TLV Cospect MC-COS-16 Instruction Manual Download Page 35

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172-65169MA-08 (MC-COS Multi-control Valve) 28 May 2010

Drive Section Troubleshooting

The drive section has a built-in microcomputer with a self-diagnosis function for
malfunctions of the drive section. Identify the cause of the trouble with the following
procedures.

1. Turn OFF the power supply to the drive section.

2. Remove the motor cover (blue housing) of the drive section.

3. Confirm the position of the 4 LEDs (LE1 – 4) and the switch (PS1) mounted on the

board from the terminal block side.

4. Turn ON the power supply to the drive section, being careful not to be electrocuted

or cause a short out since the electrical circuit is exposed.

5. Press the PS1 switch. Confirm the lighting status of the 4 LEDs. Different LEDs light

up depending on the malfunction. Refer to the
table on the next page and take proper
measures.

Summary of Contents for Cospect MC-COS-16

Page 1: ...ve 28 May 2010 High precision Multi control Valve for Steam COSPECT MC COS 3 MC COS 16 Actuator MC GA2 Copyright 2010 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: ... 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 multi control valves The high precision multi con...

Page 3: ...f 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 leading to serious injury or damage to property and equipment CAUTION Install properly and D...

Page 4: ...onditions 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 inspect...

Page 5: ... 50 60 Hz Power Consumption With motor running 75 VA max Insulation Resistance 500 V DC 100 MΩ min between the power source terminal and ground terminal Power Source Withstand Voltage Between the power source terminal and ground terminal 1500 V AC 1 min or 1800 V AC 1 second Drive System Positional control by DC brushless motor Operation Input Valve Opening 4 20 mA DC input impedance 250 Ω Emergen...

Page 6: ...l MC COS 3 MC COS 16 Primary Pressure Range 0 1 0 3 MPaG 15 45 psig 0 2 1 6 MPaG 30 250 psig Secondary Pressure Adjustable Range All conditions must be met 0 01 0 05 MPaG 1 5 7 psig Within 10 84 of the primary pressure Minimum adjustable pressure of 0 03 MPaG 5 psig Allowable pressure differential between 0 07 0 85 MPa 10 120 psi Minimum Adjustable Flow Rate 5 or greater of rated flow rate 5 or gr...

Page 7: ...impossible chattering occurs momentarily To save energy 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 equipment and the multi control valve 3...

Page 8: ...r more when another 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 d Outlet secondary side of the multi control valve 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 r...

Page 9: ...ve 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 Stem 18 Pilot Valve Seat 19 Diaphragm 20 Diaphragm Support 21 Spring Housing 22 Coil Spring 23 Plug Sensing Line Port 24 Motor Unit 25 Drive Unit 26 Mounting Plate 27 Adjustment Screw Guide 28 Adjustment Screw 29 Terminal Block Cover 30 Motor Cover 31 Insulation Plat...

Page 10: ...ve 11 Main Valve Holder 12 Piston 13 Cylinder 14 Silencer 15 Pilot Screen 16 Pilot Screen Holder 17 Pilot Body 18 Pilot Cover 19 Pilot Valve Stem 20 Pilot Valve Seat 21 Diaphragm 22 Diaphragm Support 23 Spring Housing 24 Coil Spring 25 Plug Sensing Line Port 26 Motor Unit 27 Drive Unit 28 Mounting Plate 29 Adjustment Screw Guide 30 Adjustment Screw 31 Terminal Block Cover 32 Motor Cover 33 Insulat...

Page 11: ...oid 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 1 Blowdown Be...

Page 12: ...cessive load bending and vibration Support the inlet and outlet pipes securely 6 Maintenance Space Leave sufficient space for maintenance inspection and repair 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 o...

Page 13: ...a blowdown valve 1 Remove the plug from the pressureless main body 2 Install the blowdown valve 3 Open the blowdown valve while MC COS is pressurized and blow any residual dirt and scale off the separator screen 4 Periodically activate the blowdown valve to keep the system free of dirt and scale 10 Piping Size Diffuser If the secondary steam flow velocity is expected to be more than 30 m s 100 ft ...

