TLV JH7.2R-P User manual

172-65459MA-04 (JH7.2R-P) 14 July 2015
Free Float Steam Trap
JH7.2R-P
(Optional Models)
JH7.2R-W / JH7.2R-F / JH7.2R-V
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
Instructions for Plug / Holder Disassembly and Reassembly 12
Troubleshooting ..............................................................13
Product Warranty ............................................................14
Options............................................................................15
Introduction
Thank you for purchasing the 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 instruction manual is edited based on the JH-P Series (with cover plug). The JH-W
Series (with socket welded cover connection), JH-F Series (with flanged cover
connection) and JH-V Series (with manual air vent valve) are described at the end of this
manual in the 'Option’ section.
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.
This free float steam trap is suitable for process systems and steam-using
equipment under long continuous operation with the introduction of almost no air.
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
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.
Safety considerations continued on 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 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 a bypass valve installed?
6. 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?
7. 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 f
low 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 condensate discharge:
As much air as possible should be eliminated at start-up using a bypass valve or
blowdown line.
1. Condensate Discharge
As steam is supplied, condensate flow begins.
The rising condensate level causes the float to
rise due to buoyancy, opening the orifice (A)
and allowing condensate to be discharged.
2. 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 (A), 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.
3. Closed Position
When the condensate flow rate decreases,
the float falls, closing off the orifice (A)
opening. A water seal is maintained at all
times over the orifice (A) to prevent steam
loss.
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*
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
No.
Name
M*
R*
F*
No.
Name
M*
R*
1
Body
10
Cover Gasket


2
Cover
11
Cover Bolt
3
Float

12
Cover Nut
4
Orifice

13
Nameplate
5
Orifice Gasket
 
14
Flange / Socket
6
Orifice Plug
15
Cover Plug Gasket
 
7
Orifice Plug Gasket
 
16
Cover Plug
8
Screen

17
Drain Plug Gasket


9
Screen Holder
18
Drain Plug
* Replacement parts are available only in the following kits:
M = Maintenance Kit, R = Repair Kit, F = Float

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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
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. Air in the system at start-up should be discharged using a bypass valve or
blowdown line.
7. 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, TLV Pocket TrapMan or 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 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 [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
Float:
check for scratches or dents
Body interior:
check for build-up
Orifice Opening:
check for dirt, oil film, wear or scratches
White jet
containing
water droplets
Clear, slightly
bluish jet

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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 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.)
Drain Plug
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
surface
Replace with a new gasket; coat
surfaces with anti-seize
Detaching / Reattaching the Cover and its Components
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, being careful not to scratch
the gasket sealing surface
Make sure there are no pieces of
the old gasket left on the sealing
surfaces of the body and cover,
align the arrows on the body and
cover and reattach
Cover Gasket
Remove the gasket and clean sealing
surface
Replace with a new gasket
Cover Plug
Remove with a socket wrench
Consult the table of tightening torques
and tighten to the proper torque
Cover Plug
Gasket
Remove the gasket and clean sealing
surface
Replace with a new gasket; coat
surfaces with anti-seize

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Disassembly / Reassembly of Components Inside the Body
Part
During Disassembly
During Reassembly
Screen
Remove by grasping the
wire ring and lifting straight
up and out
Set the screen on the screen holder and screen
holder retainer and insert as far as the snap ring
groove
Screen Holder
Remove without bending
Place on the ledge inside the body, making sure
the rounded side is on top
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 surface
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 surface
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)
Cover Nut
180
(130)
24
(15/16)
Orifice Plug
700
(510)
46
(113/
16
)
Orifice
350
(260)
38
(1½)
Cover Plug (JH7.2R-P)
100
(73)
26
(1)
Drain Plug
100
(73)
26
(1)
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.

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Exploded View
Cover Gasket
Cover
Cover Plug
Cover Nut
Cover Plug Gasket
Screen Holder
Body
Screen
Cover Bolt
Float
Drain Plug
Drain Plug Gasket
Orifice Gasket
Orifice
Orifice Plug
Orifice Plug Gasket

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3
5
6
Gasket
Do not pinch gasket
in thread recesses
4
Coat with anti-seize
Gasket Surface
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
①Remove the plug/holder using
a tool of the specified size
(distance across flats).
②The gasket should not be
reused. Be sure to replace it
with a new gasket.
③Clean 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.
④Coat 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.
⑤Hold 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.
⑥Screw 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.
⑦Tighten the plug/holder to the proper torque.
⑧Next, 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.

