TLV PowerTrap GP5C Instruction Manual Download Page 9

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172-65637MA-05 (GP5C PowerTrap) 8 Jun 2020

Configuration

GP5C

No.

Parts

Maintenance

Kit

Repair Kit

Float

Snap-action

Spring

Body

Cover

Cover Gasket
Gasket

✔

Cover Bolt

Nameplate

Float

✔

Snap-action Unit

✔

Snap-action Spring

✔

Intake-Exhaust Valve Unit

✔

Outlet Check Valve Unit

✔

Exhaust Plug

✔

Inlet Check Valve Unit

✔

(Flange)

Plug (for drainage)

Seal Set

✔

For details, please refer to

“Replacement Parts”.

The maintenance kit should be purchased along with a repair kit or other parts, as gaskets

might be required.

A snap-action spring is also contained in the snap-action unit.

Motive Medium Inlet

Screw:

Condensate

Inlet Flange: 1 in

Exhaust Outlet Plug

Screw:

Condensate Outlet
Screw/Flange: 1 in

Condensate

Screwed

Inlet/Outlet

Connection*

lan

JIS 10K

Rc(PT)

JPI 150

Rc(PT)

ASME 150 NPT
PN16

BSP

rew

Rc(PT)

NPT

BSP

*Exhaust outlet, motive medium inlet

and all plugs

Summary of Contents for PowerTrap GP5C

Page 2: ...stallation 15 Operation and Periodic Inspection 16 Operation 16 Periodic Inspection and Diagnosis 17 Disassembly Reassembly 18 Replacement Parts 19 Recommended Tools List for Disassembly Reassembly 20 1 Before Removing Reattaching 21 2 Removing Reattaching the Body from to the Cover 21 3 Removing Reattaching the Snap action Unit 22 4 Removing Reattaching Each Unit 23 Troubleshooting 24 Determining...

Page 3: ...nary Also be sure to read this manual carefully before use and follow the instructions to be sure of using the product properly If detailed instructions for special order specifications or options not contained in this manual are required please contact TLV for full details This instruction manual is intended for use with the model listed on the front cover It is necessary not only for installatio...

Page 4: ...h or serious injury Indicates that there is a possibility of injury or equipment product damage 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...

Page 5: ...dents Be sure to install a vent pipe and an overflow pipe Failure to install an overflow pipe is dangerous as condensate may spurt from the vent pipe and could result in burns and other injuries Pipe the vent pipe and the overflow pipe to a safe place such as a pit After completing all piping work based on the designed piping system make sure that all piping connections are properly and securely t...

Page 6: ...e model for the open system Check to make sure that the PowerTrap model purchased is suitable for use on the type of system that is being planned for installation Type of System Closed System Open System System Overview Features There is no piping system that opens to the atmosphere and the condensate of 100 C 212 F or more can be recovered No venting of flash steam Small reservoir compared to the...

Page 7: ...e pressure supplied by the motive medium causes the internal pressure in the unit to become greater than the back pressure The inlet check valve closes and the outlet check valve is pushed open thus discharging the condensate in the unit through the outlet pipe as shown in B below 3 As a result of the condensate in the unit being discharged the water level in the unit drops and the float descends ...

Page 8: ...ts 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 Body Material Cast Iron Body Material Stainless Steel Maximum allowable pressure...

Page 9: ...g for drainage 15 Seal Set For details please refer to Replacement Parts 1 The maintenance kit should be purchased along with a repair kit or other parts as gaskets might be required 2 A snap action spring is also contained in the snap action unit Motive Medium Inlet Screw 1 2 in Condensate Inlet Flange 1 in Exhaust Outlet Plug Screw 1 4 in Condensate Outlet Screw Flange 1 in Condensate Screwed In...

