TLV DC3-L User manual

172-65236MA-04 (DC3-L) 7 October 2021
Cyclone Separator
DC3-L
Copyright © 2021 by TLV CO., LTD.
All rights reserved

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Contents
Introduction .......................................................................1
Safety Considerations.......................................................2
Specifications....................................................................4
Configuration.....................................................................4
Installation.........................................................................5
Maintenance......................................................................6
Disassembly/Reassembly.................................................6
Troubleshooting ................................................................8
TLV EXPRESS LIMITED WARRANTY.............................9
Service ............................................................................11
Introduction
Thank you for purchasing the TLV cyclone separator.
This product has been thoroughly inspected before being shipped from the
factory. When the product 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 product properly.
This cyclone separator uses centrifugal force to separate condensate from air
or steam in piping lines.
If detailed instructions for special order specifications or options not contained
in this manual are required, please contact TLV for full details.
This instruction manual is intended for use with the model(s) 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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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.
Indicates an urgent situation which poses a threat of death or
serious injury
Indicates that there is a potential threat of death or serious injury
Indicates that there is a possibility of injury or equipment / product
damage
DO NOT use for toxic, flammable or otherwise hazardous
fluids.
This product is a separator for steam or air that separates and
discharges condensate from steam or air piping systems. Use
only for steam, air and/or condensate. This product is for
intended use only. Improper use may result in such hazards as
damage to the product or malfunctions that may lead to serious
accidents.
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.
Use hoisting equipment for heavy objects (weighing
approximately 20 kg (44 lb) or more).
Failure to do so may result in back strain or other injury if the
object should fall.
Continued on the next page
DANGER
WARNING
CAUTION
WARNING
CAUTION

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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.
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.
CAUTION

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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.
**Valve No. is displayed for products with options. This item is omitted from the nameplate
when there are no options.
Configuration
No.
Name
1
Body
2
Separator Body
3
Cover
4
Separator
5
Body Gasket
6
Guide Pin
7
Body Bolt
8
Cover Bolt
9
Cover Gasket
10
Wave Spring
11
Float Cover
12
Float Cover Bolt
13
Spring Washer
14
Nameplate
15
Flange
(15 –25 mm (1/2–1 in)
DO NOT use for toxic, flammable or otherwise hazardous fluids.
This product is a separator for steam or air that separates and
discharges condensate from steam or air piping systems. Use only for
steam, air and/or condensate. This product is for intended use only.
Improper use may result in such hazards as damage to the product or
malfunctions that may lead to serious accidents.
WARNING
Model
Production Lot No.
Maximum Allowable
Temperature (TMA)*
Maximum Operating
Temperature (TMO)
Nominal Diameter
Maximum Allowable
Pressure*
Maximum Operating
Pressure
Valve No.**
Air/Steam Trap Outlet
Separator
Outlet
Condensate
Outlet
Separator
Outlet

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Installation
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 hoisting equipment for heavy objects (weighing approximately
20 kg (44 lb) or more). Failure to do so may result in back strain or other
injury if the object should fall.
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
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 product, blow out the inlet piping to remove any piping
scraps, dirt and oil. Close the inlet valve after blowdown.
3. Install the product at the point on the piping where the separation of condensate
will have the greatest effect on efficiency. For example, on a steam or air main or
branch at the inlet of equipment requiring high-quality dry steam or air.
4. Install the product so the arrow on the product is pointing in the direction of flow.
5. The product should be inclined no more than 10° horizontally and front-to-back.
6. Install an air trap or steam trap at the condensate outlet. Use of the TLV free float
type trap is advised.
7. To facilitate inspection and maintenance, install a union at the condensate outlet
and ensure that there is sufficient space for maintenance.
8. Open the inlet valve and outlet valves and check to make sure that the product
functions properly.
If there is a problem, determine the cause using the “Troubleshooting” section in this
manual.
Tolerance Angle for Installation: 10°
Make sure the product is
installed with the raised
TLV lettering on the body
horizontal.
DO NOT use for toxic, flammable or otherwise hazardous fluids.
This product is a separator for steam or air that separates and
discharges condensate from steam or air piping systems. Use only for
steam, air and/or condensate. This product is for intended use only.
Improper use may result in such hazards as damage to the product or
malfunctions that may lead to serious accidents.
WARNING

