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172-65604MA-00 (

PN-COSR

Pneumatic Control Valve) 10 Sep 2014

1

Contents

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

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

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

Acceptable Operating Range ............................................. 4

Correct Usage of the

PN-COSR-16

................................... 5

Configuration ...................................................................... 7

Installation .......................................................................... 9

Operation ......................................................................... 14

Maintenance..................................................................... 17

Disassembly..................................................................... 18

Reassembly ..................................................................... 22

Troubleshooting ............................................................... 23

Product Warranty ............................................................. 25

Introduction

Thank you for purchasing the

pneumatic control valve for steam, model

PN-

COSR-16

.

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.
The

PN-COSR-16

can operate automatically and provide accurate pressure control and

temperature control when combined with the

SC-F70 digital indicator controller or

a general-purpose controller. Manual remote setting is possible by combination with an
air regulator.
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.

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Содержание PN-COSR-16

Страница 1: ...6 Pneumatic Control Valve 10 September 2014 Pneumatic Control Valve for Steam PN COSR 16 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 ...

Страница 2: ...ing 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 The PN COSR 16 can operate automatically and provide accurate pressure control and temperature control when combined with the SC F70 digital indicator controller or a general purpose controller Manual remote setting is possible by combination with an...

Страница 3: ...h poses a threat of 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 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 produc...

Страница 4: ...er 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 with the power on there is a danger that equipment may malfunction or electric shock may occur le...

Страница 5: ...tem 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 in Adjustment Section Drive Section Motive Air Air Quality Oil free air filtered to 5 m 1 MPa 10 197 kg cm2 CV Value Size mm in 15 1...

Страница 6: ...ressure Passing through an area of the reducing ratio of less than 10 1 where adjustment is impossible 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 t...

Страница 7: ... is 25 mm 1 in have 750 mm 30 in or more PN COSR Motorized Valve 30 d or more PN COSR 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 COSR Pressure Reducing Valve 30 d or more PN COSR Pressure Reducing Valve Less than 30 d 2 Outle...

Страница 8: ...ain Body 18 Pilot Screen Holder 19 PilotScreenHolderGasket 20 Pilot Screen 21 Pilot Valve 22 Pilot Valve Seat 23 Pilot Body 24 Hex Bolt Pilot Body Main Body 25 Pilot Valve Spring 26 Pilot Valve Seat Gasket 27 Diaphragm 28 Diaphragm Gasket 29 Spring Housing 30 Diaphragm Support 31 Hex Bolt Spring Housing Pilot Body 32 Coil Spring 33 Spring Retainer 34 Steel Ball 35 Gland Packing 36 O ring 37 Spanne...

Страница 9: ...reen Holder 19 Pilot Screen Holder Gasket 20 Pilot Screen 21 Pilot Valve 22 Pilot Valve Seat 23 Pilot Body 24 Hex Bolt Pilot Body Main Body 25 Pilot Valve Spring 26 Pilot Valve Seat Gasket 27 Diaphragm 28 Diaphragm Gasket 29 Spring Housing 30 Diaphragm Support 31 Hex Bolt Spring Housing Pilot Body 32 Coil Spring 33 Spring Retainer 34 Steel Ball 35 Gland Packing 36 O ring 37 Spanner Cap 38 Adjustme...

Страница 10: ...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 When the PN COSR 16 is used with electrical equipment such as an elec...

Страница 11: ...curely 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 Pressure Sensor Installation for pressure control The length of piping between the PN COSR 16 and the pressure sensor should be no more than 5 m 17 ft If the piping distance is too great pressure loss and delay of pressure change along this distance will increase...

Страница 12: ...condensate accumulation PN COSR Diffuser Straight run piping lengths d pipe diameter Upstream 10 d or more Downstream 15 d ore more PN COSR 9 Two stage Pressure Reduction Whenever the pressure cannot be reduced to the desired level with a single PN COSR 16 due to operating range limitations such as when the reduction ratio is greater than 10 1 the pressure reducing valve should be installed at the...

Страница 13: ... to install an external pressure sensing line to detect the secondary pressure Installation of an external secondary pressure sensing line involves closing the internal pressure sensing channel and 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 flow rate fluctuati...

Страница 14: ...installed in place of the blind pin and a threaded secondary pressure sensing plug Follow the connecting tube installation procedure shown below 1 Loosen and remove the four 4 bolts that attach the pilot body to the main body and remove the pilot body 2 Install the connecting tube by first removing the blind pin from the secondary side of the main body and then substituting the connecting tube 3 R...

Страница 15: ...c Transducer PN COSR 16 Example Temperature control as control valve Temperature Sensor Controller Air Regulator Electro Pneumatic Transducer PN COSR 16 Automatic control is possible when the PN COSR 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 ...

Страница 16: ... steps shown in the Setting the pressure with an adjustment screw on the following page Example 2 point pressure switching as pressure reducing valve ON OFF Switch 3 Way Solenoid Valve Air Regulator with relief PN COSR 16 Pressure at the secondary side can be switched manually between 2 points with an ON OFF switch To do so an air regulator with relief function which adjusts the motive air a 3 way...

Страница 17: ...nt Stay clear of any pressurized blow out from the safety valve 2 Make sure that the shut off valve and the bypass valve located upstream and downstream of the PN COSR 16 are completely closed 3 Remove the spanner cap and turn the adjustment screw counterclockwise to reduce tension on the coil spring NOTE Do not pull up the adjustment screw forcibly once the adjustment screw has reached the point ...

Страница 18: ...ction or electric shock may occur leading to injury or other accidents CAUTION Operational Check To ensure long service life of the PN COSR 16 the following inspection and maintenance should be performed regularly Part Inspection and Maintenance Frequency Pilot Screen Disassemble and clean annually If there is substantial blockage install a strainer approximately 60 mesh ahead of the PN COSR 16 Ma...

Страница 19: ...rained maintenance personnel Remove all steam from the piping both upstream and downstream Stop supplying motive air to the PN COSR 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 COSR 16 from the line as it may be heated with the residual heat of steam Then remove the inlet and o...

Страница 20: ...P mark on the top Diaphragm Pilot Valve Seat Gasket Pilot Valve Pilot Valve Spring Plug Pilot Body Upper Pilot Body Gasket Notch Pilot Screen Pilot Screen Holder Gasket Hex Bolt 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 ...

Страница 21: ...seat gaskets and sliding surfaces of each part 15 25 mm 1 2 1 in Main Body Main Valve Seat Gasket Main Valve Main Valve Holder Main Valve Spring Cover Plug Cover Plug Gasket 40 50 mm 11 2 2 in Cover Main Body Main Valve Seat Gasket Main Valve Main Valve Holder Main Valve Spring Cover Bolt Cover Gasket Cleaning After inspection and removal of any abnormality clean and reassemble the parts The follo...

Страница 22: ...neumatic Control Valve 10 Sep 2014 21 Exploded View Adjustment Section Drive Section Pilot Section Piston Main Valve Section 15 25 mm 1 2 1 in 40 50 mm 11 2 2 in NOTE Configuration of each part varies depending on nominal size ...

Страница 23: ...n ring 2 The ring gaps should be opposite each other 5 Standard fastening torque and the distance across flats for the tools to be used are as follows PN COSR 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 ...

Страница 24: ...n 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 Major causes for the above problems are usage under non specified conditions out of specifications insuf...

Страница 25: ... 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 The...

Страница 26: ...s 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 ...

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