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172-65588MA-02 (

PN-COS

Pneumatic Control Valve) 5 Sep 2014

Problem Symptom

Cause

Remedy

The piston rings are worn Replace with new piston

rings

The small hole in the
piston is clogged

Clean

There is a build-up of dirt
on the sliding surfaces of
the pilot valve, piston or
main valve

Clean

The setting for the motive
air is inappropriate

Check the motive air
supply line; check the set
pressure

Flow rate exceeds rated
flow rate

Check the flow rate,
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

PN-COS-16

necessary

Adjustment is
difficult, and set
pressure varies

The

PN-COS-16

inappropriate for the
service conditions
(specifications)

Check the model
selection, replace the

PN-

COS-16

if necessary

The bypass valve is
leaking

Check, clean, and replace
with a new bypass valve if
necessary

The secondary
pressure
cannot be
adjusted or
increases
abnormally

Upon 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
steam demand

It is being used below the
minimum adjustable flow
rate

Replace with a smaller
size

There is too high a
reduction ratio (operated
at below 10% of the
primary pressure)

Use two-stage reduction

Hunting never stops

The

PN-COS-16

inappropriate for the
service conditions
(specifications)

Check the model
selection, replace the

PN-

COS-16

if necessary

Condensate is contained,
or the trap is blocked

Check the trap
Check the piping

Hunting or
chattering
occurs

Chattering never
stops

The

PN-COS-16

inappropriate for the
service conditions
(specifications)

Check the model
selection, replace the

PN-

COS-16

if necessary

Troubleshooting continued on the next page

Содержание COSPECT PN-COS-16

Страница 1: ...umatic 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 ...

Страница 2: ...ems 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 pneumatic control valve for steam model PN COS 16 has a built in cyclone 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 an...

Страница 3: ...e 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 use this product outside the recommended operat...

Страница 4: ...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 w...

Страница 5: ...ucts with options This item is omitted from the nameplate when there are no options Required utilities 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 Adjustment Section Drive Section Motive Air Air Quality Oil free air filtered to 5 m 1 MPa 10 197 kg cm2 CV ...

Страница 6: ...mpossible 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...

Страница 7: ...d Valve 30 d or more PN COS Motorized Valve Less than 30 d Maintain a straight piping run of 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 PN COS Pressure Reducing Valve 30 d or more PN COS Pressure Reducing Valve Less than 30 d 2 Outlet secondary side of the PN COS 16 Maintain a straight piping...

Страница 8: ...sion 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 Packin...

Страница 9: ...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 insta...

Страница 10: ...ad bending and vibration Support the inlet and outlet pipes securely 6 Maintenance Space Leave sufficient space for maintenance inspection and repair Unit mm in 200 8 200 8 150 6 100 4 150 6 200 8 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 c...

Страница 11: ...owdown valve and blow any residual dirt and scale off of the screen 4 Periodically activate the blowdown valve to keep the system free of dirt and scale Remove the 10 mm 3 8 in plug optional and install the blowdown valve 10 Piping Size If the secondary steam flow velocity is expected to be more than 30 m s 100 ft s install a diffuser in order to keep the flow velocity below 30 m s 100 ft s If the...

Страница 12: ...an Models North American Models are factory prepared for external sensing An external sensing line MUST be installed DO NOT SUPPLY STEAM until all piping and a 10 mm 3 8 in secondary pressure sensing line with a slightly falling pitch have been properly installed Install a shutoff valve in the pressure sensing line for maintenance purposes Keep the shutoff valve open at all times during operation ...

Страница 13: ... with a slightly falling pitch The end of the secondary pressure sensing line should be connected to the place on the main piping where the pressure is to be sensed see the piping example on the next page A shut off valve and union should be installed in the secondary pressure sensing line Pilot Body Body Secondary Pressure Sensing Line Port Rc PT 3 8 BSP3 8 or NPT 3 8 Hex Bolt Secondary Pressure ...

Страница 14: ...ind pin from the secondary side of the main body and then substituting the connecting tube Blind Pin Connecting Tube 3 Re install the pilot body and fasten the four 4 bolts evenly See the torque chart in the Reassembly section in this manual for torque requirements of these bolts 4 If a secondary pressure sensing pipe has previously been installed remove it and be certain to install the threaded s...

