TLV J3X Free Float Steam Trap Instruction Manual

J3X Free Float Steam Trap

INSTRUCTION MANUAL
Keep this manual in a safe place for future reference
TLV. FREE FLOAT STEAM TRAPS
JX SERIES Copyright (C) 2022 by TLV CO,, LTD. Allights reserved.

Introduction

Before you begin, please read this manual to ensure correct usage of the product, and keep it in asafe place for future reference.
The JX Series steam traps with thermostatic air vent (X-element) are suitable for a wide range of applications up to 2.1 MPaG (300 psig), such as tracer lines, unit and process heaters, heating coils, heat exchangers, etc. The traps discharge condensate continuously and automatically, at a temperature slightly lower than saturation temperature.
1MPa = 10.197 kg/em?, 1 bar =0.1 MPa
For products with special specifications or with options not included in this manual, contact TLV for instructions.
The contents of this manual are subject to change without notice.

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 occurting as a result of failure to observe these precautions.

DANGER
Tndicates an urgent situation which poses a threat of potential threat of death possibility of injury or equip- death or serious injury.
WARNING
Indicates that there is a potential threat of death or serious injury.
CAUTION
Tndicates 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.
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 malfunciions, which 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.
DO NOT subject this product to condensate loads that exceed its. discharge capacity. Failure to observe this precaution may lead to condensate accumuiation upstream of the trap, resulting in reduced equipment performance or damage to the equipment.
Use hoisting equipment for heavy objects (weighing approximately 20kg (44 Ib) or more). Ealle to do so may resultn back sirain or other injury it the object should fall.
Take measures to prevent people from coming info direct contact with product outlets. Failure to do so may result in burns or other injury from the discharge of fluids.
CAUTION
When disassembling or removing the product, wait unti the internal pressure equals atmospheric pressure and the surface of the product has cooled to room temperature. Disassembling or removing the product when itis hot or under pressure may lead to discharge of fuids, 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 resuit in damage to the product or burns or other injury due to malfunction or the discharge of fluids.
Do not use excessive force when connecting threaded pipes to the product. Overtightening may cause breakage leading to fluid discharge, Wwhich may cause burns or other injury.
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 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 bums or other injury.

Configuration Aufbau Configuration

*Option for JaX, J5X ** See page 6

Exploded View

* JF5X 20, 25 mm (%, 1) only. JFSX 32 -50 mm (174″~ 27) and all other models have cast-in flanges.

Maintenance Parts and Repair Parts

Replacement float avalable.
Note: All replacement parts are avallable only in thelr respective Kits.
M = Malntenance Kit
R = Repalr Kit

• Option

Specifications

Refer to the product nameplate for detailed specifications.A Model
B Nominal Diameter
C Maximum Allowable Pressure
D Maximum Allowable Temperature TMA
E Maximum Differential Pressure
F Maximum Operating Temperature
G Production Lot No.
H Valve 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.
  CAUTION
  To avoid malfunctions, product damage, accidents or serious injury, install properly and DO NOT use this product outside the Specification range. Local regulations may restrict the use of this product to below the conditions quoted.

Proper Installation

CAUTION

• Installation, inspection, maintenance, repairs, disassembly, adjustment  and valve opening/closing should be carried out only by trained maintenance personnel.
• Take measures to prevent people from coming into direct contact with product outlets.
• Do not use excessive force when connecting threaded pipes.
• Install for se under conditions in which o freeze-up will ocour.
• Install for use under conditions in which no water hammer will occur.

1. Before installation, be sure to remove all protective seals.
2. Before installing the trap, blow out the inlet piping to remove al it and oil.
3. When hoisting the prodiuct, hang the rope around the inlet/outlet as close to the body as ossible.
4. Intall the steam trap within the allowable inclination, as shown below. Also make sure that the amow mark on the body corresponds with the direction of flow.
5. Install the trap in the lowest part of the pipeline or equipment so the condensate flows naturally into the trap by gravity. The nlet pipe should be as short and have as few bends as possible.
6. Support the pipes properly within 800 mm (2.5 ) on either side of the trap.
7. Install a bypass valve to discharge condensate, and inlet and outlet valves to isolate the trap in the event of trap failure or when perfoming maintenance.
8. Install a check valve at the trap outiet whenever more than one trap is connected to the condensate collection pipeline.
9. The use of unions is recommended to facilitate connection and disconnection of screwed models.

