TLV COSPECT PN-COS-16 Instruction Manual
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 September 2014
ISO 9001/ ISO 14001
Manufacturer
Kakogawa, Japan
is approved by LRQA LTD. to ISO 9001/14001
Pneumatic Control Valve for Steam
COSPECT
PN-COS-16
Copyright © 2014 by TLV CO., LTD.
All rights reserved
Contents
1
Introduction ........................................................................ 1
Safety Considerations ........................................................ 2
Specifications ..................................................................... 4
Acceptable Operating Range ............................................. 4
Correct Usage of the PN-COS-16...................................... 5
Configuration...................................................................... 7
Installation .......................................................................... 8
Operation ......................................................................... 14
Maintenance..................................................................... 17
Disassembly..................................................................... 18
Reassembly ..................................................................... 22
Troubleshooting ............................................................... 23
Product Warranty ............................................................. 26
Introduction
Thank you for purchasing the pneumatic control valve for steam, model
COS-16
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.
The
pneumatic control valve for steam that utilizes the structure of the COSPECT series
pilot operated pressure reducing valve, which is our unique product. Steam-using
equipment can achieve its intended efficiency only if the steam being used is very dry.
Using steam in which matter such as condensate, scale, types of grease or air is
entrained can not only result in problems with the steam-using equipment and in
lowered productivity, but can also lead to shortened service life for and malfunction of
the control valves.
The
separator, screen, and steam trap that eliminates these problems and makes possible
the supply of very dry steam at a stable pressure.
The PN-COS-16 can operate automatically and provide accurate pressure control and
temperature control when combined with the
a general-purpose controller. (However, for process temperature control, the desired
process temperature must be controllable by a secondary pressure within the adjustable
pressure range of the PN-COS-16.) Additionally, manual remote setting or 2 point
pressure switching as a pressure reducing valve is possible by combination with an air
regulator (with relief function).
If detailed instructions for special order specifications or options not contained in this
manual are required, please contact
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.
.
pneumatic control valve for steam, model PN-COS-16 is a new type of
pneumatic control valve for steam, model PN-COS-16, has a built-in cyclone
SC-F70 digital indicator controller or
for full details.
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
PN-
2
R
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.
DANGE
WARNING
CAUTION
WARNING
CAUTION
Indicates an urgent situation which poses a threat of death or
serious injury
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 steam trap
impossible (blocked).
Use hoisting equipment for heavy objects (weighing
approximately 20 kg (44 lb) 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 continued on the next page
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
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.
Make sure the power supply is OFF before carrying out
work on the wiring or inspections involving disassembly.
If such work is carried out with the power on, there is a danger
that equipment may malfunction or electric shock may occur,
leading to injury or other accidents.
Make sure that wiring work requiring a special license is
carried out by qualified personnel.
If carried out by unqualified personnel, overheating or short circuits
leading to injury, fires, damage or other accidents may occur.
When using this product, NEVER stand close to, or leave
tools anywhere near moving parts, such as the shaft.
Contact with moving parts or objects becoming caught in moving
parts could lead to injury or damage or other accidents.
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
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 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 steam trap
impossible (blocked).
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
<Required utilities>
Adjustment
Section
(Drive Section)
Motive
Air
Maximum Pressure 1.6 MPaG (250 psig)
Required Air Pressure [Desired secondary pressure + 0.1] MPaG
or higher
[Desired secondary pressure + 15] psig
or higher
Air Connecting Port Rc(PT), BSP or NPT 1/4"
Air Quality
Oil-free air, filtered to 5 m
(1 MPa = 10.197 kg/cm2)
<CV Value>
Size: mm (in) 15 (1/2) 20 (3/4) 25 (1) 40 (11/2) 50 (2)
CV (US) 3.8 6.9 11.1 24.0 37.2
CV (UK) 3.2 5.7 9.2 20.0 31.0
Kvs (DIN) 3.3 5.9 9.5 20.6 31.9
Acceptable Operating Range
Model PN-COS-16
Primary Pressure Range* 0.2 –1.6 MPaG (30 – 250 psig)
Adjustable Pressure Range
(All conditions must be met)
Pressure differential between 0.07
Minimum Adjustable Flow Rate 5% of rated flow rate
*For process temperature control, the desired process temperature must be controllable by a
secondary pressure within the adjustable pressure range of the PN-COS-16.
