TLV LV6-CE User manual

172-65230m-02 (LV6 Clean Steam Trap) 19 February 2009
Clean Steam Trap
LV6CE / LV6SF / LV6P / LV6EP
Copyright © 2009 by TLV CO., LTD.
All rights reserved
ISO 9001/ ISO 14001
Manufacturer
Kakogawa, Japan
is approved by LRQA LTD. to ISO 9001/14001

172-65230m-02 (LV6 Clean Steam Trap) 19 Feb 2009
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Contents
Introduction ........................................................................ 1
Safety Considerations........................................................ 2
Checking the Piping........................................................... 3
Operation ........................................................................... 4
Specifications..................................................................... 5
Configuration...................................................................... 5
Installation.......................................................................... 6
Maintenance....................................................................... 7
Disassembly / Reassembly................................................ 8
Troubleshooting ................................................................. 9
Product Warranty............................................................. 10
Option............................................................................... 11
Introduction
Thank you for purchasing the clean steam trap.
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 clean steam trap is of a revolutionary design that employs 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, thus preventing air-binding.
The above-listed superior features of the X-element employed in this clean
steam trap help to 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 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.
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 considerations continued on next page.

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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.
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.
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.
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 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. Is there any vibration in the piping?

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Operation
Principles of air and condensate discharge:
1. Start-up Air and Cold Condensate
Discharge
When the system is cold before the
supply of steam, the X-element is in its
contracted state and the valve is open.
This allows for the rapid discharge of
large quantities of air and cold
condensate through the open valve, thus
reducing start-up time.
2. Closed Position
When the discharge of initial air and cold
condensate is completed, steam flows
into the trap. This raises the temperature
of the interior of the trap, causing the
thermoliquid inside the X-element to
expand. The valve remains open as the
temperature inside the trap approaches
the inlet steam pressure’s saturation
temperature. When the temperature
reaches a point slightly below the
saturation temperature, the valve closes.
3. Condensate Discharge
With the influx of condensate, the
X-element is cooled, causing the valve to
immediately open and discharge the
condensate. Additionally, the X-element
responds with great sensitivity to the
temperature difference of air that is close
to saturation temperature and discharges
the air rapidly.
A
i
r
Valve
Steam
Valve
Condensate
Steam
Valve

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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.
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.
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.
** CNo. (Charge / Mill No.) is displayed for products with options. This item is omitted when there are no
options.
Configuration
No. Name
1 Lower Body
2 Upper Body
3 X-Element
4 Body Clamp
5 Gasket
6 Wing Nut
Model Maximum Allowable Pressure*
Nominal Diamete
r
Maximum Operating Temperature
Maximum Operating Pressure
CNo.**
Maximum Allowable Temperature*
LV6CE / LV6SF LV6P / LV6EP

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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.
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.
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 so that the arrow on the body is pointing in the direction of flow.
Please note that this product is intended for installation on vertical piping. It is
possible to install it in horizontal piping, however there will be some condensate
pooling inside the piping.
4. Install condensate outlet piping.
5. Open the inlet and outlet valves and check to make sure that the product functions
properly.
6. After steam has passed through the piping, allow the trap to cool and then further
tighten the clamp.
If there is a problem, determine the cause using the “Troubleshooting” section in this
manual.

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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 in
j
ury from the
discharge of fluids.
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.
Operational Inspection
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 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 : During either intermittent or continual condensate discharge
flash steam is discharged and the sound of flow can be
heard.
Blocked
(Discharge
Impossible)
: No condensate is discharged. The trap is quiet, making 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.
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
X-element Valve Area and Valve Seat Area of
Body: check for scratches, foreign matter or oil film
Check inside of body for foreign matter build-up, oil
film, scratches and wear

