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Summary of Contents for TLV COSPECT MC-COS-3
- Page 1 172-65169MA-08 (MC-COS Multi-control Valve) 28 May 2010 ISO 9001/ ISO 14001 Manufacturer Kakogawa, Japan is approved by LRQA LTD. to ISO 9001/14001 High-precision Multi-control Valve for Steam COSPECT MC-COS-3/MC-COS-16 Actuator: MC-GA2 Copyright © 2010 by TLV CO., LTD. All rights reserved...
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Page 2: Table Of Contents
Contents Introduction ................ 1 Safety Considerations ............2 Specifications ..............4 Correct Usage of the MC-COS Multi-control Valve .... 6 Configuration..............8 Installation ................ 10 Wiring Instructions............17 Setting the Valve Coefficient ..........19 Operation ................. 20 Inspection and Maintenance ..........22 Disassembly.............. -
Page 3: Safety Considerations
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. - Page 4 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.
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Page 5: Specifications
Specifications Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges. CAUTION 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. - Page 6 CV Value (mm) Size (in) (US) 11.1 15.5 24.0 37.2 59.3 85.0 (UK) 12.9 20.0 31.0 49.4 70.8 (DIN) 13.3 20.6 31.9 50.8 72.9 Acceptable Operating Range Model MC-COS-3 MC-COS-16 Primary Pressure 0.1 – 0.3 MPaG 0.2 – 1.6 MPaG Range (15 –...
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Page 7: Correct Usage Of The Mc-Cos Multi-Control Valve
Correct Usage of the MC-COS Multi-control Valve Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges. CAUTION 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. - Page 8 4. Recommended Straight Pipe Runs In order to ensure stable steam flow, the piping upstream and downstream of the multi-control valve must be straight runs. If a multi-control valve is installed either directly before or after an elbow or control valve, unevenness in steam flow may result in chattering and unstable pressure.
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Page 9: Configuration
Configuration 15 – 50 mm ( – 2 in) 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 Main Valve Holder 12 Piston 13 Cylinder... - Page 10 65 – 100 mm (2 – 4 in) 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 Main Valve Holder 12 Piston 13 Cylinder...
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Page 11: Installation
Installation Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges. CAUTION 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. - Page 12 4. Spacer Installation If spacing adjustment is necessary to accommodate Correct Incorrect installation, install a spacer Spacer Spacer on the outlet flange. The Location Location spacer should consist of a spacer, gaskets, bolts and nuts. Fit gaskets to both sides of the spacer between the MC-COS outlet and the pipe flange.
- Page 13 8. Pressure Sensor Installation (for pressure control) The length of piping Pressure between the MC-COS and Sensor pressure sensor should be no more than 5 m (17 ft). If the piping distance is too straight straight great, pressure loss and pipe pipe delay of pressure change...
- Page 14 11. Two-stage Pressure Reduction Install a pressure reducing valve at the inlet side of MC-COS whenever the pressure cannot be reduced to the desired level with a single multi-control valve due to operating range limitations, such as when the reduction ratio is greater than 10:1.
- Page 15 13. External secondary pressure-sensing line (when required) North American Models are factory prepared for external sensing. An external sensing line MUST be installed. DO NOT SUPPLY STEAM until all piping and a 10 mm ( in) secondary pressure sensing line with a slightly falling pitch have been properly installed. Install a shutoff valve in the pressure sensing line for maintenance purposes.
- Page 16 15 – 50 mm ( 65 – 100 mm (2 – 2 in) – 4 in) Pilot Valve Body Plug (Rc(PT) ⅜ or NPT ⅜) Pilot Body Hex Bolt Secondary Pressure Pilot Cover Detection Port Connector Main Body Replace the factory-installed connector with the blind pin Blind Connector...
- Page 17 All models except North American models are factory prepared for internal sensing. When internal pressure sensing is required for North American models, please contact the nearest TLV representative to request both a connector, which must be installed in place of the blind pin, and a threaded secondary pressure sensing plug.* Follow the connector installation procedure shown below:...
- Page 18 Wiring Wiring Notes Background electromagnetic noise that has no effect on analog equipment may cause digital equipment to malfunction or fail. To prevent adverse effects from electro-magnetic (EM) interference, carefully follow the wiring instructions below: 1. Power Source 1) If there is EM noise from the power source, a filter should be used. To prevent interference, do not bundle the EM filter's power source input and output lines together.
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Page 19: Wiring Instructions
Wiring Instructions Make sure the power supply switch is OFF before carrying out work on CAUTION 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. -
Page 20: Setting The Valve Coefficient
There are five different valve coefficients; labeled A through E. Valve coefficients are derived by TLV for each valve through tests before shipment from the factory. They are stamped on the valve coefficient nameplate label attached to the valve and a removable label to be utilized for putting the valve coefficients into the controller. -
Page 21: Operation
Operation When using this product, NEVER stand close to, or leave tools anywhere CAUTION near moving parts, such as the ajustment screw. Contact with moving parts or objects becoming caught in moving parts could lead to injury or damage or other accidents. Procedure 1. - Page 22 In the Event of a Power Outage Make sure the power supply switch is OFF before carrying out work on CAUTION 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.