Page 14: ...inlet and outlet shut off valves The bypass pipe should be at least of the size of the inlet primary side pipe If installing a strainer before the multi control valve horizontal installation with the basket in the same horizontal plane to the piping is recommended in order to prevent condensate pooling Pressure Gauge Bypass Valve Outlet Side Pressure Gauge Shutoff Valve Shutoff Valve Safety Valve ...

Page 15: ...nd installing a line from the sensing line port to the point where pressure should be controlled This can increase stability of pressure control where steam loss in secondary piping and flowrate fluctuation is high In addition the rated flowrate will be greater than an internal pressure sensing channel under the operational pressure reduction ratio of 2 1 or more Installation procedure 1 Loosen an...

Page 16: ...n Pressure Sensing Line with a slightly falling pitch towards the sensing point MC COS Valve 15 d or more 1 m 3 3 ft or 15 d whichever is larger Connector Pilot Valve Body Pilot Body Plug Rc PT or NPT Hex Bolt Main Body Replace the factory installed connector with the blind pin optional Connector Pilot Cover Secondary Pressure Detection Port ...

Page 17: ...he main body 15 50 mm 1 2 2 in or the pilot cover 65 100 21 2 4 in and remove the pilot valve body 2 Install the connector by first removing the blind pin from the secondary side of the main body or pilot cover and then substituting the connector 3 Re install the pilot body and fasten the four 4 bolts evenly Consult page 30 in this manual for torque requirements of these bolts 4 If a secondary pre...

Page 18: ... power supply lines both poles to prevent overcurrent Recommended rating of the device 250V 2A Delay type 2 Input Output Signal Lines for Valve Operation 1 Use shielded cables for the I O signal lines Connect the shielded cables to the receiver s shield terminal 2 Separate the I O signal cables from power cables drive cables and EM noise generating equipment Do not insert I O signal cables in comm...

Page 19: ...cuits leading to injury fires damage or other accidents may occur CAUTION Drive Section Terminal Box When making a connection to the terminal block use crimp style jacks for M4 with insulation sleeves Recommended Cable Specifications Cable Specifications Actuator Terminal No Minimum Cross Section mm2 in2 Maximum Wire Gauge No AWG Cable Type Power Source 1 2 1 25 0 002 in2 16 GND 2 00 0 003 in2 14 ...

Page 20: ... before shipment from the factory They are stamped on the valve coefficient nameplate label attached to the valve and a removable label to be utilized for putting the valve coefficients into the controller Combining the MC COS and the TLV SC F70 or SP F70 Controller The SC F70 digital indicator controller and SP F70 programmable indicator controller made by TLV use proprietary control algorithms d...

Page 21: ...the MC COS Check to make sure that when viewed from above the adjustment screw in the drive section is rotating clockwise while moving downward Check to make sure that steam begins to flow to the secondary side of the MC COS and the secondary steam pressure rises 6 A the same time begin reducing the value of the operation signal to the MC COS on the controller Check to make sure that when viewed f...

Page 22: ...operation signal to the actuator has been cut off The actuator will rotate counter clockwise to raise the adjustment screw to the 0 or lower position As a result the multi control valve will close cutting off the supply of steam to the secondary side 3 When power is restored The adjustment screw will return to the position specified by the operation signals from the controller Manual Operation 1 B...

Page 23: ... the MC COS the following inspection and maintenance should be performed regularly Part Inspection and Maintenance Frequency Screens Separator and Pilot Disassemble and clean annually If there is substantial blockage install a strainer approximately 60 mesh ahead of the MC COS Main Valve Main Valve Seat Pilot Valve and Pilot Valve Seat Replace after approximately 15 000 hours If there is chatterin...

Page 24: ...e value of the valve operation signal from the controller to the MC COS to 0 4mA or less The drive section will operate in response to the valve operation signal with the adjustment screw moving counterclockwise and up to close the valve Wait for the body to cool before attempting to remove the MC COS from the line Turn OFF the power to both the drive section and the valve operation signal control...

Page 25: ...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 15 50 mm 1 2 2 in 65 100 mm 21 2 4 in Diaphragm Diaphragm Pilot Valve Seat with gasket Pilot Valve Seat with gasket Pilot Valve Stem Pilot Valve Stem Pilot Valve Pilot Valve Pilot Spring Pilot Spring Bolt Bolt No...

