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TLV COSPECT M-COS-16, Instruction Manual

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TLV COSPECT M-COS-16 Instruction Manual Download Page 33

 

172-65188M-08  (

M-COS  3,16,21

  Pressure  Reducing Valve)   24 Jun 2015

 

32

 

Troubleshooting 

 

 

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. 

 

WARNING 

 

 

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.

 

CAUTION 

 

 

 

Make sure the power supply switch 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. 

CAUTION 

 

 

 

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. 

CAUTION 

 

 

 

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, damage or other accidents. 

CAUTION 

 

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 

M-COS

, consult the 

“Troubleshooting Chart” shown from the following page. 

Problems are classified as follows: 

1.  The secondary pressure does not rise 
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.  Abnormal noises 
6.  Steam leaks from the steam or condensate is not discharged 
7.  Power supply LED does not light even after turning ON the power switch 
8.  Pressure indication is abnormal 
9.  Motor remains inoperative even after pressure setting switch is turned ON 

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 “Correct 
Usage of the 

M-COS

 Motorized Pressure Reducing Valve” and “Controller 

Operation” sections be reviewed

. 

Summary of Contents for COSPECT M-COS-16

Page 1: ...ducing Valve 24 June 2015 Motorized Pressure Reducing Valve for Steam COSPECT M COS 3 M COS 16 M COS 21 Copyright 2015 by TLV CO LTD All rights reserved ISO 9001 ISO 14001 Manufacturer Kakogawa Japan is approved by LRQA LTD to ISO 9001 14001 ...

Page 2: ...y before use and follow the instructions to be sure of using the product properly The motorized pressure reducing valve for steam model M COS is a high performance motor actuated remote type pressure reducing valve adding a remote control function to the COS pressure reducing valve It can be easily adjusted by remote to supply dry saturated steam to the process at the set pressure as needed withou...

Page 3: ...a DANGER WARNING or CAUTION item DANGER Indicates an urgent situation which poses a threat of death or serious injury WARNING Indicates that there is a potential threat of death or serious injury CAUTION Indicates that there is a possibility of injury or equipment product damage WARNING NEVER apply direct heat to the float The float may explode due to increased internal pressure causing accidents ...

Page 4: ...kage 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 inju...

Page 5: ... Temperature Valve No Secondary Pressure Adjustable Range Primary Pressure Range Production Lot No Valve No is displayed for products with options This item is omitted from the nameplate when there are no options Actuator Model M COS 3 M COS 16 M COS 21 Drive System ON OFF control of reversible motor Line Voltage 100 110 VAC 10 or 200 220 VAC 10 50 60 HZ Supplied from controller Single phase Power...

Page 6: ...allation Wall mounting M5 screw x 4 Material Coating Steel plate black melamine Pressure Indication Indication Range 0 1999 kPaG Indication Accuracy 0 5 F S Pressure Sensor Standard type Allowable Pressure Setting Range 0 1999 kPaG Pressure Sensor Standard type Model M COS 3 M COS 16 M COS 21 Pressure Measurement Range 0 0 5 MPaG 500 kPaG type 0 2 0 MPaG type 0 0 5MPaG 500kPaG type 1 Signal Output...

Page 7: ... Pressure Adjustable Pressure Range All conditions must be met 0 01 0 05 MPaG Within 10 84 of the primary pressure Minimum adjustable pressure of 0 03 MPaG Minimum adjustable pressure of 0 55 MPaG Pressure differential between 0 07 0 85 MPa Maximum pressure differential of 0 85 MPa Minimum Adjustable Flow Rate 5 of rated flow rate 5 of rated flow rate 10 of rated flow rate for sizes 65 mm 100 mm ...

Page 8: ...ing 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 c...

Page 9: ...talled Example if nominal size is 25 mm have 750 mm or more 30 d or more M COS Automatic Valve Automatic Valve Less than 30 d M COS 2 Outlet secondary side of the M COS 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 have 375 mm or more M COS 15 d or more Less than 15 d M COS Maintain a straight piping run ...

Page 10: ...Screen 9 Main Valve Seat 10 Main Valve 11 Main Valve Holder 12 Piston 13 Cylinder 14 Pilot Screen 15 Pilot Screen Holder 16 Pilot Body 17 Pilot Valve 18 Pilot Valve Seat 19 Diaphragm 20 Diaphragm Support 21 Spring Housing 22 Coil Spring 23 Adjustment Screw 24 Adjustment Screw Guide 25 Plug Sensing Line Port 26 Mounting Plate 27 Insulation Plate 28 Splined Shaft 29 Sleeve 30 Motor Cover 31 Motor Un...

