TLV UFO3-BN User manual

172-65176MA-03 (UFO3 Series) 27 August 2015
Free Ball-Bucket Steam Trap
UFO3-BN
•
UFO3F-BN
Copyright © 2015 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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Contents
Introduction .......................................................................1
Safety Considerations.......................................................2
Checking the Piping..........................................................4
Operation ..........................................................................5
Specifications....................................................................6
Configuration.....................................................................6
Installation.........................................................................7
Maintenance......................................................................8
Disassembly / Reassembly...............................................9
Troubleshooting ..............................................................11
Product Warranty ............................................................12
Option: Insulation Cover..................................................13
Introduction
Thank you for purchasing the Free Ball-Bucket 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.
The Free Ball-Bucket Steam Trap is suitable for applications where there is a
possibility of steam-locking or for batch process equipment, such as heat
exchangers, heaters, cylinder dryers and pressing machines.
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.
DO NOT use this product in excess of
the maximum operating
pressure differential.
Such use could make discharge impossible (blocked).
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.
Safety considerations continued on next page.

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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 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.

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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.

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Operation
Principles of air and condensate discharge:
1. Start-up Air and Cold Condensate
Discharge
At start-up, The UFO is on the launching
pad and initial air is discharged. When air
flows in with cold condensate, the UFO
floats off of the launching pad. However,
the bimetal is contracted due to the low
temperature. This holds the UFO away,
preventing it from closing against the
drain-jet allowing the discharge of all initial
air and cold condensate.
2. Entry of Steam
When steam flows in, the higher
temperature causes the bimetal to
expand, releasing the UFO. This allows
the UFO to float up and close off the
drain-jet.
3. Entry and Discharge of Condensate
As hot condensate enters replacing the
steam, the UFO looses buoyancy and
sinks back down to the launching pad,
allowing condensate discharge through
the drain-jet. When steam flows in again,
the UFO will once more rise and close off
the drain-jet.
Air
Steam
Condensate

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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
DO NOT use this product in excess of the maximum operating pressure
differential; such use could make discharge impossible (blocked).
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.
Model
Maximum Allowable
Temperature (TMA)*
Maximum Allowable
Pressure*
Maximum Operating
Temperature
Nominal Diameter
Maximum Differential
Pressure
Valve No.**
Production Lot No.
* 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
M
R
U
No.
Name
M
R
No.
Name
M
R
U
1
Case
8
Cover Gasket


15
Guide Pin
2
Cover
9
Launching Pad
16
Bimetal Strip

3
UFO Ball-bucket

10
Screen

17
Pin

4
Drain-jet

11
Screen Holder Gasket


18
Spring Washer

5
Drain-jet Gasket


12
Screen Holder
19
Screw

6
Bushing
13
Cover Bolt
7
Blast-off Nozzle
14
Nameplate
Replacement parts are available only in the following kits: M = Maintenance Kit; R = Repair Kit; U = UFO kit

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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
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, open the inlet valve and blow out the piping to
remove any piping scraps, dirt and oil. Close the inlet valve after blowdown.
3. Install the product so the arrow on the body is pointing in the direction of flow.
4. The trap should be inclined no more than 5° horizontally and front-to-back.
5. Install a condensate outlet valve and outlet piping.
6. Open the inlet 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 - 5°
Make sure the trap is installed with the raised lettering on the body horizontal.

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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
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 or 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, together with flash steam, is discharged intermittently,
and the sound of flow can be heard at the time of discharge.
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 Leakage
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
Screen: check for clogging or corrosion
Drain-jet: Check for damage
UFO Ball-bucket: check for scratches or dents
White jet
containing
water droplets
Clear, slightly
bluish jet

