TLV A46S User manual

172-65203MA-02 (A-Series+BD2) 21 April 2010
Thermodyne Steam Trap
A46S / A46SW / A65S
Copyright © 2010 by TLV CO., LTD.
All rights reserved
ISO 9001/ ISO 14001
Manufacturer
Kakogawa, Japan
is approved by LRQA LTD. to ISO 9001/14001

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
Contents
Introduction ........................................................................ 1
Safety Considerations........................................................ 2
Checking the Piping........................................................... 4
Specifications..................................................................... 5
Configuration...................................................................... 5
Operation ........................................................................... 6
Installation.......................................................................... 7
Maintenance....................................................................... 8
Disassembly / Reassembly................................................ 9
Troubleshooting ............................................................... 11
Product Warranty............................................................. 12
Options............................................................................. 13
Introduction
Thank you for purchasing the Thermodyne 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.
The Thermodyne Steam Trap features a bimetal ring for thermostatic air
venting, which allows the quick, automatic discharge of large quantities of initial
air and cold condensate 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 binding.
The Thermodyne Steam Trap, with its superior features listed above, in
combination with the proven performance record of the bimetal thermostatic air
vent, increases heating efficiency and reduces 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 intended for use with the models listed on the front
cover. It is necessary not only for installation but for subsequent maintenance,
disassembly/reassembly and troubleshooting. Please keep it in a safe place for
future reference.

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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.
DANGER 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.

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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.

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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. Has sufficient space been secured for maintenance?
3. Have maintenance valves been installed at the inlet and outlet? If the outlet is
subject to back pressure, has a check valve (TLV-CK) been installed?
4. 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?
5. Has the piping work been done with the proper methods, 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 (1 – 2 in)
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.

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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.
* Maximum allowable pressure (PMA) and maximum allowable temperature (TMA) are
PRESSURE SHELL DESIGN CONDITIONS, NOT OPERATING CONDITIONS.
** TAG NO. is displayed for products with options. This item is omitted from the nameplate
when there are no options.
Configuration
No. Name Maintenance
Kit Repair Kit
1 Body
2 Module Valve Seat √
3 Inner Cover √
4 Disc √
5 Disc Holder Ring √
6 Air Vent Ring √
7 Outer Module Gasket √√
8 Nameplate
9 Inner Module Gasket √√
10 Screen √
11 Screen Holder Gasket √√
12 Screen Holder
13 Cap
Model
Maximum Allowable
Maximum Allowable
Nominal
Maximum Operating Maximum Operating
TAG NO.**
Serial Number

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
Operation
Principle of Air and Condensate Discharge
1. Start-up: Discharge of Initial Air and Cold Condensate
At start-up, the bimetal air vent ring is cold and has therefore contracted, causing it to
ride up to the narrower area under the disc, thus lifting the disc off the seat and
holding the valve open. This allows for the rapid discharge of initial air and cold
condensate.
2. Steam Enters, Valve Closes
As the bimetal air vent ring is heated by the entering steam, it expands and slips back
down, freeing the disc. The rapid flow of steam creates a low-pressure region under
the disc, which suctions it onto the seat. The pressure chamber above the disc
becomes a high pressure region when entering steam is compressed. This difference
in the pressures above and below the disc gives the closed valve a tight seal.
3. Condensate Discharge
When condensate enters the trap, the temperature in the pressure chamber drops,
causing the steam to condense and the pressure to drop. The inlet pressure then
pushes up the disc, opening the valve and allowing condensate to discharge. The
bimetal air vent ring remains in its expanded, low position state. When steam again
enters the trap, the valve closes, as in step 2, while allowing no steam to escape.
Cold Condensate
Air
Pressure
Steam
Condensate

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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
Note: For products with socket weld connections, electric weld with a single pass. As
internal parts are not damaged by the welding process if limited to a single
pass, there is no need to remove them before welding.
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 the trap so the arrow on the trap is pointing in the direction of condensate
flow.
4. The trap may be installed either horizontally or vertically; there are no restrictions
on the direction of installation. (Fix the trap securely in place.)
5. Connect the outlet piping.
6. Open the inlet valve and check to make sure that the trap functions properly.
If there is a problem, determine the cause by using the “Troubleshooting” section in
this manual.

