TLV CV-COS Bedienungsanleitung

172-65443A-01 (CV-COS) 17 November 2014

Manufacturer

881 Nagasuna, Noguchi, Kakogawa, Hyogo, 675-8511 Japan

Tel: [81]-(0)79-422-1122 Fax: [81]-(0)79-422-0112

ISO 9001/ ISO 14001

Manufacturer

Kakogawa, Japan

is approved by LRQA LTD. to ISO

9001/14001

Pneumatic Control Valve

with Built-in Separator and Steam Trap

CV-COS

Contents

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

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

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

Configuration...................................................................... 6

Installation .......................................................................... 7

Electrical Wiring ............................................................... 10

Operational Check ............................................................11

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

Disassembly / Reassembly .............................................. 14

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

EXPRESS LIMITED WARRANTY .......................... 20

Options............................................................................. 22

Introduction

Thank you for purchasing the Control Valve with Built-in Separator and

Steam Trap.

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 Control Valve with Built-in Separator and Steam Trap is a

revolutionary product that combines an integrated positioner / diaphragm-type

actuator with a separator and a steam trap. 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 or types of grease 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 control valve. The CV-COS is a new control valve that offers

a solution for these problems by supplying high-quality steam to the process

and offering maximum productivity.

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.

172-65443A-01 (CV-COS) 17 Nov 2014

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.

DANGE

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

DANGE

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.

CAUTION

DO NOT use the product in excess of the maximum operating

pressure differential.

Such use could make discharge through the steam trap

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.

Safety considerations continued on next page

172-65443A-01 (CV-COS) 17 Nov 2014

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.

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,

leading to injury or other accidents.

Make sure that wiring work requiring a special license is

carried out by qualified personnel.

If carried out by unqualified personnel, overheating or short circuits

leading to injury, fires, damage or other accidents may occur.

When using this product, NEVER stand close to, or leave

tools anywhere near, moving parts, such as the shaft.

Contact with moving parts or objects becoming caught in moving

parts could lead to injury or damage or other accidents.

172-65443A-01 (CV-COS) 17 Nov 2014

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 product 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.

Model

Nominal Diameter

Maximum Allowable

Pressure*

Maximum Operating

Pressure

Valve No.**

Serial No.

Cv(US) or Kvs(DIN) &

Valve Characteristic

Maximum Allowable

Temperature* (TMA)

Maximum Operating

Temperature (TMO)

* Maximum allowable pressure (PMA) and maximum allowable temperature (TMA) are

PRESSURE SHELL DESIGN CONDITIONS, NOT OPERATING CONDITIONS.

** Valve No. is displayed for products with options. This item is omitted from the nameplate when

there are no options.

*** Nameplate layout depends on product specifications.

Actuator / Pneumatic Positioner

Actuator Area 120 cm2(18.6 in2)

Operation Air-to-Open (Reverse Action)

Air Supply Connection Port Pneumatic positioner body G1/4(with adapter for

G1/4x RC1/4, BSPT1/4or NPT1/4)

Maximum Air Supply Pressure 0.6 MPaG (85 psig)

Motive Medium Oil-free air, filtered to 5 m

Air Consumption At air supply pressure 0.4 MPaG: 0.16 Nm3/h

(55 psig: 5.65 ft3/h)

Electrical Input Signal/Resistance 4 to 20 mA DC / approximately 300

Electrical Connection Port PG11

Protection Class IP54 (dust and splash-proof type)

Allowable Ambient Temperature Range -10 to 60 C (14 to 140 F)

Material Die cast aluminum / synthetic resin

172-65443A-01 (CV-COS) 17 Nov 2014

Air Supply Pressure

Size Pressure Supplied

to Filter Regulator

Air Pressure Supplied to

Positioner

Air Pressure Supplied to

Actuator

(Spring Range)

15–50 mm

(1/2- 2 in)

0.40 – 0.60 MPaG

(55 – 85 psig)

0.38 MPaG

(54 psig)

0.21 – 0.33 MPaG

(30 – 48 psig)

(1 MPa = 10.197 kg/cm2)

Valve

Size mm (in) 15 (1/2) 20 (3/4) 25 (1) 40 (11/2) 50 (2)

Maximum Operating

Pressure (PMO)

Maximum Operating

Temperature (TMO)

See nameplate

Applicable Fluid Steam

Valve Plug & Stem/

Valve Seat Material Stainless steel

Valve Characteristic Equal percentage

Stroke (Travel) 15 mm (9/16 in)

Rangeability 50:1

Cv (US) 3.5 6.0 9.0 27 40

Cv (UK) 2.9 5.0 7.5 23 33

Cv and Kvs

Values Kvs (DIN) 3.0 5.1 7.7 23 34

Valve Leakage Rate

(Leak Rate Class)

