The TLV A-COS-10 is a technologically advanced self-actuated pressure reducing valve for air, combined with a condensate separator and an air trap. This integrated design provides accurate control and air conditioning to maximize process system performance while supplying dry, high-quality air.

Using air in which matter such as condensate, scale, or types of oil is entrained can not only result in problems with the air-using equipment and lowered productivity, but can also lead to shortened service life and malfunction of reducing valves. The A-COS-10 eliminates these problems and makes possible the supply of high-quality air at a constant pressure.

Features

1. Space-saving unit: Simplifies system layout, piping, and maintenance.
2. Self-aligning shock-absorbing spherical piston: Advanced pilot regulator designs maintain secondary air pressure accuracy, even during adverse process conditions.
3. Built-in cyclone separator: Condensate separation efficiency as high as 98%, combined with a self-modulating free float air trap to provide a dry, high-quality air supply.
4. Stainless steel internal components: Major internal components are made of stainless steel for long service life.
5. Large surface area integral screens: Screens for the pilot valve and main valve extend trouble-free service.
6. Internal secondary pressure-sensing channel: Makes an external sensing line unnecessary.

Specifications

Model	ACOS-10
Body Material	Ductile Cast Iron (GGG40.3/EN 5.3103) / Cast Stainless Steel (A351/A351M Gr.CF8 or CF8M)
Connection	Flanged, DIN
Size	DN 15, 20, 25, 40, 50
Maximum Operating Pressure (PMO)	9 barg
Maximum Operating Temperature (TMO)	100 °C
Primary Pressure Range	1 – 9 barg
Adjustable Pressure Range	0.5 – 7 barg
Minimum Differential Pressure	0.5 bar
Minimum Adjustable Flow Rate	10% of rated flow rate
Applicable Fluid	Air

WARNING

Do not use for toxic, flammable, or otherwise hazardous fluids. DO NOT use this product in excess of the maximum operating pressure differential. Such use could make discharge impossible (blocked).

Configuration

No.	Name	No.	Name
1	Main Body	14	Pilot Screen Holder
2	Separator Body	15	Pilot Body
3	Trap Cover	16	Pilot Valve
4	Separator	17	Pilot Valve Seat
5	Float	18	Diaphragm
6	Float Cover	19	Diaphragm Support
7	Trap Valve Seat	20	Spring Housing
8	Separator Screen	21	Coil Spring
9	Main Valve Seat	22	Adjustment Screw
10	Main Valve	23	Spanner Cap
11	Piston	24	Plug – Sensing Line Port
12	Cylinder	25	Plug (option)
13	Pilot Screen

Installation Guidelines

Correct Usage

• ON-OFF Valve: If an on-off valve (motorized valve) is required, install it at the inlet side of the product. If a solenoid valve is installed at the outlet, its opening and closing will cause heavy chattering and may lead to damage of the piston and main valve.
• Safety Valve: When installing a safety valve to protect the air-using equipment, install it on the air-using equipment or directly before its inlet. If installed between the product and a control valve, an eventual pressure rise could activate the safety valve.

Straight Piping Runs

In order to ensure stable air flow, the piping upstream and downstream of the product must be straight runs. If the product is installed either directly before or after an elbow or control valve, unevenness in air flow may result in chattering and unstable pressure.

Inlet (primary side):

• Maintain a straight piping run of 10 d or more when a manual valve, a strainer, or an elbow is installed.
• Maintain a straight piping run of 30 d or more when an automated valve (on-off valve) or another pressure reducing valve is installed.

Outlet (secondary side):

• Maintain a straight piping run of 15 d or more when a manual valve, a strainer, or an elbow is installed.
• Maintain a straight piping run of 30 d or more when a safety valve, control valve, or automated valve is installed.

(Note: d = pipe diameter)

Installation Angle and Blowdown

Make sure the product is installed on horizontal piping, so that the arrow mark on the body matches the direction of air flow and the adjustment section faces up. Allowable inclination is 10 degrees in the fore-aft direction and 15 degrees in the plane perpendicular to the air flow line.

Before installing the product, be sure to blow down all piping thoroughly. Blowdown is especially important for newly installed piping or after the system has been shut down for a long period of time.

Adjustment

1. Blow down all pipe lines thoroughly.
2. Make sure that the shut-off valve and the bypass valve located upstream and downstream of the product are completely closed.
3. Remove the spanner cap, loosen the locknut, and turn the adjustment screw counterclockwise to reduce tension on the coil spring.
4. Slowly, fully open the shut-off valve at the inlet of the product. Allow sufficient time for condensate remaining at the inlet to be discharged.
5. Slightly open the shut-off valve at the outlet of the product.
6. Turn the adjustment screw until the desired outlet pressure is obtained. Wait several minutes. (Tighten to increase pressure, loosen to decrease pressure).
7. Slowly, fully open the shut-off valve at the outlet of the product.
8. After setup, retighten the locknut and replace the spanner cap.

