flow.
Allowable inclination is 10 degrees in the fore-aft
direction and 15 degrees in the plane perpendicular
to the air flow line.
4.
Spacer Installation
If spacing adjustment is necessary
to accommodate installation,
install a spacer on the outlet
orrect Spacer
Location
flange. The spacer should consist
of a spacer, gaskets, bolts and
nuts. Fit gaskets to both sides of
the spacer between the COSPECT
outlet and the pipe flange. Fasten
with bolts and nuts.
Incorrect
Location
pacer
172-65254M-03 (A-COS-10) 27 Oct 2008
5. Piping Support
(
)
Install the COSPECT, paying
attention to avoid excessive load,
bending and vibration.
Support the inlet and outlet
pipes securely.
6. Maintenance Space
Leave sufficient space for maintenance,
inspection and repair.
Unit: mm
7. Trap Outlet Pipe
For ease of maintenance, installation of a union connection is recommended for
the trap outlet pipe.
Connect the outlet pipe to a
condensate return line, or extend it to
a trench. In the case of the latter,
make sure the end of the pipe is
above the waterline.
8. Blowdown Valve (requires optional plug)
In an environment of heavy dirt or scale, or when the air equipment is used only
periodically, be sure to install a strainer at the inlet of the
blowdown valve on the main body.
1. Remove the plug from the main body.
2. Install the 10 mm blowdown valve.
3. Open the blowdown valve and blow any residual
dirt and scale off of the screen.
4. Periodically activate the blowdown valve to keep
the system free of dirt and scale.
Small Hole
COSPECT and a
Remove the ⅜”
plug (optional)
and install the
blowdown valve
approx.
9
172-65254M-03 (A-COS-10) 27 Oct 2008
9. Piping Size
If it is expected that the secondary air flow velocity will be more than 30 m/s,
install a diffuser in order to keep the flow velocity below 30 m/s.
ディフューザ
Diffuser
減圧弁
減圧弁
Pressure Reducing Valve
0.2m以上
More than 0.2 m
Pressure Reducing Valve
減圧弁
Straight-run Piping Lengths: Upstream = 10 d or more; Downstream = 15 d or more
(d = pipe diameter)
10. Accessories
Always install a shut-off valve, pressure gauge and bypass lines at both inlet and
outlet.
Ball valves, which will not retain condensate, are recommended for inlet and
outlet shut-off valves. The bypass pipe should be at least ½ of the size of the inlet
(primary side) pipe.
COSPECT has a built-in strainer, however in case an external strainer is installed,
it should be installed ahead of COSPECT and the strainer should be installed
horizontally with the basket at the 3 or 9 o’clock position in order to prevent
condensate accumulation.
ボールバルブ
10
ボールバルブ ボールバルブ
Pressure Reducing Valve
減圧弁
減圧弁
減圧弁
172-65254M-03 (A-COS-10) 27 Oct 2008
11
Adjustment
The COSPECT reducing valve should be properly adjusted for protection of the air
equipment.
1. It is necessary to blow down all pipe lines thoroughly. The blowdown is especially
important if the line is new or has been shut down for a long period of time.
Take particular care to ensure that matter such as condensate and dirt does not
remain inside the air equipment.
(Stay clear of any pressurized blow-out from the safety valve.)
2. Make sure that the shut-off valve and the bypass valve located upstream and
downstream of the COSPECT are completely closed.
3. Remove the spanner cap, loosen the locknut and turn the adjustment screw
counterclockwise to reduce tension on the coil spring.
Counterclockwise
Loosen the locknut
Loosen the adjustment screw
4. Slowly, fully open the shut-off valve at the inlet of the COSPECT. Allow sufficient
time for condensate remaining at the inlet of the COSPECT to be discharged.
5. Slightly open the shut-off valve at the outlet of the COSPECT.
6. Turn the adjustment screw until the desired outlet pressure is obtained. Wait
several minutes.
Clockwise Counterclockwise
Tighten the Adjustment Screw
Increase Pressure
Loosen the Adjustment Screw
Decrease Pressure
7. Slowly, fully open the shut-off valve at the outlet of the COSPECT.
8. After setup, retighten the locknut and replace the cap.
9. When shutting down the system, always close the outlet shut-off valve first and
then the inlet valve.
172-65254M-03 (A-COS-10) 27 Oct 2008
Maintenance
CAUTION
Take measures to prevent people from coming into direct contact with
product outlets. Failure to do so may result in burns or other injury from
the discharge of fluids.
12
CAUTION
Operational Check
Be sure to use only the recommended components when repairing the
product, and NEVER attempt to modify the product in any way. Failure to
observe these precautions may result in damage to the product or burns
or other injury due to malfunction or the discharge of fluids.
