TLV JH7.5R-B User manual

172-65461MA-03 (JH7.5R-B) 18 November 2020
Free Float Steam Trap
JH7.5R-B
Copyright © 2020 by TLV CO., LTD.
All rights reserved

172-65461MA-03 (JH7.5R-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).
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 ham mer 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 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 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 (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. Start-up Air and Cold Condensate Discharge
At start-up, before steam is supplied, the system is
cold and the bimetal plate is contracted (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 inflowing condensate causes
the float to rise due to buoyancy, opening the orifice
(B) and allowing condensate to be discharged. The
air vent valve will remain closed throughout normal
operation due to the high operating temperatures.
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 with the orifice opening size varying
depending on the condensate flow rate.
4. Closed Position
When the condensate flow rate decreases, the float
falls, closing off the orifice opening (B). 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 DO NOT use this product outside the recommended
operating pressure, tem perature and other specification ranges.
Im proper use m ay result in such hazards as dam age 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.
** 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*
11
Cover Gasket


12
Cover Bolt
13
Cover Nut
14
Nameplate
15
Screen Holder
Retainer
16
Snap Ring

17
Air Vent Case

18
Bimetal Plate

19
Air Vent Screen

20
Air Vent Valve Seat

21
Air Vent Valve Plug

No.
Name
M*
R*
F*
No.
Name
M*
R*
22
Snap Ring

1
Body
6
Orifice Plug
23
AirVent Guide
Gasket


2
Cover
7
Orifice Plug Gasket


24
Air Vent Guide
3
Float

8
Screen

25
Flange/Socket
4
Orifice

9
Screen Holder
26
Drain Plug Gasket


5
Orifice Gasket


10
Snap Ring
27
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, tem perature and other specification ranges.
Im proper use m ay result in such hazards as dam age 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 m ay result in back strain or other
injury if the object should fall.
CAUTION
Take m easures 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 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 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 product is installed with the raised TLV lettering on the body horizontal.

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Maintenance
Take m easures 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 recom m ended com ponents when repairing the
product, and NEVER attem pt 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 m alfunction 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 or thermometer.
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.
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
Bimetal Plate, Valve Plug, Air Vent Case (Valve Seat): Check for
scratches or damage
Body Interior: Check for build-up of scale
Orifice Opening: Check dirt, oil film, wear and damage
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 equipm ent.
WARNING
Use hoisting equipment for heavy objects (weighing approximately
20 kg (44 lb) or more). Failure to do so m ay 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 m ay lead to discharge of fluids,
causing burns, other injuries or dam age.
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 surfaces
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 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,
align the arrows on the body and cover and
reattach
Cover Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket
Disassembly/Reassembly of Components inside the Air Vent Case/Guide
Part
During Disassembly
During Reassembly
Snap Ring
Pinch the insides
together and remove
from the air vent case
Insert securely into the groove in
the air vent case
Air Vent Screen
Remove, being careful
not to misshape
Replace, being careful not to
misshape.
Bimetal Unit (Bimetal
Plate / Snap Ring /
Valve Plug)
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
torque and tighten to the proper
torque
Air Vent Case
Remove from the cover
Place it in the cover
Air Vent Guide
Remove with a socket
wrench
Consult the table of tightening
torques and tighten to the proper
torque
Air Vent Guide Gasket
Remove the gasket and
clean sealing surfaces
Replace with a new gasket, coat
with anti-seize
Figure A

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Disassembly/Reassembly of Components Inside the Body
Part
During Disassembly
During Reassembly
Snap Ring
Pinch the insides together and
remove from the body
Insert securely into the groove in the body
Screen
Lift straight up and out while
turning
Place on the screen holder, making sure that
the top of the screen does not stick up out of
the body
Screen Holder
Retainer
Remove without bending
Place on the screen holder without tilting
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 box 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 box 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
600
(440)
46
(11316)
Orifice Plug
800
(590)
46
(11316)
Cover Nut
200
(150)
30
(13/16)
Air Vent Valve Seat
30
(22)
19
(¾)
Air Vent Guide
150
(110)
30
(13/16)
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 Nut
Cover Nut
Cover
Snap Ring
Screen Holder
Retainer
Screen Holder
Screen
Float
Cover Gasket
Cover Bolt
Body
Orifice Gasket
Orifice
Orifice Plug
Gasket
Orifice Plug
Drain Plug
Gasket
Drain Plug
Air Vent Valve Seat
Air Vent Case
Air Vent Guide
Air Vent Valve Plug
Air Vent Guide Gasket
Bimetal Plate
Snap Ring
Air Vent Screen
Snap Ring

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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 equipm ent.
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 m ay lead to discharge of fluids,
causing burns, other injuries or dam age.
CAUTION
When 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
Air binding has occurred (air vent valve
seat is blocked or bimetal plate is
damaged)
Clean valve seat or replace
with a new bimetal unit*
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)
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 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 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: with drain plug)
Without Drain Plug