TLV LEX3N-TZ User manual

172-65381M-03 (LEX3N-TZ) 22 April 2009
Temperature Control Trap
(with Bimetal Element)
LEX3N-TZ
Copyright © 2009 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
Specifications..................................................................... 4
Configuration...................................................................... 5
Installation.......................................................................... 6
Adjusting the Set Temperature .......................................... 7
Cleaning Function............................................................ 10
Maintenance..................................................................... 12
Disassembly / Reassembly.............................................. 13
Troubleshooting ............................................................... 16
Product Warranty............................................................. 17
Introduction
Thank you for purchasing the temperature control 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.
Unlike most steam traps, this temperature control trap (with bimetal element)
enables the desired condensate discharge temperature to be set. Note: only
the temperature of condensate discharged can be controlled; this temperature
control trap does not control product temperature nor temperature of
condensate accumulating in the system.
This temperature control trap is also ideal for heating of heavy oil tank and oil
feed pipe lines, and for the tracing of valves, instrumentation, etc.
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 needed 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.
DANGE
R
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.
Do not remove cap nut or cover while trap is under pressure.
Allow trap body temperature to cool to room temperature before
removing cap nut or cover.
Failure to do so may result in burns or other injury.
Safety considerations are continued on the next page.

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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.
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.
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 been installed?
4. Has the trap been installed so that condensate will easily flow naturally down into
the trap by gravity?
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.
* 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.
Model
Maximum Allowable
Pressure*
Size
Valve No.**
Serial Number
Maximum Operating
Pressure
Maximum Allowable
Temperature*
Maximum Operating
Temperature

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Configuration
No. Name M R No. Name M R
1 Body 12 Spring Pin √
2 Cover 13 Seal Ring √√
3 Valve Stem √14 Screen √
4 Adjusting Screw 15 Locknut
5 Bimetal Element √16 Cap Nut
6 Washer √17 Cover Gasket √√
7 Valve Seat √18 Nameplate
8 Valve Seat Gasket √√19 Spring Guide √
9 Overexpansion Spring √20 Thrust Plate √
10 Return Spring √21 Cap Nut Gasket √√
11 Snap Ring √22 Flange (Flanged type only)
Replacement parts are available only in the following kits: M = Maintenance Kit; R = Repair Kit

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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 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.
2. Before installation, be sure to remove all protective seals.
3. Install the product so the arrow on the body is pointing in the direction of
condensate flow.
4. The trap may be installed either horizontally or vertically; there are no restrictions
on the orientation of installation. However, when installing horizontally, make sure
that the trap is installed with the temperature adjusting screw positioned higher
than the piping in which the trap is installed. (Upside-down installation is not
permissible.)
5. Open the inlet valve gradually 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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Adjusting the Set Temperature
Do not remove cap nut or cover while trap is under pressure. Allow trap
body temperature to cool to room temperature before removing cap
nut or cover. Failure to do so may result in burns or other injury.
CAUTION
Always wear heat-insulated gloves when handling products with high
body temperatures, such as when in operation. Failure to do so may
result in burns.
CAUTION
Follow the procedure below to adjust.
1. For your safety, wear heat-insulated gloves or eye protectors, etc. to prevent
burns.
2. Close the external valve from which the steam and condensate flow to the trap
(the “inlet isolation valve”).
3. Close the external valve to which the condensate flows from the trap (the “outlet
isolation valve”).
4. Wait until the pressure between the inlet isolation valve and the trap equals
atmospheric pressure (when the trap body temperature cools to room
temperature).
5. Hold the cover with one wrench and use another wrench to slowly loosen the cap
nut carefully checking for any steam leaks that might occur. In the event steam
leaks are detected, immediately stop the work and proceed with maintenance
referring to “Disassembly / Reassembly” section.
6. Remove the cap nut.
7. Hold the adjusting screw in place with a flat-head screwdriver and loosen the
locknut slowly carefully checking for any steam leaks that might occur. In the
event steam leaks are detected, immediately stop the work and proceed with
maintenance referring to “Disassembly / Reassembly” section.
8. Remove the locknut.
9. Use a flat-head screwdriver to turn the adjusting screw to adjust temperature. To
raise the temperature setting, turn the adjusting screw counterclockwise. To lower
the temperature setting, turn the adjusting screw clockwise. Refer to set
temperature adjustment chart for the number of turns required from the “0”
position to reach the desired temperature.
10. After completing the adjustment, replace the locknut. Hold the adjusting screw in
place with a flat-head screwdriver and tighten the locknut securely.
11. Replace the cap nut and tighten it to the proper torque (see page 14). Hold the
cover with one wrench and use another wrench to tighten.
12. First fully open the outlet isolation valve slowly.
13. Slowly open the inlet isolation valve carefully checking for any steam leaks that
might occur. In the event steam leaks are detected, immediately close the inlet
isolation valve, then the outlet isolation valve, and repair the source of leakage.
14. Check the temperature setting by observing an inline temperature sensor or by
measuring the temperature at the wrench flat on the trap’s inlet side at least 30
minutes after supplying steam with the new setting. The trap set temperature will
be approximately 10 to 20 °C higher than the surface reading. If the resultant
temperature is not as required, repeat procedure from step “2” above.
15. Fully open the outlet isolation valve slowly.

