TLV COSR-3 Instruction Manual
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TLV COSR-3 Instruction Manual

Pressure reducing valve for steam
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172-65174MA-11 (COSR Pressure Reducing Valve)
16 February 2022
Pressure Reducing Valve for Steam
COSR-3/COSR-16/COSR-21
Copyright © 2022 by TLV CO., LTD.
All rights reserved

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Summary of Contents for TLV COSR-3

  • Page 1 172-65174MA-11 (COSR Pressure Reducing Valve) 16 February 2022 Pressure Reducing Valve for Steam COSR-3/COSR-16/COSR-21 Copyright © 2022 by TLV CO., LTD. All rights reserved...

  • Page 2: Table Of Contents

    TLV EXPRESS LIMITED WARRANTY ......26 Service ................28 Introduction Thank you for purchasing the TLV COSR pressure reducing valve for steam. 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.

  • 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 Be sure to use only the recommended components when CAUTION 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.

  • Page 5: Specifications

    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 COSR-3 COSR-16 COSR-21 0.1 to 0.3 MPaG 0.2 to 1.6 MPaG 1.35 to 2.1 MPaG...

  • Page 6: Correct Usage Of The Cosr Pressure Reducing Valve

    Correct Usage of the COSR Pressure Reducing 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.
  • Page 7 Precautions for the Installation of Additional Fittings Before or After the Reducing Valve In order to ensure stable steam flow, the piping upstream and downstream of the COSR must be straight runs. If a COSR is installed either directly before or after an elbow or control valve, unevenness in steam flow may result in chattering and unstable pressure.

  • Page 8: Configuration

    Configuration 1 in)) COSR-3/COSR-6 (15 to 25 mm 172-65174MA-11 (COSR Pressure Reducing Valve) 16 Feb 2022...
  • Page 9 B = Repair Kit for Main Valve C = Repair Kit for Piston D = Repair Kit for Piston Rings E = Repair Kit for Pilot Valve **Size 15 mm for COSR-3 is not available 172-65174MA-11 (COSR Pressure Reducing Valve) 16 Feb 2022...
  • Page 10 B = Repair Kit for Main Valve C = Repair Kit for Piston D = Repair Kit for Piston Rings E = Repair Kit for Pilot Valve Contact TLV for COSR-21 replacement parts. 172-65174MA-11 (COSR Pressure Reducing Valve) 16 Feb 2022...
  • Page 11 B = Repair Kit for Main Valve C = Repair Kit for Piston D = Repair Kit for Piston Rings E = Repair Kit for Pilot Valve Contact TLV for COSR-21 replacement parts. 172-65174MA-11 (COSR Pressure Reducing Valve) 16 Feb 2022...

  • Page 12: 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 13 Spacer Installation Correct If spacing adjustment is necessary spacer to accommodate installation, install location a spacer on the outlet flange. The spacer should consist of a spacer, gaskets, bolts and nuts. Fit gaskets Incorrect spacer to both sides of the spacer between location the COSR outlet and the pipe flange.
  • Page 14 5. Piping Support Install the COSR, paying attention to avoid excessive load, bending and vibration. Support the inlet and outlet pipes securely. 6. Maintenance Space 100 (4) Leave sufficient space for maintenance, Approx. inspection and repair. (12) 100 (4) (Unit: mm (in)) (16) (16) 7.
  • Page 15 Two-stage Pressure Reduction Two-stage pressure reduction should be performed whenever the pressure cannot be reduced to the desired level with a COSR due to operating range limitations, such as when the reduction ratio is greater than 10:1. Bypass Pressure Bypass Valve Reducing Valve...
  • Page 16 External Secondary Pressure Sensing Line For proper use of COSR with the external secondary pressure sensing line, follow the installation procedure below. Loosen and remove the bolts (nuts) that attach the pilot body to the main body or the pilot valve cover (65 to 150 mm (2 to 6 in)) and remove the pilot body.

  • Page 17: Adjustment

    Adjustment The COSR reducing valve should be properly adjusted for protection of the steam- using equipment against water hammer. 1. It is necessary to blow down all pipe lines thoroughly. The blowdown is especially important if the line is new or has been shut down for a long period of time. Take particular care to ensure that matter such as condensate and dirt does not remain inside the steam-using equipment.

  • Page 18: Maintenance

    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 19: Disassembly

    Disassembly Use hoisting equipment for heavy objects (weighing approximately 20 kg or more). Failure to do so may result in back strain or other injury if CAUTION the object should fall. 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 20 Disassembling the Pilot Section The diaphragm is removed by utilizing the notch in the pilot body. Loosen the pilot valve seat with a box wrench and remove it. Lift the pilot valve spring up and out with a pair of tweezers.
  • Page 21 Disassembling the Piston Section Remove the pilot body after loosening and removing the bolts (stud bolts). During this process, pay attention not to lose the connecting tubes (2). Remove the piston, cylinder and the silencer (for 65 to 150 mm (2 to 6 in) only) from the main body.
  • Page 22 Main Valve Holder Sleeve (fixed) Cover Plug Main Body Cover Plug Gasket Main Valve Spring COSR-3/16: 32 to 50 mm (1 to 2 in) COSR-21: 15 to 50 mm ( to 2 in) Main Valve Seat Gasket Main Valve Seat Main Valve...
  • Page 23 Cleaning After inspection and removal of any abnormality, clean and reassemble the parts. The following parts will require cleaning before reassembly: Cover Plug / Cover Main Valve Cylinder Pilot Screen Main Valve Holder Pilot Valve Main Valve Seat Piston Pilot Valve Seat Piston Ring Adjustment Screw It is permissible to clean using water, however cleaning with a mild detergent is...

  • Page 24: Reassembly

    (185) (220) Bolts (Main Valve Seat) 65, 80 , 3) (22) (4 – 5) 100, 125 16/17* (29) (51) Cover Plug COSR-3/16: 15, 20 (185) (260) 15 – 25 – 1) Cover Bolt COSR-21: 16/17* (44) 32, 40 16/17* (44) 50 –...

  • Page 25: Troubleshooting

    Troubleshooting 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. Disassembling or removing the product when it is hot or under pressure may lead to discharge of fluids, causing burns, other injuries or damage.
  • Page 26 NOTE: When replacing parts with new for the COSR-3 and COSR-16, use the parts list for reference, and replace with parts from the kits shown there. Please note that replacement parts for the COSR-3 and COSR-16 are only available as part of a replacement parts kit.

  • Page 27: Tlv Express Limited Warranty

    Subject to the limitations set forth below, TLV CO., LTD., a Japanese corporation (“TLV”), warrants that products which are sold by it, TLV International Inc. (“TII”) or one of its group companies excluding TLV Corporation (a corporation of the United States of America), (hereinafter the “Products”) are designed and manufactured by TLV, conform to the...
  • Page 28 WARRANTY NOT NEGATED HEREBY, AND ANY IMPLIED WARRANTY NOT NEGATED HEREBY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, DO NOT COVER, AND NEITHER TLV, TII NOR ITS TLV GROUP COMPANIES WILL IN ANY EVENT BE LIABLE FOR, INCIDENTAL OR...

  • Page 29: Service

    Service For Service or Technical Assistance: Contact your TLV representative or your regional TLV office. In Europe: Tel: [49]-(0)7263-9150-0 Daimler-Benz-Straße 16-18, 74915 Waibstadt, Germany Fax: [49]-(0)7263-9150-50 Tel: [44]-(0)1242-227223 Units 7 & 8, Furlong Business Park, Bishops Cleeve, Gloucestershire GL52 8TW, U.K.

This manual is also suitable for:

Cosr-16Cosr-21

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