TLV PN-COSR-16 Bedienungsanleitung

172-65604MA-00 (PN-COSR-16 Pneumatic Control Valve) 10 September 2014

Pneumatic Control Valve for Steam

PN-COSR-16

ISO 9001/ ISO 14001

Manufacturer

Kakogawa, Japan

is approved by LRQA LTD. to ISO 9001/14001

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 2014

Contents

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

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

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

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

Correct Usage of the PN-COSR-16 ................................... 5

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

Installation.......................................................................... 9

Operation ......................................................................... 14

Maintenance..................................................................... 17

Disassembly..................................................................... 18

Reassembly ..................................................................... 22

Troubleshooting ............................................................... 23

Product Warranty............................................................. 25

Introduction

Thank you for purchasing the pneumatic control valve for steam, model PN-

COSR-16.

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 PN-COSR-16 can operate automatically and provide accurate pressure control and

temperature control when combined with the SC-F70 digital indicator controller or

a general-purpose controller. Manual remote setting is possible by combination with an

air regulator.

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.

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 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

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.

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. Safety considerations continued on the next page

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 2014

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.

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 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

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.

Primary Pressure Range

Model

Serial Number

Nominal Diameter

Maximum Operating

Temperature

Valve No.*

Secondary Pressure

Adjustable Range

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

when there are no options.

<Required Utilities> Maximum Pressure 1.6 MPaG (250 psig)

Required Air

Pressure [Desired secondary pressure + 0.1] MPaG

or higher

[Desired secondary pressure + 15] psig

or higher

Air Connecting Port Rc(PT), BSP or NPT 1/4in

Adjustment

Section

(Drive Section)

Motive

Air

Air Quality Oil-free air, filtered to 5 m

(1 MPa = 10.197 kg/cm2)

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

CV (US) 3.8 6.9 11.1 24.0 37.2

CV (UK) 3.2 5.7 9.2 20.0 31.0

Kvs (DIN) 3.3 5.9 9.5 20.6 31.9

Acceptable Operating Range

Model PN-COSR-16

Primary Pressure Range* 0.2 –1.6 MPaG (30 – 250 psig)

Adjustable Pressure Range

(All conditions must be met)

Within 10 –84% of the primary pressure

(Minimum adjustable pressure of 0.03 MPaG (5 psig)

Pressure differntial between 0.07 – 0.85 MPa (10 –120 psi)

Minimum Adjustable Flow Rate 5% of rated flow rate

(1 MPa = 10.197 kg/cm2)

*For process temperature control, the desired process temperature must be controllable by a

secondary pressure within the adjustable pressure range of the PN-COSR-16.

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 2014

Correct Usage of the PN-COSR-16

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 PN-COSR-16 should be operated only within its specifications.

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

PN-COSR

Motorized

Valve

Inlet side

PN-COSR

Motorized

Valve

Inlet side

PN-COSR

Solenoid

Valve

Outlet side

PN-COSR

Solenoid

Valve

Outlet side

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 PN-COSR-16. If a

solenoid valve is installed at the outlet of the PN-COSR-16, 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 PN-

COSR-16 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 PN-COSR-16.

3. Installing a Control Valve

Control

Valve

PN-COSR Safety

Valve

Equipment

PN-COSR

Safety

Valve Control

Valve

Equipment

A control valve installed between the PN-COSR-16 and the steam-using

equipment (downstream of the PN-COSR-16) for controlling equipment

temperature may raise the pressure between the PN-COSR-16 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 PN-COSR-16 between the PN-COSR-16 and a control valve, an

eventual pressure rise could activate the safety valve.

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 2014

4 Precautions for the Installation of Additional Fittings Before or After the PN-COSR-16

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

COSR-16 must be straight runs. If the PN-COSR-16 is installed either directly before o

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 PN-COSR-

16 be installed on straight runs of piping, as illustrated below.

1) Inlet (primary side) of the PN-COSR-16 (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)

PN-COSR

Valve,

strainer,

elbow, etc.

10 d or more

PN-COSR

Valve,

strainer,

elbow, etc.

Less than

10 d

Maintain a straight piping run o

30 d or more when an

motorized valve (on-off valve)

is installed.

(Example: if nominal size is 25

mm (1 in), have 750 mm (30

in) or more)

PN-COSR

Motorized

Valve

30 d or more

PN-COSR

Motorized

Valve

Less than

30 d

Maintain a straight piping run o

30 d or more when a pressur

reducing valve is installed.

