TLV PN-DR Bedienungsanleitung

172-65119MA-01 (PN-DR) 13 June 2013

Pneumatic Direct-acting Pressure Reducing Valve

for Steam and Air

PN-DR

Manufacturer

ISO9001/ISO14001

Kakogawa, Japan

is approved by LRQA LTD. to ISO 9001/14001

Contents

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

172-65119MA-01 (PN-DR) 13 Jun 2013

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

Specifications ....................................................................

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

Correct Usage of the PN-DR Direct-acting Pressure Reducing Valve

Configuration.....................................................................

Installation .........................................................................

Adjustment ......................................................................

Maintenance....................................................................

Disassembly....................................................................

Reassembly ....................................................................

Troubleshooting ..............................................................

Product Warranty ............................................................

Introduction

Thank you for purchasing the PN-DR Pneumatic Direct-acting Pressure

Reducing Valve for Steam and 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.

The PN-DR pneumatic direct-acting pressure reducing valve provides a

more stable secondary pressure than conventional direct-acting reducing

valves. The PN-DR is designed for a long service life, and is made of stainless

steel for superior durability.

For products with special order specifications or options, if detailed

instructions for the special order specifications or options are not contained in

this manual, please contact for full details.

This instruction manual is intended for use with the model(s) listed on the front

cover. It is necessary not only for installation but for subsequent maintenance,

disassembly/reassembly and troubleshooting. Please keep it in a safe place

for future reference.

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.

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.

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.

Safety considerations continued on next page.

172-65119MA-01 (PN-DR) 13 Jun 2013

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.

CAUTION

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.

172-65119MA-01 (PN-DR) 13 Jun 2013

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.

Serial Numbe

Valve No.*

Nominal

Diameter

Model

Maximum Operating

Temperature

Primary Pressure

Range

Secondary Pressure

Adjustable Range

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

when there are no options.

Acceptable Operating Range

Model PN-DR-2 PN-DR-6

Primary Pressure Range 0.2 - 1.6 MPaG (30 – 230 psig)

0.014 – 0.2 MPaG

(2 – 30 psig)

(but limited to 1/30 of

primary pressure)

0.18 - 0.6 MPaG

(27 – 85 psig)

Adjustable Pressure Range

Secondary pressure must not exceed

90% of primary pressure

Maximum Operating Temperature 220 °C (428 °F)

Motive Air Pressure 0 - 1.0 MPaG (0 – 150 psig)

(Oil free air, filtered to 5 µm)

172-65119MA-01 (PN-DR) 13 Jun 2013

Correct Usage of the PN-DR Direct-acting 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 PN-DR should be operated only within its specifications.

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

Motorized

Valve

Inlet Side

Pressure

Reducing

Valve

Outlet Side

Solenoid

Valve

Pressure

Reducing

Valve

If an on-off valve is required to stop supply of steam or air to the equipment, install

it at the inlet side of the PN-DR.

If a solenoid valve is installed at the outlet of the PN-DR, it will cause heavy

chattering and may lead to damage of the PN-DR. (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 30:1 where

adjustment is impossible, chattering occurs momentarily.) To save energy, install

the on-off valve as near to the boiler, or compressor, as possible.

NOTE: To prevent water hammer, it is recommended that a slow-acting motorized

on-off valve be used. If a fast-acting solenoid valve is used, the potential water

hammer effect can damage the equipment and the pressure reducing valve.

3. Installing a Control and/or Safety Valve

Safety

Valve

Steam or Air-using

Equipment

Control

Valve

Pressure

Reducing

Valve

Safety

Valve

Steam or Air-using

Equipment

Control

Valve

Pressure

Reducing

Valve

Safety

Valve

Control

Valve

Steam or Air-using

Equipment

Pressure

Reducing

Valve

Safety

Valve

Control

Valve

Steam or Air-using

Equipment

Pressure

Reducing

Valve

A control valve (i.e. for temperature control) installed between the PN-DR and the

equipment (downstream of the reducing valve) may raise the pressure between

the PN-DR and the control valve when the control valve is closed, depending on

the spatial relationship. Therefore, this valve should be installed close to the

equipment, as illustrated. Also, a safety valve should be installed downstream of

the control valve.

NOTE: When installing a safety valve to protect steam or air equipment, be sure

to install it on, or directly before the inlet, of the equipment. If the safety valve is

installed between the PN-DR and a control valve, an eventual pressure rise could

activate the safety valve.

172-65119MA-01 (PN-DR) 13 Jun 2013

4. Precautions for the Installation of Additional Fittings Before or After the PN-DR

In order to ensure a stable flow of air or steam, 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 flow may result in chattering and unstable pressure.

To ensure a stable flow, it is recommended that the pressure reducing valve be

installed on straight runs of piping, as illustrated below.

172-65119MA-01 (PN-DR) 13 Jun 2013

Inlet (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 (1 in), have 250 mm (10 in)

or more)

Pressure

Reducing

Valve

10 d or more

Valve, strainer,

elbow, etc.

Pressure

Reducing

Valve

10 d or more

Valve, strainer,

elbow, etc.

Pressure

Reducing

Valve

Less than

10 d

Valve, strainer,

elbow, etc.

Pressure

Reducing

Valve

Less than

10 d

Valve, strainer,

elbow, etc.