Piping Arrangement

inlet protrudes into pipe.
To prevent rust and scale from flowing into the trap, connect the inlet pipe 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
nothing obstructs the flow of condensate.| | Condensate oll cpipeects in the pipe.

Check to make sure that the pipes connected to the trap have been installed properly.

1. Is the pipe diameter suitable?
2. Has the piping work been done with the proper methods as shown in the table on page 9? o ¢ po N
3. Has the trap been installed within the allowable inclination and with the arrow on the body pointing in the direction of flow?
4. Has sufficient space been secured for maintenance?
5. Have maintenance valves been installed at inlet and outlet? If the outlet is subject to back pressure, has a check valve been installed?
6. Is the inlet pipe as short as possible, with as few bends as possible, and installed so that the condensate will flow naturally down into the trap?

Inspection and Maintenance

Operational inspections shouild be performed at least twice per year, or as called for by trap operating conditions. Steam trap failure may result in a temperature drop in the equipment, poor product quality or losses due to steam leakage.
WARNING
NEVER apply direct heat to the float. The float may explode due to  increased intemal pressure, causing accidents leading to serious injury or property and equipment damage.
CAUTION

• Istallation,inspection, maintenance, repairs, disassembly, adjustment and valve opening/closing should be carried out only by trained maintenance personnel.
• Before attempting to open the trap, close the inlet and outlet isolation valves and wait until the trap has cooled completely. Failure to do so may resultin bums.
• Be sure to use the proper components and NEVER attempt to modify the product.

Parts Inspection Procedure

Tightening Torque and Distance Across Flats

Model

| Cover Bolt (23)| Air Vent Valve Seat (21)| Plug (24)| Orifice Holder Plug (7)|

Drain Plug (19)

---|---|---|---|---|---
N•m (Ibf•ft)| mm (in)| N-m (Ibf-ft)| mm (in)| N- m (Ibf -ft)| mm (in)| N – m (Ibf-ft)| mm (in)| N•m (Ibf•ft)| mm (in)
J3X| 50

(37)

| 16, 17 ( 5/8 , 2/1 32)| 35
(26)| 19
( 3/4 )| 30
(22)| 19
( 3/4 )| 50
(37)| 24
(15/16 )| 35
(26)| 21
(13/16 )
J5X| 80
(59)| 22
( 7/8 )| 35
(26)| 19
( 3/4 )| 30
(22)| 19
( 3/4 )| 80
(59)| 32
(11/4 )| 35(2
6)| 21
(13/16 )
J7X| 70
(51)| 16, 17 ( 5/8 , 2/1 32)| 35
(26)| 19
( 3/4 )| 30 (22)| 12
(15/32)| 120
(88)| 36
(113/32)| 30
(22)| 12
(15/32)
J7.2X| 110
(81)| 22
( 7/8 )| 35
(26)| 19
( 3/4 )| 30 (22)| 12

(15/32)

| 400
(290)| 70
(23/4 )| 30
(22)| 12
(15/32)
J7.5X| 160
(115)| 24
(15/16)| 35
(26)| 19
( 3/4 )| 30
2)| 12
(15/32)| 600
(440)| 85
(311/32)| 40
(29)| 14
( 9/16 )
J8X| 250
(185)| 32
(11/4 )| 35
(26)| 19
( 3/4 )| 30
(22)| 12
(15/32)| 800

(590)

| 105 (41/8 )| 40
(29)| 14
( 9/16 )

• Size depends on bolt standard
  ** Indicates torque values with a Sealing tape wrapped 3 – 3.5 times around the threads of the plug or drain plug
  If drawings or other special documentation were supplied for the product, any torque given theretakes precedence over valuies shown here.