Within 10 – 84% of the primary pressure
(Minimum adjustable pressure of 0.03 MPaG (5 psig)
0.85 MPa (10 – 120 psi)
–
(1 MPa = 10.197 kg/cm2)
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
Correct Usage of the PN-COS-16
5
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 lead to serious accidents. Local regulations
may restrict the use of this product to below the conditions quoted.
1. The PN-COS-16 should be operated only within its specifications.
2. Installing an ON / OFF Valve (Solenoid Valve or Motorized Valve)
Motorized
Valve
PN-COS
PN-COS
Solenoid
Valve
Inlet side
Outlet side
If an on-off valve, such as a motorized valve, is required to stop supply of steam
to the steam-using equipment, install it at the inlet side of the PN-COS-16. If a
solenoid valve is installed at the outlet of the PN-COS-16, 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 PN-
COS-16 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.) To save energy, it is recommended to install the on-off
valve as near to the boiler as possible.
NOTE: To prevent water hammer, it is recommended that a slow-acting motorized
on-off valve be used. In particular, if a fast-acting on-off solenoid valve is
used for frequent temperature control, the potential water hammer effect
can damage the steam-using equipment and the PN-COS-16.
3. Installing a Control Valve
PN-COS
Control
Valve
Safety
Valve
Equipment
PN-COS
Safety
Valve
Equipment
A control valve installed between the PN-COS-16 and the steam-using equipment
(downstream of the PN-COS-16) for controlling equipment temperature may raise
the pressure between the PN-COS-16 and the control valve when the control
valve is closed, depending on the spatial relationship. A safety valve should be
installed downstream of the control valve.
NOTE: When installing a safety valve to protect the steam-using equipment, be sure
to install it on the steam-using equipment or directly before the inlet of the
steam-using equipment. If the safety valve is installed on the outlet side of
the PN-COS-16 between the PN-COS-16 and a control valve, an eventual
pressure rise could activate the safety valve.
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
Control
Valve
f
f
)
c
5
4. Precautions for the Installation of Additional Fittings Before or After the PN-COS-16
In order to ensure stable steam flow, the piping upstream and downstream of
the PN-COS-16 must be straight runs. If the PN-COS-16 is installed either
directly before or after an elbow or control valve, unevenness in steam flow
may result in chattering and unstable pressure.
To ensure stable steam flow, it is recommended that the PN-COS-16 be
installed on straight runs of piping, as illustrated below.
1) Inlet (primary side) of the PN-COS-16
Maintain a straight piping run
of 10 d or more
when a
manual valve, a strainer or an
elbow, etc.
elbow, etc. is installed.
(Example: if nominal size is 25
mm (1 in), have 250 mm (10
in) or more)
Maintain a straight piping run o
30 d or more when an
automated valve (on-off valve)
is installed.
(Example: if nominal size is 25
mm (1 in), have 750 mm (30
in) or more)
Maintain a straight piping run o
Pressure
Reducing
30 d or more when a pressure
reducing valve is installed.
(Two-stage pressure reduction
(Example: if nominal size is 25
mm (1 in), have 750 mm (30
in) or more)
2) Outlet (secondary side) of the PN-COS-16
Maintain a straight piping run
of 15 d or more
when a
manual valve, a strainer or an
elbow, etc. is installed.
(Example: if nominal size is 25
mm (1 in), have 375 mm (15
in) or more)
Maintain a straight piping run
of 30 d or more
when a
safety valve is installed.
(Example: if nominal size is 2
mm (1 in), have 750 mm (30
in) or more)
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 (1 in), have 750 mm
(30 in) or more)
(d = pipe diameter)
Valve,
strainer,
PN-COS
10 d or more
Valve,
strainer,
elbow, etc.
