TLV A-COSR-10 User manual

172-65255M-05 (A-COSR-10) 6 October 2021
Pressure Reducing Valve for Air
A-COSR-10
Copyright © 2021 by TLV CO., LTD.
All rights reserved

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Contents
Introduction ....................................................................... 1
Safety Considerations....................................................... 2
Specifications.................................................................... 4
Acceptable Operating Range............................................ 4
Correct Usage of the A-COSR Pressure Reducing Valve
.......................................................................................... 5
Configuration..................................................................... 7
Installation......................................................................... 8
Adjustment ...................................................................... 12
Maintenance.................................................................... 13
Disassembly.................................................................... 14
Reassembly .................................................................... 18
Troubleshooting .............................................................. 19
TLV EXPRESS LIMITED WARRANTY........................... 21
Service............................................................................ 23
Introduction
Thank you for purchasing the TLV A-COSR pressure reducing valve for 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 TLV pressure reducing valve for air, model A-COSR provides a more
stable secondary pressure than conventional reducing valves. The A-COSR
is designed for long service life, with all major components made of stainless
steel for superior durability.
If detailed instructions for special order specifications or options not contained
in this manual are required, please contact TLV 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.

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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.
Indicates an urgent situation which poses a threat of death or
serious injury
Indicates that there is a potential threat of death or serious injury
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 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.
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.
Continued on the next page.
DANGER
WARNING
CAUTION
CAUTION

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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.
CAUTION

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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
DO NOT use the trap in excess of the maximum operating pressure
differential; such use could make discharge impossible (blocked).
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.
* Valve No. is displayed for products with options. This item is omitted from the nameplate when
there are no options.
Acceptable Operating Range
Use
Model
Primary
Pressure
Range
(MPaG)
Secondary
Pressure
Adjustable Range
(MPaG)
Minimum
Differencial
Pressure
(MPa)
Maximum
Operating
Temperature
(°C)
Minimum
Adjustable Flow
Rate
For Air
A-COSR-10
0.1 - 0.9
0.05 - 0.7
0.05
100
10% of rated
flow rate
Model
Nominal Diameter
Maximum Operating
Temperature
Valve No.*
Secondary Pressure
Adjustable Range
Primary Pressure
Range
Production Lot No.

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Correct Usage of the A-COSR 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 A-COSR should be operated only within its specifications.
2. Installing an ON / OFF Valve (Solenoid Valve or Motorized Valve)
If an on-off valve, such as a motorized valve is required, install it at the inlet side
of the A-COSR. If a solenoid valve is installed at the outlet of the reducing valve,
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 reducing valve 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.)
3. Installing a Safety Valve
When installing a safety valve to protect the air equipment, be sure to install it on
the air equipment or directly before the inlet of the air equipment. If the safety
valve is installed on the outlet side of the A-COSR between the A-COSR and a
control valve, an eventual pressure rise could activate the safety valve.
Motorized
Valve
A-COSR
Solenoid
Valve
A-COSR
Inlet Side
Outlet Side
A-COSR
A-COSR
Safety
Valve
Safety
Valve
Control
Valve
Control
Valve
Equipment
Equipment

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4. Precautions for the Installation of Additional Fittings Before or After the Reducing
Valve
In order to ensure stable air flow, 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 air flow
may result in chattering and unstable pressure.
To ensure stable air flow, it is recommended that the pressure reducing valve be
installed on straight runs of piping, as illustrated below.
①Inlet (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, have 250 mm or more)
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, have 750 mm or more)
②Outlet (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, have 375 mm or more)
減圧弁
15d以上
減圧弁
15d未満
Maintain a straight piping
run of 30 d or more when a
safety valve is installed.
(Example: if nominal size is 25
mm, have 750 mm or more)
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, have 750 mm or more)
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, have 750 mm or more)
15 d or more
Less than
15 d
Valve, strainer,
elbow, etc.
A-COSR
10 d or
more
A-COSR
Less
than
10 d
A-COSR
Automatic
Valve
30 d or more
Automatic
Valve
Less than
30 d
A-COSR
A-COSR
30 d or more
Safety
Valve
A-COSR
Safety
Valve
A-COSR
30 d or more
Second
Reducing
Valve
Control or
Automated
Valve
30 d or more
A-COSR
A-COSR
A-COSR
A-COSR
Less than
30 d
Less than
30 d
Less than
30 d
Second
Reducing
Valve
Control or
Automated Valve
A-COSR
Valve, strainer,
elbow, etc.