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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 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 and
remedy the cause.
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 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
Steam-locking has occurred
Perform a bypass blowdown
or close the trap inlet valve
and allow the trap to cool
Air binding has occurred
Perform a bypass blowdown
or consider switching to a
product with a built-in air
vent or air vent valve
Steam is
discharged or
leaks from the
outlet
(blowing)
(steam leakage)
Build-up on the seating surface of the orifice
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 a build-up
Clean or replace with new
float
Improper installation orientation
Correct the installation
Trap vibration
Lengthen the inlet piping and
fasten it securely
Steam is leaking
from a place
other than the
outlet
Check for gasket deterioration or damage
Replace with new gasket(s)
Check to make sure that the proper
tightening torques were used
Tighten to the proper torque
Float frequently
becomes
damaged
Check to see if 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 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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Options
The options shown below are available for this product
on request. Please compare with the product you
received.
Options for Area A (standard: with drain plug)
Without Drain Plug
Options for Area B (standard: with cover plug)
A pressure-balancing line connector can be attached to the place where the
standard product has the cover plug.
Socket Type
(Model: JH7.2R-W)
Flange Type
(Model: JH7.2R-F)
•In principle, steam traps automatically discharge inflowing condensate. However, if
low-temperature condensate in the piping blocks the trap inlet passage,
displacement inside the piping of steam by condensate is obstructed and
condensate can no longer flow into the trap (steam-locking). Traps only function in
the presence of condensate inflow. A pressure-balancing line prevents the
occurrence of steam-locking.
Install the pressure-balancing line in the following manner:
Example: Heat Exchanger
Attach the pressure-balancing line
to the trap and to either the equipment
or to an area with a steam space.
Steam
Pressure-balancing Line

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Options for Area B
With Air Vent Valve
(Model: JH7.2R-V)
Operating the Air Vent Valve
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
Installation, inspection, maintenance, repairs, disassembly, adjustment and valve
opening/closing should be carried out only by trained maintenance personnel.
1. Locate the air vent valve exhaust port before operating the air vent valve, and
take care to avoid being burned by hot air or steam blowing from the vent. The
exhaust port is a 2 mm (1/16”) diameter hole on the side of the air vent valve body.
DO NOT under any circumstances allow any unprotected part of your body to
come in front of this hole.
2. Never leave an open air vent valve unattended.
Tools required: 1) open-end wrench (distance across flats 17 mm (21/32”))
2) long-handled mirror to check for steam leakage after closing
the exhaust port (leaking steam cloud the mirror)
•Using the open-end wrench, slowly turn the hexagonal head of the valve stem
counterclockwise.
•Watch the exhaust port to determine the condition of the fluid discharged.
General guidelines:
Cloudy-water droplets and mist spraying out, indicating
that air and condensate are being discharged
Clear---indicating that steam is being discharged; the
valve port may now be closed

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CAUTION
The air vent valve stem cannot be
removed from the air vent valve
body. Attempting to remove the valve
stem by pulling it upward may
damage it and cause burns or other
injury due to malfunction or the
discharge of steam or condensate.
3. Use the following procedure to close the valve and check for leaks:
•Using the open-end wrench, close by slowly turning the hexagonal head of the
valve stem clockwise until contact with the valve seat is felt.
•Apply a little more pressure to tighten securely.
Note: Using an ordinary open-end wrench (handle length about 160 mm
(6¼”)), the valve will close with only a light turn pressure. Tightening with
too much force may result in seizure or damage to the seat.
•After tightening, place the mirror close to the front of the exhaust port. If the
mirror clouds, the valve is not fully closed; tighten a bit more.
4. When air enters the piping at start-up, it may accumulate inside the trap and
hinder the flow of condensate (air binding). Air binding may also occur during the
normal course of trap operation, due to the slow accumulation of air inside the
trap. The air vent valve on the top of this trap is to be operated only when air
binding has occurred. Follow the instructions in the earlier part of this section to
operate the air vent valve and release the air accumulated inside the trap.
(The air vent valve is to be open only for as long as is necessary to release the
accumulated air. If left open, it is extremely dangerous, so be sure to close
tightly after operation.)
Disassembly / Reassembly of Air Vent Valve
Air Vent Valve
Unit
Remove with a wrench
Consult the table of tightening torques
and tighten to the proper torque
Air Vent Valve
Gasket
Remove the gasket and clean
sealing surface
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)
Air Vent Valve Body
100
(73)
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.
Air Vent Valve Stem
Air Vent Valve Body
Exhaust Port
17 mm
(21/32”)
Cover