To ensure long service life of the COSPECT, the following inspection and
maintenance should be performed regularly.
Part Inspection and Maintenance Frequency
Screens
(Separator and Pilot)
(For Main Valve and
Disassemble and clean annually.
If there is substantial blockage, install a strainer
(approximately 60 mesh) ahead of the COSPECT.
Pilot Valve Areas)
Main Valve, Main Valve
Seat, Pilot Valve and
Pilot Valve Seat
Replace after approximately 15,000 hours.
If there is chattering or dirt, premature wear may
result.
Piston Ring Replace after approximately 8,000 hours.
If there is chattering or if scale build-up is severe,
premature wear may result.
Piston Replace after approximately 30,000 hours.
If hunting or chattering takes place, premature
wear may result.
Trap Valve Seat Replace after approximately 40,000 hours.
If scale build-up is severe, blockage may occur in a
short period of time.
Diaphragm Replace after approximately 30,000 hours.
If hunting or chattering takes place, cracks or
fatigue may develop in a short period of time.
172-65254M-03 (A-COS-10) 27 Oct 2008
Disassembly
A
r
WARNING
NEVER apply direct heat to the float. The float may explode due to
increased internal pressure, causing accidents leading to serious injury
or damage to property and equipment.
13
CAUTION
CAUTION
Use hoisting equipment for heavy objects (weighing approximately
20 kg or more). Failure to do so may result in back strain or other injury if
the object should fall.
When disassembling or removing the product, wait until the internal
pressure equals atmospheric pressure and the surface of the product
has cooled to room temperature. Disassembling or removing the
product when it is hot or under pressure may lead to discharge of fluids,
causing burns, other injuries or damage.
It is a recommended practice to dismantle and inspect the COSPECT once a year for
preventive maintenance purposes. It is especially important to perform an inspection
immediately after the initial run of a new line or before or after equipment that is out
of service for a long period of time. (Installation, inspection, maintenance, repairs,
disassembly, adjustment and valve opening/closing should be carried out only by
trained maintenance personnel.)
Remove all pressure from the piping (both upstream and downstream). Then remove
inlet and outlet flange retaining bolts and nuts to permit removal of the COSPECT.
Secure the COSPECT in a vise to perform the inspection.
Disassembling the Adjustment Section
Loosen the adjustment screw completely and remove the hex bolts. Having removed
the spring housing, you will see the diaphragm retainer, coil spring and spring
retainer. Check for seizure or any damaged screw threads.
djustment
Screw
Ball
Spring Retaine
Coil Spring
Diaphragm
Support
Locknut
Spring
Housing
Hex
Bolt
Spanner Cap
Nameplate
172-65254M-03 (A-COS-10) 27 Oct 2008
14
Disassembling the Pilot Section
The diaphragm is removed by utilizing the notch in the pilot body. Loosen the pilot
valve seat with a box wrench and remove it. Lift the pilot valve spring up and out with
a pair of tweezers. Then loosen and remove the screen holder to remove the screen.
Check for any fault on the seat of the pilot valve, flaws on the gaskets, and clogging
of the screen.
Check for deformation, corrosion or faults on the diaphragm. The diaphragm should
be convex (open downward), with the printed UP mark on the top.
Diaphragm
Gasket
Pilot Valve Seat
& Gasket
Pilot Valve
Body
Pilot Valve
Notch
Pilot Valve Spring
Pilot Screen
Pilot Screen Holder
& Gasket
Disassembling the Piston
Remove the pilot body after loosening and removing the hex bolts (stud bolts).
During this process, pay attention not to lose the connecting tubes (2).
Remove the piston and the cylinder from the body. Then remove the piston rings and
the tension rings from the piston. Do not apply too much force when removing the
piston rings and tension rings.
Inspect the interior of the cylinder, the exterior of the piston rings, the small hole on
the piston and the gasket for any fault or abnormality.
Piston Ring
Tension Ring
Piston
Connecting Tubes
Piston Ring
Tension Ring
Hex Bolt
Cylinder & Gasket
Gasket
172-65254M-03 (A-COS-10) 27 Oct 2008
15
r
Disassembling the Separator and Main Valve
Turn the COSPECT upside down for easy dismantling of the separator and main
valve. Loosen the hex bolts and remove the trap body. Be careful, as the separator
may drop off when the COSPECT is returned to the normal attitude.
Removal of the separator and pressed-in sleeve permits removal of the main valve
spring, the main valve and screen. Loosen the valve seat with a box wrench and
remove it from the body.
