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172-65254M-03 (A-COS-10) 27 October 2008

Pressure Reducing Valve for Air

COSPECT

A-COS-10

ISO 9001/ ISO 14001

Manufacturer

Kakogawa, Japan

is approved by LRQA LTD. to ISO 9001/14001

Summary of Contents for COSPECT

Page 1: ...3 A COS 10 27 October 2008 Pressure Reducing Valve for Air COSPECT A COS 10 Copyright 2008 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: ...t 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 fo...

Page 3: ...th 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 DO NOT...

Page 4: ...uct 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...

Page 5: ...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 CAUTION Refer to the product nameplate for detailed specifications Valve No is displayed for products with options This item is omitted from the nameplate when there are no options Acceptable Operating Range Use Model Primary Pressure Range MPaG Se...

Page 6: ...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 Va...

Page 7: ...ry side of the pressure reducing 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 have 375 mm or more Maintain a straight piping run of 30 d or more when a safety valve is installed Example if nominal size is 25 mm have 750 mm or more Maintain a straight piping run of 30 d or more when another pressure...

Page 8: ...ver 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 Plug option ...

Page 9: ...lowdown 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 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 pro...

Page 10: ... 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 COSPECT and a blowdown valve on the main body 1 Remove the plug from the main body 2 Install the 10 mm blowdown valve 3 Op...

Page 11: ...ll valves which will not retain condensate are recommended for inlet and outlet shut off valves The bypass pipe should be at least 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 orde...

Page 12: ...osen the locknut and turn the adjustment screw counterclockwise to reduce tension on the coil spring 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 Wa...

Page 13: ...uency Screens Separator and Pilot For Main Valve and Pilot Valve Areas Disassemble and clean annually If there is substantial blockage install a strainer approximately 60 mesh ahead of the COSPECT 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...

Page 14: ...he 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...

Page 15: ...op 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 cylind...

Page 16: ...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 Disassembling the Air Trap 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 wrenc...

Page 17: ...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 Adjustment Section Pilot Section Piston Section Separator Main Valve...

Page 18: ...bly make sure that the piston and the pilot guide operate smoothly without binding 1 Fit the piston ring to 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 COSPECT Connection Size mm Width Across Flats mm Tightening Torque N m Bolts Spring Housing All 17 40 Pilot Valve ...

Page 19: ...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 Usag...

Page 20: ...pon closing the valves on the secondary side the secondary pressure abruptly rises as high as the primary pressure There is a build up of dirt on or damage to the pilot valve seat or main valve seat Clean Align Replace if necessary Occurs at low air demand It is being operated below the lower flow rate limit Check the volume of air supply replace with a smaller diameter valve There is too high a r...

Page 21: ...eformed Check for water hammer Replace with a new float Air is blowing There is vibration in the piping Secure the piping 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 Faulty air trap No condensate is discharged The trap valve seat is clogged Cl...

Page 22: ...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 ...

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