Instruction Manual: JX Series
Instruction Manual: JX Series
Instruction Manual: JX Series
J3X / J5X
J7X
Manufacturer
1. 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.
NEVER apply direct heat to the float. The float may explode due to
WARNING 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
malfunctions, 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
CAUTION dischargecapacity. Failure to observe this precaution may lead to
condensate accumulation upstream of the trap, resulting in reduced
equipment performance or damage to the equipment.
Use hoisting equipment for heavy objects (weighing approximately
20 kg (44 lb) or more). Failure to do so may result in back strain or other
injury if the object should fall.
Take measures to prevent people from coming into direct contact
with product outlets. Failure to do so may result in burns or other injury
from the discharge of fluids.
Continued on next page
̶1̶
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
or burns or other injury due to malfunction or the discharge of fluids.
CAUTION Do not use excessive force when connecting threaded pipes to the
product. Overtightening may cause breakage leading to fluid discharge,
which 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 burns or other injury.
2. 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.
A
H Valve No.** A
B
B G
H
C D F
C
F E
E D
H
G
* 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.
̶2̶
3. Configuration Aufbau Configuration
J3X / J5X
@3 e !6 w @5 @4 @1 @8 !5 !4 J3X, J5X J7X, J7.2X,
No. Description J7.5X, J8X,
!2 M R F M R F
@2 1 Body
o 2 Cover
3 Cover Gasket
4 Float
5 Orifice
6 Orifice O-Ring
@0 7 Orifice Holder Plug
8 Orifice Plug Gasket
!9 9 Screen
10 Screen Holder
11 Screen Holder Retainer
12 Float Cover
q r y t i u
13 Snap-Ring
14 X-element
15 X-element Guide
J7X / J7.5X / J8X
16 Spring Clip
e @3 w @8 !8 !7 !6 @4 @1 !5 !4 @2 17 X-element Cover
18 Snap-Ring
19 Drain Plug*
20 Drain Plug Gasket*
21 Air Vent Valve Seat
22 Connector
23 Cover Bolt
!3 24 Plug
!1
o 25 Plug Gasket
!0 (JF5X: 20, 25 mm)
26 Flange**
(JF5X: 3/4” ,1” )
!9
(JF5X: 20, 25 mm)
27 Pipe**
(JF5X: 3/4” ,1” )
28 Nameplate
q r yt i u * Option for J3X, J5X ** See page 4
Note: All replacement parts are available only in their respective kits.
M = Maintenance Kit R = Repair Kit F = Float
J7.2X
e @3 w @8 !8 !7 !6 @4 @1 !5 !4 @2
o
!0
!9
qryt i u
̶3̶
4. Exploded View
See also: Lock release
valve, page 9. J3X / J5X
24 Plug
23 Cover Bolt
25 Plug Gasket
14 X-element
18 Snap-Ring 12 Float Cover
16 Spring Clip
13 Snap-Ring
9 Screen
9 Screen
4 Float
11 Screen Holder Retainer
1 Body
10 Screen Holder
27* Pipe
6 Orifice O-Ring
5 Orifice
19 Drain Plug
* JF5X 20, 25 mm ( 3/4” , 1” ) only. JF5X 32 - 50 mm ( 1 1/4” - 2” ) and all other models have cast-in flanges.
̶4̶
5. Proper Installation
• Installation, inspection, maintenance, repairs, disassembly, adjustment
CAUTION 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 use under conditions in which no freeze-up will occur.
• 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 all dirt and oil.
3. When hoisting the product, hang the rope around the inlet/outlet as close to the body as
possible.
4. Install the steam trap within the allowable inclination, as shown below. Also make sure that
the arrow 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 inlet pipe should be as short and have as few bends as possible.
6. Support the pipes properly within 800 mm (2.5 ft) 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 performing maintenance.
8. Install a check valve at the trap outlet 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.
Allowable Inclination
5˚
5˚
5˚ 5˚
6. Piping Arrangement
Requirement Correct Incorrect
Install a catchpot with the
proper diameter. Diameter is too
small.