Part & No.| J3X J5X| J7X| J7.2X| J7.5X J8X| Disassembly|

Reassembly

---|---|---|---|---|---|---
Plug 24| | ✓| ✓| ✓| Remove only if necessary, use a wrench to remove| Wrap threads with sealing tape
✓| | | | Coat threads with anti-seize
Plug Gasket 25| ✓| | | | Remove gasket only if worn or damaged| Replace with a new gasket only if worn or damaged
Cover Bolt 23| ✓| ✓| ✓| ✓| Use a wrench to remove| Coat threads with anti- seize
Cover 2| ✓| ✓| ✓| ✓| Lift up the cover| Align the cover with the connector to attach the cover (figure A)
Connector 22| ✓| ✓| ✓| ✓| Remove the connector| Insert the connector
Cover Gasket 3| ✓| ✓| | | Remove gasket only if worn or damaged| Replace with a new gasket only if worn or damaged
| | ✓| ✓| Remove gasket and clean sealing surfaces| Replace with a new gasket, do not appy anti-seize
Drain Plug 19| | ✓| ✓| ✓| Use a wrench to remove| Wrap threads with sealing tape
✓| | | | Coat threads with anti-seize
Drain Plug Gasket 20| ✓| | | | Remove and clean sealing surfaces| Replace with a new gasket, coat surfaces with anti-seize
Snap Ring 18
(X-element cover)| | ✓| ✓| ✓| Use appropriate pliers to squeeze and remove| Squeeze and insert securely into the groove
X-element Cover 17| | ✓| ✓| ✓| Lift up the cover| The mesh should face the float
Spring Clip 16
(X-element)| ✓| ✓| ✓| ✓| Squeeze the spring clip to remove it from the guide| Squeeze the spring clip and insert it into the X-element guide
X-element 14| ✓| ✓| ✓| ✓| Remove from the X-element guide| Make sure the X-element is not upside down (figure B)
Air Vent Valve Seat 21| ✓| ✓| ✓| ✓| Use a wrench to remove| Coat threads with anti-seize
X-element Guide 15| ✓| ✓| ✓| ✓| Remove without bending| Make certain the X-element fits in securely
Snap Ring 13 (Screen)| | ✓| | ✓| Use appropriate pliers| Insert securely into groove
Screen 9 &
Float Cover 12| ✓| | | | Lift straight up| Align arrows and insert, insert tab on bottom into guide on body and push in until top is flush (figure C)
Screen 9| | ✓| ✓| ✓| Lift straight up| Place screen holder on ledge inside body, round side up; place screen holder retainer next (if applicable), followed by screen
Screen Holder
Retainer 11| | ✓| | ✓
Screen Holder 10| | ✓| ✓| ✓| Remove without bending
Float 4| ✓| ✓| ✓| ✓| Remove, being careful not to scratch its polished surface| Insert into body, being careful not to scratch its polished surface
Orifice Holder Plug 7| ✓| ✓| ✓| ✓| Use a wrench to remove| Coat threads with anti-seize*
Orifice Plug Gasket 8| ✓| ✓| ✓| ✓| Remove gasket only if worn or damaged| Replace with a new gasket only if worn or damaged
Orifice 5| ✓| ✓| ✓| ✓| Push out from inside the body toward the plug holder| With flat surface of the orifice facing up, push from outside until it contacts interior stop (figure D)
Orifice O-Ring 6| ✓| ✓| ✓| ✓| Remove the rubber O-ring and clean sealing surfaces| Replace with a new O-ring, coat with heat-resistant grease

*Tighten to the proper torque (see table Tightening Torque and Distance Across Fiats)
“v”Indicates which modeis contaln which parts ![TLV J3X Free Float Steam Trap

• overview 10](https://manuals.plus/wp-content/uploads/2024/01/TLV-J3X-Free- Float-Steam-Trap-overview-10.jpg)

Operational Check

Avisual inspection can be cartied out to aid in determining the necessity for immediate maintenance o repair, if the trap is open to atmosphere. If the trap does not discharge to atmosphere, use diagnostic equipment such as TLV TrapMan or TLV Pocket rapMan (with in ii ts pressure and temperature measuring range).

Normal:| Condensate is discharged continuously 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:| 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 the condensate and there is 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 is highly recommended,)             

Troubleshooting

If the expected performance is unachievable after installation of the steam trap, read chapters 6 and 7 again and check the following points to take appropriate corrective measures.

