TLV BT3N Page 22 Instruction Manual Download

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BT3N: Disassembly/Reassembly of the Bypass Valve Gland Section

Part During

Disassembly During

Reassembly During

Inspection

Locknut

Remove with a wrench:

dist. across flats - 10 mm

A new locknut must be

used

Tighten to the proper torque:

torque - 2.5 N·m

(Guideline for new nut)

dist. across flats - 10 mm

—

Handle

Pull the handle up off of

the spindle

Reattach the handle, being

careful of its orientation (see

the drawing below)

Check the handle hole

in the spindle for

deformation

Disc

Spring

Remove the disc spring

Reinsert the disc spring,

referring to the drawing below

for proper operation

Check for damage or

deformation

Thrust

Washer

Remove the thrust washer Reinsert the thrust washer

Check for wear

Gland

Remove with a wrench:

dist. across flats - 17 mm

Coat threads with anti-seize,

then tighten to the proper

torque: torque - 35 N·m

dist. across flats - 17 mm

Check the spindle

sleeve area for signs

of seizure,

deformation,

scratches, etc.

Spindle

Remove the spindle

Replace with a new spindle,

coat sliding area with gland

and threads with anti-seize

—

Gland

Gasket

Remove the gland gasket Replace with a new gland

gasket only if warped or

damaged

—

Gland

Packing

Remove the gland packing Replace with a new gland

packing

—

(1 N·m

≈

10 kg·cm)

NOTE: 1. Reassemble the gland section after reassembling the valve section.

2. Finger-tightening the valve holder first makes it easier to reinsert the spindle into the

ball. After reinserting the spindle, tighten the valve holder and the gland.

Removing the handle and the locknut from the BT3N destroys the gland section

seal. Do not detach the handle and the locknut unless performing a disassembly
inspection.

Locknut

Washer

Disc Spring

Gland Gasket

Thrust Washer

Gland

Gland Packing

Spindle

Disc Spring

Orientation

Spindle Insertion

Spindle

Valve Holder

Ball

Handle

172-65162M-03 (BT3N/MBT3N/PBT3N) 5 Jul 2013

Summary of Contents for BT3N

Page 1: ...2 65162M 03 BT3N MBT3N PBT3N 5 July 2013 Manufacturer Kakogawa Japan is approved by LRQA LTD to ISO 9001 14001 Bypass Blowdown Steam Trap BT3N MBT3N PBT3N Copyright 2013 by TLV CO LTD All rights reserved ...

Page 2: ...eam Trap features a combination of the most reliable of steam traps the free float a compact ball valve with superior long lasting sealing properties and an actuator unit electric pneumatic The following models are contained in this manual BT3N Steam trap with an integrated compact bypass blowdown ball valve with a manual operation handle MBT3N Steam trap with an integrated compact bypass blowdown...

Page 3: ...jury CAUTION Indicates that there is a possibility of injury or equipment product damage WARNING NEVER apply direct heat to the float The float may explode due to increased internal pressure causing accidents leading to serious injury or damage to property and equipment Install properly and DO NOT use this product outside the recommended operating pressure temperature and other specification range...

Page 4: ...d discharge which may cause burns or other injury Do not stand on or apply body weight to the handle The handle may break resulting in injury or other accidents Make sure the power supply is OFF before carrying out work on the wiring or inspections involving disassembly If such work is carried out with the power on there is a danger that equipment may malfunction or electric shock may occur leadin...

Page 5: ...as a check valve TLV CK been installed 5 Is the inlet pipe as short as possible with as few bends as possible and installed so the liquid will flow naturally down into the trap 6 Has the piping work been done with the proper methods 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 obstru...

Page 6: ...se to the fluctuation in load and the condensate is continuously discharged no condensate will accumulate ahead of the steam trap Bypass Valve Closed 3 When the amount of condensate flowing into the chamber decreases the float gradually closes the orifice Steam leakage is prevented through the use of a 3 point seating design and the water sealing of the valve Normally the bimetal remains retracted...

