TLV LV5 Bedienungsanleitung

172-65123m-02 (LV Series) 19 Feburary 2009

Balanced Pressure Thermostatic Steam Trap

LV5 / LV13 / LV13L / LV13N

LV21 / LV21-TC

ISO 9001/ ISO 14001

Manufacturer

Kakogawa, Japan

is approved by LRQA LTD. to ISO 9001/14001

172-65123m-02 (LV Series) 19 Feb 2009

Contents

Contents............................................................................ 1

Introduction ....................................................................... 1

Safety Considerations ....................................................... 2

Checking the Piping .......................................................... 4

Specifications .................................................................... 5

Configuration..................................................................... 6

Installation ......................................................................... 7

Maintenance...................................................................... 8

Disassembly / Reassembly ............................................... 9

Troubleshooting .............................................................. 13

Product Warranty ............................................................ 14

Introduction

Thank you for purchasing the Balanced Pressure Thermostatic Steam Trap.

This product has been thoroughly inspected before being shipped from the factory.

When the trap 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

trap properly.

This steam trap is of a revolutionary design that uses a high-performance X-element.

This is a new type of valve mechanism in which a thermoliquid is sealed inside the

X-element and the valve opens or closes based on the difference between the

saturation temperatures of the thermoliquid and the water. The X-element is very

sensitive to changes in temperature, and responds with great accuracy, quickly

discharging air and the large quantities of condensate created immediately after

operation start-up, thereby greatly reducing start-up time. It also reacts with great

sensitivity to the inflow of large quantities of condensate and hot air during operation,

preventing air-locking.

The superior features of the X-element help increase heating efficiency and reduce

manpower requirements for maintenance and bypass blowdown.

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 for the models 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.

172-65123m-02 (LV Series) 19 Feb 2009

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

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.

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.

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.

Safety cautions continued on next page.

172-65123m-02 (LV Series) 19 Feb 2009

CAUTION 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.

172-65123m-02 (LV Series) 19 Feb 2009

Checking the Piping

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

Check to make sure that the pipes to be connected to the trap have been installed

properly.

1. Is the pipe diameter suitable?

2. Is the piping where the trap is to be installed horizontal?

3. Has sufficient space been secured for maintenance?

4. Have isolation valves been installed at the inlet and outlet? If the outlet is subject

to back pressure, has a check valve (TLV-CK) been installed?

5. Is the inlet pipe as short as possible, with as few bends as possible, and installed

so the liquid will flow naturally down into the trap?

6. Has the piping work been done correctly, as shown in the figures below?

Requirement Correct Incorrect

Install catchpot with the

proper diameter.

Diameter is too small.

Make sure the flow of

condensate is not

obstructed.

Diameter is too small and

inlet protrudes into pipe

interior.

To prevent rust and scale

from flowing into the trap,

the inlet pipe should be

connected 25 – 50 mm

above the base of the

T-pipe.

Rust and scale flow into the

trap with the condensate.

When installing on the

blind end, make sure the

flow of condensate is not

obstructed.

Condensate collects in the

pipe.

172-65123m-02 (LV Series) 19 Feb 2009

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.

LV13L / LV13N

LV5 / LV13 / LV21 / LV21-TC

* Maximum allowable pressure (PMA) and maximum allowable temperature (TMA) are PRESSURE

SHELL DESIGN CONDITIONS, NOT OPERATING CONDITIONS.

** Valve No. is displayed for products with options. This item is omitted from the nameplate when there

are no options.

Maximum Operating Temperature (stainless steel models):

Maximum Allowable

Temperature*

Model

Maximum Allowable

Pressure*

Nominal Diamete

Valve No.**

X-element Type

Maximum Operating

Temperature

Serial Numbe

Maximum Operating

Pressure

Maximum Allowable

Temperature*

Model

Maximum Allowable

Pressure*

Nominal Diamete

Valve No.**

X-element Type

Maximum Operating

Temperature

Serial Number

Maximum Operating

Pressure

Temperature (°C)

– Saturated Steam Curve

Operating Pressure (MPaG) (1 MPa = 10.197 kg/cm

)

LV21

LV21-TC

LV5

172-65123m-02 (LV Series) 19 Feb 2009

Configuration

LV5 / LV13 (Brass) LV5 / LV21 (Cast Stainless Steel)

LV13L (Brass) LV13N (Brass)

LV21-TC (Cast Stainless Steel)

Name

1 Body

2 Cover

3 X-element

4 Valve Seat

5 Screen

Nameplate

7 Spring Clip

8 Cover Gasket

Name

1 Body

2 Cover

3 X-element

4 Valve Seat

5 Screen

6 Nameplate

7 Spring Clip

No.

Name R **

1 Body

2 Cover

3 Valve Seat 9

4 X-element 9

5 X-element

Guide 9

6 Spring Clip 9

7 Screen 9

8 Cover

Gasket 9

9 Nameplate

No.

Name R **

1 Body

2 Cover

3 Valve Seat 9

4 X-element 9

5 X-element

Guide 9

6 Spring Clip 9

7 Screen 9

8 Cover

Gasket 9

9 Nameplate

No.