Problem| Cause|

Remedy

---|---|---
No condensate is discharged (blocked) or discharge is poor| Float is damaged or filled with condensate| Replace the float
Orifice, screen or piping is clogged with rust or scale| Clean
Steam-locking has occurred| Blowdown through the bypass or close the trap inlet valve and allow the trap to cool
X-element is damaged| Replace the X-element
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 trap outlet (blowing) (steam leakage)| Rust and scale have accumulated around the orifice or under the float| Clean
Orifice is damaged| Replace the orifice
Float is deformed or coated with scale| Clean or replace the float
Trap is installed above the maximum allowable inclination angle| Correct the installation
Vibration of trap occurs| Lengthen inlet piping, then fasten it securely
The X-element is damaged, or clogged with rust or scale| Clean or replace the X-element
Steam leaks from a place other than the trap outlet| Deterioration of or damage to gaskets| Replace with new gaskets
Leakage from eroded cavities of body or cover| Replace the trap
Improper tightening torque for cover was used| Tighten to the proper torque
Float is frequently damaged| Water hammer occurs| Examine the piping for problems that can cause water hammer

For maintenance parts and repair parts see page 7

Lock Release Valve (Option for J(F)3X and J(F)5X)

Operation
When shipped from the factory, the element retainer is i its maximum position. Use a flat-head screwdriver to adjust the amount of steam released. When not in use, the element retainer should be retured to its maximum position. If steam should leak from the gland case or gland retainer, it can be stopped by further tightening the gland retainer.
Inspection and Maintenance
Unscrew the gland retainer nut and the gland case and take off all parts. Check for dirt, oil and damage. Replace damaged parts. Before reassembiing, replace the gland packing. Replace the gasket only if necessary.

TLV EXPRESS LIMITED WARRANTY

Subject to the limitations set forth below, TLV CO., LTD., a Japanese corporation (“TLV”), warrants that products which are sold by it, TLV International Inc. (“TIF) or one of its group companies excluding TLV Corporation (a corporation of the United States of  America), (hereinafter the “Products”) are designed and manufactured by TLV, conform to the specifications published by TLV for the corresponding part numbers (the “Specifications”) and are free from defective workmanship and materials. The party from whom the Products were purchased shall be known hereinafter as the “Seller”. With regard to products or components manufactured by unrelated third parties (the “Components”), TLV provides no warranty other than the warranty from the third party manufacturer(s), if any.
Exceptions to Warranty
This warranty does not cover defects or failures caused by:

1. improper shipping, installation, use, handiing, etc., by persons other than TLV, Til or TLV group company personnel, or service representatives authorized by TLV; o
2. dirt, scale or rust, etc.; or
3. improper disassembly and reassembly, or inadequate inspection and maintenance by persons other than TLV or TLV group company personnel, or service representatives authorized by TLV;or
4. disasters or forces of nature or Acts of God; or
5. abuse, abnormal use, accidents or any other cause beyond the control of TLV, Til or TLV group companies; or
6. improper storage, maintenance or repair; or
7. operation of the Products not in accordance with instructions issued with the Products or with accepted industry practices; or
8. use for a purpose or in a manner for which the Products were not intended; or
9. use of the Products in a manner inconsistent with the Specifications; or
10. use of the Products with Hazardous Fluids (fluids other than steam, air, water, nitrogen, carbon dioxide and inert gases (helium, neon, argon, krypton, xenon and radon)); or
11. failure to follow the instructions contained in the TLV Instruction Manual for the Product.