Страница 15: ... control as control valve Controller Air Regulator Electro Pneumatic Transducer PN COS 16 Automatic control is possible when the PN COS 16 is used with a controller However an electro pneumatic transducer is required in order to control the air for operation The wiring etc should be carried out according to the instruction manual for the controller the electro pneumatic transducer or related devic...

Страница 16: ...o so an air regulator with relief function which adjusts the motive air a 3 way solenoid valve and an ON OFF switch are required Pressure setting at the higher pressure side should be adjusted with the motive air by checking the pressure gauge at the secondary side For pressure setting at the lower pressure side follow the steps in the Setting the pressure with the adjustment screw below Setting t...

Страница 17: ...tment screw has reached the point at which it stops The internal stopper C ring may break 4 Slowly fully open the shut off valve at the inlet of the PN COS 16 Allow sufficient time for condensate remaining at the inlet of the PN COS 16 to be discharged through the built in steam trap 5 Slightly open the shut off valve at the outlet of the PN COS 16 6 Turn the adjustment screw clockwise until the d...

Страница 18: ... the PN COS 16 the following inspection and maintenance should be performed regularly Part Inspection and Maintenance Frequency Screens Separator Pilot Disassemble and clean annually If there is substantial blockage install a strainer approximately 60 mesh ahead of the PN COS 16 Main Valve Main Valve Seat Pilot Valve and Pilot Valve Seat Replace after approximately 15 000 hours If there is chatter...

Страница 19: ...losing should be carried out only by trained maintenance personnel Remove all steam from the piping both upstream and downstream Stop supplying motive air to the PN COS 16 Remove the spanner cap and then pull up the adjustment screw until there is no load on the coil spring Wait for the body to cool before attempting to remove the PN COS 16 from the line as it may be heated with the residual heat ...

Страница 20: ...Valve Pilot Valve Spring Hex Bolt Pilot Body Upper Pilot Body Gasket Notch Pilot Screen Pilot Screen Holder with Gasket Plug Disassembling the Piston Section Take the pilot body off after removing the hex bolts During this process pay attention not to lose the connecting tubes 2 pcs Remove the piston guide piston and cylinder from the main body Then remove the piston rings and the tension rings fr...

Страница 21: ...ogging of the separator screen Wave Spring Main Body Main Valve Seat Main Valve Main Valve Holder Main Valve Spring Separator Screen Sleeve Separator Trap Body Gasket Hex Bolt Main Valve Seat Gasket Disassembling the Steam Trap Section Loosen the hex bolts for the trap cover and remove the trap cover Be careful as hot condensate may splash out Remove the hex bolts for the float cover and remove th...

Страница 22: ...ve Main Valve Main Valve Holder Pilot Valve Seat 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 Drive Section Pilot Section Piston Section Separator Main Valve Section Steam Trap Section NOTE Configuration of each part varies depending on ...

Страница 23: ...re as follows PN COS 16 Connection Size Distance Across Flats Tightening Torque Part mm in mm in N m lbf ft Bolts Spring Housing Pilot Body 15 50 17 21 32 40 29 Pilot Valve Seat 15 50 19 3 4 70 51 Pilot Screen Holder 15 50 24 15 16 40 29 15 40 1 2 11 2 17 21 32 60 44 Hex Bolts Pilot body Main Body 50 2 19 3 4 70 51 15 40 1 2 11 2 17 21 32 60 44 Hex Bolts MainBody Trap BodyandTrapbody TrapCover 50 ...

Страница 24: ... first Diagnosis of malfunctions in the pressure reducing section Problems are classified as follows 1 The secondary pressure does not increase 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 trap or condensate is not discharged Majo...

Страница 25: ...f necessary The bypass valve is leaking Check clean and replace with a new bypass valve if necessary The secondary pressure cannot be adjusted or increases abnormally Upon 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 ...

Страница 26: ... dirt on the trap valve seat or at the float base Clean The body is installed tilted Check the piping The float is deformed Check for water hammer Replace with a new float Steam is blowing There is vibration in the piping Secure the piping The primary pressure exceeds the trap valve seat maximum operating pressure Adjust the primary pressure Water is inside the float Replace with a new float The s...

Страница 27: ... 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 any o...

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