TLV L21S User manual

172-65122MA-04 (L Series + BD2) 9 March 2017
Balanced Pressure Thermostatic Steam Trap
L21S / L32S
L21SC / L32SC
Copyright © 2017 by TLV CO., LTD.
All rights reserved

172-65122MA-04 (L Series + BD2) 9 Mar 2017
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Contents
Introduction ........................................................................ 1
Safety Considerations........................................................ 2
Checking the Piping........................................................... 4
Specifications..................................................................... 5
Installation.......................................................................... 6
Maintenance....................................................................... 7
Disassembly/Reassembly.................................................. 8
Instructions for Plug/Holder Disassembly and Reassembly. 10
Troubleshooting ............................................................... 11
Product Warranty ............................................................. 12
Options............................................................................. 13
Introduction
Thank you for purchasing the balanced pressure thermostatic 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 steam trap is of a revolutionary design that uses a high-performance
X-element. This is a new type of valve mechanism in which a thermoliquid is
sealed inside the X-element and the valve opens or closes based on the
difference between the saturation temperatures of the thermoliquid and the
water. The X-element is very sensitive to changes in temperature, and
responds with great accuracy, quickly discharging air and the large quantities of
condensate created immediately after operation start-up, thereby greatly
reducing start-up time. It also reacts with great sensitivity to the inflow of large
quantities of condensate and hot air during operation, preventing air binding.
The superior features of this steam trap’s X-element increase heating efficiency
and reduce manpower requirements for maintenance and bypass blowdown.
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
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.
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.
Safety considerations are continued on the next page.

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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 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. Has sufficient space been secured for maintenance?
3. 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 (models L21S and L32S)?
4. 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?
5. 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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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
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.
Production Lot No.
Valve No.**
Model
Maximum Allowable
Temperature (TMA)*
Nominal Diameter**
Maximum Operating
Temperature (TMO)
Maximum Allowable
Pressure*
Maximum Operating
Pressure
X-element Type
*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.
Maximum Operating Temperature
(75)
(150)
(215)
(300)
(350)
(450)
(482)
(464)
(392)
(302)
(212)
(455)
(437)
Configuration
Saturated Steam Curve
Operating Pressure: MPaG (psig)
Temperature: °C (°F)
No.
Name
M*
R*
1
Body
2
Cover
3
X-element

4
Screen

5
Screen Holder Gasket


6
Screen Holder
7
Valve Seat

8
X-element Guide

9
Spring Clip

10
Cover Gasket


11
Cover Bolt
12
Nameplate
13
Check Valve Ball**

* Replacement parts are available only in the
following kits: M = Maintenance Kit and
R = Repair Kit
** Part No. 13 is only found in L21SC / L32SC
L21SC, L32SC

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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
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.
NOTE: For products with socket weld connections, electric weld with a single pass.
As internal parts are not damaged by the welding process if limited to a
single pass, there is no need to remove them before welding.
1. Before installation, be sure to remove all protective seals.
2. Before installing the product, blow out the inlet piping to remove any piping
scraps, dirt and oil. Close the inlet valve after blowdown.
3. Install the product so that the arrow on the body is pointing in the direction of
condensate flow.
4. Horizontal installation is recommended (with the cover facing upwards). Vertical
installation is possible; however there may be a slight increase in the amount of
steam leakage. Do not install in a reverse installation (the trap upside down) or a
sideways installation (trap on its side).
5. For socket weld connections, weld using an arc weld and keep the actual welding
time as brief as possible.
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.

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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 TrapMan or TLV Pocket 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 intermittently together with flash steam,
and the sound of flow can be heard.
Blocked
(Discharge Impossible)
: No condensate is discharged. The trap is quiet and makes no
noise, and the surface temperature of the trap is low.
Blowing
: Live steam continually flows from the outlet and there is a
continuous metallic sound.
Steam Leakage : Live steam is discharged through the trap outlet together with
condensate, accompanied by a high-pitched sound.
(When conducting a visual inspection, flash steam is sometimes mistaken for steam leakage.
For this reason, the use of a steam trap diagnostic instrument [such as TLV TrapMan if
appropriate] 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
Gasket(s):
Check for warping and damage
Screen:
Check for clogging and corrosion
X-element:
Check for damage
Valve Seat:
Check for damage
Body Interior:
Valve Area on the
X-element, Valve Seat:
Check for build-up of scale
Check dirt, oil film, wear and damage

