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TLV COS-3 Instruction Manual

Pressure reducing valve for steam
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172-65175MA-13 (COS Pressure Reducing Valve)
16 February 2022
Pressure Reducing Valve for Steam
COS-3/COS-16/COS-21
Copyright © 2022 by TLV CO., LTD.
All rights reserved

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Summary of Contents for TLV COS-3

  • Page 1 172-65175MA-13 (COS Pressure Reducing Valve) 16 February 2022 Pressure Reducing Valve for Steam COS-3/COS-16/COS-21 Copyright © 2022 by TLV CO., LTD. All rights reserved...

  • Page 2: Table Of Contents

    Also be sure to read this manual carefully before use and follow the instructions to be sure of using the product properly. The TLV pressure reducing valve for steam, model COS, is a new reducing valve that eliminates these problems and makes possible the supply of very dry steam at a constant pressure.

  • 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 When disassembling or removing the product, wait until the CAUTION 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.

  • Page 5: Specifications

    Refer to the product nameplate for detailed specifications. * Valve No. is displayed for products with options. This item is omitted from the nameplate when there are no options. Acceptable Operating Range Model COS-3 COS-16 COS-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 Cos Pressure Reducing Valve

    Correct Usage of the COS 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 4. 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 COS must be straight runs. If a COS 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 Maintain a straight piping run of 30 d or more when another pressure reducing valve is installed. (Two-stage pressure reduction) Less than (Example: if nominal size is 25 30d or more mm (1 in), have 750 mm (30 in) or more) 172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022...

  • Page 9: Configuration

    Configuration COS-3 20 to 50 mm ( to 2 in) (Cast Iron, Cast Stainless Steel) Name A B C D E F G Main Body Trap Body Trap Cover Separator  Float Float Cover  Trap Valve Seat  Separator Screen ...
  • Page 10 COS-16/COS-21 15 to 50 mm ( to 2 in) Name A B C D E F G (Cast Iron, Cast Stainless Steel) 1 Main Body 2 Trap Body 3 Trap Cover 4 Separator  5 Float 6 Float Cover  7 Trap Valve Seat ...
  • Page 11 Name A B C D E F G COS-16/COS-21 Main Body 65 to 100 mm (2 to 4 in) Trap Body (Cast Iron) Trap Cover Separator  Float Float Cover  Trap Valve Seat  Separator Screen  Main Valve Seat ...

  • 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 Install the COS, paying attention to avoid excessive load, bending and vibration. Support the inlet and outlet pipes securely. 6. Maintenance Space Leave sufficient space for maintenance, inspection and repair. (12) (Unit: mm (in)) (16) (16) 7. Trap Outlet Pipe For ease of maintenance, installation of a union connection is recommended for the trap outlet pipe.
  • Page 14 10. Two-stage Pressure Reduction Two-stage pressure reduction should be performed whenever the pressure cannot be reduced to the desired level with a COS due to operating range limitations, such as when the reduction ratio is greater than 10:1. Bypass Bypass Bypass Bypass Valve...
  • Page 15 External Secondary Pressure Sensing Line Standard model is factory prepared for internal sensing. A secondary pressure detection port has been added to all COS pilot bodies to allow for installation of a 10 mm ( in) secondary pressure sensing line, which improves performance and increases valve capacity (flow rate).

  • Page 16: Adjustment

    Adjustment The COS 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 17: 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 18: Disassembly

    Disassembly 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. 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 CAUTION injury if the object should fall.
  • Page 19 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. Then loosen and remove the screen holder to remove the screen. Check for any fault on the seat of the pilot valve, flaws on the gaskets, and clogging of the screen.
  • Page 20 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 100 mm (2 to 4 in) only) from the body.
  • Page 21 Disassembling the Separator and Main Valve Section Turn the COS upside down for easy dismantling of the separator and main valve. Loosen the hex bolts and remove the trap body. Be careful, as the separator may drop off when the COS is returned to the normal attitude. Removal of the separator and pressed-in sleeve permits removal of the main valve coil spring, the main valve, main valve holder and screen.
  • Page 22 Disassembling the Steam Trap Section Loosen the hex bolts and remove the trap cover. Be careful, as hot condensate may splash out. Remove the hex 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 determine that there is no deformation of the float, abnormality in the trap valve seat or dirt accumulation in the trap cover.
  • Page 23 Exploded View 65 – 100 mm (2 15 to 50 mm ( to 2 in) to 4 in) Adjustment Section Pilot Section Piston Section Separator/Main Valve Section Steam Trap Section 172-65175MA-13 (COS Pressure Reducing Valve) 16 Feb 2022...

  • Page 24: Reassembly

    Reassembly Assemble the unit using the same procedure as used for disassebling 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, the spring retainer, ball and adjustment screw.
  • Page 25 5. Standard fastening torque and the distance across flats for the tools to be used are as follows: Distance Across Tightening Torque Part Connection Size Flats (mm) (in) (mm) (in) (Nm) (lbfft) Bolts (Spring Housing) 16/17* (29) Pilot Valve Seat (51) Screen Holder (29)

  • Page 26: 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 27 Problem Symptom Cause Remedy The secondary Adjustment is Flow rate exceeds rated Check the flow rate, pressure difficult, and set flow rate replace with a larger size cannot be pressure varies The adjustment screw Replace with a new adjusted or has seized adjustment screw increases...
  • Page 28 Replace with a new trap valve seat NOTE: When replacing parts for the COS-3, COS-16 and COS-21, use the parts list for reference, and replace with new parts from the kits shown there. Please note that replacement parts for the COS-3, COS-16 and COS-21 are only available as part of a replacement parts kit.

  • Page 29: 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...
  • Page 30 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 31: 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:

Cos-16Cos-21

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