Check for damage on the seating and sliding surfaces of the main valve, the seating
surface of the valve seat, the gaskets, and for clogging of the screen.
At start-up following shut-down for a long period, always blow down the piston
section of the body through the plug (option).
Separator Screen
Trap Body
Gasket
Hex Bolt
Disassembling the Air Trap
Sleeve
Separato
Corrugated
Spring Washer
Body
Plug
(option)
Main Valve Seat & Gasket
Main Valve
Main Valve Spring
Loosen the hex bolts and remove the trap cover. Be careful, as hot condensate may
splash out.
Remove the hex bolts from the trap cover and the float cover to reveal the float.
Remove the float, then loosen the trap valve seat with a box wrench and remove it.
Check to determine that there is no deformation of the float, abnormality in the trap
valve seat or dirt accumulation in the trap cover.
Hex Bolt
Float Cover
Trap Valve Seat
& Gasket
Protective
Bushing
Float
Gasket
Trap Cover
Guide Pin
Hex Bolt
172-65254M-03 (A-COS-10) 27 Oct 2008
Cleaning
After inspection and removal of any abnormality, clean and reassemble the parts.
The following parts will require cleaning before reassembly:
Trap Cover Piston Ring
Float Cylinder
Trap Valve Seat Separator Screen
Pilot Screen Pilot Valve
Main Valve Seat Pilot Valve Seat
Main Valve and Valve Holder Adjustment Screw
Piston
It is permissible to clean using water, however cleaning with a mild detergent is
recommended for more effective cleaning.
(Coat threaded position with anti-seize after cleaning.)
Exploded View
16
Adjustment
Section
Pilot
Section
Piston
Section
Separator / Main
Valve Section
Air Trap
Section
172-65254M-03 (A-COS-10) 27 Oct 2008
Reassembly
Assemble the unit using the same procedure as used for disassebling it; but in
reverse order. Observe the following precautions:
1. The PTFE gaskets may be re-used if free from fault, crushing or deformation.
2. Apply anti-seize to the threaded portion of screws and bolts, the spring
retainer, ball and adjustment screw. Apply a small amount of anti-seize to the
threads of the valve seat, pilot valve seat and screen holder. Apply anti-seize
carefully to ensure it does not come into contact with other parts.
3. Fasten the bolts one at a time in an alternating diagonal pattern to provide
uniform seating.
4. After assembly, make sure that the piston and the pilot guide operate
smoothly without binding.
Assembling the Piston Ring
Piston Ring
Tension Ring
1) Fit the piston ring to the outside
of the tension ring.
2) The ring gaps should be opposite
each other.
17
Ring Gaps
5. Standard fastening torque and the width across flats for the to tools be
used are as follows:
COSPECT
Part
Connection Size
(mm)
Bolts (Spring Housing) All 17 40
Pilot Valve Seat All 19 70
Screen Holder All 24 40
Bolts
(Pilot Body)
Bolts
(Trap Cover /Trap Body)
15 – 40 17 60
50 19 70
15 – 40 17 60
50 19 70
15, 20 36 100
Valve Seat
25 41 125
32, 40 60 250
50 70 300
Bolts
(Float Cover)
15, 20 8 7
25 – 40 10 10
50 13 20
15, 20 11 10
Trap Valve Seat
25 – 40 13 15
50 17 40
Width Across
Flats (mm)
Tightening Torque
(N⋅m)
1 N⋅m ≈ 10 kg⋅cm
Caution: If a torque greater than that recommended is applied, the COSPECT or
components may be damaged.
172-65254M-03 (A-COS-10) 27 Oct 2008
Troubleshooting
WARNING
NEVER apply direct heat to the float. The float may explode due to
increased internal pressure, causing accidents leading to serious injury
or damage to property and equipment.
18
CAUTION
When disassembling or removing the product, wait until the internal
pressure equals atmospheric pressure and the surface of the product
has cooled to room temperature. Disassembling or removing the
product when it is hot or under pressure may lead to discharge of fluids,
causing burns, other injuries or damage.
This product is shipped after stringent checks and inspection and should perform its
intended function for a long period of time without failure. However, should there be
any problem encountered in the operation of the COSPECT, consult the
troubleshooting guide below.
Problems are classified as follows:
1. The secondary pressure does not increase.
2. The secondary pressure cannot be adjusted or increases abnormally.
3. Hunting (fluctuation of the secondary pressure) occurs.
4. Chattering (a heavy mechanical noise) occurs.
5. Air leaks from the air trap or condensate is not discharged.
6. Abnormal noises.
Major causes for the above problems are usage under non-specified conditions (out
of specification), insufficient pressure or flow rate, and clogs by dirt and scale.