Page 11: ... Seat 10 Main Valve 11 Main Valve Holder 12 Piston 13 Cylinder 14 Pilot Screen 15 Pilot Screen Holder 16 Pilot Body 17 Pilot Cover 18 Pilot Valve 19 Pilot Valve Seat 20 Diaphragm 21 Diaphragm Support 22 Spring Housing 23 Coil Spring 24 Adjustment Screw 25 Adjustment Screw Guide 26 Plug Sensing Line Port 27 Mounting Plate 28 Insulation Plate 29 Splined Shaft 30 Sleeve 31 Motor Cover 32 Motor Unit A...

Page 12: ... 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 CAUTION 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 damage or other acci...

Page 13: ...all the M COS paying attention to avoid excessive load bending and vibration Support the inlet and outlet pipes securely 6 Maintenance Space 150 100 100 100 400 400 Approx 300 Leave sufficient space for maintenance inspection and repair Unit mm 7 Trap Outlet Piping For ease of maintenance installation of a union connection is recommended for the trap outlet pipe Connect the outlet pipe to a conden...

Page 14: ... will be more than 30 m s install a diffuser in order to keep the flow velocity below 30 m s If the distance between the M COS and the steam using equipment is great a possible drop in pressure should be taken into consideration when selecting the piping size Straight run Piping Lengths Upstream 10 d or more Downstream 15 d or more Diffuser M COS d pipe diameter M COS 10 Two stage Pressure Reducti...

Page 15: ...ing screws inserted in the holes The controller is not waterproof Be sure to install it indoors in a suitable protected area The ambient temperature range specified for the normal operation of the unit is between 0 and 50 C Avoid operation beyond this specified range Install the controller unit in a suitable place with low humidity and vibration 13 Installation of the Pressure Sensor Install the p...

Page 16: ...ability of pressure control where steam loss in secondary piping and flow rate fluctuation is high In addition the rated flow rate will be greater than an internal pressure sensing channel under the operational pressure reduction ratio of 2 1 or more Installation procedure 1 Loosen and remove the bolts that attach the pilot body to the main body 15 50 mm or the pilot cover 65 100 mm and remove the...

Page 17: ...w the connecting tube installation procedure shown below 1 Loosen and remove the four 4 bolts that attach the pilot body to the main body 15 50 mm or the pilot cover 65 100 mm and remove the pilot body 2 Install the connecting tube by first removing the blind pin from the secondary side of the main body or pilot cover and then substituting the connecting tube 3 Re install the pilot body and fasten...

Page 18: ...istance extending up to 20 m 4 Wiring should be routed in the shortest distance practical located at least 0 5 m away from other pieces of equipment that can be noise generating sources Wiring should never contact any exposed steam piping Cables used for wiring shall be as follows Power Cable min 0 5 mm 2 AWG 20 x 2 core Motor Cable min 0 5 mm2 AWG 20 x 3 core Pressure Sensor min 0 5 mm2 AWG 20 x ...

Page 19: ... causing the pressure to fall By releasing your hand the switch returns to the OFF condition NOTE Do not operate the lever switch continuously for more than 5 minutes If the motor is run beyond that limit the thermal protector for the motor is activated to bring the motor to a standstill Motor condition is restored to normal when the motor has cooled 3 Pressure Lock Switch When the pressure lock s...

Page 20: ...g is increased by turning the knob clockwise and it is decreased by turning it counterclockwise Setting for the maximum allowable pressure is possible as desired within a range from 0 to 1999 500 kPa If after setting the maximum allowable pressure the measured pressure should rise to that limit the internal pressure switch is triggered making the pressure setting lever switch 2 inactive thus preve...

Page 21: ...ing at a rate of about 20 to 40 kPa per second Use this as the guideline in case there is a delay in the change of the pressure indication due to a large volume of steam space for example Where the maximum allowable pressure has been set if the pressure rises to that maximum allowable pressure the internal pressure switch is activated the allowable maximum pressure LED is lighted The UP side of th...

Page 22: ...ccur CAUTION 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 damage or other accidents CAUTION Operational Check To ensure long service life of the M COS the following inspection and maintenance should be performed regularly Part Inspection and Maintena...

Page 23: ...overheating or short circuits leading to injury fires damage or other accidents may occur CAUTION 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 damage or other accidents CAUTION It is a recommended practice to dismantle and inspect the M COS once a ye...

