The TLV CV-COS-20D is an electro-pneumatic control valve featuring a digital I/P positioner combined with a compact pneumatic actuator. It includes a built-in cyclone separator and a self-modulating free float steam trap to provide high-quality, dry steam for process applications. By removing condensate while the valve is closed, it reduces scale adhesion and water hammer, improving productivity and product quality.

Features

• Built-in cyclone separator and self-modulating free float steam trap provide dry, high-quality steam supply improving productivity and product quality for process applications.
• Removal of condensate while valve is closed reduces scale adhesion and water hammer.
• Pneumatic actuator with digital I/P positioner in a compact configuration.
• Rolling actuator diaphragm ensures linearity over the operating stroke and maximizes life.
• Self-adjusting positioner features zero calibration by auto-tuning, which ensures tight shut-off and improves control during low flow.
• Positioner LCD allows simple operation with capacitive keys and displays valve travel and error codes.
• Self-adjusting chevron packing minimizes seal leaks, stem wear and stiction/hysteresis problems.

Specifications

Valve Specifications

Model	CV-COS-20D
Body Material	Ductile Cast Iron (EN 5.3103) / Cast Stainless Steel (A351/A351M Gr.CF8M)
Connection	Flanged PN25 DIN EN 1092-2 / Flanged PN40 DIN EN 1092-2
Size (DN)	15, 20, 25, 40, 50, 65, 80, 100
Max. Operating Pressure (PMO)	Up to 21 barg (depends on size and material)
Max. Operating Temperature (TMO)	220 °C
Leak Rate Class (IEC 60534-4)	Class IV / Metal sealing
Characteristic	Equal percentage or linear
Rangeability	50 : 1
Applicable Fluid	Steam

WARNING

Do not use with toxic, flammable or otherwise hazardous fluids.

Actuator / Positioner Specifications

Parameter	Value
Fail-safe Position	Valve CLOSED (Air to Open)
Motive Medium	Oil-free air, filtered to 5 μm
Electrical Input Signal (mA)	4 to 20
Load Impedance (V)	Max. 6.3
Air Supply Pressure Range for Positioner (barg)	4.4 to 6
Ambient Temperature Range (°C)	-20 to +80
Protection Class	IP 66
Intrinsically Safe Rating (optional)	ATEX II 2G Ex ia IIC T4

Maximum Operating Differential Pressure (Air to open)

DN	Actuator Area (cm²)	Spring Bench Range (bar)	Min. Air Supply Pressure (barg)	Max. Differential Pressure (bar)
15, 20, 25	175	0.8 to 2.4	2.6	21
40, 50	355	1.6 to 2.4	2.6	21
65	355	2.4 to 3.6	3.8	21
80	750	1.6 to 2.4	2.6	20
100	750	2.5 to 4.2	4.4	20.5

Subject to limitation of maximum operating pressure rating of valve (PMO).

Cv & Kvs Values

Stroke (mm)	Kvs (DIN)	Cv (UK)	Cv (US)	DN \ Seat Dia. (mm)	12	24	38	48	63	80	100
15	4	3.9	5	15	○
15	6.3	6.1	7.5	20		○
15	10	9.7	12	25			○
15	25	24.3	30	40				○
15	40	38.8	47	50					○
15	60	58.2	70	65						○
15	80	77.6	95	80							○
30	160	155	190	100

Dimensions

DN	L (PN25)	L (PN40)	Actuator Area (cm²)	H	H1	W	ΦD	Weight (kg)
15	130	130	175	605	401	105	215	22
20	150	150	175	605	401	105	215	22
25	160	160	175	645	401	150	215	24
40	200	200	355	725	445	165	280	38
50	230	230	355	780	445	195	280	51
65	290	290	355	820	484	195	280	97
80	310	310	750	970	502	394	394	121
100	350	350	750	1165	594	394	394	245

Weight is for DIN PN 25 in ductile cast iron.

Trap Discharge Capacity

1. The discharge capacity is the maximum continuous condensate discharge 6 °C below saturated steam temperature.
2. The differential pressure is the difference between the CV-COS inlet and its trap outlet pressure.

DANGER

DO NOT use this product under conditions that exceed maximum differential pressure, as condensate backup will occur!

Installation Guidelines

Installation Angle

Install the product vertically, so that the arrow mark on the body points horizontally in the direction of flow. Allowable inclination is 10 degrees in the fore-aft direction and 15 degrees in the plane perpendicular to the flow line.

Maintenance Space

Leave sufficient space for maintenance, inspection and repair.

Piping Support

Install the product, paying attention to avoid excessive load, bending and vibration. Support the inlet and outlet pipes securely.

Outlet Piping

Connect the outlet pipe to a condensate return line, or extend it to a trench. In the case of the latter, make sure the end of the pipe is above the waterline. (Dirt and water may be sucked up by the vacuum formed during trap closure and system shutdown.)

Quality of Motive Air

Supply to the actuator only clean air that does not contain water, oil or foreign matter. To prevent malfunction due to contamination of the air supply, installation of the optional air filter regulator (5 µ filter) and mist separator (0.3 µ filter) as a set is recommended.

Operational Check

A visual inspection of the following items should be done on a daily basis to determine whether the product is operating properly or has failed.

Inspection Item	Inspection Method	Remedy
Leakage from valve (when valve is closed)	Visual Inspection or Stethoscope Inspection: Is the outlet side pressure or temperature elevated, or is there the sound of the medium flowing?	Adjust the zero/span; if that does not solve the problem, replace with a new valve plug & stem and valve seat
Leakage from gland area	Visual Inspection: Is liquid leaking from the slit between the gland and the valve stem?	Coat the gland and the valve stem thoroughly with grease; thoroughly grease the V-ring slot; or replace with a new V-ring
Leakage from the gaskets	Visual inspection: Is fluid leaking from the gasket areas on pressurized parts?	Apply additional tightening (refer to recommended torque) or replace with new gaskets
Leakage from pressure-bearing parts	Visual Inspection: Is fluid leaking from the body or bonnet?	Replace any pressurized parts at leak locations
Leakage from the trap area	Visual inspection or stethoscope inspection: Is live steam being discharged from the trap outlet piping, or can the sound of a steam leak be heard?	Clean the sealing surface of the trap valve seat or replace the valve seat

Troubleshooting

Valve Section

Problem	Cause	Remedy
Valve Leakage	The pressure of the air supply to the actuator or positioner is too high	Adjust the pressure of the air supply for the positioner to match the product specifications
	The positioner's zero point is miscalibrated	Adjust the positioner's zero point
	The inlet pressure for the product is too high	Decrease the inlet pressure to the maximum operating pressure (PMO) or less
	The valve plug and valve seat are off-center	Reassemble the valve bonnet section correctly
	There is a problem with the sealing surfaces	Replace with a new valve plug & stem and valve seat

Steam Trap Section

Problem	Cause	Remedy
Steam is blowing	Build-up of dirt on the trap valve seat or on the float	Clean or replace with a new trap valve seat or float
	The body is installed tilted	Correct the installation
	The float is deformed	Replace with a new float
	There is vibration in the piping	Remove the source of the vibration or reinforce the piping supports
No condensate is discharged	Primary pressure exceeds the trap valve seat maximum working pressure	Decrease the inlet pressure to the maximum operating pressure (PMO) or less
	Water is inside the float	Replace with a new float
	Output piping is clogged	Clean or modify the piping
	The trap valve seat is clogged	Clean or replace with a new trap valve seat