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Page 23: Inspection And Maintenance
Inspection and Maintenance 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 CAUTION the discharge of fluids. Be sure to use only the recommended components when repairing the product, and NEVER attempt to modify the product in any way. -
Page 24: Disassembly
A slight torque is necessary since Retainer the motor has a rotational load. If the adjustment screw Bearing does not rotate smoothly, contact TLV immediately. Coil Note: Do not remove the drive section cover. The Spring... - Page 25 Disassembling the Pilot Section The diaphragm is removed by utilizing the notch in the pilot body. Loosen and remove the pilot valve seat with a box wrench. Pick up the pilot valve and the pilot valve spring with a pair of tweezers. Loosen and remove the pilot screen holder to remove the pilot screen.
- Page 26 Disassembling the Piston Section Remove the pilot body after loosening and removing the bolts. During this process, pay attention not to lose the two connectors. Remove the piston and the cylinder from the main body. Then remove the piston ring and the tension ring from the piston.
- Page 27 Disassembling the Separator and Main Valve Sections Turn the MC-COS upside down for easy dismantling of the separator and main valve. Loosen the bolts and remove the trap body. Be careful, as the separator may drop off when the MC-COS is returned to the normal attitude. Removal of the separator and pressed-in sleeve permits removal of the main valve spring, the main valve, the main valve holder and the separator screen.
- Page 28 Disassembling the Steam Trap Loosen the bolts and remove the trap cover. Be careful, as hot condensate may splash out. Remove the bolts from the trap cover and the float cover to reveal the float. Remove the float, then loosen the trap valve seat with a box wrench and remove it. Check to verify that there is no deformation of the float, abnormality in the trap valve seat or dirt accumulation in the trap cover.
- Page 29 Exploded View Drive Section Adjustment Section Pilot Section Piston Section Separator / Main Valve Section Steam Trap Section NOTE: The shape of individual parts may vary depending on the model size. 172-65169MA-08 (MC-COS Multi-control Valve) 28 May 2010...
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Page 30: Reassembly
Reassembly Assemble the unit using the same procedure as used for disassembling it; but in reverse order. Observe the following precautions: 1. The PTFE gaskets may be re-used if free from fault, crushing or deformation. 2. Apply anti-seize to the threaded portion of screws and bolts and adjustment screw. Apply a small amount of anti-seize to the threads of the main valve seat, pilot valve seat and pilot screen holder. -
Page 31: Troubleshooting
Troubleshooting NEVER apply direct heat to the float. The float may explode due to increased internal pressure, causing accidents leading to serious injury WARNING or damage to property and equipment. When disassembling or removing the product, wait until the internal pressure equals atmospheric pressure and the surface of the product CAUTION has cooled to room temperature. - Page 32 10 – N m (7 lbf ft) torque to do so, contact a Pressure Decreases TLV serviceperson. 10. Check to make sure that the secondary steam pressure increases when, as seen Clockwise from above, the adjustment screw has –...
- Page 33 Pressure Reducing Valve Troubleshooting Problems are classified as follows: 1. The secondary pressure does not increase. 2. The secondary pressure cannot be adjusted or increases abnormally. 3. Hunting occurs (fluctuation of the secondary pressure). 4. Chattering occurs (a heavy mechanical noise). 5.
- Page 34 Troubleshooting Chart (continued) Problem Symptom Cause Remedy Secondary Upon closing The bypass valve is leaking Check; clean; replace pressure secondary side with a new valve if cannot be valves, secondary necessary adjusted or pressure abruptly The pilot valve seat or main Replace damaged parts increases rises as high as...
- Page 35 Drive Section Troubleshooting The drive section has a built-in microcomputer with a self-diagnosis function for malfunctions of the drive section. Identify the cause of the trouble with the following procedures. Turn OFF the power supply to the drive section. Remove the motor cover (blue housing) of the drive section. Confirm the position of the 4 LEDs (LE1 –...
- Page 36 (0 to 50 °C (32 – 122 F°). ○○●● Motor is overloaded Motor shuts down, then Motor is abnormally keeps rebooting after a overloaded. Contact TLV. few seconds. ○●○● Continuous operation Low motor load Possibility of abnormal wear (reducer gear wear, of the gear in the reducer.
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Page 37: Product Warranty
One year following product delivery. 2. Warranty Coverage TLV CO., LTD. warrants this product to the original purchaser to be free from defective materials and workmanship. Under this warranty, the product will be repaired or replaced at our option, without charge for parts or labor.
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