TLV MC-COSR-3 User manual

172-65185A-08 (MC-COSR Multi-control Valve) 20 November 2014
Manufacturer
881 Nagasuna, Noguchi, Kakogawa, Hyogo, 675-8511 Japan
Tel: [81]-(0)79-422-1122 Fax: [81]-(0)79-422-0112
Copyright © 2014 by TLV Co., Ltd. All rights reserved
ISO 9001/ ISO 14001
Manufacturer
Kakogawa, Japan
is approved by LRQA LTD. to ISO
9001/14001
High-precision Multi-control Valve for Steam
MC-COSR-3/MC-COSR-16
Actuator: MC-GA2

1
Contents
Introduction ......................................................................... 1
Safety Considerations ........................................................ 2
Specifications ..................................................................... 4
Correct Usage of the MC-COSR Multi-control Valve .......... 6
Configuration ...................................................................... 8
Installation......................................................................... 12
Wiring................................................................................ 18
Setting the Valve Coefficient ............................................ 20
Operation .......................................................................... 21
Inspection and Maintenance............................................. 23
Disassembly ..................................................................... 24
Reassembly...................................................................... 29
Troubleshooting ................................................................ 30
EXPRESS LIMITED WARRANTY .......................... 36
Introduction
Thank you for purchasing the MC-COSR high-precision multi-control 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. Also be sure
to read this manual carefully before use and follow the instructions to be sure of
using the product properly.
Steam-using equipment can achieve its intended efficiency only if the steam being
used is very dry. Using steam in which matter such as condensate, scale, types of
grease or air is entrained can not only result in problems with the steam-using
equipment and in lowered productivity, but can also lead to shortened service life
for and malfunction of the multi-control valves.
The high-precision multi-control valve, model MC-COSR, provides accurate
pressure control (MC-COSR-3, MC-COSR-16) and temperature control (MC-
COSR-16) when combined with the SC-F70 digital indicator controller or the
SP-F70 programmable indicator controller.
If detailed instructions for special order specifications or options not contained in
this manual are required, please contact 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.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

2
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
R
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
CAUTION 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 (44 lb) 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.
Safety considerations are continued on the next page.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

3
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.
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.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

4
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.
Primary Pressure Range
Model
Serial Number
Nominal Diameter
Maximum Operating
Temperature
Secondary Pressure
Adjustable Range
Valve No.*
* Valve No. is displayed for products with options. This item is omitted from the nameplate when there are no
options.
Actuator Specifications
Actuator Model MC-GA2
Power Source Voltage Free between 100 and 240 V AC (50/60 Hz)
Power Consumption With motor running: 75 VA max.
Insulation Resistance 500 V DC, 100 Mmin. between the power source
terminal and ground terminal
Power Source
Withstand Voltage Between the power source terminal and ground terminal:
1500 V AC, 1 min. or 1800 V AC, 1 second
Drive System Positional control by DC brushless motor
Operation Input
(Valve Opening)
4 – 20 mA DC (input impedance 250 )
Emergency Action Valve fully closed by an operation signal interruption.
When input power is cutoff: held at position just before
power cutoff
Time Rating Continuous
Thermal Protection Built-in overcurrent protection circuit
Time Required to Fully
Open/Close
Fully closed →fully open: Approx. 15 seconds
Operation
Manual Operation Possible with the power OFF
Allowable Ambient Temperature Range 0 to 50 °C (32 to 122 °F)
Allowable Ambient Humidity 10% to 90% RH (without dew)
Allowable altitude 2000m (6600 ft) max.
Vibration Resistance 0.5 G max.
Water Resistance Rain resistant (equivalent to IP54)
Environment
Material Motor cover: Aluminum
Main mounting plate: FC25 (cast iron)
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