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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 items on the following page 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 TrapMan or TLV Pocket 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 [TLV: TrapMan] in
conjunction with the visual inspection is highly recommended.)
Flash Steam Live Steam
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
Gaskets: check for warping or damage
Screen: check for clogging or corrosion damage
Disc: check for damage or wear
Disc Holder Ring: check for damage or wear
Air Vent Ring: check for damage or wear
Module Valve Seat Surface: check for damage or wear
White jet
containing water
droplets
Clear, slightly
bluish jet

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
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 procedures in
reverse to reassemble.
(Installation, inspection, maintenance, repairs, disassembly, adjustment and valve
opening/closing should be carried out only by trained maintenance personnel.)
Removing / Replacing the Cap
Part During Disassembly During Reassembly
Cap Gently turn the cap until
the notch on the cap
lines up with the knob on
the body, then remove
Being careful not to bend it,
gently turn the cap until the
notch on the cap lines up
with the knob on the body,
then tighten (see Figure A)
Removing / Replacing the Valve Seat Unit
Part During Disassembly During Reassembly
Inner Cover Remove with a socket
wrench Consult the table of tightening torques and tighten to the
proper torque
Disc Remove, being careful not
to scratch the lapped
surface
Make sure that the seat surface
(lapped side with groove) is
facing down toward the valve
seat (see Figure B)
Disc Holder
Ring Remove without bending Set on the air vent ring and make sure that it does not sit on
the valve seat surface
A
ir Vent Ring Remove without bending,
as it will not return to its
proper shape
Reinsert without bending
Module Valve
Seat Remove carefully, being careful not to scratch the
polished seat surface
Insert into the body levelly,
being careful not to tilt
Outer Module
Gasket Remove with a screwdriver, or other suitable tool and
clean the gasket housing
Replace with a new gasket
Inner Module
Gasket Remove with a screwdriver, or other suitable tool and
clean the gasket housing
Replace with a new gasket
Removing / Replacing the Parts Inside the Body
Part During Disassembly During Reassembly
Screen Holder Remove with a socket
wrench Consult the table of tightening torques and tighten to the proper torque
Screen Holder
Gasket — Can be reused if not damaged, but replacement with a new gasket is recommended
Screen Remove without bending Reinsert, being careful not to bend
Figure B
Figure A
Body
Knob
Valve
Seat
Cap

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
Table of Tightening Torques
Inner Cover Screen Holder
Model Torque Distance
Across Flats Torque Distance Across Flats
N·m (ft·lb) mm (in) N·m (ft·lb) mm (in)
A46S, A65S 250 (185) 46 (113⁄16) 100 (73) 30 (13⁄16)
A46SW 320 (235) 50 (2) 100 (73) 30 (13⁄16)
NOTE: Be sure to coat threads with anti-seize (1 N·m ≈10 kg·cm)
Exploded View
* Asterisked parts make up the valve seat unit
Nameplate
Cap
Inner Cover
Disc
Disc Holder Ring
Air Vent Ring
Valve Seat
Outer Module Gasket
Inner Module Gasket
Body
Screen Holder
Screen
Screen Holder Gasket
Valve Seat Unit

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
Troubleshooting
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
When the trap fails to operate properly, use the following table to locate the cause.
Problem Cause Remedy
Check the module valve seat, screen and
piping to see if they are clogged with rust
or scale
Clean parts
Check to see if the disc is stuck to the
module valve seat Clean parts
Check to see if air-locking has occurred Perform a bypass blowdown,
or close the trap inlet valve
and allow the trap to cool
Air-locking has occurred due to disc
holder ring and or air vent ring wear Replace with new disc holder ring or air vent ring
Check to see if steam-locking has
occurred Perform a bypass blowdown, or close the trap inlet valve
and allow the trap to cool
No condensate
is discharged
or discharge is
poor
(blocked)
Check to see if the trap operating
pressure exceeds the maximum specified
pressure, or whether there is insufficient
pressure differential between the trap
inlet and outlet
Compare specifications and
actual operating conditions
Check to see if there is rust or scale on
the disc or on the module valve seat Clean parts
Check the disc and the module valve
seat for damage or wear Replace with new disc or module valve seat
Check for improper installation Correct the installation
Check for trap vibration Lengthen inlet piping and
fasten securely
Steam is
discharged or
leaks from the
outlet
(blowing)
(steam
leakage)
Check to see if the trap operating
pressure is less than the minimum
specified pressure or whether the back
pressure exceeds the allowable back
pressure
Compare specifications and
actual operating conditions
Check for gasket deterioration or damage Replace with new gasket(s)Steam is
leaking from a
place other
than the outlet
Check to make sure that the proper
tightening torques were used Tighten to the proper torque
NOTE: When replacing parts with new, use the parts list for reference, and replace with parts
from the Maintenance Kit and/or Repair Kit. Please note that replacement parts are only
available as part of a replacement parts kit.

