TLV CV-COS-20 Instruction Manual Download Page 1

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172-654741MA-01 (CV-COS-20/CV-COS-20D) 7 October 2021

Electro-Pneumatic Control Valve

with Built-in Separator and Steam Trap

CV-COS-20/CV-COS-20D

(for Valve Unit)

Summary of Contents for CV-COS-20

Page 1: ... 654741MA 01 CV COS 20 CV COS 20D 7 October 2021 Electro Pneumatic Control Valve with Built in Separator and Steam Trap CV COS 20 CV COS 20D for Valve Unit Copyright 2021 by TLV CO LTD All rights reserved ...

Page 2: ...ctro pneumatic control valve with built in separator and steam trap is a revolutionary product that combines a digital positioner a diaphragm type actuator a separator and a steam trap 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 or types of grease is entrained can not only result in problems...

Page 3: ...es 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 prod...

Page 4: ...o 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 t...

Page 5: ...to fluid discharge which may cause burns or other injury CAUTION Refer to the product nameplate for detailed specifications Valve Section Actuator Section Maximum allowable pressure PMA and maximum allowable temperature TMA are PRESSURE SHELL DESIGN CONDITIONS NOT OPERATING CONDITIONS Valve No is displayed for products with options This item is omitted from the nameplate when there are no options ...

Page 6: ...ve Seat 16 Trap Cover Bolt 17 Valve Bonnet 18 Stem Connector Nut 19 Locknut 20 Guide Bushing 21 Stuffing Box V ring Packing 22 Stuffing Box Washer 23 Stuffing Box Spring 24 Plug 25 Valve Bonnet Gasket 26 Valve Bonnet Bolt 27 Valve Bonnet Nut 28 Valve Seat 29 Nameplate 30 Travel Indicator Scale 31 Stem Bracket Clamp 32 Actuator Stem 33 Fixing Nut Replacement parts are available only in the followin...

Page 7: ...Valve Seat Gasket 15 Trap Valve Seat 16 Trap Cover Bolt 17 Valve Bonnet 18 Stem Connector Nut 19 Locknut 20 Guide Bushing 21 Stuffing Box V ring Packing 22 Stuffing Box Washer 23 Stuffing Box Spring 24 Plug 25 Valve Bonnet Gasket 26 Valve Bonnet Bolt 27 Valve Bonnet Nut 28 Valve Seat 29 Nameplate 30 Travel Indicator Scale 31 Stem Bracket Clamps 32 Actuator Stem 33 Fixing Nut 34 Baffle Nut 35 Baffl...

Page 8: ...t Gasket 15 Trap Valve Seat 16 Trap Cover Bolt 17 Valve Bonnet 18 Stem Connector Nut 19 Locknut 20 Guide Bushing 21 Stuffing Box V ring Packing 22 Stuffing Box Washer 23 Stuffing Box Spring 24 Plug 25 Valve Bonnet Gasket 26 Valve Bonnet Bolt 27 Valve Bonnet Nut 28 Valve Seat 29 Nameplate 30 Travel Indicator Scale 31 Stem Bracket Clamps 32 Actuator Stem 33 Fixing Nut Replacement parts are available...

Page 9: ...p Cover Bolt 17 Valve Bonnet 18 Stem Connector Nut 19 Locknut 20 Guide Bushing 21 Stuffing Box V ring Packing 22 Stuffing Box Washer 23 Stuffing Box Spring 24 Plug 25 Valve Bonnet Gasket 26 Valve Bonnet Bolt 27 Valve Bonnet Nut 28 Valve Seat 29 Nameplate 30 Travel Indicator Scale 31 Stem Bracket Clamps 32 Actuator Stem 33 Fixing Nut 34 Baffle Nut 35 Baffle Replacement parts are available only in t...

Page 10: ...he product Over tightening may cause breakage leading to fluid discharge which may cause burns or other injury CAUTION Installation inspection maintenance repairs disassembly and adjustment and valve opening closing should be carried out only by trained maintenance personnel Check to make sure that the piping where the product is to be installed is constructed properly If the piping is not correct...