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16. Slowly open the inlet isolation valve carefully checking for any steam leaks that
might occur.
17. In the event steam leaks are detected, immediately close the inlet isolation valve,
then the outlet isolation valve, and repair the source of leakage. In the event
steam leaks are detected somewhere other than the outlet piping, immediately
close the inlet isolation valve, then the outlet isolation valve and repair the leaks
referring to “Disassembly / Reassembly” section.
CAUTION
The standard factory setting is
100 °C at 0.9 MPaG. Change from
this to the desired setting, as
indicated in the Adjustment Chart.
4.6 MPaG Specification
Operating Pressure (MPaG)
2.1 MPaG Specification
Temperature Setting Range (°C)
Number of Turns of Adjusting Screw
Set Temperature (°C)
2.1 MPaG Specification
4.6 MPaG Specification
Operating Pressure (MPaG)

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Temperature Setting Example
As shown in the figure on the right, this
temperature control trap is positioned with the
bottom of the adjuster slot in the adjusting
screw (A) even with the very top of the cover
(B) , which represents the 100 °C at 0.9
MPaG setting.
This is the standard factory setting.
For example, to set the trap to 70 °C at 0.4 MPaG, refer to the adjustment chart
below to determine the number of turns.
For this example, the number of turns is -1½. Because this is a negative number, turn
the adjusting screw clockwise (tighten) one and a half turns.
Cover
4.6 MPaG Specification
2.1 MPaG Specification
Adjusting
Screw
Adjuster
Slot
Number of Turns
of Adjusting Screw
Operating Pressure (MPaG)

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Cleaning Function
Do not remove cap nut or cover while trap is under pressure. Allow trap
body temperature to cool to room temperature before removing cap
nut or cover. Failure to do so may result in burns or other injury.
CAUTION
Always wear heat-insulated gloves when handling products with high
body temperatures, such as when in operation. Failure to do so may
result in burns.
CAUTION
Rust, scale and other buildup on the valve seat can hinder the sealing ability of the
steam trap leading to steam leakage and higher product temperatures, or block the
valve seat opening preventing condensate discharge and resulting in the decrease of
the product temperature. Follow the steps below to remove any accumulation from
around the valve opening.
1. For your safety, wear heat-insulated gloves or eye protector, etc. to prevent
burns.
2. Close the external valve from which the steam and condensate flow to the trap
(the “inlet isolation valve”).
3. Close the external valve to which the condensate flows from the trap (the “outlet
isolation valve”).
4. Wait until the pressure between the inlet isolation valve and the trap equals
atmospheric pressure (when the trap body temperature cools to room
temperature).
5. Hold the cover with one wrench and use another wrench to slowly loosen the cap
nut carefully checking for any steam leaks that might occur. In the event steam
leaks are detected, immediately stop the work and proceed with maintenance
referring to “Disassembly / Reassembly” section.
6. Remove the cap nut.
7. Hold the adjusting screw in place with a flat-head screwdriver and loosen the
locknut slowly carefully checking for any steam leaks that might occur. In the
event steam leaks are detected, immediately stop the work and proceed with
maintenance referring to “Disassembly / Reassembly” section.
8. Remove the locknut.
9. Check the current set position of the adjusting screw.
10. Check and record the number of turns required to return to the standard factory
setting (when points (A) and (B) are even with each other as shown on page 9).
11. Use a flat-head screwdriver to slowly turn the adjusting screw clockwise (to
tighten) until it stops. (This causes the cleaning edge of the stem to reach the
valve seat and loosen debris).
12. Slowly turn the adjusting screw counterclockwise (to loosen) until it stops. (This
will allow flushing once the steam is safely turned on using the instructions that
follow).
13. Replace the cap nut and tighten it to the proper torque (see page 14). Hold the
cover with one wrench and use another wrench to tighten.
14. First fully open the outlet isolation valve slowly.
15. Slowly open the inlet isolation valve carefully checking for any steam leaks that
might occur. In the event steam leaks are detected, immediately close the inlet
isolation valve, then the outlet isolation valve, and repair the source of leakage.