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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.
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.
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.)
Disassembly / Reassembly of Upper and Lower Bodies
Part During Disassembly During Reassembly
Wing Nut Loosen the nut with a tool such
as an adjustable wrench, then
remove the body clamp
Consult the table of tightening torques and tighten to
the proper torque;
avoid lopsided tightening by making sure that both
sides are tightened evenly;
after making sure that the interior pressure of the trap
has equalized to atmospheric pressure and that the
surface of the trap has cooled, further tighten;
if further tightening does not take place, steam leakage
may occur
Upper Body,
Lower Body Take apart without scratching the gasket sealing surfaces ⎯
Gasket ⎯Replace with new gasket if damaged
Removing / Reassembling Parts Inside Lower Body
Part During Disassembly During Reassembly
X-element Grasp the steel ball on the top
of the X-element and remove After making sure that the X-element is right-side-up, insert straight down into the guide-part of the lower
body, making sure it does not catch on the sides
Table of Tightening Torques
Part Name Torque
N⋅m Distance Across Flats
mm
Wing Nut 8.0 -
1 N⋅m = 9.80665 x 1 kg⋅cm ≈10 kg⋅cm

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Exploded View
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.
If the trap fails to operate properly, use the following table to locate the cause and remedy.
Problem Cause Remedy
X-element is sticking to the valve seat Clean parts
Valve seat is blocked Clean valve area of the
lower body or replace
lower body
No condensate
is discharged or
discharge is
poor
( blocked) Trap operating pressure exceeds the maximum
specified pressure or there is insufficient pressure
differential between the trap inlet and outlet
Compare specifications
and actual operating
conditions
There is build-up of rust or scale between the
X-element valve and valve seat on the lower body Clean parts
X-element valve and/or valve seat on the lower
body are damaged Replace with new X-element and/or replace
with new lower body
X-element is broken Replace with new
X-element
Steam is
discharged or
leaks from the
outlet
(blowing)
(steam leakage)
Improper installation Correct the installation
Trap vibration Lengthen inlet piping and
fasten securely
Gasket deterioration or damage Replace with new gasket
Improper tightening torque was used on clamp bolt
and nut Tighten to the proper torque
Steam is leaking
from a place
other than the
outlet The piping has been forcibly joined using a coupling
with the incorrect bore Correct the piping
Upper Body
X-element
Gasket
Lower Bod
y
Body Clamp

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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:
• Malfunctions due to improper installation, use, handling, etc., by
other than TLV CO., LTD. authorized service representatives.
• Malfunctions due to dirt, scale, rust, etc.
• Malfunctions due to improper disassembly and reassembly, or
inadequate inspection and maintenance by other TLV CO., LTD.
authorized service representatives.
• Malfunctions due to disasters or forces of nature.
• Accidents or malfunctions due to any other cause beyond the control
of TLV CO., LTD.
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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Option
Configuration
No. Name
1 Lower Body
2 Upper Body
3 X-Element
4 Body Clamp
5 Gasket
6 Clamp Bolt
7 Clamp Nut

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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.
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.
Use the procedures on the following page 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.)
Disassembly / Reassembly of Upper and Lower Bodies
Part During Disassembly During Reassembly
Body Clamp,
Clamp Bolt,
Clamp Nut
Remove with a socket wrench Consult the table of tightening torques and tighten to
the proper torque;
after making sure that the interior pressure of the trap
has equalized to atmospheric pressure and that the
surface of the trap has cooled, further tighten;
if further tightening does not take place, steam
leakage may occur
Upper Body,
Lower Body Take apart without scratching
the gasket sealing surfaces ⎯
Gasket ⎯Replace with new gasket if damaged
Removing / Reassembling Parts Inside Lower Body
Part During Disassembly During Reassembly
X-element Grasp the steel ball on the top
of the X-element and remove After making sure that the X-element is right-side-up, insert straight down into the guide-part of the lower
body, making sure it does not catch on the sides
Table of Tightening Torques
Part Name Torque
N⋅m Distance Across Flats
mm
Clamp Bolt, Clamp Nut 8.0 13
1 N⋅m = 9.80665 x 1 kg⋅cm ≈10 kg⋅cm

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Exploded View
Upper Body
X-element
Gasket
Lower Bod
y
Clamp Nut
Clamp Bolt
Body Clamp