Maintenance and Operational Check

To ensure long service life, the following inspection and maintenance is recommended to be performed regularly:

Part	Inspection and Maintenance Frequency
Screens (Separator and Pilot)	Disassemble and clean annually. If there is substantial blockage, install a strainer (approx. 60 mesh) ahead of the product.
Main Valve, Main Valve Seat, Pilot Valve, 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.
Trap Valve Seat	Replace after approximately 40,000 hours. If scale build-up is severe, blockage may occur in a short period of time.
Diaphragm	Replace after approximately 30,000 hours. If hunting or chattering takes place, cracks or fatigue may develop in a short period of time.

Disassembly and Reassembly

It is a recommended practice to dismantle and inspect the product once a year for preventive maintenance purposes.

1. Adjustment Section: Loosen the adjustment screw completely and remove the hex bolts. Remove the spring housing, diaphragm support, and coil spring.
2. Pilot Section: Remove the diaphragm. Loosen the pilot valve seat and remove it. Lift the pilot valve spring up and out. Loosen and remove the screen holder to remove the screen.
3. Piston Section: Remove the pilot body. Remove the piston and cylinder from the body. Remove the piston rings and tension rings from the piston.
4. Separator and Main Valve Section: Turn the product upside down. Loosen the hex bolts and remove the separator body. Remove the main valve spring, main valve, and screen. Loosen the valve seat and remove it.
5. Air Trap Section: Loosen the trap cover bolts and remove the trap cover. Remove the float cover bolts to reveal the float. Remove the float and the trap valve seat.

Assemble the unit using the same procedure in reverse order. Apply anti-seize to the threaded portion of screws and bolts. Fasten the bolts one at a time in an alternating diagonal pattern to provide uniform seating.

Troubleshooting

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 piping at the primary side
		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 product 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	Clean
		The adjustment screw has seized	Replace with a new adjustment screw
		The small hole on the piston is clogged	Clean
		The diaphragm is distorted or damaged	Replace with a new diaphragm
	Upon closing the valves on the secondary side, the secondary pressure abruptly rises	The bypass valve is leaking	Check, clean, and replace with a new valve if necessary
		There is a build-up of dirt on or damage to the pilot valve seat or main valve seat	Clean, align, replace if necessary
Hunting or chattering occurs	Occurs at low air demand	It is being operated below the lower flow rate limit	Check the volume of air supply, replace with a smaller diameter valve
	Hunting never stops	There is too high a reduction ratio	Change to an acceptable operating range
	Chattering never stops	Condensate is contained, or the trap is blocked	Check the trap, check the piping
Abnormal noises	Makes a high-pitched noise	There is too high a reduction ratio / The flow is too great	Use two-stage reduction, check the flow rate and use a larger size valve
Faulty air trap	Air is blowing	There is a build-up of dirt on the trap valve seat or at the float base	Clean
		The float is deformed	Check for water hammer, replace with a new float
	No condensate is discharged	The primary pressure exceeds the trap valve seat maximum working pressure	Adjust primary pressure
		Water is inside the float	Replace with a new float
		The trap valve seat is clogged	Clean, replace with a new trap valve seat

Dimensions

ACOS-10 Flanged (DIN2501 PN25/40)

DN	L (mm)	H (mm)	H1 (mm)	W (mm)	Weight (kg)
15	150	495	285	105	15
20	150	495	285	105	15
25	160	522	282	150	20
40	200	572	302	165	27
50	230	635	315	195	44

(Weight is for ductile cast iron. Flange to flange dimension of DN 15 is not according to DIN standard, due to size of separator and steam trap.)

Sizing Chart and Discharge Capacity

Rated flow rates represent equivalent flow rates of air at 20°C under atmospheric pressure.

1. Differential pressure is the difference between the inlet pressure of the ACOS-10 and the outlet pressure of the trap.
2. Capacities are based on continuous discharge of condensate below 100°C with specific gravity of 1.

Installation Example

No.	Part Name	No.	Part Name
1	Valve Body	5	Siphon Tube*
2	Holder Plug	6	Dampener*
3	Holder Plug Gasket	7	Dampener Gasket*
4	Elbow (male/female)*	8	Pressure Gauge*

(Parts marked with * must be purchased separately. A pressure gauge unit option is available to replace the standard screen holder plug.)