To ensure performance for a long period of time, it is recommended that the
“Acceptable Operating Range”, “Correct Usage of the COSPECT Pressure
Reducing Valve” and “Adjustment” sections be reviewed
.
Troubleshooting Chart
Problem Symptom Cause Remedy
The secondary
pressure does
not rise
The secondary
pressure
cannot be
adjusted or
increases
abnormally
The pressure
does not increase
Adjustment is
difficult, and set
pressure varies
No air is being supplied
or the inlet valve is
closed
The entrance to the
screens or strainer is
clogged
The pilot screen is
clogged
There is insufficient air
flow
The piston is clogged
with dirt
The piston ring is worn Replace with a new
There is a build-up of
dirt on the sliding
surfaces of the pilot,
piston or main valve
Troubleshooting continued on next page
Check the valves and
piping
Clean or blow down
Clean
Check the flow, replace
the COSPECT if
necessary
Clean
Check the piston ring
piston ring
Clean
172-65254M-03 (A-COS-10) 27 Oct 2008
Troubleshooting Chart (continued)
Problem Symptom Cause Remedy
The secondary
pressure
cannot be
adjusted or
increases
abnormally
(continued)
Hunting or
chattering
occurs
Adjustment is
difficult, and set
pressure varies
Upon closing the
valves on the
secondary side,
the secondary
pressure abruptly
rises as high as
the primary
pressure
Occurs at low air
demand
Hunting never
stops
Chattering never
stops
The adjustment screw
has seized
The small hole on the
piston is clogged
The diaphragm is
distorted or damaged
There is fluctuation in
air consumption
The selected model is
inappropriate for the
service conditions
(specifications)
The bypass valve is
leaking
There is a build-up of
dirt on or damage to
the pilot valve seat or
main valve seat
It is being operated
below the lower flow
rate limit
There is too high a
reduction ratio
The selected model is
inappropriate for the
service conditions
(specifications)
Condensate is
contained, or the trap is
blocked
The selected model is
inappropriate for the
service conditions
(specifications)
Troubleshooting continued on next page
Replace with a new
adjustment screw
Clean
Replace with a new
diaphragm
Check the flow rate,
replace the COSPECT if
necessary
Check the model
selection, replace the
COSPECT if necessary
Check, clean, and
replace with a new valve
if necessary
Clean
Align
Replace if necessary
Check the volume of air
supply, replace with a
smaller diameter valve
Change to an
acceptable operating
range
Check the model
selection, replace the
COSPECT if necessary
Check the trap
Check the piping
Check the model
selection, replace the
COSPECT if necessary
19
172-65254M-03 (A-COS-10) 27 Oct 2008
Troubleshooting Chart (continued)
Problem Symptom Cause Remedy
Faulty air trap
Air is blowing
No condensate is
discharged
There is a build-up of
dirt on the trap valve
seat or at the float base
The body is installed
tilted
The float is deformed Check for water hammer
There is vibration in the
piping
The primary pressure
exceeds the trap valve
seat maximum working
pressure
Water is inside the float Replace with a new float
The outlet piping is
clogged
The trap valve seat is
clogged
Clean
Check the piping
Replace with a new float
Secure the piping
Adjust primary pressure
Check the piping
Clean
Clean
Replace with a new trap
valve seat
20
172-65254M-03 (A-COS-10) 27 Oct 2008
21
Product Warranty
1. Warranty Period
One year following product delivery.
2. Warranty Coverage
TLV CO., LTD. warrants this product to the original purchaser to be free
from defective materials and workmanship. Under this warranty, the
product will be repaired or replaced at our option, without charge for parts
or labor.
3. This product warranty will not apply to cosmetic defects, nor to any product
whose exterior has been damaged or defaced; nor does it apply in the
following cases:
• Malfunctions due to improper installation, use, handling, etc., by
other than TLV CO., LTD. authorized service representatives.
• Malfunctions due to dirt, scale, rust, etc.
• Malfunctions due to improper disassembly and reassembly, or
inadequate inspection and maintenance by other TLV CO., LTD.
authorized service representatives.
• Malfunctions due to disasters or forces of nature.
• Accidents or malfunctions due to any other cause beyond the
control of TLV CO., LTD.
Under no circumstances will TLV CO., LTD. be liable for consequential
economic loss damage or consequential damage to property.
* * * * * * *
For Service or Technical Assistance:
Contact your
representative or your regional office.
Manufacturer
881 Nagasuna, Noguchi
Kakogawa, Hyogo 675-8511 JAPAN
Tel: 81–(0)79–427–1800
CO., LTD.
172-65254M-03 (A-COS-10) 27 Oct 2008
Loading...