Page 7: ...roducts with options This item is omitted from the nameplate when there are no options MBT3N Motor Unit Motor Type Reversible motor condenser run type single phase induction motor Power Consumption 52 VA 100 110 V 62 VA 200 220 V Control System ON OFF fully open fully closed Overload Protection Built in thermal protector 120 5 C Direction of Rotation 90 reciprocating Open Close Time 90 rotation 3 ...

Page 8: ... rotation 0 09 0 8 seconds Actuator Capacity 42 cm 3 Ambient Temp Range 60 C or lower Water Resistance Rainproof Manual Override Possible in absence of motive pressure Air Consumption Graph represents consumption for one reciprocating cycle 1 5 1 0 0 5 0 0 4 0 6 0 8 1 0 kg cm2 G Air Supply Pressure MPaG 4 6 8 10 Air Consumption N litre 1 MPa 10 197 kg cm 2 172 65162M 03 BT3N MBT3N PBT3N 5 Jul 2013...

Page 9: ...me No Name No Name 1 Body 11 Nameplate 21 Disc Spring 2 Cover 12 Screen 22 Gland Packing 3 Float 13 Ball 23 Washer 4 Orifice 14 Outlet Valve Seat 24 Thrust Washer 5 Orifice Gasket 15 Inlet Valve Seat 25 Washer 6 Air Vent Strip Bimetal 16 Spindle 7 Screw Spring Washer 17 Gland 26 O ring Inlet Outlet Valve Seat 8 Cover Gasket 18 Gland Gasket 27 Valve Holder 9 Cover Bolt 19 Handle 28 Locknut 10 Orifi...

Page 10: ...Valve Seat 5 Orifice Gasket 17 Gland Holder 28 Valve Holder 6 Air Vent Strip Bimetal 18 Gland Holder Gasket 7 Screw Spring Washer 19 Gland Seat 29 Holder Screw Gland Holder 8 Cover Gasket 20 Disc Spring 30 Bushing 9 Cover Bolt 21 Disc Spring 31 Motor Unit 10 Orifice Plug 22 Gland Packing 32 Shaft Coupling 11 Nameplate 23 Washer 12 Screen 24 Guide Bushing Included only with 15 and 20 mm sizes 172 6...

Page 11: ...alve Seat 5 Orifice Gasket 17 Gland Holder 28 Valve Holder 6 Air Vent Strip Bimetal 18 Gland Holder Gasket 7 Screw Spring Washer 19 Gland Seat 29 Holder Screw Gland Holder 8 Cover Gasket 20 Disc Spring 30 Bushing 9 Cover Bolt 21 Disc Spring 31 Actuator Unit 10 Orifice Plug 22 Gland Packing 32 Shaft Coupling 11 Nameplate 23 Washer 12 Screen 24 Guide Bushing Included only with 15 and 20 mm sizes 172...

Page 12: ...rcuits leading to injury fires damage or other accidents may occur CAUTION When using this product NEVER stand close to or leave tools anywhere near moving parts such as the shaft Contact with moving parts or objects becoming caught in moving parts could lead to injury damage or other accidents CAUTION Installation inspection maintenance repairs disassembly adjustment and valve opening closing sho...

Page 13: ... to make sure that the product functions properly as a steam trap If there is a problem determine the cause by using the Troubleshooting section in this manual 2 To use the bypass function turn the handle to a position parallel to the piping The integrated ball valve will open 3 Return the handle to a position perpendicular to the piping to stop using the bypass function The integrated ball valve ...

Page 14: ...can check whether the valve is opened or closed by checking the orientation of the flat surfaces on the shaft coupling at the base of the motor unit See p 15 When the flat surfaces of the shaft coupling are lined up with the piping the valve is open when they are perpendicular the valve is closed 5 Make sure the control switch is OFF at start up The integrated ball valve is closed causing the prod...

Page 15: ...tion to ensure that the air is supplied properly The Open Closed Indicator located in the lower part of the actuator indicates whether the valve is opened closed 6 Make sure that the integrated ball valve is closed at start up causing the product to function as a trap The state of the integrated ball valve can be confirmed using the open closed indicator Open the inlet and outlet valves slowly and...