Page 26: ...ension ring from the piston Note Do not apply too much force when removing the piston ring and tension ring Inspect 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 Piston Ring Tension Ring Lower Pilot Body Gasket Piston Retainer Bolt Cylinder with gasket Pilot Cover Gasket Piston Connector Bolt Piston 65 100 mm...

Page 27: ...ain valve seat from the main body with a box wrench 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 At startup following shutdown for a long period always blow down the piston section of the main body through the plug if optional plug is supplied Separato...

Page 28: ...65 100 mm 21 2 4 in Cleaning After inspection and removal of any abnormality clean and reassemble the parts The following parts will require cleaning before reassembly Trap Cover Piston Float Piston Ring Trap Valve Seat Cylinder Separator Screen Pilot Screen Main Valve Seat Pilot Valve Main Valve Pilot Valve Seat It is permissible to clean using water however cleaning with a mild detergent is reco...

Page 29: ...ti control Valve 28 May 2010 28 Exploded View NOTE The shape of individual parts may vary depending on the model size Adjustment Section Pilot Section Piston Section Separator Main Valve Section Steam Trap Section Drive Section ...

Page 30: ...Plate Spring Housing All 17 21 32 30 22 Bolt for Spring Housing Pilot Body All 17 21 32 40 29 Pilot Valve Seat All 19 3 4 70 51 Pilot Screen Holder All 24 15 16 40 29 15 40 1 2 11 2 17 21 32 60 44 Bolt for Pilot Body Main Body 50 2 19 3 4 70 51 Bolt for Pilot Body Pilot Cover 65 100 21 2 4 17 21 32 60 44 65 80 21 2 3 19 3 4 70 51 Bolt for Pilot Cover Main Body 100 4 24 15 16 150 110 15 40 1 2 11 2...

Page 31: ...arises the trouble may lie in the MC COS drive section pressure reducing valve including separator trap or the controller Identifying Problem Areas 1 Set the operation mode to MANUAL MAN on the controller connected to the MC COS This is to enable the operation signal to the drive section to be changed to any value 2 Set the control output on the controller to any value Check to make sure that the ...

Page 32: ...alfunction in the drive unit Refer to Drive Section Troubleshooting and take appropriate measures 7 Turn OFF the power to the drive section 8 Using a wrench turn the adjustment screw slowly Be careful not to apply excessive force 9 If the adjustment screw cannot be turned by hand or if it requires more than 10 Nwm 7 lbfwft torque to do so contact a TLV serviceperson 10 Check to make sure that the ...

Page 33: ...e The body is warm but the pressure does not increase The screens or strainer are clogged Clean or blow down The motor is not turning over The controller is malfunctioning Check repair The pilot screen is clogged Clean There is insufficient steam flow Check the flow replace the MC COS if necessary The piston is clogged with dirt Clean check the piston ring The piston ring is worn Replace with a ne...

Page 34: ...nsate is contained or the trap is blocked Check the trap check the piping Hunting or chattering occurs Chattering never stops The selected model is inappropriate for the service conditions specifications Check the model selection replace the MC COS if necessary Abnormal noises Makes a high pitched noise There is too high a reduction ratio the flow is too great or there is a high speed open close v...

Page 35: ...ve section 2 Remove the motor cover blue housing of the drive section 3 Confirm the position of the 4 LEDs LE1 4 and the switch PS1 mounted on the board from the terminal block side 4 Turn ON the power supply to the drive section being careful not to be electrocuted or cause a short out since the electrical circuit is exposed 5 Press the PS1 switch Confirm the lighting status of the 4 LEDs Differe...

Page 36: ...rloaded Contact TLV Low motor load reducer gear wear motor slippage Continuous operation Possibility of abnormal wear of the gear in the reducer Contact TLV Potentiometer signal error Stops when malfunction occurs Potentiometer is abnormal Contact TLV Initialization error Stops when malfunction occurs E2 PROM Store Error Stops when malfunction occurs If the same phenomenon occurs after switching t...

Page 37: ...ue 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 any oth...

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