TLV A-COSR-10 Bedienungsanleitung

172-65255M-05 (A-COSR-10) 6 October 2021

Pressure Reducing Valve for Air

A-COSR-10

172-65255M-05 (A-COSR-10) 6 Oct 2021

Contents

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

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

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

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

Correct Usage of the A-COSR Pressure Reducing Valve

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

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

Installation......................................................................... 8

Adjustment ...................................................................... 12

Maintenance.................................................................... 13

Disassembly.................................................................... 14

Reassembly .................................................................... 18

Troubleshooting .............................................................. 19

TLV EXPRESS LIMITED WARRANTY........................... 21

Service............................................................................ 23

Introduction

Thank you for purchasing the TLV A-COSR pressure reducing valve for air.

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 TLV pressure reducing valve for air, model A-COSR provides a more

stable secondary pressure than conventional reducing valves. The A-COSR

is designed for long service life, with all major components made of stainless

steel for superior durability.

If detailed instructions for special order specifications or options not contained

in this manual are required, please contact TLV 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.

172-65255M-05 (A-COSR-10) 6 Oct 2021

Safety Considerations

Read this section carefully before use and be sure to follow the instructions.

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve

opening/closing should be carried out only by trained maintenance personnel.

The precautions listed in this manual are designed to ensure safety and prevent

equipment damage and personal injury. For situations that may occur as a result

of erroneous handling, three different types of cautionary items are used to

indicate the degree of urgency and the scale of potential damage and danger:

DANGER, WARNING and CAUTION.

The three types of cautionary items above are very important for safety: be sure to

observe all of them as they relate to installation, use, maintenance, and repair.

Furthermore, TLV accepts no responsibility for any accidents or damage occurring

as a result of failure to observe these precautions.

Symbols

Indicates a DANGER, WARNING or CAUTION item.

Indicates an urgent situation which poses 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

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 accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

Use hoisting equipment for heavy objects (weighing

approximately 20 kg or more).

Failure to do so may result in back strain or other injury if the object

should fall.

Take measures to prevent people from coming into direct

contact with product outlets.

Failure to do so may result in burns or other injury from the discharge

of fluids.

When disassembling or removing the product, wait until the

internal pressure equals atmospheric pressure and the surface

of the product has cooled to room temperature.

Disassembling or removing the product when it is hot or under

pressure may lead to discharge of fluids, causing burns, other

injuries or damage.

Continued on the next page.

DANGER

WARNING

CAUTION

172-65255M-05 (A-COSR-10) 6 Oct 2021

Be sure to use only the recommended components when

repairing the product, and NEVER attempt to modify the product

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 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.

CAUTION

172-65255M-05 (A-COSR-10) 6 Oct 2021

Specifications

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 which may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

CAUTION

DO NOT use the trap in excess of the maximum operating pressure

differential; such use could make discharge impossible (blocked).

CAUTION

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.

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)

Secondary

Pressure

Adjustable Range

(MPaG)

Minimum

Differencial

Pressure

(MPa)

Maximum

Operating

Temperature

(°C)

Minimum

Adjustable Flow

Rate

For Air

A-COSR-10

0.1 - 0.9

0.05 - 0.7

0.05

100

10% of rated

flow rate

Model

Nominal Diameter

Maximum Operating

Temperature

Valve No.*

Secondary Pressure

Adjustable Range

Primary Pressure

Range

Production Lot No.

172-65255M-05 (A-COSR-10) 6 Oct 2021

Correct Usage of the A-COSR Pressure Reducing Valve

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 which may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

CAUTION

1. The A-COSR should be operated only within its specifications.

2. Installing an ON / OFF Valve (Solenoid Valve or Motorized Valve)

If an on-off valve, such as a motorized valve is required, install it at the inlet side

of the A-COSR. If a solenoid valve is installed 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 Valve

When installing a safety valve to protect the air equipment, be sure to install it on

the air equipment or directly before the inlet of the air equipment. If the safety

valve is installed on the outlet side of the A-COSR between the A-COSR and a

control valve, an eventual pressure rise could activate the safety valve.

Motorized

Valve

A-COSR

Solenoid

Valve

A-COSR

Inlet Side

Outlet Side

A-COSR

Safety

Valve

Safety

Valve

Control

Valve

Control

Valve

Equipment

172-65255M-05 (A-COSR-10) 6 Oct 2021

4. Precautions for the Installation of Additional Fittings Before or After the Reducing

Valve

In order to ensure stable air flow, the piping upstream and downstream of the

reducing valve must be straight runs. If a pressure reducing valve is installed

either directly before or after an elbow or control valve, unevenness in air flow

may result in chattering and unstable pressure.