Page 16: ...motor unit with a wrench and turn in the direction of the arrows When the flat surfaces of the shaft coupling are lined up with the piping the valve is open when they are perpendicular the valve is closed distance across flats 19 mm PBT3N 1 Perform manual operation only after shutting off the air supply first and making sure there is no pressure remaining inside the actuator unit Manual operation ...

Page 17: ...ried out only by trained maintenance personnel To determine whether the bypass valve is closed make sure that the flat surfaces of the spindle BT3N or the shaft coupling MBT3N and PBT3N are perpendicular to the piping If the valve is not fully closed when the flat surfaces are in this position there is a problem Refer to the Troubleshooting section to determine the cause then correct the problem I...

Page 18: ...ctuator check the operation angle of rotation time required to open close the valve sound 3 After shutting off the air supply manually operate the valve check for foreign matter in the valve and confirm torques Refer to the following table for tightening torques A torque of more than 2 times the shown torque is considered abnormal and an inspection should be performed Tightening Torque N m No load...

Page 19: ...ing 1 Loosen the holder screw 2 Tighten the gland holder further in with a socket wrench Holder Screw Gland Holder Hex Key Diameter 2 mm Socket Wrench diameter 17 mm 3 Retighten the holder screw Cautions when applying additional tightening Do not tighten the gland holder completely the first time Do not tighten it any more than necessary to stop leakage If leakage continues even after applying add...

Page 20: ...e 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 BT3N MBT3N PBT3N Disassembly Reassembly of the Steam Trap Part During Disassembly During Reassembly During Inspection Orifice Plug Remove with a wrench dist across flats 17 mm Wrap 3 3 5 turns of sealing ...

Page 21: ... tighten to the proper torque torque 0 8 N m Hex Key Bolt Remove with a hex key dist across flats 5 mm Coat threads with anti seize and tighten to the proper torque torque 10 N m dist across flats 5 mm Spring Washer Remove the spring washer Reinsert the spring washer Motor or Actuator Unit Detach the motor or the actuator unit Reattach the motor or the actuator unit Shaft Coupling Detach the shaft...

Page 22: ...rque 35 N m dist across flats 17 mm Check the spindle sleeve area for signs of seizure deformation scratches etc Spindle Remove the spindle Replace with a new spindle coat sliding area with gland and threads with anti seize Gland Gasket Remove the gland gasket Replace with a new gland gasket only if warped or damaged Gland Packing Remove the gland packing Replace with a new gland packing 1 N m 10 ...

Page 23: ...e the gland seat Replace with a new gland seat Washer Remove the washer Reinsert the washer Check for damage deformation etc Disc Spring Remove the disc springs Reinsert with the proper orientation see the fig below Check for damage deformation etc Gland Holder Gasket Remove the gland holder gasket Replace with a new gland holder gasket only if misshapen or damaged being careful of the orientation...

Page 24: ...at Remove the o ring Replace with a new o ring insert into the inlet valve seat Washer Remove the washer Reinsert the washer Check for damage deformation etc Disc Spring Remove the disc spring Reinsert with the proper orientation refer to the fig below Check for damage deformation etc Washer Remove the washer Reinsert the washer Check for damage deformation etc Disc Spring Remove the disc spring R...

Page 25: ...ogged orifice or rust and scale under the float Clean parts Check for damage to the orifice Replace with a new orifice Check that the float is not misshapen or coated with scale Clean or replace with a new float Check for the improper installation Correct the installation Check for trap vibration Lengthen inlet piping and fasten securely Check to see if the bypass valve is open Close the bypass va...

Page 26: ...e the full 90 stops at a partial rotation Check to see if there is a problem with the control system Correct the problem If after attempting all of the above remedies the product still does not operate properly contact TLV after confirming operating pressure operating temperature operating frequency and serial number All motor units must be repaired by TLV DO NOT disassemble the motor unit yoursel...

Page 27: ...if the filter and the air supply ports are clogged Clean parts Check to see if there is a problem with the air supply Correct the problem Does not rotate the full 90 stops at a partial rotation Check to see if the filter and the air supply ports are clogged Clean parts If after attempting all of the above remedies the product still does not operate properly contact TLV after confirming operating p...

Page 28: ...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 cau...

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