TLV JH5RL-B User manual

172-65452MA-04 (JH5RL-B/JH5RH-B) 18 November 2020
Free Float Steam Trap
JH5RL-B
JH5RH-B
Copyright © 2020 by TLV CO., LTD.
All rights reserved

172-65452MA-04 (JH5RL-B/JH5RH-B) 18 Nov 2020
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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
Instructions forPlug/HolderDisassemblyandReassembly...12
Troubleshooting ..............................................................13
Product Warranty ............................................................14
Options............................................................................15
Introduction
Thank you for purchasing the TLV free float 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 free float steam trap employs a hinge-less and lever-less free float to rapidly,
automatically and continuously discharge the inflowing condensate that is
continuously generated inside the equipment, thus preventing the accumulation of
condensate and thereby improving the heat transfer efficiency of the equipment. In
addition, the integral bimetal type automatic air vent allows for the rapid release of
start-up air and thereby reduces start-up time.
These features make this free float steam trap suitable for applications requiring
condensate discharge from process systems and equipment (steam-using
equipment).
This steam trap also employs a precision-ground float and three-point that supports
the float securely at three points and ensures a high degree of sealing when even
only minute quantities of condensate are present. This free float steam trap is also
ideal for places at which extremely small amounts of condensate are generated,
such as superheated and saturated steam mains and branches, and trace 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.
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
WARNING
NEVER apply direct heat to the float.
The float may explode due to increased internal pressure, causing
accidents leading to serious injury or damage to property and
equipment.
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).
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.
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.
Continued on the next page

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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.
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.
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 causeburns or other injury.
CAUTION
Check to make sure that the pipes to be connected to the product have been
installed properly.
1. Is the pipe diameter suitable?
2. Is the piping where the product is to be installed horizontal?
3. Has sufficient space been secured for maintenance?
4. 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?
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 (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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Operation
Principles of air and condensate discharge:
1. Initial Air and Cold Condensate Discharge
At startup, before steam is supplied the system is
cold and the bimetal plate is flexed downward,
keeping the air vent valve (A) open. When steam is
first supplied to the system, air is discharged
through the vent (A) while cold condensate is
discharged through the orifice (B).
2. Condensate Discharge
After the discharge of initial air and cold
condensate, the heat of the inflowing steam and
condensate cause the bimetal plate to flex upward,
closing the air vent valve (A). The rising
condensate level causes the float to rise due to
buoyancy, opening the orifice (B) and allowing
condensate to be discharged.
The flexed bimetal keeps the valve closed while in
normal operation.
3. Discharge of Large Quantities of Condensate
Increases in the condensate inflow rate cause the
condensate level in the trap to rise. The float
consequently rises and enlarges the opening of the
orifice (B), allowing more condensate to be
discharged. In this manner, continuous condensate
discharge occurs while the opening size of the
orifice varies depending on the condensate flow
rate.
4. Closed Position
When the condensate flow rate decreases, the float
falls, closing off the orifice (B) opening. A water
seal is maintained at all times over the orifice (B) to
prevent steam loss.
Air
Steam
Condensate

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Specifications
Install properly and DONOT usethis 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 useof this product tobelowthe conditions quoted.
CAUTION
DONOT usethetrapin excess of themaximumoperatingpressure
differential; suchusecouldmakedischargeimpossible(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*
Nominal Diameter
Maximum Differential
Pressure
Production Lot No.
Valve No.**
Maximum Operating
Temperature
* 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
* Replacement parts are available only in the following kits: M=maintenance kit; R=repair kit; F=float
No.
Name
M*
R*
F*
No.
Name
M*
R*
No.
Name
M*
R*
1
Body
9
Screen

17
Air Vent Case

2
Cover
10
Flange/Socket
18
Bimetal Plate

3
Float

11
Cover Bolt
19
Air Vent Screen

4
Orifice

12
Cover Nut
20
Air Vent Valve
Seat

5
Orifice Gasket


13
Cover Gasket


21
Air Vent Valve Plug

6
Orifice Plug
14
Connector
22
Snap Ring

7
OrificePlugGasket


15
ConnectorGasket


23
Nameplate
8
Float Cover

16
Snap Ring


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Installation
Install properly and DONOT usethis 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 useof this product tobelowthe conditions quoted.
CAUTION
Use hoisting equipment for heavy objects (weighingapproximately
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 fromcoming into direct contact with
product outlets. Failure to do so may result in burns or other injury from
the discharge of fluids.
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 product 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 ensure 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 product is installed with the raised TLV lettering on the body horizontal.