Less than
Motorized
Valve
30 d or more
Valve
30 d or more
PN-COS Valve,
15 d or more
PN-COS
30 d or more
PN-COS
PN-COS
strainer,
elbow, et
Safety
Valve
Motorized
Valve
Less than
Pressure
Reducing
Valve
Less than
PN-COS
PN-COS
Control or
Automated
Valve
PN-COS
30 d or more
PN-COS
Less than
PN-COS
10 d
PN-COS
30 d
PN-COS
30 d
Valve,
strainer,
elbow, etc.
Less than
15 d
Safety
Valve
Less than
30 d
Control or
Automated
Valve
30 d
6
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
Configuration
15 – 50 mm (1/2 – 2 in)
8 mm (1/4in)
Motive Air
Port
10 mm
3
/8in)
(
15 mm (1/2in)
Condensate
Discharge Port
*North American model does not equip this plug.
7
No. Name
1 Main Body
2 Trap Body
3 Trap Cover
4 Separator
5 Float
6 Float Cover
7 Guide Pin
8 Trap Valve Seat
9 Trap Valve Seat Gasket
10 Gasket (Trap Body/Trap Cover)
11 Wave Spring
12 Gasket (Main Body/Trap Body)
13 Separator Screen
14 Main Valve Seat
15 Main Valve Seat Gasket
16 Main Valve
17 Main Valve Holder
18 Steel Ball
19 Main Valve Spring
*
20 Piston
21 Piston Ring
22 Tension Ring
23 Cylinder
24 Gasket (Pilot Body/Main Body)
25 Connecting Tube
26 Pilot Screen
27 Pilot Screen Holder
28 Pilot Screen Holder Gasket
29 Pilot Valve Spring
30 Pilot Body
31 Piston Guide
32 Sleeve
33 Pilot Valve
34 Pilot Valve Seat
35 Pilot Valve Seat Gasket
36 Diaphragm
37 Diaphragm Gasket
38 Diaphragm Support
39 Spring Housing
40 Coil Spring
41 Spring Retainer
42 Adjustment Screw
43 Packing Retainer
44 Spanner Cap
45 Hex Bolt (Trap Body/Trap Cover)
46 Hex Bolt (Main Body/Trap Body)
47 Hex Bolt (Pilot Body/Main Body)
48 He x Bol t (Spring Housing/Pilot Body)
49 Bushing
50 Plug – Sensing Line Port*
51 Float Cover Bolt
52 Spring Washer
53 Cylinder Gasket
54 Nameplate
55 C-ring
56 Gland Packing
57 O-ring
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
Installation
CAUTION
CAUTION
Install properly and DO NOT use this product outside the recommended
operating pressure, temp erature and other specification ranges.
Improper use may result in such hazards as da mage t o the product or
malfunctions which may lead to serious accidents. Local regulations
may restrict the use of this product to below the conditions quoted.
Use hoisting equipmen t for heavy objects (weighing approximately
20 kg (44 lb) 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.
Installation Environment
Avoid installation in the following types of environments:
Locations with ambient temperatures above 50 °C (122 °F) or below 0 °C (32 °F)*
Locations with ambient humidity above 90% RH and below 10% RH
Locations where corrosive gas is generated
Locations with heavy vibration or shock
Locations with high inductive interference or other factors that would have a
harmful effect on electrical circuitry*
*When the PN-COS-16 is used with electrical equipment such as an electro-pneumatic
transducer, controller, etc.
1. Blowdown
Before installing the PN-COS-16 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 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.)
Open
Closed
Blowdown with the Bypass Valve
PN-COS
Closed
①
②
3. Installation Angle
Install the PN-COS-16 vertically, so that the arrow
mark on the body points horizontally in the direction
of steam flow.
Allowable inclination is 10 degrees in the fore-aft
direction and 15 degrees in the plane perpendicular
to the steam flow line.
172-65588MA-02 (PN-COS Pneumatic Control Valve) 5 Sep 2014
10
10
10
10
③
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