Page 11: ...that the arrow mark on the valve body points horizontally in the direction of steam flow and it should be installed horizontally in the piping with the actuator at the top Allowable inclination is 10 degrees in the fore aft direction and 15 degrees in the plane perpendicular to the steam flow line CV COS 20 CV COS 20D 6 Piping support Install the product paying attention to avoid excessive load be...

Page 12: ...shut off valve pressure gauge and bypass lines at both inlet and outlet Ball valves which will not retain condensate are recommended for inlet and outlet shut off valves The bypass pipe should be at least 1 2 of the size of the inlet primary side pipe 10 Installation environment Check the installation environment to make sure that the ambient temperature does not exceed the actuator ambient temper...

Page 13: ...n into account in order to select a gasket of a suitable material 15 Air line blowdown purge Before connecting the air lines for the motive air that is to be piped to the actuator blow out the air in the lines to purge any dirt foreign matter oil or water from inside of the piping 16 Quality of motive air Supply to the actuator only clean air that does not contain water oil or foreign matter To pr...

Page 14: ...e sound of the medium flowing Adjust the zero span if that does not solve the problem replace with a new valve plug stem and valve seat Leakage from gland area Visual inspection is fluid leaking from the gap between the guide bushing and the valve stem or are there signs it has leaked previously Coat the guide bushing and the valve stem with grease if that does not solve the problem replace with n...

Page 15: ...ned maintenance personnel For details of the actuator and the electro pneumatic digital positioner refer to the respective instruction manuals issued by the manufacturer Refer to Disassembling Reassembling the Valve and Actuator Sections on the following page when removing the actuator section Consult the table of tightening torques when mounting the actuator section on the valve section NOTE Be s...

Page 16: ...ug is slightly suspended Do not supply air to the actuator at a pressure of 0 6 MPaG 85 psig 6 barg or more Consult the table of tightening torques and tighten to the proper torque If the instructions given are not followed when reassembly is carried out malfunctions such as insufficient lift insufficient flow capacity and or insufficient closing force valve leakage may result give the proper atte...

Page 17: ...em will descend Fig 3 NOTE Be careful not to pinch your fingers 4 Turn the stem connector nut until it comes into contact with the actuator stem and turn the stem connector nut a further 1 4 turn to contact the actuator stem Make sure that the valve plug is seated in the valve seat Hold the stem connector nut with a spanner and tighten the locknut with a proper torque Fig 4 5 Shut off the air supp...

Page 18: ... the stem connector nut a further 1 4 turn to contact the actuator stem Make sure that the valve plug is seated in the valve seat Hold the stem connector nut securely in place with a tool such as a spanner and tighten the locknut Fig 4 5 Shut off the air supply to the actuator NOTE Be careful not to pinch your fingers 6 Secure the stem connector nut and the actuator stem with the stem bracket clam...

Page 19: ... Disassembly During Reassembly Guide Bushing Remove with a socket wrench Consult the table of tightening torques and tighten to the proper torque Stuffing Box V ring Packing Pull up and out Make sure to reassemble the V ring packing in the proper orientation coat the groove with heat resistant silicon grease reattach the V ring packing with the grooves facing downward Stuffing Box Washer Stuffing ...

Page 20: ...e seat Reattach being careful not to damage the valve plug or valve seat insert the bonnet securely into the gasket housing without tilting check to make sure that there is no catching or biting when the valve plug is seated in the valve seat and that the valve plug is securely seated in the valve seat Valve Bonnet Gasket Remove the gasket and clean sealing surfaces Replace with a new gasket make ...

Page 21: ...ion for Cv values of 30 or greater When the Cv value is 20 or less there is no designated reassembly orientation Cv Value 20 or less Cv Value 30 or more Valve Plug Viewed from side Valve Plug Viewed from bottom Removing Reinserting the Valve Seat Special tool required Part During Disassembly During Reassembly Valve Seat This procedure requires a special tool contact TLV for details Over tightening...

Page 22: ...all out Consult the table of tightening torques and tighten to the proper torque Separator Screen Remove the separator screen Being careful not to bend it insert it securely onto the slanted part of the separator Separator Remove the separator Insert it into the groove in the main body Wave Spring Remove the wave spring Insert it into the groove in the trap body Wave Spring Separator Separator Scr...