J5X 80 22 35 19 30 19 80 32 35 21
(59) ( 7/ 8 ) (26) ( 3/4 ) (22) ( 3/ 4 ) (59) (11/4 ) (26) ( 13/16 )
J7X 70 17 35 19 30* 12 120 36 30* 12
(51) (21/32) (26) ( 3/4 ) (22)* (15/32) (88) (113/32) (22)* (15/32)
J7.2X 110 22 35 19 30* 12 400 70 30* 12
(81) ( 7/ 8 ) (26) ( 3/4 ) (22)* (15/32) (290) (2 3/4 ) (22)* (15/32)
J7.5X 160 24 35 19 30* 12 600 85 40* 14
(115) (15/16) (26) ( 3/4 ) (22)* (15/32) (440) (311/32) (29)* ( 9/16 )
J8X 250 32 35 19 30* 12 800 105 40* 14
(185) (11/4 ) (26) ( 3/4 ) (22)* (15/32) (590) (41/8 ) (29)* ( 9/16 )
* 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 there
takes precedence over values shown here.
1 N・m ∼
∼ 10 kg・cm
̶6̶
J3X J7.5X
Part & No. J7X J7.2X During Disassembly During Reassembly
J5X J8X
Remove only if necessary, Wrap threads with sealing tape*
Plug 24
use a wrench to remove Coat threads with anti-seize*
Remove gasket only if Replace with a new gasket only
Plug Gasket 25
worn or damaged if worn or damaged
Cover Bolt 23 Use a wrench to remove Coat threads with anti-seize*
Align the cover with the connector
Cover 2 Lift up the cover
to attach the cover (figure A)
Connector 22 Remove the connector Insert the connector
Remove gasket only if Replace with a new gasket only
worn or damaged if worn or damaged
Cover Gasket 3
Remove gasket and Replace with a new gasket, do
clean sealing surfaces not appy anti-seize
Wrap threads with sealing tape*
Drain Plug 19 Use a wrench to remove
Coat threads with anti-seize*
Remove and clean sealing Replace with a new gasket, coat
Drain Plug Gasket 20
surfaces surfaces with anti-seize
Snap Ring 18 Use appropriate pliers to Squeeze and insert securely into
(X-element cover) squeeze and remove the groove
X-element Cover 17 Lift up the cover The mesh should face the float
Spring Clip 16 Squeeze the spring clip to Squeeze the spring clip and insert
(X-element) remove it from the guide it into the X-element guide
Remove from the Make sure the X-element is not
X-element 14
X-element guide upside down (figure B)
Air Vent Valve Seat 21 Use a wrench to remove Coat threads with anti-seize*
Make certain the X-element fits in
X-element Guide 15 Remove without bending
securely
Snap Ring 13 (Screen) Use appropriate pliers Insert securely into groove
Align arrows and insert, insert tab
Screen 9 &
Lift straight up on bottom into guide on body and
Float Cover 12
push in until top is flush (figure C)
Screen 9 Place screen holder on ledge
Screen Holder Lift straight up inside body, round side up; place
Retainer 11 screen holder retainer next (if
Screen Holder 10 Remove without bending applicable), followed by screen
Remove, being careful not Insert into body, being careful not
Float 4
to scratch its polished surface 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 Replace with a new gasket only
worn or damaged if worn or damaged
Push out from inside the With flat surface of the orifice
Orifice 5 body toward the plug facing up, push from outside until
holder it contacts interior stop (figure D)
Remove the rubber O-ring Replace with a new O-ring, coat
Orifice O-Ring 6
and clean sealing surfaces with heat-resistant grease
* Tighten to the proper torque (see table Tightening Torque and Distance Across Flats)
“ ” indicates which models contain which parts
Arrow
Figure A Figure B X-element
Figure C Figure D
Flat surface facing
Valve seat Tab straight up
Hole for
connector
Guide
Condensate
discharge hole
̶7̶
8. Operational Check
A visual inspection can be carried out to aid in determining the necessity for immediate
maintenance or 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 TrapMan (within
its 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 Live steam is discharged through the trap outlet together with the
Leakage: 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.)
9. Troubleshooting
If the expected performance is unachievable after installation of the steam trap, read chapters 5
and 6 again and check the following points to take appropriate corrective measures.