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Maintenance
Take measures to prevent people fromcoming 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
observetheseprecautions may result in damageto the product or burns
or other injury due tomalfunction 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 product 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 TrapMan.
If the product 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 continuously, together with flash steam,
and the sound of flow can be heard. If there is very little
condensate, there is almost no sound of flow.
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 –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
Gaskets:
Check for warping or scratches
Screens:
Check for clogging or corrosion
Bimetal Plate:
Check for damage
Air Vent Valve (and Seat):
Check for damage
Float:
Check for scratches or dents
Body Interior:
Check for build-up
Orifice Opening:
Check for dirt, oil film wear or scratches
Flash Steam
Clear, slightly
bluish jet
Live Steam Leakage
White jet
containing
water droplets

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Disassembly/Reassembly
NEVER apply direct heat to the float. The float may explode due to
increased internal pressure, causing accidents leading to serious injury
or damage to property and equipment.
WARNING
Use hoistingequipment 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 roomtemperature. Disassembling or removing the
product when it is hot or under pressure may leadto discharge of fluids,
causingburns, 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.)
Drain Plug (Option)
Part
During Disassembly
During Reassembly
Drain Plug
Remove with a socket
wrench
Consult the table of tightening torques and
tighten to the proper torque
Drain Plug
Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket; coat surfaces with
anti-seize
Detaching/Reattaching the Cover
Part
During Disassembly
During Reassembly
Cover Nut
Remove with a socket
wrench
Consult the table of tightening torques and
tighten to the proper torque
Cover
Remove by lifting up and off
Make sure there are no pieces of the old gasket
left on the sealing surfaces of the body and
cover, then reattach, lining up the connector
Cover Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket
Connector
Remove the connector
Reinsert into hole in body
Connector
Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket
Disassembly/Reassembly of Components Inside the Cover
Part
During Disassembly
During Reassembly
Snap Ring
Pinch the insides together
and remove from the cover
Insert securely into
groove
Air Vent Screen
Remove, being careful not
to misshape
Replace, being careful not
to misshape
Bimetal Plate/Air
Vent Valve
Plug/Snap Ring
Remove air vent parts from
cover
Make sure to reinsert in
the proper orientation
(Fig. A)
Air Vent Valve
Seat
Remove with a socket
wrench
Consult the table of
tightening torques and
tighten to the proper
torque
Air Vent Case
Remove from the cover
Place it in the cover

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Disassembly/Reassembly of Components Inside the Body
Part
During Disassembly
During Reassembly
Float Cover/
Screen
Lift straight up and
out while gently
rocking
Align the arrows on the float
cover/screen and body and
insert the tab on the bottom
of the float cover/screen into
the slot in the body; make
sure the top of the float
cover/screen does not stick
up out of the body (Fig. B)
Float
Remove, being
careful not to scratch
the polished surface
Insert, being careful not to
scratch the polished surface
Orifice Plug
Remove with a
socket wrench
Consult the table of
tightening torques and
tighten to the proper torque
Orifice Plug
Gasket
Remove the gasket
and clean sealing
surfaces
Replace with a new gasket;
coat surfaces with anti-seize
Orifice
Remove with a
socket wrench
Consult the table of
tightening torques and
tighten to the proper torque
Orifice
Gasket
Remove the gasket
and clean sealing
surfaces
Replace with a new gasket;
coat surfaces with anti-seize
Table of Tightening Torques
Part Name
Torque
Distance Across Flats
Nm
(lbfft)
mm
(in)
Orifice
140
(100)
17
(21/32)
Orifice Plug
180
(130)
38
(11/2)
Air Vent Valve Seat
30
(22)
19
(3/4)
Cover Nut (JH5RL-B)
110
(81)
22
(7/8)
Cover Nut (JH5RH-B)
170
(125)
24
(15/16)
NOTE: - Coat all threaded portions with anti-seize. (1 Nm 10 kgcm)
- If drawings or other special documentation were supplied for the product, any torque
given there takes precedence over values shown here.
Figure B
Tab
Arrow