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Configuration
No.
Name
No.
Name
1
Main Body
10
Diaphragm
2
Cover
11
Pilot Screen
3
Main Valve Seat
12
Pilot Screen Holder
4
Main Valve
13
Diaphragm Support
5
Piston
14
Coil Spring
6
Cylinder
15
Spring Housing
7
Pilot Valve Body
16
AdjustmentScrew
8
Pilot Valve
17
SpannerCap
9
Pilot Valve Seat
18
Plug–SensingLinePort

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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 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.
1. Blowdown
Before installing the
A-COSR, 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 Seal and Cap
Before installation, be sure to remove all protective seals and caps.
(Found in 2 locations, on the product inlet and outlet.)
3. Installation Angle
Install the A-COSR vertically, so
that the arrow mark on the body
points horizontally in the direction
of air flow.
Allowable inclination is 10 degrees
in the fore-aft direction and 15
degrees in the plane perpendicular
to the air flow line.
4. Spacer Installation
If spacing adjustment is
necessary to accommodate
installation, install a spacer on
the outlet flange. The spacer
should consist of a spacer,
gaskets, bolts and nuts.
スペーサ
A-COSR
Blowdown Using Bypass Valve
Blowdown Piping
Before Installation
Correct
Spacer
Location
Incorrect
Spacer
Location

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スペーサ
Fit gaskets to both sides of the spacer between the A-COSR outlet and the pipe
flange. Fasten with bolts and nuts.
5. Piping Support
Install the A-COSR, 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.
(Unit: mm)
7. Piping Size
If it is expected that the secondary air flow velocity will be more than 30 m/s,
install a diffuser in order to keep the flow velocity below 30 m/s. If the distance
between the reducing valve and the air equipment is great, a possible drop in
pressure should be taken into consideration when selecting the piping size.
Strainer should be angled in the 3 o 9 o’clock positions for horizontal installations
to prevent condensate accumulation.
0.2m以上
ディフューザ
減圧弁
Straight-run Piping Lengths: Upstream = 10 d or more; Downstream = 15 d or more
(d = pipe diameter)
Diffuser
A-COSR
0.2 m or more
approx
. 300

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減圧弁
A-COSR

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8. Accessories
A strainer should always be installed ahead of the A-COSR. The strainer should
be 60 mesh or finer, but not so fine as to constrict flow area resulting in a
pressure drop. The strainer should be installed horizontally with the basket at the
3 or 9 o’clock position in order to prevent condensate accumulation.
Always install a shut-off valve, pressure gauge and bypass line at both inlet and
outlet.
Ball valves, which will not retain condensate, are recommended for inlet and
outlet shut-off valves. The bypass pipe should be at least one half of the size of
the inlet (primary side) pipe.
ボールバルブ ボールバルブ
ボールバルブ
減圧弁
減圧弁
Globe Valve
Ball Valve
Pressure
Gauge
Pressure
Gauge
A-COSR
Safety Valve
(Relief Valve)
A-COSR
Ball Valve