5
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
CV Value
(mm) 15 20 25 32 40 50 65 80 100 125 150
Size (in) (1/2) (3/4) (1) (11/4)(1
1/2)(2)(2 1/2) (3) (4) (5) (6)
Cv (US) 3.8 6.9 11.1 15.5 24.0 37.2 59.3 85.0 128 180 275
Cv (UK) 3.2 5.7 9.2 12.9 20.0 31.0 49.4 70.8 107 150 229
Kvs (DIN) 3.3 5.9 9.5 13.3 20.6 31.9 50.8 72.9 110 154 236
Acceptable Operating Range
Model MC-COSR-3 MC-COSR-16
Primary Pressure
Range
0.1 – 0.3 MPaG
(15 – 45 psig)
0.2 – 1.6 MPaG
(30 – 250 psig)
Secondary Pressure
Adjustable Range
(All conditions must
be met)
0.01 – 0.05 MPaG
(1.5 – 7 psig)
Within 10 – 84% of the primary pressure
(Minimum adjustable pressure of
0.03 MPaG (5 psig))
Allowable pressure differential between
0.07 – 0.85 MPa (10 – 120 psi)
Minimum Adjustable
Flow Rate
5% or greater of
rated flow rate
5% or greater of rated flow rate
NOTE:10% or greater of rated flow rate
for sizes 65 – 150 mm (21/2– 6 in)
(1 MPa = 10.197 kg/cm2)

6
Correct Usage of the MC-COSR Multi-control 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 MC-COSR should be operated only within its specifications.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
2. Installing an ON / OFF Valve (Solenoid Valve or Motorized Valve)
MC-COSR
MC-COSR
電動弁
入口側
電磁弁
出口側
If an on-off valve, such as a motorized valve, is required to stop supply of steam to the
steam-using equipment, install it at the inlet side of the MC-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 multi-control 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.)
To save energy, install the on-off valve as near to the boiler as possible.
Note: To prevent water hammer, it is recommended that a slow-acting motorized on-off
valve be used. In particular, if a fast-acting on-off solenoid valve is used for
frequent temperature control, the potential water hammer effect can damage the
steam equipment and the multi-control valve.
3. Installing a Control Valve
安全弁
蒸気使用装置
制御弁
MC-COSR
安全弁
蒸気使用装置
制御弁
MC-COSR
Motorized
Valve Solenoid
Valve
A control valve (i.e. for temperature control) installed between the MC-COSR and the
steam equipment (downstream of the MC-COSR) may raise the pressure between the MC-
COSR and the control valve when the control valve is closed, depending on their spatial
relationship. Therefore, the control valve should be installed close to the steam equipment.
Also, a safety valve should be installed downstream of the control valve.
Note: When installing a safety valve to protect the steam equipment, be sure to install it
on the steam equipment or directly before the inlet of the steam equipment. If the
safety valve is installed between the MC-COSR and a control valve, an eventual
pressure rise could activate the safety valve.
Inlet Side Outlet Side
Safety
V veal
C
ontro
l
Valve
C
ontro
l
Valve
Safety
Valve
Equipment
Equipment

7
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
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.
To ensure stable steam flow, it is recommended that the multi-control valve be installed
on straight runs of piping, as illustrated below.
Inlet (primary side) of the multi-control 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)
MC-COSR
10d以上
10d未満
MC-COSR
Valve, strainer,
elbow, etc.
Valve, strainer,
elbow, etc.
L
ess
th
an
10 d
10 d 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 m
m
(1 in), have 750 mm (30 in) or
more)
MC-COSR
30d以上
自動弁
自動弁
30d未満
MC-COSR
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)
30d以上
減圧弁
MC-COSR
30d未満
MC-COSR
減圧弁
Outlet (secondary side) of the multi-control 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)
MC-COSR
15d以上
15d未満
MC-COSR
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)
安全弁
30d以上
MC-COSR
30d未満
安全弁MC-COSR
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 (1 in), have 750 mm (30
in) or more)
制御弁または自動弁
30d以上
MC-COSR
30d未満
制御弁または自動弁
MC-COSR
Automatic
Valve
Automatic
Valve
Less than
30 d moreor 30 d
Pressure
Reducing Valve
Pressure
Reducing Valve
Less than
30 d or more 30 d
Less than
15 d
15 d or more
Safet
y
Valve
Safety
Valve
30 ored or m Less than
30 d
Control or
e
Control or
e
Automated Valv Automated Valv
30 d or more
Less than
30 d

8
Configuration
15 – 25 mm (1/2– 1 in)
No. Name
1 Main Body
2 (Main Body) Plug
3 Main Valve Seat
4 Main Valve
5 Main Valve Holder
6 Piston
7 Cylinder
8 Pilot Screen
9 Pilot Screen Holder
10 Pilot Body
11 Pilot Valve Stem
12 Pilot Valve Seat
13 Diaphragm
14 Diaphragm Support
15 Spring Housing
16 Coil Spring
17 Plug – Sensing Line Port
18 Motor Unit
19 Drive Unit
20 Mounting Plate
21 Adjustment Screw Guide
22 Adjustment Screw
23 Terminal Block Cover
24 Motor Cover
25 Insulation Plate
26 Cable Lock
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

