TLV COS-3 Bedienungsanleitung

172-65175MA-13 (COS Pressure Reducing Valve) 16 February 2022

Pressure Reducing Valve for Steam

COS-3/COS-16/COS-21

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

Contents

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

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

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

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

Correct Usage of the COS Pressure Reducing Valve....... 5

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

Installation....................................................................... 11

Adjustment ...................................................................... 15

Maintenance.................................................................... 16

Disassembly.................................................................... 17

Reassembly .................................................................... 23

Troubleshooting .............................................................. 25

TLV EXPRESS LIMITED WARRANTY........................... 28

Service ............................................................................ 30

Introduction

Thank you for purchasing the TLV COS pressure reducing 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.

The TLV pressure reducing valve for steam, model COS, is a new reducing

valve that eliminates these problems and makes possible the supply of very

dry steam at a constant pressure.

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.

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

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

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 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.

DO NOT use the product in excess of the maximum operating

pressure differential.

Such use could make discharge through the product impossible

(blocked).

Use hoisting equipment for heavy objects (weighing

approximately 20 kg (44 lb) 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.

Continued on the next page

DANGER

WARNING

CAUTION

WARNING

CAUTION

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

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.

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

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

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

Model

COS-3

COS-16

COS-21

Primary Pressure Range

0.1 to 0.3 MPaG

(15 to 45 psig)

0.2 to 1.6 MpaG

(30 to 250 psig)

1.35 to 2.1 MPaG

(190 to 300 psig)

Adjustable Pressure

Range

(All conditions must

be met)

0.01 to 0.05 MPaG

(1.5 to 7 psig)

Within 10 –84% of the primary pressure

Minimum adjustable

pressure of 0.03 MPaG

(5 psig)

Minimum adjustable

pressure of 0.55 MPaG

(80 psig)

Pressure differential

between

0.07 to 0.85 MPa

(10 to 120 psi)

Maximum pressure

differential of 0.85 MPa

(120 psi)

Maximum Operating

Temperature

220 °C (428 F)

Minimum Adjustable

Flow Rate

5% of rated

flow rate

5% of rated flow rate; 10% of rated flow rate for

sizes 65 mm (21/2in) and larger

(1 MPa = 10.197 kg/cm2)

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

Correct Usage of the COS 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

The COS should be operated only within its specifications.

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

If an on-off valve, such as a motorized valve, is required to stop supply of

steam to the steam-using equipment, install it at the inlet side of the COS. If a

solenoid valve is installed at the outlet of the COS, 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 COS 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.) 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 the COS.

Installing a Control Valve and Safety Valve

A control valve installed between the COS and the steam-using equipment

(downstream of the COS) for controling equipment temperature may raise the

pressure between the COS and the control valve when the control valve is

closed, depending on the spatial relationship. A safety valve should be

installed downstream of the control valve.

Note: When installing a safety valve to protect the steam-using equipment, be

sure to install it on the steam-using equipment or directly before the inlet of the

steam-using equipment. If the safety valve is installed on the outlet side of the

COS between the COS and a control valve, an eventual pressure rise could

activate the safety valve.

COS

Inlet side

Motorized

Valve

COS

Outlet side

Solenoid

Valve

Steam-using

Equipment

Steam-using

Equipment

COS

Control

Valve

Safety

Valve

Steam-using

Equipment

Steam-using

Equipment

COS

Control

Valve

Safety

Valve

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

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

Valve

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

COS must be straight runs. If a COS is installed either directly before or after an

elbow or control valve, unevenness in steam flow may result in chattering and

unstable pressure.

To ensure stable steam flow, it is recommended that the COS be installed on

straight runs of piping, as illustrated below.

1) Inlet (primary side) of the COS 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

(1 in), have 250 mm (10 in) 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 (1 in), have 750 mm (30 in)

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 (1 in), have 750 mm (30 in)

or more)

2) Outlet (secondary side) of the COS

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 (1 in), have 375 mm (15

in) or more)

Maintain a straight piping run of

30 d or more when a safety

valve is installed.

(Example: if nominal size is 25

mm (1 in), have 750 mm (30

in) 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 (1 in), have 750 mm (30

in) or more)

COS

10d or more

Valve, strainer,

elbow, etc.

COS

Valve, strainer,

elbow, etc.

Less

than

10d

COS

30d or more

Automated

Valve

COS

Automated

Valve

Less than

30d

30d or more

COS

Less than

30d

COS

15d or more

Valve, strainer,

elbow, etc.

COS Valve, strainer,

elbow, etc.

Less than

15d

COS

30d or more

Safety

Valve

COS Safety

Valve

Less than

30d

COS

30d or more

Control or

Automated

Valve

COS

Control or

Automated Valve

Less than

30d

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

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 or more

COS

Less than

30d

COS

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

Configuration

COS-3

20 to 50 mm (3/4to 2 in)

(Cast Iron, Cast Stainless Steel)

No.

Name

Main Body

Trap Body

Trap Cover

Separator

Float



Float Cover

Trap Valve Seat



Separator Screen



Main Valve Seat



Main Valve



Main Valve Holder



Piston



Cylinder



Pilot Screen



Pilot Screen Holder

Pilot Body

Pilot Valve



Pilot Valve Seat



Diaphragm

Diaphragm Support

Spring Housing

Coil Spring

Adjustment Screw

Spanner Cap

Plug –Sensing Line Port

Gasket

(Pilot Body/Main Body)



Trap Valve Seat Gasket



Gasket

(Trap Body/Trap Cover)



Gasket

(Main Body/Trap Body)



Main Valve Seat Gasket



Pilot Screen Holder Gasket



Pilot Valve Seat Gasket



Diaphragm Gasket



Cylinder Gasket



Piston Ring



Tension Ring



Main Valve Spring



Pilot Valve Spring



Maintenance Kit

Repair Kit for Main Valve

Repair Kit for Piston

Repair Kit for Piston Ring

Repair Kit for Pilot Valve

Repair Kit for Trap Valve Seat

Float

172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022

COS-16/COS-21

15 to 50 mm (1/2to 2 in)

(Cast Iron, Cast Stainless Steel)

No.

Name

Main Body

Trap Body

Trap Cover

Separator

Float



Float Cover

Trap Valve Seat



Separator Screen



Main Valve Seat



Main Valve



Main Valve Holder



Piston



Cylinder



Pilot Screen



Pilot Screen Holder

Pilot Body

Pilot Valve



Pilot Valve Seat



Diaphragm

Diaphragm Support

Spring Housing

Coil Spring

Adjustment Screw

Spanner Cap

Plug –Sensing Line Port

Gasket

(Pilot Body/Main Body)



Trap Valve Seat Gasket



Gasket

(Trap Body/Trap Cover)



Gasket

(Main Body/Trap Body)



Main Valve Seat Gasket



Pilot Screen Holder

Gasket



Pilot Valve Seat Gasket



Diaphragm Gasket



Cylinder Gasket



Piston Ring



Tension Ring



Main Valve Spring



Pilot Valve Spring



Maintenance Kit

Repair Kit for Main Valve

Repair Kit for Piston

Repair Kit for Piston Ring

Repair Kit for Pilot Valve

Repair Kit for Trap Valve Seat

Float

NOTE: No kits available for COS-21 parts. Please order per parts if needed.

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