Page 23: ...careful not to scratch the polished surface Trap Valve Seat Remove with a socket wrench Consult the table of tightening torques and tighten to the proper torque Trap Valve Seat Gasket Remove the gasket and clean sealing surfaces Replace with a new gasket if warped or damaged Trap Cover Gasket Remove the gasket and clean sealing surfaces Replace with a new gasket if warped or damaged Trap Cover Bol...

Page 24: ... 15 to 20 1 2 to 3 4 7 5 1 8 5 16 25 to 40 1 to 11 2 10 7 10 3 8 50 to 100 2 to 4 20 15 13 1 1 2 1 14 1 9 16 1 Trap Valve Seat 15 to 20 1 2 to 3 4 10 7 11 7 16 25 to 40 1 to 11 2 15 11 13 1 1 2 1 14 1 9 16 1 50 to 80 2 to 3 40 29 16 1 5 8 1 17 1 21 32 1 100 4 55 40 19 3 4 Fixing Nut 15 to 100 1 2 to 4 150 110 Special tool required 2 Stem Connector Nut Locknut 15 to 80 1 2 to 3 50 37 161 5 8 1 17 1...

Page 25: ...sket Wave Spring Separator Separator Screen Main Body Valve Bonnet Bolt Valve Seat Valve Bonnet Gasket Valve Plug Stem Valve Bonnet Coupling Nut Locknut Stuffing Box V ring Packing Guide Bushing Stuffing Box Washer Stuffing Box Spring Nameplate Front Model size date of manufacture Back Spring range Cv value etc The shape of the plug differs depend on the size and the Cv value A special tool is req...

Page 26: ... Check the inlet pressure for the control valve Decrease the inlet pressure Cv value and the spring range must be changed The valve plug and valve seat are off center Move the valve plug stem up and down and check to see if it catches Reassemble the valve bonnet section correctly Wear of the sealing surfaces of the valve plug and valve seat Check the valve plug and valve seat Replace the valve plu...

Page 27: ... cause beyond the control of TLV TII or TLV group companies or 6 improper storage maintenance or repair or 7 operation of the Products not in accordance with instructions issued with the Products or with accepted industry practices or 8 use for a purpose or in a manner for which the Products were not intended or 9 use of the Products in a manner inconsistent with the Specifications or 10 use of th...

Page 28: ...ST OF DISASSEMBLY AND SHIPMENT OF THE DEFECTIVE PRODUCT INJURY TO OTHER PROPERTY DAMAGE TO BUYER S OR THE FIRST END USER S PRODUCT DAMAGE TO BUYER S OR THE FIRST END USER S PROCESSES LOSS OF USE OR OTHER COMMERCIAL LOSSES WHERE DUE TO OPERATION OF LAW CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER THIS WARRANTY UNDER ANY OTHER EXPRESS WARRANTY NOT NEGATED HEREBY OR UNDER ANY IMPLIED WARRANTY NOT NEGAT...

Page 29: ...Rooks Road Nunawading Victoria 3131 Australia Tel Fax 61 0 3 9873 5610 61 0 3 9873 5010 In East Asia 36 Kaki Bukit Place 02 01 02 Singapore 416214 Tel Fax 65 6747 4600 65 6742 0345 Room 5406 No 103 Cao Bao Road Shanghai China 200233 Tel Fax 86 0 21 6482 8622 86 0 21 6482 8623 No 16 Jalan MJ14 Taman Industri Meranti Jaya 47120 Puchong Selangor Malaysia Tel Fax 60 3 8065 2928 60 3 8065 2923 252 94 K...

Page 30: ...vailable to meet individual specification requirements so please verify your particular product Body Options for Section A Standard No Plug No Plug With Plug NOTE Wrap sealing tape 3 to 3 5 times around the threaded portions 1 N m 10 kg cm Torque Dist Across Flats N m lbf ft mm in 30 22 12 1 2 Applications for Use Where there are large amounts of dirt or scale or for applications such as heating i...

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