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
Product Warranty
1. Warranty Period
One year following product delivery.
2. Warranty Coverage
TLV CO., LTD. warrants this product to the original purchaser to be free
from defective materials and workmanship. Under this warranty, the product
will be repaired or replaced at our option, without charge for parts or labor.
3. This product warranty will not apply to cosmetic defects, nor to any product
whose exterior has been damaged or defaced; nor does it apply in the
following cases:
1) Malfunctions due to improper installation, use, handling, etc., by
other than TLV CO., LTD. authorized service representatives.
2) Malfunctions due to dirt, scale, rust, etc.
3) Malfunctions due to improper disassembly and reassembly, or
inadequate inspection and maintenance by other than TLV CO.,
LTD. authorized service representatives.
4) Malfunctions due to disasters or forces of nature.
5) Accidents or malfunctions due to any other cause beyond the
control of TLV CO., LTD.
4. Under no circumstances will TLV CO., LTD. be liable for consequential
economic loss damage or consequential damage to property.
* * * * * * *
For Service or Technical Assistance:
Contact your representative or your regional office.
Manufacturer
CO., LTD.
881 Nagasuna, Noguchi
Kakogawa, Hyogo 675-8511 JAPAN
Tel: 81-(0)79 - 427 - 1800

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
Options
When operating the blowdown valve, stand to the side well clear of the
outlet to avoid contact with internal fluids that will be discharged. Failure
to do so may result in burns or other injury.
CAUTION
Do not use excessive force when opening the blowdown valve. Such
force may break the pin equipped as a valve stopper pin, causing a
blowout from internal pressure resulting in burns or other injury.
CAUTION
With Blowdown Valve (TLV BD2)
Configuration
TLV Blowdown Valve: BD2
The BD2 Blowdown Valve, installed in the screen area of the body, uses the
trap’s internal pressure to blow any condensate, steam, dirt or scale
accumulated around the screen area out to atmosphere.
Discharge Hole
BD2 Valve
BD2 Valve Seat
(Screen Holder)
Screen Holder Gasket
Valve Stopper Pin
Screen

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172-65203MA-02 (A-Series+BD2) 21 Apr 2010
BD2 Blowdown Valve Operation
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
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
1. The BD2 valve is in the closed position when the BD2 is shipped from the factory.
Before attempting to operate the BD2, reconfirm that the BD2 valve is still in the
closed position. Locate the blow outlet and, during operation, stand to the side and
well clear of it, as the jet of condensate or steam could cause burns.
2. Remain in the area the entire time the BD2 valve is in the open position. Before
opening the BD2 valve, grip the BD2 valve seat with a wrench and hold firmly in
place so that it will not rotate when the BD2 valve is loosened. Grip the BD2 valve
with another wrench and slowly loosen. Condensate and steam will discharge from
the blow outlet in a jet stream. Be careful not to loosen the BD2 valve so far that it
becomes removed from the BD2 valve seat. (If the grooved pin becomes damaged,
large quantities of steam will be discharged in a jet stream.)
3. Close the BD2 valve until the flow of fluid completely stops. If the flow of fluid
does not stop, re-open the valve (as in step “2”) to blow out any scale or dirt that
may be caught in the valve. Re-tighten the valve until the flow of fluid stops
completely.
Tightening Torques and Distance Across Flats
Torque Distance Across
Flats
Part N·m (lbf·ft) mm (in)
BD2 Valve 30 (22) 17 (21/32)
(1 N·m ≈10 kg·cm)
Note: Avoid the use of excessive tightening torques, as threaded
parts may become damaged.