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Adjustment
The A-COSR reducing valve should be properly adjusted for protection of the air
equipment.
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 air equipment.
(Stay clear of any pressurized blow-out from the safety valve.)
2. Make sure that the shut-off valve and the bypass valve located upstream and
downstream of the A-COSR are completely closed.
3. Remove the spanner cap, loosen the locknut and turn the adjustment screw
counter-clockwise to reduce tension on the coil spring.
4. Slowly, fully open the shut-off valve at the inlet of the A-COSR. Allow sufficient
time for condensate remaining at the inlet of the A-COSR to be discharged.
5. Slightly open the shut-off valve at the outlet of the A-COSR.
6. Turn the adjustment screw until the desired outlet pressure is obtained. Wait
several minutes.
7. Slowly, fully open the shut-off valve at the outlet of the A-COSR.
8. After setup, retighten the locknut and replace the cap.
9. When shutting down the system, always close the outlet shut-off valve first and
then the inlet valve.
Loosen the locknut
Loosen the adjustment screw
Loosen the Adjustment Screw
Decrease Pressure
Counter-clockwise
Clockwise
Counter-clockwise
Tighten the Adjustment Screw
Increase Pressure

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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
the discharge of fluids.
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 or burns
or other injury due to malfunction or the discharge of fluids.
CAUTION
Operational Check
To ensure long service life of the A-COSR, the following inspection and maintenance
should be performed regularly.
Part
Inspection and Maintenance Frequency
Pilot Screen
Disassemble and clean annually.
If there is substantial blockage, install a strainer
(approximately 60 mesh) ahead of the A-COSR.
Main Valve, Main
Valve Seat, Pilot Valve
and Pilot Valve Seat
Replace after approximately 15,000 hours.
If there is chattering or dirt, premature wear may result.
Piston Ring
Replace after approximately 8,000 hours.
If there is chattering or if scale build-up is severe,
premature wear may result.
Piston
Replace after approximately 30,000 hours.
If hunting or chattering takes place, premature wear
may result.
Diaphragm
Replace after approximately 30,000 hours.
If hunting or chattering takes place, cracks or fatigue
may develop in a short period of time.

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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
the object should fall.
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.
CAUTION
It is a recommended practice to dismantle and inspect the A-COSR once a year for
preventive maintenance purposes. It is especially important to perform an inspection
immediately after the initial run of a new line or before or after equipment that heater
is out of service for a long period of time. (Installation, inspection, maintenance,
repairs, disassembly, adjustment and valve opening/closing should be carried out
only by trained maintenance personnel.)
Remove all pressure from the piping (both upstream and downstream). Then
remove inlet and outlet flange retaining bolts and nuts to permit removal of the A-
COSR. Secure the A-COSR in a vise to perform the inspection.
Disassembling the Adjustment Section
Loosen the adjustment screw completely and remove the bolts. Having removed the
spring housing, you will see the diaphragm support, coil spring and spring guide.
Check for seizure or any damaged screw threads.
Nameplate
Adjustment
Screw
Locknut
Spring
Housing
Bolt
Coil Spring
Diaphragm
Support
Ball
Spring Guide
Spanner Cap

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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 pilot screen holder to remove the
pilot screen.
Check for any fault on the pilot valve seat, flaws on the gaskets and clogging of the
pilot screen.
Check for deformation, corrosion or faults on the diaphragm. The diaphragm should
be convex (open downward), with the printed “UP” mark on the top.
Diaphragm
Pilot Valve Seat
& Gasket
Pilot Valve
Pilot Valve
Spring
Pilot Valve Body
Notch
Pilot Screen
Pilot Screen Holder
& Gasket
Bolt
Upper Pilot Valve Body Gasket