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Exploded View
Cover Nut
Air Vent Case
Air Vent
Valve Seat
Air Vent Valve Plug
Bimetal Plate
Connector
Cover Gasket
Snap Ring
Air Vent Screen
Snap Ring
Float Cover /
Screen
Float
Body
Orifice Plug
Orifice Gasket
Orifice
Orifice Plug Gasket
Cover
Connector Gasket
Cover Bolt

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Instructions for Plug/Holder Disassembly and Reassembly
The seal on the threaded plugs/holders found on TLV products is formed by a flat
metal gasket. There are various installation orientations for the gaskets, such as
horizontal, diagonal and downward, and the gasket may be pinched in the thread
recesses during assembly.
Instructions for Disassembly and Reassembly
1. Remove the plug/holder using a tool of the specified size (distance across flats).
2. The gasket should not be reused. Be sure to replace it with a new gasket.
3. Clean the gasket surfaces of the
plug/holder and the product body using
a rag and/or cleaning agents, then
check to make sure the surfaces are
not scratched or deformed.
4. Coat both the gasket surface of the
plug/holder and the threads of the
plug/holder with anti-seize, then press
the gasket onto the center of the
gasket surface of the plug/holder,
making sure the anti-seize affixes the
gasket tightly to the plug/holder.
Check to make sure the gasket is not
caught in the recesses of the threads.
5. Hold the plug/holder upside down to
make sure that the anti-seize makes
the gasket stick to the plug/holder
even when the plug/holder is held
upside down.
6. Screw the plug/holder by hand into
the product body while making sure
that the gasket remains tightly affixed
to the center of the gasket surface of
the plug/holder. Make sure the entire gasket is making contact with the gasket
surface of the product body. It is important at this point to make sure the gasket is
not pinched in the thread recesses of the plug/holder.
7. Tighten the plug/holder to the proper torque.
8. Next, begin the supply of steam and check to make sure there is no leakage
from the part just tightened. If there is leakage, immediately close the inlet valve
and, if there is a bypass valve, take the necessary steps to release any residual
pressure. After the surface of the product cools to room temperature, repeat the
procedure beginning from step 1.
Gasket
Do not pinch gasket in
threaded recesses
Coat with
anti-seize Gasket Surface
3.
4.
5.
6.

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Troubleshooting
NEVER apply direct heat to the float. The float may explode due to
increased internal pressure, causing accidents leading to serious injury
or damage to property and equipment.
WARNING
When disassembling or removing the product, wait until the internal
pressure equals atmospheric pressure and the surface of the product
has cooled to roomtemperature. Disassembling or removing the
product when it is hot or under pressure may leadto discharge of fluids,
causingburns, other injuries or damage.
CAUTION
If the product fails to operate properly, use the following table to locate the cause and
remedy.
Problem
Cause
Remedy
No condensate is
discharged
(blocked) or
discharge is poor
The float is damaged or filled with
condensate
Replace with a new float
The orifice opening, screen or piping are
clogged with rust and scale
Clean parts
The bimetal is damaged
Replace with a new bimetal
Steam locking has occurred
Perform a bypass blowdown,
or close the trap inlet valve
and allow the trap to cool
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 is
discharged or leaks
from the outlet
(blowing)
(steam leakage)
Clogged orifice opening or rust and scale
build-up beneath the float
Clean parts
Scratches on the orifice
Replace with a new orifice
The float is misshapen or has surface
build-up
Clean or replace with a new
float
Improper installation orientation
Correct the installation
Trap vibration
Lengthen the inlet piping and
fasten it securely
The bimetal air vent valve surface and/or
the air vent valve seat has a build-up or is
scratched
Clean or replace with a new
bimetal and/or air vent valve
seat
The bimetal is damaged
Replace with a new bimetal
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
Float frequently
becomes damaged
Water hammer has occurred
Study and correct the piping
NOTE: 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 TLV representative or your regional TLV office.
Manufacturer
881 Nagasuna, Noguchi
Kakogawa, Hyogo 675-8511, JAPAN
Tel: [phone]

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Options
The options shown below are available for this product on
request. Please compare with the product you received.
Options for Area A (standard: without drain plug)
With Drain Plug
Torque
Nm (lbf·ft)
Distance
Across Flats
mm (in)
35 (26)
21 (13/16)
(1 Nm 10 kgcm)