Name R **

1 Body

2 Cover

3 Cover

Gasket 9

4 Screen 9

5 X-element

Guide 9

6 Spring

Clip 9

7 X-element 9

8 Valve

Seat 9

Nameplate

10 Sleeve

Nut (×2) 9

11 Sleeve

(×2) 9

** Parts available in repair kit

172-65123m-02 (LV Series) 19 Feb 2009

Installation

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

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.

CAUTION

Installation, inspection, maintenance, repairs, disassembly, adjustment, and valve

opening/closing should be carried out only by trained maintenance personnel.

1. Before installation, be sure to remove all protective seals.

2. Before installing the trap, blow out the inlet piping to remove any piping scraps,

dirt and oil. Close the inlet valve after blowdown.

3. Install with the arrow on the product pointing in the direction of flow.

4. All models except LV13L may be installed either vertically or horizontally,

whichever is necessary to make sure the arrow on the product points in the

direction of flow. DO NOT install traps upside-down. Model LV13L MUST be

installed with the inlet horizontal and the outlet vertical.

5. Connect the piping.

6. Open the inlet valve and check to make sure that the trap functions properly.

7. LV21-TC Instructions:

• Connect to pipe sections that are not scratched or deformed.

• When cutting pipes, make straight cuts perpendicular to the pipe length.

Remove any pipe scraps or dirt.

• Reconnection: Compression fitting attachment allows repeated disconnection

and reattachment.

• Refer to the following table proper compression fitting torque

LV21-TC Compression Fitting Torque

Pipe Diameter (mm) 8 10 9.53 (3/8”*) 12.7 (1/2”*)

Tightening Torque (N·m) 46 56 53 98

Distance Across Flats (mm) 17 19 21 24

* Nominal diameter 1 N·m ≈10 kg·cm

If there is a problem, determine the cause by using the “Troubleshooting” guide in

this manual.

172-65123m-02 (LV Series) 19 Feb 2009

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

A visual inspection of the following items should be done on a daily basis to

determine whether the trap is operating properly or has failed. Periodically (at least

biannually) the operation should also be checked by using diagnostic equipment,

such as a stethoscope, thermometer, TLV Pocket TrapMan or TLV TrapMan.

If the trap should fail, it may cause damage to piping and equipment, resulting in

faulty or low quality products or losses due to steam leakage.

Normal : Condensate is discharged intermittently together with flash

steam, and the sound of flow can be heard.

Blocked

(Discharge Impossible)

: No condensate is discharged. The trap is quiet and makes no

noise, and the surface temperature of the trap is low.

Blowing : Live steam continually flows from the outlet and there is a

continuous metallic sound.

Steam Leakage : Live steam is discharged through the trap outlet together with

condensate, accompanied by a high-pitched sound.

(When conducting a visual inspection, flash steam is sometimes mistaken for steam leakage.

For this reason, the use of a steam trap diagnostic instrument [such as TLV TrapMan if

appropriate] in conjunction with the visual inspection is highly recommended.)

Parts Inspection

When parts have been removed, or during periodic inspections, use the following

table to inspect the parts and replace any that are found to be defective.

Procedure

Gasket: Check for warping or damage

Screen: Check for clogging or corrosion damage

X-element: Check for damage

Valve seat: Check for damage

Check inside of body for rust and scale

Check X-element valve and valve seat for rust and scale or

oil film, and also check for wear

172-65123m-02 (LV Series) 19 Feb 2009

Disassembly / Reassembly

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

Use the following procedures to remove components. Use the same procedure in

reverse to reassemble. (Installation, inspection, maintenance, repairs, disassembly,

adjustment, and valve opening/closing should be carried out only by trained

maintenance personnel.)

Removing / Reattaching Body (LV5 / LV13 / LV21)

Part During Disassembly During Reassembly

Body Use a socket wrench to

remove

Consult the table of tightening torques and

tighten to the proper torque

Removing / Reassembling Parts Inside Cover (LV5 / LV13 / LV21)

Part During Disassembly During Reassembly Figure A

Screen Remove without

bending

Being careful not to bend it,

insert with the right side up

Spring Clip Remove with

needle-nose pliers

Fit securely into the spring clip

slots

X-element Remove from the

X-element guide

Holding the ball on the top of the

X-element with pliers, insert

slowly, keeping the X-element

level and making sure it does

not catch on the guide (Fig. A)

Cover

Gasket*

Remove carefully to

avoid damaging

Replace with new gasket when

necessary

* Only for brass LV5 and LV13

Table of Tightening Torques (LV5 / LV13 / LV21)

Part Size

Torque

N⋅m

Distance Across Flats

8 – 15 80 27Body / Cover (Brass)

(LV5, LV13) 20, 25 80 41

Body / Cover (Stainless Steel)

(LV5, LV21) 8 – 15 120 27

Note: Be sure to coat screw threads with anti-seize only on

stainless steel models of LV5 and LV21

Spring

clip

slots

1 N⋅m ≈10 kg⋅cm

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