Duration of Warranty
This warranty is effective for a period of one (1) year aiter delivery of Products to the first end user. Notwithstanding the foregoing, asserting a claim under this warranty must be brought within three (3) years after the date of delivery to the initial buyer if not sold initially to the first end user. ANY IMPLIED WARRANTIES NOT NEGATED HEREBY WHICH MAY ARISE BY OPERATION OF LAW, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY EXPRESS WARRANTIES NOT NEGATED HEREBY, ARE GIVEN SOLELY TO THE INITIAL BUYER AND ARE LIMITED IN DURATION TO ONE (1) YEAR FROM THE DATE OF SHIPMENT BY THE SELLER.
Exclusive Remedy
THE EXCLUSIVE REMEDY UNDER THIS WARRANTY, UNDER ANY EXPRESS WARRANTY OR UNDER ANY IMPLIED WARRANTIES NOT NEGATED HEREBY (NCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE), IS REPLACEMENT; PROVIDED: (a) THE CLAIMED DEFECT IS REPORTED TO THE SELLER IN WRITING WITHIN THE WARRANTY PERIOD, INCLUDING A DETAILED WRITTEN DESCRIPTION OF THE CLAIMED DEFECT AND HOW AND WHEN THE CLAIMED DEFECTIVE PRODUCT WAS USED; AND (b) THE CLAIMED DEFECTIVE PRODUCT AND A COPY OF THE PURCHASE INVOICE IS RETURNED TO THE SELLER, FREIGHT AND TRANSPORTATION COSTS PREPAID, UNDER A RETURN MATERIAL AUTHORIZATION AND TRACKING NUMBER ISSUED BY THE SELLER. ALL LABOR COSTS, SHIPPING COSTS, AND TRANSPORTATION COSTS ASSOCIATED WITH THE RETURN OR REPLACEMENT OF THE CLAIMED DEFECTIVE PRODUCT ARE SOLELY THE RESPONSIBILITY OF BUYER OR THE FIRST END USER. THE SELLER RESERVES THE RIGHT TO INSPECT ON THE FIRST END USER’S SITE ANY PRODUCTS CLAIMED TO BE DEFECTIVE BEFORE ISSUING A RETURN MATERIAL AAUTHORIZATION. SHOULD SUCH INSPECTION REVEAL, IN THE SELLER’S REASONABLE DISCRETION, THAT THE CLAIMED DEFECT IS NOT COVERED BY THIS WARRANTY, THE PARTY ASSERTING THIS WARRANTY SHALL PAY THE SELLER FOR THE TIME AND EXPENSES RELATED TO SUCH ON-SITE INSPECTION.

Exclusion of Consequential and Incidental Damages
ITIS SPECIFICALLY ACKNOWLEDGED THAT THIS WARRANTY, ANY OTHER EXPRESS WARRANTY NOT NEGATED HEREBY, AND ANY IMPLIED WARRANTY NOT NEGATED HEREBY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, DO NOT COVER, AND NEITHER TLV, Tl NOR ITS TLV GROUP COMPANIES WILL IN ANY EVENT BE LIABLE FOR, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO LOST PROFITS, THE COST OF DISASSEMBLY AND SHIPMENT OF THE DEFECTIVE PRODUCT, INJURY TO OTHER PROPERTY, DAMAGE TO BUYER’S OR THE FIRST END USER’S PRODUCT, DAMAGE TO BUYER’S OR THE FIRST END USER’S PROCESSES, LOSS OF USE, OR OTHER COMMERCIAL LOSSES. WHERE, DUE TO OPERATION OF LAW, CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER THIS WARRANTY, UNDER ANY OTHER EXPRESS WARRANTY NOT NEGATED HEREBY OR UNDER ANY IMPLIED WARRANTY NOT NEGATED HEREBY (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) CANNOT BE EXCLUDED, SUCH DAMAGES ARE EXPRESSLY LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THE DEFECTIVE PRODUCT. THIS EXCLUSION OF CONSEQUENTIAL AND INCIDENTAL DAMAGES, AND THE PROVISION OF THIS WARRANTY LIMITING REMEDIES HEREUNDER TO REPLACEMENT, ARE INDEPENDENT PROVISIONS, AND ANY DETERMINATION THAT THE LIMITATION OF REMEDIES FAILS OF ITS ESSENTIAL PURPOSE OR ANY OTHER DETERMINATION THAT EITHER OF THE ABOVE REMEDIES IS UNENFORCEABLE, SHALL NOT BE CONSTRUED TO MAKE THE OTHER PROVISIONS UNENFORCEABLE.
Exclusion of Other Warranties
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY DISCLAIMED.
Severability
Any provision of this warranty which is invalid, prohibited or unenforceable in any jurisdiction shall, as to such jurisdiction, be ineffective to the extent of such invalidity, prohibition or unenforceability without invalidating the remaining provisions hereof, and any such invalicity, prohibition or unenforceability in any such jurisdiction shall not invalidate or render unenforceable such provision in any other jurisdiction.

For Service or Technical Assistance:
Contact your TLV representative or your regional TLV office.
USA and Canada: TLV. CORPORATION
USA und Kanada: 13901 South Lakes Drive, Charlotte,
E.U. et le Canada: NC 28273-6790, U.S.A.
Tel: [11-704-597-9070
Fax: [1]-704-583-1610

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