Less than 0.01% of the rated Cv and Kvs value

(IEC/ANSI/EN Class IV)

(1 MPa = 10.197 kg/cm2)

Configuration

No. Part Name

1 Actuator Body

2 Pressure Gauge

3 Bushing

4 Specifications Sticker

5 Guide Bushing

6 Valve Bonnet Nut

7 Valve Bonnet

8 Stuffing Box V-Rings

9 Stuffing Box Washer

10 Stuffing Box Spring

11 Valve Plug & Stem

12 Valve Bonnet Gasket

13 Bolt

14 Flange

15 Valve Bonnet Guide

16 Valve Bonnet Guide Gasket

17 Main Body

18 Valve Seat

19 Valve Seat Gasket

20 Separator Screen

21 Separator

22 Wave Spring

23 Trap Body Gasket

24 Guide Pin

25 Bolt

26 Trap Body

27 Float Cover

28 Float

29 Float Cover Bolt

30 Spring Washer

31 Trap Cover Gasket

32 Trap Valve Seat Gasket

33 Trap Valve Seat

34 Bushing

35 Nameplate

36 Trap Cover

37 Trap Cover Bolt

38 Bolt

39 Nut

40 Stem Bracket Connector

Plate Set

172-65443A-01 (CV-COS) 17 Nov 2014

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 (44 lb) or more). Failure to do so may result in back strain or other

if the ob

ect 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 and adjustment and

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

Check to make sure that the piping where the product is to be installed is constructed

properly. If the piping is not correctly constructed, the valve may not perform optimally.

1. Blowdown

Before installing the CV-COS 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 any Protective Caps and Seals

Before installation, be sure to remove all protective seals and caps.

10

15

3. Installation Angle

Install the CV-COS so that the arrow mark on the body

points horizontally in the direction of steam flow, and it

should be installed horizontally in the piping with the

actuator at the top. Allowable inclination is 10 degrees in

the fore-aft direction and 15 degrees in the plane

perpendicular to the steam flow line.

4. Piping

Support

Install the CV-COS, paying attention to avoid excessive

load, bending and vibration. Support the inlet and outlet

pipes securely.

172-65443A-01 (CV-COS) 17 Nov 2014

Leave sufficient space for maintenan n and

repair. (Units: mm)

re and system shutdown.) If the end

must be underwater, make sure the piping has a small hole, as shown in the

drawing below.

hich will not retain condensate, are recommended for inlet and

ff valves. The bypass pipe should be at least 1/2 of the size of the inlet

installation environment to make sure that the ambient temperature does

not exceed the actuator ambient temperature limit and that no corrosive gasses are

extended use will result in a drop in its performance as an isolation valve. Be sure

is needed.

10.

f valve

It must be installed near the equipment it is to protect, on the outlet side of the

shut-off valve.

Maintenance Space

ce, inspectio

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. (Dirt

and water may be sucked up by the vacuum formed

during trap closu

Approx.

300

400

100

01 0

11 0

100 mm ≈4"

110 mm ≈4 /2"

300 mm ≈12"

400 mm ≈16"

Small hole

15 mm

(

in)

Accessories

Always install a shut-off valve, pressure gauge and bypass lines at both inlet and

outlet. Ball valves, w

outlet shut-o

(primary side) pipe.

Installation Environment

Check the

present.

Shut-off Valve Installation

Though the CV-COS adequately performs the function of a shut-off valve initially

to install a separate shut-off or automatic valve if complete isolation

Safety Valve Installation

When installing a safety valve, be sure not to install it between the control valve

and the shut-of

172-65443A-01 (CV-COS) 17 Nov 2014

11.

Do not install in locations in the piping where foreign matter accumulates or where

r pressure (water hammer) occurs.

12. askets

The type of medium being used and the temperature must be taken into account in

a suitable material.

13.

ting the air lines for the motive air that is to be piped to the actuator,

blow out the air in the lines to purge any dirt, foreign matter, oil or water from inside

14. f Motive Air

nction due to contamination of the air supply, installation of the

If air quality results in operation failure, the entire actuator unit (including the

there is a problem in operation, determine the cause using the “Troubleshooting”

section in this manual.

Avoid Foreign Matter and Water Hammer

impact from wate

Piping G

Be careful that the piping gaskets do not protrude outside the inner bore of the

flange.

order to select a gasket of

Air Line Blowdown/Purge

Before connec

of the piping.

Quality o

Supply to the actuator only clean air that does not contain water, oil or foreign

matter.

To prevent malfu

optional air filter regulator (5µ filter) and mist separator (0.3µ filter) as a set is

recommended.

integrated positioner) must be replaced.

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