The TLV A-COSR-10 is a technologically advanced, self-actuated pressure reducing valve designed for accurate control in compressed air systems. It provides a more stable secondary pressure than conventional reducing valves and features a self-aligning shock-absorbing spherical piston. The A-COSR-10 is designed for long service life, with all major internal components made of stainless steel for superior durability.

Features

1. Self-aligning shock-absorbing spherical piston and advanced pilot regulator designs maintain secondary pressure accuracy, even during adverse process conditions.
2. Major internal components made of stainless steel for long service life.
3. Large surface area integral screen for pilot valve extends trouble-free service.
4. Internal secondary pressure-sensing channel makes external sensing line unnecessary.

Specifications

Parameter	Value
Model	A-COSR-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, 32, 40, 50
Maximum Operating Pressure (PMO)	9 barg (0.9 MPaG)
Maximum Operating Temperature (TMO)	100 °C
Primary Pressure Range	1 – 9 barg (0.1 - 0.9 MPaG)
Adjustable Pressure Range	0.5 – 7 barg (0.05 - 0.7 MPaG)
Minimum Differential Pressure	0.5 bar (0.05 MPa)
Minimum Adjustable Flow Rate	10% of rated flow rate
Applicable Fluid	Air

WARNING

Do not use for toxic, flammable or otherwise hazardous fluids. Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges. Use only under conditions in which no freeze-up will occur.

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	Adjustment Screw
8	Pilot Valve	17	Spanner Cap
9	Pilot Valve Seat	18	Plug – Sensing Line Port

Installation Guidelines

Straight Piping Runs

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.

• 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 30 d or more when an automated valve (on-off 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 30 d or more when a safety valve, another pressure reducing valve, or a control valve is installed. (Note: d = pipe diameter)

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.

Blowdown

Before installing the A-COSR, 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. Make sure that the shut-off valve and the bypass valve located upstream and downstream of the A-COSR are completely closed.
2. Remove the spanner cap, loosen the locknut and turn the adjustment screw counter-clockwise to reduce tension on the coil spring.
3. Slowly, fully open the shut-off valve at the inlet of the A-COSR. Allow sufficient time for condensate remaining at the inlet to be discharged.
4. Slightly open the shut-off valve at the outlet of the A-COSR.
5. Turn the adjustment screw until the desired outlet pressure is obtained. Wait several minutes.
6. Slowly, fully open the shut-off valve at the outlet of the A-COSR.
7. After setup, retighten the locknut and replace the cap.

Maintenance and Operational Check

To ensure long service life, 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.

Exploded View

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 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	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
		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 within the specification range
	Chattering never stops	Condensate is contained, or the trap is blocked	Check the trap, Check the piping

Dimensions and Sizing

(Rated flow rates represent equivalent flow rates of air at 20 °C under atmospheric pressure. 1 bar = 0.1 MPa)