Page 10: ...n manual s provided The following 4 pipes shall be connected to the GP5C condensate inlet pipe condensate outlet pipe motive medium supply pipe and exhaust pipe Refer to Sizing the Condensate Receiver Pipe for the size of the condensate inlet pipe Si length of Dh Q Pumped Medium Sr Condensate Recovery Line St Steam Trap A Filling Head Sm1 Motive Medium Supply Pipe Vi Valve on Condensate Inlet Pipe...

Page 11: ...werTrap as possible and install a union joint for maintenance while allowing sufficient space for maintenance of the strainer Strainers should be angled in the 3 or 9 o clock positions for horizontal installations if installed on a horizontal piping Only use steam compressed air or nitrogen as the motive medium The maximum motive medium supply pressure is 0 5 MPaG 75 psig 5 barg When the motive me...

Page 12: ...pe thickness should be schedule 40 or less for proper operation Install a condensate inlet strainer Ki 40 mesh or finer on the PowerTrap pumped medium inlet pipe and install a union joint for maintenance The condensate outlet pipe So diameter should be at least 25 mm 1 in During pumping operation the PowerTrap uses the motive medium supply pressure to push out the condensate from the body The GP5C...

Page 13: ...spurt from the vent pipe and could result in burns and other injuries Pipe the vent pipe and the overflow pipe to a safe place such as a pit Piping size of the overflow pipe should be the same or larger than condensate inlet pipe CAUTION Examples of Overflow Piping for Open Systems Explanations for overflow piping for open systems 1 If flash steam can be discharged from overflow pipe Install overf...

Page 14: ...f rust becoming clogged and or corrosion since water always present in the loop seal the possibility is greater if the piping diameter is too small generally 25 mm 1 in or smaller Do not install loop seal on the vent pipe Contact TLV if neither 1 nor 2 above can be installed ...

Page 15: ...1 shown on the next page 3 Determine the overflow pipe diameter Dop refer to the figure below NOTE The overflow pipe diameter should be at least as large as the condensate inlet pipe diameter Dcip refer to the figure below 4 Determine the minimum condensate receiver diameter Dcr refer to the figure below by selecting the largest value among those from i ii and iii based on a condensate receiver le...

Page 16: ... or less 11 2 100 40 11 2 200 11 2 200 40 11 2 400 11 2 300 50 2 600 2 400 65 21 2 800 21 2 500 80 3 1000 3 NOTE When amount of flash steam and condensate are between two values in the table select the larger value one line below Maintenance Space and Tolerance Angle for Installation Maintenance Space The maintenance space shown in the figure on the left should be provided to enable inspection and...

Page 17: ...ing or removing the product when it is hot or under pressure may lead to discharge of fluids causing burns other injuries or damage 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 o...

Page 18: ...be operating cyclically without continuous sound in the motive medium supply pipe or the exhaust pipe during the pumping operation equipment side pressure back pressure c Condensate should not accumulate in the steam using equipment and the temperature of the equipment should not be abnormally low d There should not be any abnormal noise such as water hammer from the pumped medium outlet pipe or t...

Page 19: ...arge of fluids causing burns other injuries or damage CAUTION Do not use excessive force when connecting threaded pipes to the product Over tightening may cause breakage leading to fluid discharge which may cause burns or other injury CAUTION Use the procedures on the following pages to remove components Use the same procedures in reverse to reassemble Installation inspection maintenance repairs d...

Page 20: ...e Unit 9 Outlet Check Valve Unit For Body Material FC250 cast iron L 51 5 2 CF8M cast stainless steel L 56 5 21 4 Weight 0 33 kg 0 73 lb Weight 0 38 kg 0 84 lb 139 51 2 194 7 5 8 O ring 4 pcs PTFE Gasket 3 pcs Metal Gasket 1 pc 100 315 16 117 45 8 100 4 84 X Hex Bolt Spring Washer Snap action Unit Coil Spring 19 3 4 11 5 7 16 70 23 4 90 7 3 9 16 60 8 2 3 8 18 5 3 4 Screen Bolt Steel Ball Intake Ex...