9
32 – 50 mm (11/4 – 2 in)
No. Name
1 Main Body
2 (Main Body) Cover
3 Main Valve Seat
4 Main Valve
5 Main Valve Holder
6 Piston
7 Cylinder
8 Pilot Screen
9 Pilot Screen Holder
10 Pilot Body
11 Pilot Valve Stem
12 Pilot Valve Seat
13 Diaphragm
14 Diaphragm Support
15 Spring Housing
16 Coil Spring
17 Plug – Sensing Line Port
18 Motor Unit
19 Drive Unit
20 Mounting Plate
21 Adjustment Screw Guide
22 Adjustment Screw
23 Terminal Block Cover
24 Motor Cover
25 Insulation Plate
26 Cable Lock
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

10
65 – 125 mm (21/2– 5 in)
No. Name
1 Main Body
2 (Main Body) Cover
3 Main Valve Seat
4 Main Valve
5 Main Valve Holder
6 Piston
7 Cylinder
8 Silencer
9 Pilot Screen
10 Pilot Screen Holder
11 Pilot Body
12 Pilot Cover
13 Pilot Valve Stem
14 Pilot Valve Seat
15 Diaphragm
16 Diaphragm Support
17 Spring Housing
18 Coil Spring
19 Plug – Sensing Line
Port
20 Motor Unit
21 Drive Unit
22 Mounting Plate
23 Adjustment Screw
Guide
24 Adjustment Screw
25 Terminal Block Cover
26 Motor Cover
27 Insulation Plate
28 Cable Lock
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

11
150 mm (6 in)
No. Name No. Name No. Name
1 Main Body 11 Pilot Body 21 Drive Unit
2 (Main Body) Cover 12 Pilot Cover 22 Mounting Plate
3 Main Valve Seat 13 Pilot Valve Stem 23 Adjustment Screw
Guide
4 Main Valve 14 Pilot Valve Seat 24 Adjustment Screw
5 Main Valve Holder 15 Diaphragm 25 Terminal Block Cover
6 Piston 16 Diaphragm Support 26 Motor Cover
7 Cylinder 17 Spring Housing 27 Insulation Plate
8 Silencer 18 Coil Spring 28 Cable Lock
9 Pilot Screen 19
Plug – Sensing Line
Port
10 Pilot Screen Holder 20 Motor Unit
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
12
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 (44 lb) 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.
Installation Environment
Avoid installation in the following types of environments:

Locations with ambient temperatures above 50 °C (122 °F) or below 0 °C (32 °F)
Locations with ambient humidity above 90% RH and below 10% RH
Locations where corrosive gas is generated
Locations with heavy vibration or shock
Locations with high inductive interference or other factors that would have a
harmful effect on electrical circuitry
1. Blowdown
Before installing the MC-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.
開
閉閉
バイパス配管利用のブロー
MC-COSR
Open
Closed Closed
Blowdown with the Bypass Valve
2. Removing Seal and Cap
Before installation, be sure to remove all protective seals and caps
covering the product inlet and outlets. (Found in 2 locations.)
①②
3. Installation Angle
Install the MC-COSR vertically, so that the arrow mark on
the body points horizontally in the direction of steam flow.
Allowable inclination is 10 degrees in the fore-aft direction
and 15 degrees side to side in the plane perpendicular to
the steam flow line.

13
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
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. Fit gaskets
to both sides of the spacer between
the MC-COSR outlet and the pipe
flange. Fasten with bolts and nuts.
スペーサ スペーサ
5. Piping Support
Install the MC-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.
7. Pressure
(for pressure
control)
The length of piping
between the MC-
COSR and pressure
sensor should be no
more than 5 m (17
ft). If the piping
distance is too great,
距離5m 以下
圧力センサ
MC-COSR 直管長さ
15d以上
直管長さ
5d以上
pressure loss and delay of pressure change along this distance will increase,
resulting in steam flowrate fluctuations. Steam fluctuations at the pressure
sensor may impair the stability of the pressure control. Ensure a straight piping
run of at least 15 d upstream and 5 d downstream from the pressure sensor.
Pressure Sensor
distance of 5m or less
15 d or more
5 d or
more
Unit: mm (in)
Correct
Spacer
Location
Incorrect
Spacer
Location
(8)
(6)
(6)
(8) (8)
(4)
straight
pipe
straight
pipe