To ensure stable air flow, it is recommended that the pressure reducing valve be

installed on straight runs of piping, as illustrated below.

①Inlet (primary side) of the pressure reducing valve NOTE: d = pipe diameter

Maintain a straight piping

run of 10 d or more when a

manual valve, a strainer or

an elbow, etc. is installed.

(Example: if nominal size is 25

mm, have 250 mm or more)

Maintain a straight piping

run of 30 d or more when

an automated valve (on-off

valve) is installed.

(Example: if nominal size is 25

mm, have 750 mm or more)

②Outlet (secondary 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)

減圧弁

15d以上

減圧弁

15d未満

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 reducing

valve is installed. (Two-stage

pressure reduction)

(Example: if nominal size is 25

mm, have 750 mm or more)

Maintain a straight piping

run of 30 d or more when a

control valve or an

automated valve (on-off

valve) is installed.

(Example: if nominal size is 25

mm, have 750 mm or more)

15 d or more

Less than

15 d

Valve, strainer,

elbow, etc.

A-COSR

10 d or

A-COSR

Less

than

10 d

A-COSR

Automatic

Valve

30 d or more

Automatic

Valve

Less than

30 d

A-COSR

30 d or more

Safety

Valve

A-COSR

Safety

Valve

A-COSR

30 d or more

Second

Reducing

Valve

Control or

Automated

Valve

30 d or more

A-COSR

Less than

30 d

Less than

30 d

Less than

30 d

Second

Reducing

Valve

Control or

Automated Valve

A-COSR

Valve, strainer,

elbow, etc.

172-65255M-05 (A-COSR-10) 6 Oct 2021

Configuration

No.

Name

No.

Name

Main Body

Diaphragm

Cover

Pilot Screen

Main Valve Seat

Pilot Screen Holder

Main Valve

Diaphragm Support

Piston

Coil Spring

Cylinder

Spring Housing

Pilot Valve Body

AdjustmentScrew

Pilot Valve

SpannerCap

Pilot Valve Seat

Plug–SensingLinePort

172-65255M-05 (A-COSR-10) 6 Oct 2021

Installation

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 which may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

CAUTION

Use hoisting equipment for heavy objects (weighing approximately

20 kg or more). Failure to do so may result in back strain or other injury if

the object should fall.

CAUTION

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids.

CAUTION

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve

opening/closing should be carried out only by trained maintenance personnel.

1. Blowdown

Before installing the

A-COSR, 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 2 locations, on the product inlet and outlet.)

3. Installation Angle

Install the A-COSR vertically, so

that the arrow mark on the body

points horizontally in the direction

of air flow.

Allowable inclination is 10 degrees

in the fore-aft direction and 15

degrees in the plane perpendicular

to the air flow line.

4. Spacer Installation

If spacing adjustment is

necessary to accommodate

installation, install a spacer on

the outlet flange. The spacer

should consist of a spacer,

gaskets, bolts and nuts.

スペーサ

A-COSR

Blowdown Using Bypass Valve

Blowdown Piping

Before Installation

Correct

Spacer

Location

Incorrect

Spacer

Location

172-65255M-05 (A-COSR-10) 6 Oct 2021

スペーサ

Fit gaskets to both sides of the spacer between the A-COSR outlet and the pipe

flange. Fasten with bolts and nuts.

5. Piping Support

Install the A-COSR, paying

attention to avoid excessive load,

bending and vibration.

Support the inlet and outlet pipes

securely.

6. Maintenance Space

Leave sufficient space for

maintenance, inspection and

repair.

(Unit: mm)

7. Piping Size

If it is expected that the secondary air flow velocity will be more than 30 m/s,

install a diffuser in order to keep the flow velocity below 30 m/s. If the distance

between the reducing valve and the air equipment is great, a possible drop in

pressure should be taken into consideration when selecting the piping size.

Strainer should be angled in the 3 o 9 o’clock positions for horizontal installations

to prevent condensate accumulation.

0.2m以上

ディフューザ

減圧弁

Straight-run Piping Lengths: Upstream = 10 d or more; Downstream = 15 d or more

(d = pipe diameter)

Diffuser

A-COSR

0.2 m or more

approx

. 300

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