TLV COSPECT Bedienungsanleitung

172-65254M-03 (A-COS-10) 27 October 2008

Pressure Reducing Valve for Air

COSPECT

A-COS-10

ISO 9001/ ISO 14001

Manufacturer

Kakogawa, Japan

is approved by LRQA LTD. to ISO 9001/14001

172-65254M-03 (A-COS-10) 27 Oct 2008

Contents

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

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

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

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

Correct Usage of the

COSPECT

Pressure Reducing Valve 5

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

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

Adjustment ......................................................................... 11

Maintenance ...................................................................... 12

Disassembly....................................................................... 13

Reassembly ....................................................................... 17

Troubleshooting ................................................................. 18

Product Warranty ............................................................... 21

Introduction

Thank you for purchasing the COSPECT 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.

Air-using equipment can achieve its intended efficiency only if the air being

used is very dry. Using air in which matter such as condensate, scale or types

of oil is entrained can not only result in problems with the air-using equipment

and in lowered productivity, but can also lead to shortened service life for and

malfunction of the reducing valves.

The COSPECT pressure reducing valve for air, model A-COS, is a new

reducing valve that eliminates these problems and makes possible the supply

of very dry air at a constant pressure.

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.

172-65254M-03 (A-COS-10) 27 Oct 2008

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.

DANGER Indicates an urgent situation which 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

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 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 air trap impossible

(blocked).

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.

Safety considerations are continued on the next page.

172-65254M-03 (A-COS-10) 27 Oct 2008

CAUTION 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.

172-65254M-03 (A-COS-10) 27 Oct 2008

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-COS-10 0.1 - 0.9 0.05 - 0.7 0.05 100 10% of rated flow

rate

Primary Pressure Range

Model

Serial Numbe

Nominal Diamete

Maximum Operating

Temperature

Valve No.*

Secondary Pressure

Adjustable Range

172-65254M-03 (A-COS-10) 27 Oct 2008

Correct Usage of the

COSPECT

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 COSPECT should be operated only within its specifications.

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

減圧弁

電動弁

入口側

出口側

電磁弁

減圧弁

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

of the COSPECT. 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

減圧弁

安全弁

制御弁

エア使用装置

安全弁

エア使用装置

制御弁

減圧弁

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 COSPECT between the COSPECT and

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

Motorized

Valve COSPECT

Inlet Side

Safety

Valve

Equipment

COSPECT

Outlet Side

Solenoid

Valve

Equipment

Safet

Valve

Control

Valve

Control

Valve

COSPEC

172-65254M-03 (A-COS-10) 27 Oct 2008

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)

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)

Valve, strainer,

elbow, etc.

COSPECT

10 d or

COSPECT

Less

than

10 d

COSPECT

Automatic

Valve

30 d or more

Automatic

Valve

Less than

30 d

COSPECT

15 d or more

COSPECT

30 d or more

Safety

Valve COSPECT

Safety

Valve

COSPECT

30 d or more

Second

Reducing

Valve

Control or

Automated

Valve

30 d or more

COSPECT

Less than

15 d

Less than

30 d

Less than

30 d

Second

Reducing

Valve

Control or

Automated Valve

COSPECT

Valve, strainer,

elbow, etc.

Less than

30 d

172-65254M-03 (A-COS-10) 27 Oct 2008

Configuration

No. Name

1 Main Body

2 Trap Body

3 Trap Cover

4 Separator

5 Float

6 Float Cover

7 Trap Valve Seat

8 Separator Screen

9 Main Valve Seat

10 Main Valve

11 Piston

12 Cylinder

13 Pilot Screen

14 Pilot Screen Holder

15 Pilot Valve Body

16 Pilot Valve

17 Pilot Valve Seat

18 Diaphragm

19 Diaphragm Support

20 Spring Housing

21 Coil Spring

22 Adjustment Screw

23 Spanner Cap

24 Plug – Sensing Line Port

Plug (option)

172-65254M-03 (A-COS-10) 27 Oct 2008

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 COSPECT unit, 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 3 locations, on the product inlet and outlets.)

3. Installation Angle

Install the COSPECT 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. Fit gaskets to both sides of

the spacer between the COSPECT

outlet and the pipe flange. Fasten

with bolts and nuts.

orrect

pacer

Location

Incorrect

pacer

Location

Blowdown Using

Bypass Valve

Blowdown

Piping Before

Installation

172-65254M-03 (A-COS-10) 27 Oct 2008

5. Piping Support

Install the COSPECT, 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.

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 case of the latter,

make sure the end of the pipe is

above the waterline.

8. Blowdown Valve (requires optional plug)

In an environment of heavy dirt or scale, or when the air equipment is used only

periodically, be sure to install a strainer at the inlet of the COSPECT and a

blowdown valve on the main body.

1. Remove the plug from the main body.

2. Install the 10 mm blowdown valve.

3. Open the blowdown 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.

Small Hole

Remove the ⅜”

plug (optional)

and install the

blowdown valve

(

Unit: mm

)

approx.

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