14
8. Piping Size / Diffuser
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
If the secondary steam flow
velocity is expected to be more
than 30 m/s (100 ft/s), install a
diffuser in order to keep the
flow velocity below 30 m/s (100
ft/s). If the distance between
the multi-control valve and the
steam equipment is great, a
possible drop in pressure
should be taken into
consideration when selecting
the piping size.
直管部は上流側 10d 以上、下流側 15d 以上 （d：呼径）
ディフュー ザ
Diffuser
MC-COSR
MC-COSR
Upstream Downstream (d = pipe diameter)
=10 d or more =15 d or more
Straight-run
Piping Lengths:
9. Two-stage Pressure Reduction
Install a pressure reducing valve at the inlet side of MC-COSR 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.
MC-COSR
計
計
パス弁
弁出口弁 口弁
弁（レリーフ弁）
入口 出
安全
圧力
圧力
バイ
一次側 二次側
バイパス弁
入口弁
減圧弁
一次側
圧力計
圧力計
入口弁 出口弁
安全弁（レリー フ弁 ）
二次側
バイパス弁
MC-COSR
10. Accessories
Always install a shut-off valve, pressure gauge and bypass lines 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 ½ of the size of the
inlet (primary side) pipe. If installing a strainer before the multi-control valve,
horizontal installation with the basket in the same horizontal plane to the piping is
recommended in order to prevent condensate pooling.
ボールバルブボールバルブ
玉形弁
MC-COSR MC-COSR
Pressure
Gauge
Bypass Valve
Inle det Si Ou Sidetlet
Shutof
f
Valve
Shutof
f
Valve
P ure Gauress
g
e
Safet
y
Valve
(
Relief Valve
)
Pressure
Gauge
Bypass Valve
Inlet Side Outlet Side
Shutof
f
Valve Shutof
f
Valve
Pressure Gau
g
e
Safet
y
Valve
(
Relief Valve
)
Shutof
f
Bypass Valve
Valve
Shutof
f
Valve Pressure
Reducing
Valve
Glove Valve
Ball Valve Ball Valve

15
11. 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 (3/8in) 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.
Keep the shutoff valve open at all times during operation. If the shutoff
valve is closed, MC-COSR will fully open and PRIMARY PRESSURE WILL BE
SUPPLIED TO THE EQUIPMENT (see “Piping Example” on next page).
CAUTION
Non-North American Models
Factory-standard MC-COSR employs an internal secondary pressure-sensing
channel built into the body, saving the need to install an external pressure-
sensing line to detect the secondary pressure.
Installation of an external secondary pressure-sensing line involves closing the
internal pressure-sensing channel and installing a line from the sensing line port
to the point where pressure should be controlled. This can increase stability of
pressure control where steam loss in secondary piping and flowrate fluctuation is
high. In addition, the rated flowrate will be greater than an internal pressure-
sensing channel under the operational pressure reduction ratio of 2:1 or more.
Installation procedure
1) Loosen and remove the bolts that attach the pilot body to the main body (15 –
50 mm (1/2– 2 in)) or the pilot cover (65 – 150 mm (21/2– 6 in)) and remove
the pilot body.
2) Install the blind pin (optional) by first removing the connector from the main
body or pilot cover and then substituting the blind pin.
3) Re-install the pilot body and fasten the bolts evenly to the proper torque
(see Reassembly, page 29).
4) Remove the plug Rc(PT) ⅜or NPT ⅜and connect the secondary pressure
sensing line.
5) Install the secondary pressure sensing line with a slightly falling pitch. The end
of the secondary pressure sensing line should be connected to the place on
the main piping where the pressure is to be sensed (see the piping example
on the next page). A shut-off valve and union should be installed in the
secondary pressure sensing line.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