(Two-stage pressure

reduction)

(Example: if nominal size is

25 mm (1 in), have 750 mm

(30 in) or more)

PN-COSR

Pressure

Reducing

Valve

30 d or more

PN-COSR

Pressure

Reducing

Valve

Less than

30 d

2) Outlet (secondary side) of the PN-COSR-16

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)

PN-COSR Valve,

strainer,

elbow, etc.

15 d or more

PN-COSR Valve,

strainer,

elbow, etc.

Less than

15 d

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)

PN-COSR Safety

Valve

30 d or more

PN-COSR Safety

Valve

Less than

30 d

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)

PN-COSR

30 d or more

Control or

Automated

Valve

PN-COSR

Less than

30 d

Control or

Automated

Valve

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 2014

Configuration

15 – 25 mm (1/2– 1 in) No. Name

1Main Body

2Cover Plug

3Cover Plug Gasket

4Main Valve Seat

5Main Valve Seat Gasket

6Main Valve

7Main Valve Holder

8Main Valve Spring

9Sleeve

10 Cylinder

11 Piston

12 Piston Ring

13 Tension Ring

14 Cylinder Gasket

15 Piston Guide

16 Connecting Tube

17 Gasket (Pilot Body/

Main Body)

18 Pilot Screen Holder

19 PilotScreen HolderGasket

20 Pilot Screen

21 Pilot Valve

22 Pilot Valve Seat

23 Pilot Body

24 Hex Bolt (Pilot

Body/Main Body)

25 Pilot Valve Spring

26 Pilot Valve Seat Gasket

27 Diaphragm

28 Diaphragm Gasket

29 Spring Housing

30 Diaphragm Support

31 Hex Bolt (Spring

Housing/Pilot Body)

32 Coil Spring

33 Spring Retainer

34 Steel Ball

35 Gland Packing

36 O-ring

37 Spanner Cap

38 Adjustment Screw

39 Packing Retainer

40 C-ring

41 Nameplate

10 mm (3/8in)

8 mm (1/4in)

Motive Air Port

42 Plug – Sensing line Port*

*North American model does not equip this plug.

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 2014

40, 50 mm (11/2, 2 in) No. Name

1 Main Body

2 Cover

3 Cover Gasket

4 Main Valve Seat

5 Main Valve Seat Gasket

6 Main Valve

7 Main Valve Holder

8 Main Valve Spring

9 Sleeve

10 Cylinder

11 Piston

12 Piston Ring

13 Tension Ring

14 Cylinder Gasket

15 Piston Guide

16 Connecting Tube

17 Gasket

(Pilot Body/Main Body)

18 Pilot Screen Holder

19 Pilot Screen Holder Gasket

20 Pilot Screen

21 Pilot Valve

22 Pilot Valve Seat

23 Pilot Body

24 Hex Bolt (Pilot

Body/Main Body)

25 Pilot Valve Spring

26 Pilot Valve Seat Gasket

27 Diaphragm

28 Diaphragm Gasket

29 Spring Housing

30 Diaphragm Support

31 Hex Bolt (Spring

Housing/Pilot Body)

32 Coil Spring

33 Spring Retainer

34 Steel Ball

35 Gland Packing

36 O-ring

37 Spanner Cap

38 Adjustment Screw

39 Packing Retainer

40 C-ring

41 Nameplate

42 Plug – Sensing line

Port*

8 mm (

in)

Motive Air Port

10 mm (

in)

43 Cover Bolt

*North American model does not equip this plug.

172-65604MA-00 (PN-COSR Pneumatic Control Valve) 10 Sep 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

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.

Installation Environment

Avoid installation in the following types of environments:

Locations with ambient temperatures above 50 °C (122 °F) or below 0 °C (32 °F)*

Locations with ambient humidity above 90% RH and below 10% RH

Locations where corrosive gas is generated

Locations with heavy vibration or shock

Locations with high inductive interference or other factors that would have a

harmful effect on electrical circuitry*

*When the PN-COSR-16 is used with electrical equipment such as an electro-

pneumatic transducer, controller, etc.

1. Blowdown

Before installing the PN-COSR-16 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.

PN-COSR

Open

Closed Closed

Blowdown with the Bypass Valve

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.)

①②

3. Installation Angle

Install the PN-COSR-16 vertically, so that the

arrow mark on the body points horizontally in the

direction of steam flow.

Allowable inclination is 10 degrees in the fore-aft

direction and 15 degrees in the plane

perpendicular to the steam flow line.

10

1515

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