TLV JH8R-B User manual

172-65464MA-02 (JH8R-B) 18 November 2020
Free Float Steam Trap
JH8R-B
Copyright © 2020 by TLV CO., LTD.
All rights reserved

172-65464MA-02 (JH8R-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 for Plug/Holder Disassembly and Reassembly..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.
Use the eye bolts for removing the cover only; DO NOT use the
eye bolts for hoisting the product.
Eye bolts may break under strain, possibly resulting in serious injury.
Continued on the next page

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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.
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 nowater hammer will occur. The
impact of water hammer may damage the product, leading to fluid
discharge, whichmay 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, temperature and other specification ranges.
Improper usemay result in such hazards as damageto theproduct or
malfunctions which may lead to serious accidents. Local regulations
may restrict the useof this product to belowtheconditions quoted.
CAUTION
DONOT usethis product in excess of the maximumoperating pressure
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*
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*
6
Outlet Cover Gasket


7
Screen

8
Screen Holder
9
Snap Ring
10
Cover Gasket


11
Cover Bolt
12
Cover Nut
13
Outlet Cover
14
Outlet Cover Bolt
15
Outlet Cover Nut
16
Snap Ring

17
Air Vent Case

18
Bimetal Plate

19
Air Vent Screen

20
Air Vent Valve Seat

21
Air Vent Valve Plug

22
Snap Ring

23
Air Vent Guide Gasket


24
Air Vent Guide
No.
Name
M*
R*
F*
25
Nameplate
1
Body
26
Screen Holder Retainer
2
Cover
27
Eye Bolt
3
Float

28
Socket / Flange
4
Orifice

29
Drain Plug Gasket


5
Orifice Gasket


30
Drain Plug
* Replacement parts are available only in the following kit
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 damageto theproduct or
malfunctions which may lead to serious accidents. Local regulations
may restrict the useof this product to belowtheconditions quoted.
CAUTION
Usehoistingequipment for heavyobjects (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
Use the eye bolts for removing the cover only; DO NOT use the eye bolts
for hoistingthe product. Eye bolts may break under strain, possibly
resulting in serious injury.
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. When hoisting the product, hang a wire around the inlet/outlet as close to the body
as possible.
4. Install the product so the arrow on the body is pointing in the direction of flow.
5. The product should be inclined no more than 5° horizontally and front-to-back.
6. Install a condensate outlet valve and outlet piping.
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 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
observethese precautions may result in damage to theproduct or burns
or other injury due to malfunction or thedischarge 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 equipment.
WARNING
Usehoistingequipment for heavyobjects (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
Use the eye bolts for removing the cover only; DO NOT use the eye bolts
for hoistingthe product. Eye bolts may break under strain, possibly
resulting in serious injury.
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 lead todischarge 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 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
Use all four (4) eye bolts to lift up
and off, making sure to evenly
distribute the weight of the cover
among them
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

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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 the 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
Disassembly/Reassembly of Components Inside the Body
Part
During Disassembly
During Reassembly
Snap Ring
Pinch insides together and remove
from the body
Insert securely into the groove in the
body
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
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
Outlet Cover Nut
Remove with a socket wrench
Consult the table of tightening
torques and tighten to the proper
torque
Outlet 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
Outlet Cover
Gasket
Remove the gasket and clean
sealing surfaces
Replace with a new gasket
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
Figure A

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Table of Tightening Torques
Part Name
Torque
Distance Across Flats
Nm
(lbfft)
mm
(in)
Orifice
1000
(730)
60
(238)
Outlet Cover Nut
160
(115)
24
(1516)
Cover Nut
450
(330)
36
(11332)
Air Vent Valve Seat
30
(22)
19
(34)
Air Vent Guide
150
(110)
30
(1316)
Drain Plug
100
(73)
26
(1)
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.
(1 Nm 10 kgcm)
Exploded View
CoverNut
Cover
CoverGasket
SnapRing
Screen
ScreenHolder
Retainer
ScreenHolder
Float
BimetalPlate
AirVentValvePlug
AirVentValveSeat
AirVentCase
AirVentGuide
Air VentGuideGasket
CoverBolt
Body
OutletCoverBolt
OrificeGasket
Orifice
OutletCoverGasket
OutletCover
OutletCoverNut
DrainPlug
DrainPlugGasket
SnapRing
AirVentScreen
SnapRing

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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 lead to dischargeof fluids,
causing burns, 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
Air binding has occurred (air vent
valve seat is blocked or bimetal
plate is damaged)
Clean the 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 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.
Cover Nut

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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
A