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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
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 scratches
Body Interior: Check for build-up
Disassembly/Reassembly
Use hoisting equipment for heavy objects (weighing approximately
20 kg (44 lb) or more). Failure to do so may result in back strain or other
injury if the object should fall.
CAUTION
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.)
Detaching/Reattaching the Cover
Part
During Disassembly
During Reassembly
Cover Bolt
Remove with a socket
wrench
Consult the table of tightening torques and
tighten to the proper torque
Cover
Remove the cover by pulling
it down, being careful not to
scratch the seating surface
Make sure there are no pieces of the old
gasket left on the sealing surfaces of the
separator body and cover, align the guide pin
on the cover with the guide pin hole on the
separator body and reattach
Cover Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket
Detaching/Reattaching Parts Inside the Cover
Float Cover
Bolt
(Spring
Washer)
Remove with a socket
wrench
Consult the table of tightening torques and
tighten to the proper torque
Float Cover
Remove by lifting up and off
Place it into position

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Separating/Reattaching Body and Separator Body
Part
During Disassembly
During Reassembly
Body Bolt
Remove with a socket
wrench
Consult the table of tightening torques and
tighten to the proper torque
Separator
Body
Pull down and out from the
body, being careful not to let
the separator fall as it comes
out with the separator body
Make sure there are no pieces of the old gasket
left on the sealing surfaces of the separator
body and body, align the guide pin on the
separator body with the guide pin hole on the
body and reattach
Separator
Remove when detaching the
separator body
Insert it into the groove in the separator body
Wave Spring
Remove with the separator
Insert it into the groove
Body Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket
Table of Tightening Torques
Part
Size
Torque
Distance Across Flats
mm
(in)
Nm
(lbfft)
mm
(in)
Body Bolt
15 –40
(1/2–11/2)
60
(44)
17
(21/32)
50
(2)
70
(51)
19
(3/4)
Cover Bolt
15 –40
(1/2–11/2)
60
(44)
17
(21/32)
50
(2)
70
(51)
19
(3/4)
Float Cover Bolt
15 –40
(1/2–11/2)
10
(7)
10
(3/8)
50
(2)
20
(15)
13
(1/2)
NOTE:
-Coat all threaded portions with anti-seize.
-If drawings or other special documentation were supplied
for the product, any torque given there takes precedence
over values shown here.
(1 Nm 10 kgcm)
Exploded View
Body
Separator
Spring Washer
Wave Spring
Body Gasket
Separator Body
Guide Pin
Body Bolt
Float Cover
Float Cover Bolt
Cover Gasket
Cover
Cover Bolt

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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 product fails to operate properly, use the following table to locate the
cause and remedy.
Problem
Cause
Remedy
Steam or air is
leaking from
sealing surfaces
Gasket deterioration or damage
Replace with new gasket(s)
Improper tightening torques were
used
Tighten to the proper torque
Water is mixed in
with the steam or air
from the separator
outlet
Steam/air flow velocity is too high
Take steps necessary to lower the
steam/air flow velocity
Improper installation
Correct the installation