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Disassembly/Reassembly
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.)
Detaching/Reattaching the Cover
Part
During Disassembly
During Reassembly
Cover Bolt
Remove with a socket wrench
Consult the table of tightening torques and
tighten to the proper torque
Cover
Remove by lifting up and off, being
careful not to scratch the sealing
surfaces
Make sure there are no pieces of the old
gasket left on the sealing surfaces and
then reattach
Cover Gasket
Remove with a flat-blade screwdriver
Replace with a new gasket
Removing/Reassembling the Components Inside the Body
Part
During
Disassembly
During Reassembly
Spring Clip
Remove with a
needle-nose pliers
Insert securely into the slot in the
X-element guide (Figure A)
X-element
Grasp the ball on
the top of the
X-element with a
pliers and remove
Make sure the side of the X-element
with the ball on it is facing up and
insert, keeping the X-element level
and making sure it does not catch on
the guide (Figure B)
Valve Seat
Remove with a
socket wrench
Consult the table of tightening torques
and tighten to the proper torque
X-element
Guide
Remove without
bending
Insert the X-element carefully
Screen
Holder
Remove with a
socket wrench
Consult the table of tightening torques
and tighten to the proper torque
Screen
Holder
Gasket
—
Replace with a new gasket; coat
sealing surfaces with anti-seize
Screen
Remove without
bending
Insert without bending
Table of Tightening Torques
Part Name
Torque
Distance Across Flats
N∙m
(lbf∙ft)
mm
(in)
Cover Bolt
35
(26)
13
(1⁄2)
Valve Seat
35
(26)
19
(3⁄4)
Screen Holder
60
(44)
22
(7⁄8)
NOTE:
-Coat all threaded portions of the cover bolt, valve seat and screen
holder 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)
Figure B
Spring Clip
Slots
Figure A

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Exploded View
Cover Bolt
Nameplate
Cover
Spring Clip
X-element
Valve Seat
X-element Guide
Cover Gasket
Body
Screen
Screen Holder Gasket
Screen Holder

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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
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 the cause
and remedy.
Problem
Cause
Remedy
No condensate is
discharged
(blocked) or
discharge is poor
The X-element is sticking to the valve
seat
Clean parts
The screen is clogged
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 is
discharged or
leaks from the
outlet
(blowing)
(steam leakage)
There is rust or scale between the
valve area on the X-element and the
valve seat
Clean parts
The X-element valve and valve seat
are damaged
Replace with a new X-element and/or
valve seat
The X-element is broken
Replace with a new X-element
The installation is incorrect
Correct the installation
There is vibration of the trap
Lengthen the inlet piping and fasten it
securely
Steam is leaking
from a place
other than the
outlet
Gasket deterioration or damage
Replace with a new gasket
Improper tightening torques were
used
Tighten to the proper torque
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 in pre-packaged kits.)

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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
881 Nagasuna, Noguchi
Kakogawa, Hyogo 675-8511 JAPAN
Tel: [phone]

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Options
With Blowdown Valve (TLV BD2)
Always wear eye protection and heat-resistant gloves when operating
the blowdown valve. Failure to do so may result in burns or other injury.
CAUTION
When operating the blowdown valve, stand to the side well clear of the
outlet to avoid contact with internal fluids that will be discharged.
Operate the valve slowly and surely, taking care to avoid the area from
which internal fluids are discharged and any fluids deflected off piping
or the ground etc. Failure to do so may result in burns or other injury.
CAUTION
Do not tighten the BD2 valve or the BD2 valve seat in excess of the
appropriate tightening torque. Over-tightening may cause breakage to
threaded portions, which may cause burns, other injuries or damage.
CAUTION
Do not excessively loosen the BD2 valve when opening the blowdown
valve. The valve stopper pin installed to prevent the BD2 valve from
being removed may break and internal pressure may result in the BD2
valve being blown off, leading to injuries, damage and fluid discharge,
causing burns.
CAUTION
Configuration
Screen Holder Gasket
BD2 Valve Seat
(Screen Holder)
Screen
Valve Stopper Pin
BD2 Valve Discharge Hole
TLV Blowdown Valve: BD2
The BD2 Blowdown Valve, installed in the screen area of the body, uses the trap’s
internal pressure to blow any condensate, steam, dirt or scale accumulated around the
screen area out to atmosphere.
BD2 Blowdown Valve Operation
1. The BD2 valve is in the closed position when the BD2 is shipped from the factory.
Before attempting to operate the BD2, reconfirm that the BD2 valve is still in the
closed position. Locate the blow outlet and, during operation, stand to the side and
well clear of it, as the jet of condensate or steam could cause burns.
2. Remain in the area the entire time the BD2 valve is in the open position. Before
opening the BD2 valve, grip the BD2 valve seat with a wrench and hold firmly in
place so that it will not rotate when the BD2 valve is loosened. Grip the BD2 valve
with another wrench and slowly loosen. Condensate and steam will discharge from
the blow outlet in a jet stream. Be careful not to loosen the BD2 valve so far that it
becomes removed from the BD2 valve seat. (If the valve stopper pin becomes
damaged, large quantities of steam will be discharged in a jet stream.)

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3. Close the BD2 valve until the flow of fluid completely stops. If the flow of fluid does
not stop, re-open the BD2 valve (as in step “2”) to blow out any scale or dirt that
may be caught in the BD2. Re-tighten the BD2 valve until the flow of fluid stops
completely.
Tightening Torques and Distance Across Flats
Part
Torque
Distance Across
Flats
N·m
(lbf·ft)
mm
(in)
BD2 Valve 30 (22) 17 (
21
/32)
BD2 Valve Seat (Screen Holder) 60 (44) 22 (7/8)
NOTE: Avoid the use of excessive tightening torques,
as threaded parts may become damaged.
(1 N⋅m ≈10 kg⋅cm)
With Automatic Non-freeze Valve (TLV NF6)
Valve Seat with 1 mm (0.04 in) drain hole
The valve seat has a 1 mm (0.04 in) drain hole to ensure no condensate remains in the
trap after operation.
NOTE: Option for L21S/L32S only. Not available for L21SC/L32SC.
1 mm
(0.04 in)