Page 21: ...4 in 22 mm 7 8 in 3 4 6 2 5 4 3 Extension Bar L 150 mm 57 8 in 5 4 Offset Wrench 13 mm 1 2 in 19 mm 3 4 in 22 mm 7 8 in 3 4 6 2 4 5 Adjustable Wrench L 200 300 mm 8 12 in 1 6 6 Needle Nose Pliers 3 7 Hex Key 2 5mm 3 32 in 6 8 Internal Snap Ring Pliers 4 1 N m 10 kg cm2 NOTE If drawings or other special documentation were supplied for the product any torque given there takes precedence over values ...

Page 22: ...t Body When removing the body lift the float and the float lever slightly to avoid contact with the float Reverse steps in disassembly while referring to the figure below Cover Gasket The gasket may be damaged or destroyed upon disassembly as it is inlaid in the body and may adhere to that groove using a scratch free scraper carefully scrape the gasket from the body Replace with a new gasket if da...

Page 23: ...e exhaust valve into the bottom of their respective valve seats then continuing to insert all the way up into the valve seat as you reattach the snap action unit Align the snap action unit bolt holes to the bolt holes in the cover Intake Exhaust Valve Remove the intake exhaust valve by rotating it 90 Remove the coil spring Reattach the intake exhaust valve by rotating it 90 Reattach the coil sprin...

Page 24: ... upwards Tighten to a torque of 10 N m 7 lbf ft Holder Gasket Coil Spring Valve for Outlet Check Valve Take out the holder gasket coil spring and the valve for outlet check valve before removing the outlet check valve Remove the spring holder with a 22 mm 7 8 in socket wrench Be careful not to let the coil spring and the gasket fall Be sure to clean the inside of the outlet check valve Replace wit...

Page 25: ...ling 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 desired performance is not attained with the system in many cases it is due to the following 1 Loose chips from pipe cutting and tapping and or welding scraps or sealant get caught in the intake valve motive medium or check valve and prevent them fro...

Page 26: ...al to or lower than back pressure Pb Types of Failure Category A G and Corrective Measures Causes 1 4 G 1 2 F 3 1 1 1 1 E 1 4 2 1 2 3 1 3 4 D 1 1 2 3 1 C 1 2 3 1 2 B 2 1 A 1 2 3 1 Is there a continuous flowing sound from the exhaust pipe NO YES NO NO YES NO NO YES NO NO YES Is there a continuous flowing sound from the motive medium supply pipe NO YES NO YES YES NO YES YES NO YES YES Has pumped med...

Page 27: ...or connect to a separate high pressure line If the back pressure has increased check to see if a steam trap connected to the condensate recovery line is blowing see Steam System Example and check for any valves that have been left closed on the condensate recovery line The motive medium pressure should be equal to or greater than 0 05 MPa 7 psi 0 5 bar higher than the back pressure 2 Insufficient ...

Page 28: ...the motive medium supply pipe tube and the exhaust pipe tube it is possible that the PowerTrap is faulty Note however that this phenomenon will also occur when the motive medium pressure is equal to or less than the back pressure If the PowerTrap does not operate for long periods of time and the sound of the operating medium can be heard continuously in the motive medium supply pipe tube the Power...

Page 29: ...aged 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...

Page 30: ...ictoria 3131 Australia Tel Fax 61 0 3 9873 5610 61 0 3 9873 5010 In East Asia 36 Kaki Bukit Place 02 01 02 Singapore 416214 Tel Fax 65 6747 4600 65 6742 0345 Room 5406 No 103 Cao Bao Road Shanghai China 200233 Tel Fax 86 0 21 6482 8622 86 0 21 6482 8623 No 16 Jalan MJ14 Taman Industri Meranti Jaya 47120 Puchong Selangor Malaysia Tel Fax 60 3 8065 2928 60 3 8065 2923 252 94 K L 17th Floor Muang Tha...

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