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16. Wait 10 seconds to allow any loose scale to be flushed internally. Be aware of
any external steam leak including the outlet connection if opened to atmosphere.
Be careful to not come in contact with any steam that is discharging from an open
outlet connection. If any steam leaks are detected somewhere other than the
outlet piping, immediately close the inlet isolation valve, then the outlet isolation
valve, and repair the source of leakage.
17. Close the inlet isolation valve.
18. Close the outlet isolation valve.
19. Wait until the pressure between the inlet isolation valve and the trap equals
atmospheric pressure (when the trap body temperature cools to room
temperature).
20. Hold the cover with one wrench and use another wrench to slowly loosen the cap
nut carefully checking for any steam leaks that might occur. In the event steam
leaks are detected, immediately stop the work and proceed with maintenance
referring to “Disassembly / Reassembly” section.
21. Remove the cap nut.
22. Slowly turn the adjusting screw clockwise (to tighten) to return to the original
position checked in step “10” above.
23. Hold the adjusting screw in place with a flat-head screwdriver and tighten the
locknut securely.
24. Replace the cap nut and tighten to the proper torque (see page 14).
25. First fully open the outlet isolation valve.
26. Slowly open the inlet isolation valve carefully checking for any steam leaks. In the
event steam leaks are detected, immediately close the inlet isolation valve, then
the outlet isolation valve, and repair the source of leakage.
27. Check the temperature setting by observing an inline temperature sensor or by
measuring the temperature at the trap inlet wrench flat at least 30 minutes after
supplying steam with the new settings. The trap set temperature will be
approximately 10 to 20°C higher than the temperature reading on the trap body
surface.
28. If the resultant temperature is no as desired, use the above instructions for
adjusting temperature settings. (See “Adjusting the Set Temperature”)

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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 trap diagnostic instrument or a thermometer.
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 being discharged from the discharge outlet.
Condensate temperature should be around the set
temperature. (The surface temperature of the trap should be
about 10 to 20°C lower than the set temperature.)
Blocked
(Discharge Impossible) : No condensate is discharged and the surface temperature of the trap is low.
Blowing : Live steam continually flows from the outlet and there is a
continuous hissing sound of flow.
(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
Seal Ring: Check for scratches and wear
Valve Stem: Check for scratches and wear
Bimetal Element: Check wear and deformation
Over-expansion and
Return Springs: Check for wear
Screen: Check for clogging and corrosion
Valve Seat: Check the seating surfaces for damage or wear
(After cleaning inside
the body) Check gasket for warping and damage Check valve seat for damage or wear