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TLV EXPRESS LIMITED WARRANTY
Subject to the limitations set forth below, TLV CO., LTD., a Japanese corporation
(“TLV”), warrants that products which are sold by it, TLV International Inc. (“TII”) or
one of its group companies excluding TLV Corporation (a corporation of the United
States of America), (hereinafter the “Products”) are designed and manufactured by
TLV, conform to the specifications published by TLV for the corresponding part
numbers (the “Specifications”) and are free from defective workmanship and
materials. The party from whom the Products were purchased shall be known
hereinafter as the “Seller”. With regard to products or components manufactured by
unrelated third parties (the “Components”), TLV provides no warranty other than the
warranty from the third party manufacturer(s), if any.
Exceptions to Warranty
This warranty does not cover defects or failures caused by:
1. improper shipping, installation, use, handling, etc., by persons other than TLV,
TII or TLV group company personnel, or service representatives authorized by
TLV; or
2. dirt, scale or rust, etc.; or
3. improper disassembly and reassembly, or inadequate inspection and
maintenance by persons other than TLV or TLV group company personnel, or
service representatives authorized by TLV; or
4. disasters or forces of nature or Acts of God; or
5. abuse, abnormal use, accidents or any other cause beyond the control of TLV,
TII or TLV group companies; or
6. improper storage, maintenance or repair; or
7. operation of the Products not in accordance with instructions issued with the
Products or with accepted industry practices; or
8. use for a purpose or in a manner for which the Products were not intended; or
9. use of the Products in a manner inconsistent with the Specifications; or
10. use of the Products with Hazardous Fluids (fluids other than steam, air, water,
nitrogen, carbon dioxide and inert gases (helium, neon, argon, krypton, xenon
and radon)); or
11. failure to follow the instructions contained in the TLV Instruction Manual for the
Product.
Duration of Warranty
This warranty is effective for a period of one (1) year after delivery of Products to the
first end user. Notwithstanding the foregoing, asserting a claim under this warranty
must be brought within three (3) years after the date of delivery to the initial buyer if
not sold initially to the first end user.
ANY IMPLIED WARRANTIES NOT NEGATED HEREBY WHICH MAY ARISE BY
OPERATION OF LAW, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE AND ANY EXPRESS WARRANTIES NOT
NEGATED HEREBY, ARE GIVEN SOLELY TO THE INITIAL BUYER AND ARE LIMITED IN
DURATION TO ONE (1) YEAR FROM THE DATE OF SHIPMENT BY THE SELLER.
Exclusive Remedy
THE EXCLUSIVE REMEDY UNDER THIS WARRANTY, UNDER ANY EXPRESS
WARRANTY OR UNDER ANY IMPLIED WARRANTIES NOT NEGATED HEREBY
(INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE), IS REPLACEMENT; PROVIDED: (a) THE CLAIMED DEFECT IS

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REPORTED TO THE SELLER IN WRITING WITHIN THE WARRANTY PERIOD, INCLUDING
A DETAILED WRITTEN DESCRIPTION OF THE CLAIMED DEFECT AND HOW AND WHEN
THE CLAIMED DEFECTIVE PRODUCT WAS USED; AND (b) THE CLAIMED DEFECTIVE
PRODUCT AND A COPY OF THE PURCHASE INVOICE IS RETURNED TO THE SELLER,
FREIGHT AND TRANSPORTATION COSTS PREPAID, UNDER A RETURN MATERIAL
AUTHORIZATION AND TRACKING NUMBER ISSUED BY THE SELLER. ALL LABOR
COSTS, SHIPPING COSTS, AND TRANSPORTATION COSTS ASSOCIATED WITH THE
RETURN OR REPLACEMENT OF THE CLAIMED DEFECTIVE PRODUCT ARE SOLELY
THE RESPONSIBILITY OF BUYER OR THE FIRST END USER. THE SELLER RESERVES
THE RIGHT TO INSPECT ON THE FIRST END USER’S SITE ANY PRODUCTS CLAIMED
TO BE DEFECTIVE BEFORE ISSUING A RETURN MATERIAL AUTHORIZATION. SHOULD
SUCH INSPECTION REVEAL, IN THE SELLER’S REASONABLE DISCRETION, THAT THE
CLAIMED DEFECT IS NOT COVERED BY THIS WARRANTY, THE PARTY ASSERTING
THIS WARRANTY SHALL PAY THE SELLER FOR THE TIME AND EXPENSES RELATED
TO SUCH ON-SITE INSPECTION.
Exclusion of Consequential and Incidental Damages
IT IS SPECIFICALLY ACKNOWLEDGED THAT THIS WARRANTY, ANY OTHER EXPRESS
WARRANTY NOT NEGATED HEREBY, AND ANY IMPLIED WARRANTY NOT NEGATED
HEREBY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, DO NOT COVER, AND NEITHER TLV, TII NOR ITS TLV
GROUP COMPANIES WILL IN ANY EVENT BE LIABLE FOR, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO LOST PROFITS, THE
COST OF DISASSEMBLY AND SHIPMENT OF THE DEFECTIVE PRODUCT, INJURY TO
OTHER PROPERTY, DAMAGE TO BUYER’S OR THE FIRST END USER’S PRODUCT,
DAMAGE TO BUYER’S OR THE FIRST END USER’S PROCESSES, LOSS OF USE, OR
OTHER COMMERCIAL LOSSES. WHERE, DUE TO OPERATION OF LAW,
CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER THIS WARRANTY, UNDER ANY
OTHER EXPRESS WARRANTY NOT NEGATED HEREBY OR UNDER ANY IMPLIED
WARRANTY NOT NEGATED HEREBY (INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) CANNOT BE
EXCLUDED, SUCH DAMAGES ARE EXPRESSLY LIMITED IN AMOUNT TO THE
PURCHASE PRICE OF THE DEFECTIVE PRODUCT. THIS EXCLUSION OF
CONSEQUENTIAL AND INCIDENTAL DAMAGES, AND THE PROVISION OF THIS
WARRANTY LIMITING REMEDIES HEREUNDER TO REPLACEMENT, ARE INDEPENDENT
PROVISIONS, AND ANY DETERMINATION THAT THE LIMITATION OF REMEDIES FAILS
OF ITS ESSENTIAL PURPOSE OR ANY OTHER DETERMINATION THAT EITHER OF THE
ABOVE REMEDIES IS UNENFORCEABLE, SHALL NOT BE CONSTRUED TO MAKE THE
OTHER PROVISIONS UNENFORCEABLE.
Exclusion of Other Warranties
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
AND ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
ARE EXPRESSLY DISCLAIMED.
Severability
Any provision of this warranty which is invalid, prohibited or unenforceable in any
jurisdiction shall, as to such jurisdiction, be ineffective to the extent of such invalidity,
prohibition or unenforceability without invalidating the remaining provisions hereof,
and any such invalidity, prohibition or unenforceability in any such jurisdiction shall
not invalidate or render unenforceable such provision in any other jurisdiction.

