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Contents

Introduction......................................................................... 1

Safety Considerations ........................................................ 2

Specifications ..................................................................... 4

Correct Usage of the

Multi-control Valve .......... 6

Configuration ...................................................................... 8

Installation......................................................................... 12

Wiring................................................................................ 18

Setting the Valve Coefficient ............................................ 20

Operation.......................................................................... 21

Inspection and Maintenance............................................. 23

Disassembly ..................................................................... 24

Reassembly...................................................................... 29

Troubleshooting................................................................ 30

EXPRESS LIMITED WARRANTY .......................... 36

Introduction

Thank you for purchasing the

MC-COSR

high-precision multi-control valve

for steam.
This product has been thoroughly inspected before being shipped from the factory.
When the product is delivered, before doing anything else, check the specifications
and external appearance to make sure nothing is out of the ordinary. Also be sure
to read this manual carefully before use and follow the instructions to be sure of
using the product properly.
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-control valve, model

MC-COSR

, provides accurate

pressure control (MC-COSR-3, MC-COSR-16) and temperature control (MC-
COSR-16) when combined with the

SC-F70 digital indicator controller or the

SP-F70 programmable indicator controller.
If detailed instructions for special order specifications or options not contained in
this manual are required, please contact

for full details.

This instruction manual is intended for use with the model(s) listed on the front
cover. It is needed not only for installation, but also for subsequent maintenance,
disassembly/reassembly and troubleshooting. Please keep it in a safe place for
future reference.

172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

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Содержание MC-COSR-16

Страница 1: ...i Kakogawa Hyogo 675 8511 Japan Tel 81 0 79 422 1122 Fax 81 0 79 422 0112 Copyright 2014 by TLV Co Ltd All rights reserved ISO 9001 ISO 14001 Manufacturer Kakogawa Japan is approved by LRQA LTD to ISO 9001 14001 High precision Multi control Valve for Steam MC COSR 3 MC COSR 16 Actuator MC GA2 ...

Страница 2: ...y 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 control valve model MC COSR provides accurate pressure contr...

Страница 3: ...es that there is a potential threat of death or serious injury CAUTION Indicates that there is a possibility of injury or equipment product damage CAUTION Install properly and DO NOT use this product outside the recommended operating pressure temperature and other specification ranges Improper use may result in such hazards as damage to the product or malfunctions that may lead to serious accident...

Страница 4: ...ing 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 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 produc...

Страница 5: ... and 240 V AC 50 60 Hz Power Consumption With motor running 75 VA max Insulation Resistance 500 V DC 100 M 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 2...

Страница 6: ...rating Range Model MC COSR 3 MC COSR 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 rate...

Страница 7: ...djustment is 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 co...

Страница 8: ...0d以上自動弁自動弁 30d未満 M C C O SR Maintain a straight piping run of 30 d or 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 30d以上減圧弁 M C C O SR 30d未満 M C C O SR 減圧弁 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...

Страница 9: ... Holder 10 Pilot Body 11 Pilot Valve Stem 12 Pilot Valve Seat 13 Diaphragm 14 Diaphragm Support 15 Spring Housing 16 Coil Spring 17 Plug Sensing Line Port 18 Motor Unit 19 Drive Unit 20 Mounting Plate 21 Adjustment Screw Guide 22 Adjustment Screw 23 Terminal Block Cover 24 Motor Cover 25 Insulation Plate 26 Cable Lock 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 ...

Страница 10: ...r 10 Pilot Body 11 Pilot Valve Stem 12 Pilot Valve Seat 13 Diaphragm 14 Diaphragm Support 15 Spring Housing 16 Coil Spring 17 Plug Sensing Line Port 18 Motor Unit 19 Drive Unit 20 Mounting Plate 21 Adjustment Screw Guide 22 Adjustment Screw 23 Terminal Block Cover 24 Motor Cover 25 Insulation Plate 26 Cable Lock 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 ...

Страница 11: ... 11 Pilot Body 12 Pilot Cover 13 Pilot Valve Stem 14 Pilot Valve Seat 15 Diaphragm 16 Diaphragm Support 17 Spring Housing 18 Coil Spring 19 Plug Sensing Line Port 20 Motor Unit 21 Drive Unit 22 Mounting Plate 23 Adjustment Screw Guide 24 Adjustment Screw 25 Terminal Block Cover 26 Motor Cover 27 Insulation Plate 28 Cable Lock 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 ...

Страница 12: ...rew Guide 4 Main Valve 14 Pilot Valve Seat 24 Adjustment Screw 5 Main Valve Holder 15 Diaphragm 25 Terminal Block Cover 6 Piston 16 Diaphragm Support 26 Motor Cover 7 Cylinder 17 Spring Housing 27 Insulation Plate 8 Silencer 18 Coil Spring 28 Cable Lock 9 Pilot Screen 19 Plug Sensing Line Port 10 Pilot Screen Holder 20 Motor Unit 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 ...

Страница 13: ...ion 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 Before installi...

Страница 14: ... sufficient space for maintenance inspection and repair 7 Pressure for pressure control The length of piping between the MC COSR and pressure sensor should be no more than 5 m 17 ft If the piping distance is too great 距離5m 以下圧力センサ M C C O SR 直管長さ 15d以上直管長さ 5d以上 pressure loss and delay of pressure change along this distance will increase resulting in steam flowrate fluctuations Steam fluctuations...

Страница 15: ...ction ratio is greater than 10 1 M C C O SR 計計パス弁弁出口弁口弁弁レリーフ弁入口出安全圧力圧力バイ一次側二次側バイパス弁入口弁減圧弁一次側圧力計圧力計入口弁出口弁安全弁レリーフ弁二次側バイパス弁 M C C O SR 10 Accessories Always install a 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 o...

