TLV JH7RM-P User manual

172-65456MA-04 (JH7RM-P) 14 July 2015
Free Float Steam Trap
JH7RM-P
(Optional Models)
JH7RM-W / JH7RM-F / JH7RM-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 steam trap also employs a precision-ground float and three-point seating 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 suitable for applications with the introduction of almost no
air (such as process systems and steam-using equipment under long continuous
operation, or superheated and saturated steam mains, branches and trace lines).
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 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 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 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 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*
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*
F*
1
Body
2
Cover
3
Float

4
Orifice

5
Orifice Gasket


6
Orifice Plug
7
Orifice Plug Gasket


8
Screen Holder
9
Screen

10
Flange · Socket
11
Cover Bolt
12
Cover Nut
13
Cover Gasket


14
Cover Plug Gasket


15
Cover Plug
16
Nameplate
17
Drain Plug Gasket


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.)
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
Flash Steam
Clear, slightly
bluish jet
Live Steam Leakage

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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 lifting straight up
and out while turning
Set the screen on the screen holder, making
sure the top of the screen does not stick up out
of the body
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 or misshape
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)
Orifice
280
(205)
26
(1)
Orifice Plug
420
(310)
50
(131⁄32)
Cover Nut
200
(150)
24
(15⁄16)
Cover Plug (JH7RM-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 Plug
Cover Plug Gasket
Cover Nut
Cover
Cover Gasket
Screen
Screen Holder
Float
Cover Bolt
Body
Drain Plug
Drain Plug Gasket
Orifice Gasket
Orifice
Orifice Plug Gasket
Orifice Plug

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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)
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 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
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: JH7RM-W)
Flange Type
(Model: JH7RM-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 Valve
(Model: JH7RM-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 valve, in order to
avoid being burned by hot air or steam blowing from the air vent valve. The
exhaust port is a 2 mm (1⁄16 in) diameter hole on the side of the air 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 in))
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)
(1 N⋅m ≈10 kg⋅cm)
NOTE: -Coat all threaded portions with anti-seize.
-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 in)
Cover