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Disassembling the Piston
Remove the pilot valve body after loosening and removing the bolts.
During this process, pay attention not to lose the connecting tubes (2).
Remove the piston and the cylinder from the main body. Then remove the piston
rings and the tension rings from the piston. Do not apply too much force when
removing the piston rings and tension rings.
Inspect the interior of the cylinder, the exterior of the piston rings, the small hole on
the piston and the gaskets for any fault or abnormality.
Disassembling the Main Valve
Turn the A-COSR upside down for easy dismantling of the main valve.
Remove the cover plug or loosen the bolts and remove the cover. Remove the main
valve and the mani valve spring. Loosen the main valve seat by using a box wrench
and remove from the main body.
Check for damage on the seating and sliding surfaces of the main valve and main
valve holder, the seating surface of the main valve seat, and for damage on the
gaskets.
At start-up following shut-down for a long period, always blow down the piston
section of the body through the plug (option).
Cover
Cover Gasket
Piston Ring
Tension Ring
Cylinder & Gasket
Lower Pilot Valve Body Gasket
Piston
Connecting Tubes
Piston Ring
Tension Ring
Cover Bolt
Main Valve Seat (with Gasket)
Main Valve
Main Valve Spring
Main Body

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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
recommended for more effective cleaning.
(Coat threaded position with anti-seize after cleaning.)
Exploded View
Adjustment
Section
Pilot Section
Piston Section
Main Valve
Section

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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. Apply a small amount of anti-seize to the
threads of the main valve seat, pilot valve seat and pilot screen holder. Apply
anti-seize carefully to ensure it does not come into contact with other parts.
3. Fasten the bolts one at a time in an alternating diagonal pattern to provide
uniform seating.
4. After assembly, make sure that the piston and the pilot guide operate
smoothly without binding.
1) Fit the piston ring to the outside
of the tension ring.
2) The ring gaps should be opposite
each other.
5. Standard fastening torque and the distance across flats for the tools to be
used are as follows:
Part
A-COSR
Connection Size (mm)
Distance Across
Flats (mm)
Tightening Torque
(Nm)
Bolts for
Spring Housing / Pilot Body
All
17
40
Pilot Valve Seat
All
19
70
Pilot Screen Holder
All
24
40
Bolt for
Pilot Body
Size 15 –40
17
60
50
19
70
Main Valve Seat
15, 20
36
100
25
41
125
32, 40
60
250
50
70
300
Cover Bolt
15 - 40
17
60
50
19
70
Caution: If a torque greater than that recommended is applied,
the A-COSR or components may be damaged.
1 Nm 10 kgcm
Tension Ring
Assembling the Piston Ring
Ring Gaps
Piston Ring

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Troubleshooting
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
This product is shipped after stringent checks and inspection and should perform its
intended function for a long period of time without failure. However, should there be
any problem encountered in the operation of the A-COSR, consult the
troubleshooting guide below.
Problems are classified as follows:
1. The secondary pressure does not increase.
2. The secondary pressure cannot be adjusted or increases abnormally.
3. Hunting (fluctuation of the secondary pressure) occurs.
4. Chattering (a heavy mechanical noise) occurs.
5. Abnormal noises.
Major causes for the above problems are usage under non-specified conditions (out
of specification), insufficient pressure or flow rate, and clogs by dirt and scale.
To ensure performance for a long period of time, it is recommended that the
“Acceptable Operating Range”, “Correct Usage of the A-COSR Pressure Reducing
Valve” and “Adjustment” sections be reviewed.
Troubleshooting Chart
Problem
Symptom
Cause
Remedy
The secondary
pressure does
not rise
The pressure
does not increase
No air is being
supplied or the inlet
valve is closed
Check the valves and
pipings
The entrance to the
screens or strainer is
clogged
Clean or blow down
The secondary
pressure
cannot be
adjusted or
increases
abnormally
Adjustment is
difficult, and set
pressure varies
The pilot screen is
clogged
Clean
There is insufficient air
flow
Check the flow, replace
the A-COSR if necessary
The piston is clogged
with dirt
Clean
Check the piston ring
The piston ring is worn
Replace with a new
piston ring
There is a build-up of
dirt on the sliding
surfaces of the piston,
pilot or main valve
Clean
Flow rate exceeds
rated flow rate
Check the flow rate,
replace with a larger size
The adjustment screw
has seized
Replace with a new
adjustment screw
Continued on the next page