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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.
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
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
Lift up the cover; remove,
being careful not to damage
the seating surface
Make sure there are no pieces of the old gasket
left on the seating surfaces
; make sure the arrow
points in the direction of condensate flow
Cover Gasket
Remove, being careful not
to damage the seating
surface and clean the
seating surface
Replace with a new gasket
Disassembly / Reassembly of Components Inside the Cover
Part
During Disassembly
During Reassembly
Bimetal Strip
Remove with a screwdriver;
being careful not to bend the
bimetal strip
Consult the table of tightening torques and
tighten to the proper torque, being careful not to
bend the bimetal strip
Drain-jet
Remove with a socket
wrench
Consult the table of tightening torques and
tighten to the proper torque
Drain-jet
Gasket
Remove the gasket and
clean the seating surface
Replace with a new gasket if warped or
damaged
Disassembly / Reassembly of Screen Parts
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
Remove the gasket and
clean sealing surfaces
Replace with a new gasket; coat surfaces with
anti-seize
Screen
Remove without bending
Reinsert without bending
Disassembly / Reassembly of Components Inside the Body
Part
During Disassembly
During Reassembly
UFO Ball-
bucket
Use needle-nose pliers to
grasp the UFO by the pin on
the top and lift up to remove
Insert, being careful not to mishape the UFO
ball-bucket

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Table of Tightening Torques
Part Name
Torque
Dist. Across Flats
N∙m
(lbf·ft)
mm
(in)
Cover Bolt
30
(22)
13
(1/2)
Drain Jet
15
(11)
13
(1/2)
Screen Holder
60
(44)
22
(7/8)
Screw (for Bimetal Strip)
0.3
(0.22)
+
(1 N⋅m ≈10 kg⋅cm)
NOTE: -Coat all threaded portions and orifice gasket with anti-seize.
-If drawings or other special documentation were supplied for the product, any torque
given there takes precedence over values shown here.
Exploded View
Pin
UFO Ball-bucket
Blast-off Nozzle
Launching Pad
Screw
Spring Washer
Bimetal Strip
Cover Gasket
Drain-jet &
Gasket
Bushing
Cover
Cover Bolt Guide Pin
Case
Screen
Holder
Screen Holder
Gasket
Screen

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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
If the product fails to operate properly, use the following table to locate and remedy
the cause.
Problem
Cause
Remedy
No condensate
is discharged
(blocked) or
discharge is
poor
The UFO ball-bucket is stuck to the drain-jet
Clean Parts
The drain-jet valve port, screen or piping is
clogged with rust or scale
Clean parts
The steam trap has an insufficient capacity
Compare specifications with
actual operating conditions
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
Steam-locking has occurred
Perform a bypass blowdown or
close the trap inlet piping and
allow the trap to cool
Steam is
discharged or
leaks from the
outlet
(blowing)
(steam leakage)
Build-up of rust or scale on the drain-jet
valve port or on the UFO ball-bucket surface
Clean parts
Drain-jet is damaged
Replace with a new drain-jet
The UFO ball-bucket is misshapen or
damaged
Replace with a new UFO ball-
bucket
Improper installation orientation
Correct the installation
The bimetal strip is damaged
Replace with a new bimetal strip
Trap vibration
Lengthen the inlet piping and
fasten it securely
Steam is leaking
from a place
other than the
outlet
Gasket deterioration or damage
Replace with new gasket(s)
Improper tightening torques were used
Tighten to the proper torque
NOTE: -Blowing may occur on bucket-type steam traps used at less than 10% of their
maximum discharge capacity. Therefore, do not use this trap for applications in which
only small quantities of condensate are produced.
-When replacing parts with new, use the parts list for reference, and replace with parts
from the Maintenance kit, Repair kit, etc. Please note that replacement parts are only
available as part of a replacement parts kit.

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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:
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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Option: Insulation Cover
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
One insulation cover set consists of a soft ceramic fiber case and 2 binding straps.
Use the following procedures to install the insulation cover. (Installation, inspection,
maintenance, repairs, disassembly, adjustment and valve opening/closing should be
carried out only by trained maintenance personnel.)
Attaching the Insulation Cover to the Steam Trap
1. Allow the trap to cool to ambient temperature.
2. Open the cover along the Velcro strip.
3. Place cover evenly around the body with the arrow on the cover facing the same
direction as the arrow on the trap body.
4. Reattach the Velcro strip.
5. Secure the ends of the cover around the trap inlet and outlet with the binding
straps.
Applicable insulation cover for UFO3-BN/UFO3F-BN: RK3
放熱キラー
205 (81/16)
70 (23/4)150 (57/8)
80 (31/8)70 (23/4)
40 (19/16)
100 (4)
6 (1/4)
15 (9/16)
Insulation Cover (side) Insulation Cover (top)
Binding Strap (2 pc.)
Velcro Strip
Thickness: 0.2 (0.008)
Unit: mm (in)