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Service
For Service or Technical Assistance: Contact your TLV representative or your regional TLV office.
In Europe:
Daimler-Benz-Straße 16-18, 74915 Waibstadt, Germany
Tel:
Fax:
[49]-(0)7263-9150-0
[49]-(0)7263-9150-50
Units 7 & 8, Furlong Business Park, Bishops Cleeve, Gloucestershire GL52
8TW, U.K.
Tel:
Fax:
[44]-(0)1242-227223
[44]-(0)1242-223077
Parc d’Ariane 2, bât. C, 290 rue Ferdinand Perrier, 69800 Saint Priest,
France
Tel:
Fax:
33–(0)4-72482222
[33]-(0)4-72482220
In North America:
13901 South Lakes Drive, Charlotte, NC 28273-6790, U.S.A.
Tel:
Fax:
[1]-704-597-9070
[1]-704-583-1610
In Mexico and Latin America:
Av. Jesús del Monte 39-B-1001, Col. Hda. de las Palmas, Huixquilucan,
Edo. de México, 52763, Mexico
Tel:
Fax:
[52]-55-5359-7949
[52]-55-5359-7585
In Oceania:
Unit 8, 137-145 Rooks Road, Nunawading, Victoria 3131, Australia
Tel:
Fax:
[61]-(0)3-9873 5610
[61]-(0)3-9873 5010
In East Asia:
36 Kaki Bukit Place, #02-01/02, Singapore 416214
Tel:
Fax:
[65]-6747 4600
[65]-6742 0345
Room 5406, No. 103 Cao Bao Road, Shanghai, China 200233
Tel:
Fax:
[86]-(0)21-6482-8622
[86]-(0)21-6482-8623
No.16, Jalan MJ14, Taman Industri Meranti Jaya, 47120 Puchong,
Selangor, Malaysia
Tel:
Fax:
[60]-3-8065-2928
[60]-3-8065-2923
252/94 (K-L) 17th Floor, Muang Thai-Phatra Complex Tower B,
Rachadaphisek Road, Huaykwang, Bangkok 10310, Thailand
Tel:
Fax:
[66]-2-693-3799
[66]-2-693-3979
#302-1 Bundang Technopark B, 723 Pangyo-ro, Bundang, Seongnam,
Gyeonggi, 13511, Korea
Tel:
Fax:
[82]-(0)31-726-2105
[82]-(0)31-726-2195
In the Middle East:
Building 2W, No. M002, POBox 371684, Dubai Airport Free Zone, Dubai, UAE
Email:
[email protected]
In Other Countries:
881 Nagasuna, Noguchi, Kakogawa, Hyogo 675-8511, Japan
Tel:
Fax:
[81]-(0)79-427-1818
[81]-(0)79-425-1167
Manufacturer:
881 Nagasuna, Noguchi, Kakogawa, Hyogo 675-8511, Japan
Tel:
Fax:
[81]-(0)79-422-1122
[81]-(0)79-422-0112