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)

Automatic

Valve

Pressure

Reducing

Valve

30 d or more

Automatic

Valve

Pressure

Reducing

Valve

30 d or more

Automatic

Valve

Pressure

Reducing

Valve

Less than

30 d

Automatic

Valve

Pressure

Reducing

Valve

Less than

30 d

Outlet (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 (1 in), have 375 mm (15 in)

or more)

Pressure

Reducing

Valve Valve, strainer,

elbow, etc.

15 d or more

Pressure

Reducing

Valve Valve, strainer,

elbow, etc.

15 d or more

Pressure

Reducing

Valve Valve, strainer,

elbow, etc.

Less than

15 d

Pressure

Reducing

Valve 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)

Pressure

Reducing

Valve

Safety Valve

30 d or more

Pressure

Reducing

Valve

Safety Valve

30 d or more

Less than

30 d

Pressure

Reducing

Valve

Safety Valve

Less than

30 d

Pressure

Reducing

Valve

Safety Valve

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)

Pressure

Reducing

Valve

Pressure

Reducing

Valve

30 d or more

Pressure

Reducing

Valve

Pressure

Reducing

Valve

30 d or more

Pressure

Reducing

Valve

Pressure

Reducing

Valve

Less than

30 d

Pressure

Reducing

Valve

Pressure

Reducing

Valve

Less than

30 d

–

Configuration

No. Name A*1B*1C*1D*1E*1

1 Body

2 Cover

3 Screen 

4 Coil Spring 

5 Main Valve 

6 Valve Seat

Gasket



7 Valve Seat 

8 Spacer*3

9 Snap Ring

10 Valve Stem 

11 Bellows 

12 Cover Gasket*2

13 Coil Spring

14 Spring Guide

15 Steel Ball

16 Cover Bolt

17 Holder Nut

18 Adjustment

Handle



19 Nameplate

20 Retaining Ring 

21 Retainer 

22 Seal Ring 

23 Packing 

24 Slide Bearing*2*3

25 Snap Ring*2*3

*1Replacement parts are available

only in the following kits:

A: Maintenance Kit

B: Repair Kit for Spacer

C: Repair Kit for Main Valve,

D: Repair Kit for Bellows

E: Repair Kit for Adjustment Handle

*2Number of parts: 2 pieces

*3Shipped as a unit

172-65119MA-01 (PN-DR) 13 Jun 2013

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

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

Open

Closed Closed

Pressure

Reducing

Valve

Blowdown using a bypass line

Before installing the PN-DR

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 the Protective Caps

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

(Found in 3 locations; on the product inlet and outlet, motive air

connecting port.)





3. Tolerance Angle for Installation

10°

15°15°

Make sure the PN-DR is installed on horizontal piping

with the adjustment handle facing up.

Ensure the raised TLV lettering on the body is

horizontal and the arrow is pointing in the direction of

flow. The allowable inclination of the PN-DR is 10°

front-to-back and 15°horizontally.

4. Piping Support

Pay attention to avoid excessive load, bending and

vibration. Supporting the inlet and outlet pipes

securely is recommended.

172-65119MA-01 (PN-DR) 13 Jun 2013

5. Maintenance Space

200 (8)

200 (8) 200 (8)

Leave sufficient space for maintenance, inspection

and repair.

Unit: mm (in)

6. Piping Size

Straight piping: 10 d or longer upstream,

15 d or longer downstream

Diffuser

Pressure

Reducing

Valve

Straight piping: 10 d or longer upstream,

15 d or longer downstream

Diffuser

Pressure

Reducing

Valve

Pressure

Reducing

Valve

Pressure

Reducing

Valve

Pressure

Reducing

Valve

If it is expected that the

secondary flow velocity will

be more than 30m/s (100

ft/s), install a diffuser in

order to keep the flow

velocity below 30m/s(100

ft/s). If the distance

between the reducing valve

and the equipment is great,

a possible drop in pressure

should be taken into

consideration when

selecting the piping size.

If installing a strainer,

horizontal installation is

recommended in order to

prevent pooling of

condensate.

7. Two-stage Pressure Reduction

Pressure

Gauge

Bypass Valve

Inlet

Valve Outlet

Valve

Safety Valve

(Relief Valve)

Primary

Side

Pressure

Reducing

Valve

Bypass Valve

Secondary

Side

Inlet

Valve Outlet

Valve

Pressure

Reducing

Valve

Pressure

Gauge

Pressure

Gauge

Bypass Valve

Inlet

Valve Outlet

Valve

Safety Valve

(Relief Valve)

Primary

Side

Pressure

Reducing

Valve

Bypass Valve

Secondary

Side

Inlet

Valve Outlet

Valve

Pressure

Reducing

Valve

Pressure

Gauge

Pressure

Gauge

Inlet

Valve Outlet

Valve

Safety Valve

(Relief Valve)

Primary

Side

Pressure

Reducing

Valve

Bypass Valve

Secondary

Side

Pressure

Gauge

Pressure

Gauge

Inlet

Valve Outlet

Valve

Safety Valve

(Relief Valve)

Primary

Side

Pressure

Reducing

Valve

Bypass Valve

Secondary

Side

Pressure

Gauge

Employ 2-stage pressure

reduction if the required

reduction is not possible due to

PN-DR operating range

limitations

(when it is not possible to reduce

to the desired pressure using a

single pressure reducing valve).

Inlet

Valve Outlet

Valve

172-65119MA-01 (PN-DR) 13 Jun 2013

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