Страница 16: ...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 and remove the bolts that attach the pilot body to the ma...

Страница 17: ...Pilot Body Plug Rc PT or NPT Secondary Pressure Detection Port Hex Bolt Main Body Blind Pin Connector Secondary Pressure Detection Port Replace the factory installed connector with the blind pin optional Connector 10 mm 3 8 in Pressure Sensing Line with a slightly falling pitch towards the sensing point Valve 15 d or more 1 m 3 3 ft or 15 d whichever is larger Equipment ...

Страница 18: ... mm 21 2 6 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 Blind Pin 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 pressure sensing pipe has previously...

Страница 19: ... unit See Wiring Instructions Ground 4 Install an overcurrent protection device on the 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 ...

Страница 20: ...cidents may occur CAUTION Drive Section Terminal Box Drive Section Terminal Block MC COSR Terminal Box Controller Terminal Block Shield Shield Cable Power Supply 100 240 V AC When making a connection to the terminal block use crimp style jacks for M4 with insulation sleeves 0 35 in 0 24 in 6 3 mm 0 24 in 4 3 mm 0 17 in 6 6 mm 0 26 in MAX MIN 9 0 mm 0 35 in Recommended Cable Specifications Cable Sp...

Страница 21: ...he 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 COSR 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 designed to take full advantage of MC COSR s potential ...

Страница 22: ...lve 20 Nov 2014 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 COSR and the secondary steam pressure rises Adjustment Screw 6 At the same time begin reducing the value of the operation signal to the MC COSR on the controller Adjustment S...

Страница 23: ... 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 Before beginning manual operation turn OFF the power t...

Страница 24: ...long service life of the MC COSR the following inspection and maintenance should be performed regularly Part Inspection and Maintenance Frequency Screens Pilot Disassemble and clean annually If there is substantial blockage install a strainer 60 mesh or finer ahead of the MC COSR Main Valve Main Valve Seat Pilot Valve and Pilot Valve Seat Replace after approximately 15 000 hours If there is chatte...

Страница 25: ...peration 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 COSR from the line Turn OFF the power to both the drive section and the valve operation signal controller and disconnect the cables Then remove inlet and outlet flange retaining bolts and nuts to permit removal of the MC COSR Secure the MC COSR in...

Страница 26: ...formation 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 Diaphragm 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 65 150 mm 21 2 6 in Diaphragm Pilot Valve Seat with gasket Pilot Valve Seat with gasket Pilot Valve Stem Pilot Valve Stem Pilot Valve Spring Bolt Bolt Notch Notch Pilot Body Pilot Body Pilot...

Страница 27: ...en 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 15 50mm 1 2 2 in 62 125 mm 21 4 5 in Piston Ring Tension Ring Lower Pilot Body Gasket Piston Retainer Bolt Cylinder with gasket Pilot Cover Gasket Piston Connector Bolt Piston Piston Ring Tension Ring Piston Ret...

Страница 28: ... for a long period always blow down the piston section of the main body through the plug if equipped 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 Main Body Cover 15 25 mm 1 2 1 in Gasket A A Main Valve Seat with gasket B Main Valve C Main Valve Holder D Main Valve Spring E Bolt B Main Valve Section C D 15 25 mm 1 2 1 in 32 50 mm 11 4 2 in 65 150 mm 21 2 6 in Plug Option A B C D E Main Val...

Страница 29: ...er Main Valve Pilot Valve Piston Pilot Valve Seat It is permissible to clean using water however cleaning with a mild detergent is recommended for more effective cleaning Exploded View Drive Section Adjustment Section Pilot Section Main Body Main Valve Section Cover Section NOTE The shape of individual parts may vary depending on the model size 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014...

Страница 30: ...e Part mm in mm in N m lbf ft Bolt for Mounting 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 65 150 21 2 6 17 21 32 60 44 65 80 21 2 3 19 3 4 70 51 100 125 4 5 24 15 16...

Страница 31: ... the operation mode to MANUAL MAN on the controller connected to the MC COSR 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 pressure adjustment screw in the drive section is stopped completely and is not hunting the secondary steam pressure is stabilized 172 65185A 08 MC COSR...

Страница 32: ...nd take appropriate measures Drive Section Terminal Block MC COSR Terminal Box Shielded Cable Power Supply 100 240 V AC approx 1 V DC approx 3 V DC approx 5 V DC Controller Terminal Block SC F70 SP F70 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 172 65185A 08 MC COSR Multi control Valve 20 Nov 2014 9 If the adj...

Страница 33: ...e 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 COSR if necessary The piston is clogged with dirt Clean check the piston ring The piston ring is worn Replace with a new piston ring The small hole on t...

Страница 34: ...eck the volume of steam supply replace with a smaller diameter valve There is too high a reduction ratio operated at below 10 of the primary pressure Use a two stage reduction arrangement Hunting never stops The selected model is inappropriate for the service conditions specifications Check the model selection replace the MC COSR if necessary Condensate is contained check the piping Hunting or cha...

Страница 35: ...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 Ref...

Страница 36: ...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 the power...

Страница 37: ...ctions contained in the TLV Instruction Manual for the Product Duration Of Warranty This warranty is effective for a period of the earlier of i three 3 years after delivery of Products to the first end user in the case of sealed SST Series Products for use in steam pressure service up to 650 psig ii two 2 years after delivery of Products to the first end user in the case of PowerTrap units or iii ...

Страница 38: ...IAL 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 NEGATED HEREBY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE CANNOT BE EXCLUDED SUCH DAMAGES ARE EXPRESSLY LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THE DEFECTIVE PRODUCT T...

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