TLV CV-COSR Bedienungsanleitung

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 June 2019

Pneumatic Control Valve

CV-COSR

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

Contents

Introduction ........................................................................ 2

Safety Considerations........................................................ 3

Specifications..................................................................... 5

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

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

Electrical Wiring ................................................................11

Operational Check ........................................................... 12

Maintenance..................................................................... 14

Disassembly/Reassembly................................................ 15

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

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

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

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

Introduction

Thank you for purchasing the TLV pneumatic control valve.

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.

This product employs an integrated positioner/diaphragm-type actuator with

no lever, making it very compact. In addition, a threaded condensate drainage

port is provided at the bottom of the body to allow installation of a blow valve

or steam/air trap in order to eliminate condensate flowing in the piping,

contributing to prevention of valve seat erosion and rapid start-up of the

equipment.

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.

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

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

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.

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.

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 next page

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

CAUTION

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.

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

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

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

Maximum Allowable

Temperature (TMA)*

Maximum Operating

Temperature (TMO)

Valve No.**

Production Lot No.

Cv(US) or Kvs(DIN) & Valve Characteristic

* 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

G1/4× RC1/4, BSPT1/4or NPT1/4)

Maximum Air Supply Pressure

0.6 MPaG (85 psig)

Motive Medium

Oil-free air, filtered to 5 µm

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 Ω

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

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)

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

Valve

Size mm (in)

15 (1/2)

20 (3/4)

25 (1)

40 (11/2)

50 (2)

Maximum Operating

Pressure (PMO)

See nameplate

Maximum Operating

Temperature (TMO)

See nameplate

Applicable Fluid*

Steam, Water, Air

Valve Plug & Stem/

Valve Seat Material

Stainless steel

Valve Characteristic

Equal percentage

Stroke (Travel)

15 mm (9/16 in)

Rangeability

50:1

Cv and Kvs

Values

Cv (US)

3.5

6.0

9.0

Cv (UK)

2.9

5.0

7.5

Kvs (DIN)

3.0

5.1

7.7

Valve Leakage Rate

(Leak Rate Class)

Less than 0.01% of the rated Cv and Kvs value

(IEC/ANSI/EN Class IV)

Condensate Drainage

Port

Rc(PT)1/2, BSPT1/2or NPT1/2

(1 MPa = 10.197 kg/cm2)

*Do not use for toxic, flammable or otherwise hazardous fluids.

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

Configuration

Size: 15 –25 mm

No.

Part Name

Actuator Body

Pressure Gauge

Bushing

Specifications Sticker

Guide Bushing

Valve Bonnet Nut

Valve Bonnet

Stuffing Box V-rings



Stuffing Box Washer



Stuffing Box Spring



Valve Plug & Stem



Valve Bonnet Gasket



Bolt

Flange

Valve Bonnet Guide

Valve Bonnet Guide Gasket



Body

Valve Seat



Valve Seat Gasket



Cover Plug

Cover Plug Gasket



Nameplate

Gasket

Bolt

Nut

Stem Bracket Connector Plate Set

Drain Plug

Size: 40, 50 mm

No.

Part Name

Actuator Body

Pressure Gauge

Bushing

Specifications Sticker

Guide Bushing

Valve Bonnet Nut

Valve Bonnet

Stuffing Box V-rings



Stuffing Box Washer



Stuffing Box Spring



Valve Plug & Stem



Valve Bonnet Gasket



Bolt

Flange

Valve Bonnet Guide

Valve Bonnet Guide Gasket



Body

Valve Seat



Valve Seat Gasket



Cover

Cover Gasket



Nameplate

Gasket

Bolt

Nut

Stem Bracket Connector Plate Set

Cover Bolt

Drain Plug

*Replacement parts are available only in the following kits:

M = Maintenance Kit R = Repair Kit

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

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

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 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-COSR 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.

(Found in 2 locations, on the product inlet and outlet.)

3. Installation Orientation

Install the CV-COSR so that the arrow mark on

the body points in the direction of fluid flow.

If the CV-COSR is going to be used with the drain

plug in place, there are no further restrictions on

the installation orientation. If a blow valve or a

steam/air trap is going to be installed, the CV-

COSR should be installed horizontally in the

piping with the actuator at the top.

4. Piping Support

Install the CV-COSR, paying attention to avoid excessive

load, bending and vibration. Support the inlet and outlet

pipes securely.

① ②

172-65587MA-02 (CV-COSR Pneumatic Control Valve) 3 Jun 2019

5. Maintenance Space

Leave sufficient space for maintenance, inspection

and repair.

6. Drainage Port Usage Example

The threaded condensate drainage port at the

bottom of the body makes possible installation of

a blow valve or steam/air trap. Because the

condensate drainage port is located on the

primary side of the CV-COSR, condensate

flowing in the primary side piping can quickly be

eliminated, contributing to prevention of valve

seat erosion and rapid start-up of the equipment.

7. Accessories

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

outlet. Ball valves, which will not retain condensate, are recommended for inlet

and outlet shut-off valves. The bypass pipe should be at least 1/2of the size of the

inlet (primary side) pipe.

8. Installation Environment

Check the installation environment to make sure that the ambient temperature

does not exceed the actuator ambient temperature limit and that no corrosive

gasses are present.

9. Shut-off Valve Installation

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

initially, extended use will result in a drop in its performance as an isolation valve.

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

needed.

10. Safety Valve Installation

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

and the shut-off valve. It must be installed near the equipment it is to protect,

on the outlet side of the shut-off valve.

Safety Valve

Drainage Pit

Approx.

300 mm

(12 in)

100 mm

(4 in)

100 mm

(4 in)

110 mm

(41/2in)

100 mm

(4 in)

400 mm

(16 in)

400 mm

(16 in)

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