TLV COSPECT Instruction Manual

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