Page 24: ...the pilot screen Check for any fault on the pilot valve seat flaws on the gaskets and clogging of the pilot 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 Notch Diaphragm Pilot Valve Seat Gasket Pilot Cover Bolt Pilot Body Gasket Pilot Screen Pilot Screen Holder Gasket Pilot Valve Pilot Valve Spring...

Page 25: ...piston rings and the tension rings from the piston Do not apply too much force when removing the piston rings and tension rings Check for the interior of the cylinder the exterior of the piston rings the small hole on the piston and the gaskets for any fault or abnormality 15 50 mm Piston Ring Tension Ring Piston Ring Tension Ring Piston Connecting Tube Cylinder Gasket Cylinder Pilot Cover Gasket ...

Page 26: ...nd the separator screen Loosen the main valve seat with a box wrench and remove it from the main body Check for damage on the seating and sliding surfaces of the main valve and main valve holder the seating surface of the main valve seat and the gaskets and for clogging of the separator screen Main Body Main Body Separator Screen Sleeve Separator Trap Body Trap Body Gasket Bolt Main Valve Seat Gas...

Page 27: ...loat Cover Float Trap Cover Trap Cover Gasket Guide Pin Bolt Bolt Spring Washer Float Cover Float Trap Cover Trap Cover Gasket Guide Pin Bolt Trap Valve Seat Gasket Trap Valve Seat Gasket U Nut Cleaning After inspection and removal of any abnormality clean and reassemble the parts The following parts will require cleaning before reassembly Trap Cover Main Valve Pilot Screen Float Main Valve Holder...

Page 28: ...r seizing chipping or similar defects on the threaded portion of the adjustment screw If the actuator section is stuck and does not work contact our sales representative Insulation Plate Motor Unit Actuator Adjustment Screw Bolt Mounting Plate Actuator Section Disassembling the Adjustment Section Remove the bolts By removing the spring housing the diaphragm support coil spring ball and spring reta...

Page 29: ...ment used for adjustment DC current generator 1 An electric current of 4mA DC is fed from the DC current generator to the pressure signal input terminals on the controller terminal numbers 8 side and 9 side 2 Check to see that the digital pressure indication then reads 002 002 0 1 FS 3 If the pressure reading indicated falls outside this range adjust with the zero adjustment screw shown in Fig 5 3...

Page 30: ...e sensor itself requires a power supply multi meter etc involving complicated procedures Use a controller which has been properly adjusted as described in the previous paragraph Inspecting and Adjusting Pressure Indication 1 Check to see that the pressure reading indicates 010 to 010 003 to 003 for 500 kPa type with no pressure applied under atmospheric pressure 2 Applying a randomly selected pres...

Page 31: ...ent Section Pilot Section Piston Section Piston Section Separator Main Valve Section Steam Trap Section Steam Trap Section 15 50 mm 60 100 mm Adjustment Section Pilot Section Separator Main Valve Section Actuator Drive Unit Actuator Drive Unit Adjustment Section Pilot Section Piston Section Piston Section Separator Main Valve Section Steam Trap Section Steam Trap Section 15 50 mm 60 100 mm ...

Page 32: ...the outside of the tension ring 2 The ring gaps should be opposite each other 5 Standard fastening torque and the width across flats for the to tools be used are as follows Part M COS Connection Size mm Distance Across Flats mm Tightening Torque N m Bolt for Mounting Plate Spring Housing All 13 20 Bolts for Spring Housing Pilot Body All 17 40 Pilot Valve Seat All 19 70 Pilot Screen Holder All 24 4...

Page 33: ...and 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 damage or other accidents CAUTION 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 ope...

Page 34: ...replace with a larger size The adjustment screw has seized Replace with a new adjustment screw The diaphragm is distorted or damaged Replace with a new diaphragm There is fluctuation in steam consumption Check the flow rate replace the M COS if necessary The selected model is inappropriate for the service conditions specifications Check the model selection replace the M COS if necessary Upon closi...

Page 35: ...ater hammer replace with a new float There is vibration in the piping Secure the piping No condensate is discharged The primary pressure exceeds the trap valve seat maximum working pressure Adjust primary pressure Water is inside the float Replace with a new float The outlet piping is clogged Check the piping clean The trap valve seat is clogged Clean or replace with a new trap valve seat Power su...

Page 36: ...ons due to improper installation use handling etc by other than TLV CO LTD authorized service representatives 2 Malfunctions due to dirt scale rust etc 3 Malfunctions due to improper disassembly and reassembly or inadequate inspection and maintenance by other than TLV CO LTD authorized service representatives 4 Malfunctions due to disasters or forces of nature 5 Accidents or malfunctions due to an...

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