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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
and adjustment should be done only by trained maintenance personnel.)
Detaching / Reattaching the Cap Nut, Locknut and Cover Unit
Part During Disassembly During Reassembly
Cap Nut Remove with a spanner or socket
wrench Consult the table of tightening torques and tighten to the proper torque
Cap Nut
Gasket Remove gasket and clean sealing surface Replace with a new gasket if warped or damaged
Locknut Remove with a spanner or socket
wrench Tighten enough to prevent the adjustment screw from turning
Cover Remove with a spanner or socket
wrench Consult the table of tightening torques and tighten to the proper torque
Cover
Gasket Remove gasket and clean sealing surface Replace with a new gasket; coat surfaces with anti-seize
Adjusting
Screw &
Seal Ring
Screw in by using a flat-head
screwdriver Be careful not to damage the seal ring during reassembly and coat seal ring
surface with heat resistant silicon
grease.
Disassembly / Reassembly of the Valve Unit
Part During Disassembly During Reassembly
Snap Ring Remove the snap ring from the
valve stem Reattach to the valve stem
Washer Remove washer from the valve
stem by lifting up and off Slide onto the valve stem
Return Spring Remove the return spring from the
valve stem by lifting up and off Place on the valve stem
Thrust Plate Remove the thrust plate from the
valve stem by lifting up and off Slide onto the valve stem
Bimetal
Element
(2 discs)
Remove the bimetal element from
the valve stem by lifting up and off Reassemble the bimetal elements, paying special
attention to the proper orientation
(the TLV marks on the outside)
Washer
5 sets
Remove the washer from the valve
stem by lifting up and off Place 1 washer between each pair of bimetal disks

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Disassembly / Reassembly of the Body Unit
Part During Disassembly During Reassembly
Screen Remove without bending Reinsert without bending
Spring
Guide Remove from the trap body Reassemble, being extremely careful to reinsert in the correct orientation
Overexpan-
sion Spring Remove from the trap body Reassemble, being careful not to place it on the valve seat
Valve Seat The surfaces of the valve seat are
highly polished; remove by using a
socket wrench, being careful not
to scratch the sealing surfaces
Consult the table of tightening torques
and tighten to the proper torque; be
careful not to scratch the seating
surfaces during reassembly
Valve Seat
Gasket Remove without bending and clean sealing surface Replace with a new gasket; coat surfaces with anti-seize
Table of Tightening Torques
Cap Nut Locknut Cover Valve Seat
Torque Distance
Across Flats Torque Torque Torque
N⋅mmm N⋅m
Distance
Across Flats
mm N⋅m
Distance
Across Flats
mm N⋅m
Distance
Across Flats
mm
35 24 - 14 250 46 30 19
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.

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Exploded View
Ca
p
Nut
Cap Nut
Gasket
Locknut
Body Unit
Valve Unit
Cover Unit
Cover Gasket
Cover
A
djusting
Screw
Seal Ring
Spring Pin
Valve Stem
Bimetal Element
Washer
Thrust Plate
Return Spring
Washer
Snap Ring
Spring Guide
Overexpansion
Spring
Screen
Valve Seat
Valve Seat Gasket
Body
TLV Mark
Nameplate

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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
The bimetal element is broken Replace with a new bimetal
element
The assembly (orientation) of the
bimetal elements is not correct Correct the assembly of the bimetal elements
There is a build-up of dirt, etc. in the
spaces between the bimetal elements Clean the bimetal elements
The valve seat is clogged with rust
and scale Use built-in cleaning function
The screen or piping are clogged with
rust and scale Clean parts
No
condensate is
discharged or
temperature
doesn’t rise to
the set
temperature
The adjusting screw is not correctly
positioned Readjust the screw
There is a build-up of dirt or scale on
the valve stem or seating surfaces of
the valve seat
Use built-in cleaning function
The valve stem is worn Replace with a new valve stem
The valve seat is worn Replace with a new valve seat
The sealing surfaces of the valve
stem are damaged Replace with a new valve stem
The sealing surfaces of the valve seat
are damaged Replace with a new valve seat
The valve seat has loosened Retighten totheproper torque
The valve seat gasket is damaged Replace with a new gasket
Steam is
blowing or the
temperature
rises above
the set
temperature
The adjusting screw is not correctly
positioned Readjust the screw
Leakage from the cap nut gasket:
The gasket or the seal ring is
damaged or deteriorated
Replace with a new gasket or
seal ring
Leakage from the adjusting screw:
The seal ring is damaged or
deteriorated
Replace with a new seal ring
There is
leakage to the
outside of the
trap
Leakage from the cover gasket:
The gasket is damaged Replace with a new gasket
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