Problem Cause Remedy
No condensate Float is damaged or filled with condensate Replace the float
is discharged Orifice, screen or piping is clogged with rust or Clean
(blocked) or scale
discharge is Steam-locking has occurred Blowdown through the
poor 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 Compare specifications
specified pressure, or there is insufficient pressure and actual operating
differential between the trap inlet and outlet conditions
Steam is Rust and scale have accumulated around the Clean
discharged or orifice or under the float
leaks from the Orifice is damaged Replace the orifice
trap outlet Float is deformed or coated with scale Clean or replace the float
(blowing) Trap is installed above the maximum allowable Correct the installation
(steam leakage) inclination angle
Vibration of trap occurs Lengthen inlet piping, then
fasten it securely
The X-element is damaged, or clogged with rust Clean or replace the
or scale X-element
Steam leaks Deterioration of or damage to gaskets Replace with new gaskets
from a place Leakage from eroded cavities of body or cover Replace the trap
other than Improper tightening torque for cover was used Tighten to the proper
the trap outlet torque
Float is Water hammer occurs Examine the piping for
frequently problems that can cause
damaged water hammer
For maintenance parts and repair parts see page 3
̶8̶
10. Lock Release Valve (Option for J(F)3X and J(F)5X)
Stamped 3 or 5
Gland Retainer Nut 3 = J(F)3X
5 = J(F)5X
Distance across flats :
Gland Packing 22 mm ( 7/8 ” )
Gland Case
Spring Pin
1 N・m 10 kg・cm
Operation
When shipped from the factory, the element retainer is in its maximum position. Use a flat-head
screwdriver to adjust the amount of steam released. When not in use, the element retainer should
be returned 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.
̶9̶
11. Express Limited Warranty
Subject to the limitations set forth below, TLV Corporation, a North Carolina corporation (“TLV”)
warrants that products which are sold by it or TLV International, Inc., a Japanese corporation
(“TII”), which products (the “Products”) are designed and manufactured by TLV Co., Ltd., a
Japanese corporation (“TLVJ”), conform to the specifications published by TLV for the
corresponding part numbers (the “Specifications”) and are free from defective workmanship
and materials. 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).
Exceptions To Warranty
This warranty does not cover defects or failures caused by:
1. improper shipping, installation, use, handling, etc., by other than TLV or service
representatives authorized by TLV; or
2. dirt, scale or rust, etc.; or
3. improper disassembly and reassembly, or inadequate inspection and maintenance by other
than TLV or service representatives authorized by TLV; or
4. disasters or forces of nature; or
5. abuse, abnormal use, accidents or any other cause beyond the control of TLV; 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. 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 the earlier of: (i) three (3) years after delivery of Products
to the first end user in the case of sealed SST-Series Products for use in steam pressure service
up to 650 psig; (ii) two (2) years after delivery of Products to the first end user in the case of
PowerTrap® units; or (iii) one (1) year afterdelivery of Products to the first end user in the case of
all other Products. Notwithstanding the foregoing, asserting a claim under this warranty must be
brought by the earlier of one of the foregoing periods, as applicable, or within five (5) 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 TLV.
Exclusive Remedy
THE EXCLUSIVE REMEDY UNDER THIS WARRANTY, UNDER ANY EXPRESS WARRANTY OR
UNDER ANY IMPLIED WARRANTIES NOT NEGATED HEREBY (INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE), IS
REPLACEMENT; PROVIDED: (a) THE CLAIMED DEFECT IS REPORTED TO TLV IN WRITING
WITHIN THE APPLICABLE 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 TLV, FREIGHT AND TRANSPORTATION COSTS
PREPAID, UNDER A RETURN MATERIAL AUTHORIZATION AND TRACKING NUMBER ISSUED
BY TLV. 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. TLV
RESERVES THE RIGHT TO INSPECT ON THE FIRST END USER'S SITE ANY PRODUCTS
̶ 10 ̶
CLAIMED TO BE DEFECTIVE BEFORE ISSUING A RETURN MATERIAL AUTHORIZATION.
SHOULD SUCH INSPECTION REVEAL, IN TLV’S REASONABLE DISCRETION, THAT THE
CLAIMED DEFECT IS NOT COVERED BY THIS WARRANTY, THE PARTY ASSERTING THIS
WARRANTY SHALL PAY TLV FOR THE TIME AND EXPENSES RELATED TO SUCH ON-SITE
INSPECTION.
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 invalidity,
prohibition or unenforceability in any such jurisdiction shall not invalidate or render
unenforceable such provision in any other jurisdiction.