16
15 – 50 mm (1/2– 2 in) 65 – 150 mm (21/2– 6 in)
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
Piping Example:
MC-COSR
1m または15dの
大きい方
バルブ
15d以上
蒸気使用装置
Pilot Valve Body
Pilot Body
Plug (Rc(PT) ⅜or NPT ⅜)
Secondary Pressure
Detection Port
Hex Bolt
Main Body
Blind Pin
Connector
Secondary Pressure
Detection Port
Replace the factory-installed
connector with the blind pin
(optional)
Connector
10 mm (
3
/8in) Pressure Sensing Line
(with a slightly falling pitch towards the
sensing point)
Valve
15 d or more
1 m (3.3 ft) or 15 d,
whichever is
larger
Equipment

17
12. Internal sensing for North American models
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:
1) Loosen and remove the four (4) bolts that attach the pilot body to the main
body (15 – 50 mm (1/2– 2 in)) or the pilot cover (65 – 150 mm (21/2– 6 in)),
and remove the pilot valve body.
2) Install the connector by first removing the blind pin from the secondary side of
the main body or pilot cover and then substituting the connector.
Blind Pin Connector
3) Re-install the pilot body and fasten the four (4) bolts evenly.
Consult page 30 in this manual for torque requirements of these bolts.
4) If a secondary pressure sensing pipe has previously been installed, remove it
and be certain to install the threaded secondary pressure sensing line plug in
its place.
*Internal sensing should not be used when 15 mm (1/2in) and 20 mm (3/4in) MC-
COS-16 will be used below 0.3 MPaG (45 psig) and 0.1 MPaG (15 psig)
respectively, and below 50% of primary pressure.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014

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.
2) Although there is a built-in fuse in the controller, there is no power switch. It is
required that a power switch be installed on an external circuit near the main
unit. Do not install a power switch between the EM filter and the valve, as this
will reduce the effectiveness of the filter.
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014
EM Signal Filter
Power Switch Drive
Section
Terminal
Block
Power Su
pp
l
y
3) A power cable is not included with the unit. See “Wiring Instructions”.
G
r
ou
n
d
4) Install an overcurrent protection device on the power supply lines (both poles)
to prevent overcurrent.
Recommended rating of the device: 250V/2A, Delay type
2. Input/Output Signal Lines for Valve Operation
1) Use shielded cables for the I/O signal lines.
Connect the shielded cables to the receiver's shield terminal.
2) Separate the I/O signal cables from power cables, drive cables, and EM noise-
generating equipment. Do not insert I/O signal cables in common piping or
ducts with aforementioned cables.
3. Ground
1) Be sure to ground the MC-COSR and the controller.
2) Use a one-point ground at the same point as the ground for the controller to be
used with the valve. Do not use extension wiring. Failure to ground the valve as
specified may cause it to malfunction.
3) For the ground terminal, use a flexible copper wire, at least 2 mm2 (0.003 in2).
Ground with a ground resistance of 100 or less (Class 3 ground).
Drive
Section
Terminal
Block
Power Supply
Controller
Terminal
Block
Shield
Shielded Cable
Power Supply Drive
Section
Terminal
Block
Controller
Terminal
Block
Ground

19
Wiring Instructions
Make sure the power supply switch is OFF before carrying out work on
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.
CAUTION
Make sure that wiring work requiring a special license is carried out by
qualified personnel.If carried out by unqualified personnel, overheating
or short circuits leading to injury, fires, damage or other accidents may
occur.
CAUTION
Drive Section Terminal Box
Drive Section Terminal Block
MC-COSR
Terminal
Box
Controlle
r
Terminal Block
Shield
Shield Cable
Power Suppl
y
100 – 240 V AC
When making a connection to the terminal block, use crimp-style jacks (for M4) with
insulation sleeves.
(0.35 in)
(0.24 in)
6.3 mm
(
0.24 in
)
4.3 mm
(
0.17 in
)
6.6 mm
(0.26 in)
MAX
MIN
9.0 mm
(0.35 in)
Recommended Cable Specifications
Cable Specifications
Actuator
Terminal No. Minimum
Cross Section
mm2(in
2)
Maximum Wire
Gauge No.
(AWG)*
Cable Type
Power Source 1, 2 1.25 (0.002) 16
GND 2.00 (0.003) 14
Cabtyre cable
Valve Operation
Signals
3 (shield),
4 (), 5 () 0.75 (0.001) 18 2 conductor
shielded cable
* (American Wire Gauge)
172-65185A-08 (MC-COSR Multi-control Valve) 20 Nov 2014