TLV PowerTrap GT5C Instruction Manual Download Page 2

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172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

Contents

Introduction ......................................................................... 2

Safety Considerations ........................................................ 3

General Description ............................................................ 5

Application ................................................................................................................ 5

Operation ............................................................................ 6

Specifications ..................................................................... 7

Configuration ...................................................................... 8

Installation .......................................................................... 9

Steam System Example ........................................................................................... 9

Installation Procedure ............................................................................................. 11

Sizing the Condensate Reservoir Pipe ................................................................... 13

Maintenance Space and Tolerance Angle for Installation 14

Operation and Periodic Inspection ................................... 15

Operation ................................................................................................................ 15

Periodic Inspection and Diagnosis .......................................................................... 16

Disassembly/Reassembly ................................................ 17

Recommended Tools List for Disassembly/Reassembly ........................................ 18

1. Before Removing/Reattaching ............................................................................ 19

2. Removing/Reattaching the Body from / to the Cover .......................................... 20

3. Removing/Reattaching the Snap Action Unit ...................................................... 20

4. Removing/Reattaching Each Unit ....................................................................... 22

5. Removing/Reattaching of Air Vent Unit............................................................... 23

6. Positioning Adjustment of the Trap Valve ........................................................... 24

Troubleshooting ................................................................ 25

Determining the Problem from the Symptoms ........................................................ 25

Types of Failure and their Causes .......................................................................... 26

Causes and Corrective Measures ........................................................................... 27

Replacement Parts ........................................................... 30

Product Warranty ............................................................. 31

Service ............................................................................. 32

Summary of Contents for PowerTrap GT5C

Page 2: ...Operation 15 Periodic Inspection and Diagnosis 16 Disassembly Reassembly 17 Recommended Tools List for Disassembly Reassembly 18 1 Before Removing Reattaching 19 2 Removing Reattaching the Body from to the Cover 20 3 Removing Reattaching the Snap Action Unit 20 4 Removing Reattaching Each Unit 22 5 Removing Reattaching of Air Vent Unit 23 6 Positioning Adjustment of the Trap Valve 24 Troubleshooti...

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: ... threat of death or serious injury 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 CAUTION Install properly and DO NOT use this product outside the recommended operating pressure tem...

Page 5: ...harge 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 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 Take measures to ensure...

Page 6: ...use of this product to below the conditions quoted CAUTION Application PowerTrap GT5C can be used as a standard steam trap and also has an integrated pumping function that can eliminate and pump out condensate even if condensate cannot be discharged due to very low supply steam pressure because of reduced load in the steam using equipment this phenomenon is referred to in this document as stall GT...

Page 7: ... high level the push rod on the snap action unit rises quickly simultaneously closing the exhaust valve and opening the intake motive medium valve The 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 o...

Page 8: ...er 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 Valve No Nominal Diameter Model Maximum Allowable Pressure Maximum Allowable Temperature Serial No Maximum Operating Temperature Maximum Differential Pressure Maximum allowable pressure PMA...

Page 9: ...tc Gasket Seal set 4 Cover Bolt 5 Nameplate 6 Float 7 Snap Action Unit 8 Snap Action Spring 9 Intake Exhaust Valve Unit 10 Trap Unit 11 Air Vent Unit 12 Inlet Check Valve 13 Flange 14 Plug for drainage Please refer to the replacement parts list for maintenance and repair kits The maintenance kit should be purchased along with a repair kit as gaskets might be required A snap action spring is also c...

Page 10: ...e same way as a standard steam trap The condensate inlet pipe Si acts like a condensate reservoir Refer to Sizing the Condensate Reservoir Pipe at the end of this section for the size of condensate inlet pipe Si length of Dh Q Pumped medium Dh Condensate Receiver Reservoir A Filling Head Ki Condensate Inlet Strainer Pm Motive Medium Supply Pressure Km Motive Medium Strainer Pb Back Pressure St Ste...

Page 11: ...r Si Q Vb Vi Ki Dh Sm2 Backflow Water Hammer Prevention Check Valve If water hammer due to steam backflow in the condensate recovery line is expected installation of a check valve vertically and as close as possible to the recovery line is recommended When the rise in piping is 30 m 100 ft or farther from the PowerTrap installation of a check valve is recommended for the prevention of return water...

Page 12: ...he PowerTrap should also be at least 8 mm 5 16 Install a strainer Km at least 15 mm 1 2 in and at least 40 mesh on the PowerTrap motive medium supply pipe Sm1 as close to the PowerTrap 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 Only use ...

Page 13: ...0 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 installation should be in a location that allows sufficient space for maintenance of the strainer Ki Condensate outlet pipe So diameter should be at least 25 mm 1 Refer to Sizing the Condensate Reservoir Pipe at the end of th...

Page 14: ...ed in the effective volume of the reservoir Dh The filling head A represents the distance from the installation surface of the PowerTrap from grade to the bottom of the inlet piping condensate reservoir Si shown as A in the sketches in Steam System Example The minimum filling head for GT5C is 155 mm 6 Sizing the Condensate Reservoir Pipe The PowerTrap reservoir pipe size for each condensate discha...

Page 15: ...The maintenance space shown in the figure below should be provided to enable inspection and disassembly repair of the PowerTrap Tolerance Angle for Installation The product should be inclined no more than 3 Make sure the body is installed with the raised TLV lettering on the body horizontal Unit mm in 100 4 100 4 100 4 ...

Page 16: ...or the discharge of fluids CAUTION Installation inspection maintenance repairs disassembly adjustment and valve opening closing should be carried out only by trained maintenance personnel Operation 1 Valve Operation During the first operation after installation or re operation after a long shutdown open blowdown valve Vb ensuring that the area around the opening is safe to eliminate rust and scale...

Page 17: ...cally without continuous sound in the motive medium supply pipe or the exhaust pipe during the pumping operation equipment side pressure back pressure d Pumped medium should not accumulate in the steam using equipment and the temperature of the equipment should not be abnormally low e There should not be any abnormal noise such as water hammer from the pumped medium outlet pipe or the pumped mediu...

Page 18: ...rns 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 disassembly adjustment and valve opening closing should be carried out only by trained maintenance personnel In cases where sufficient maintenance space has been provided for see Maintenance Space maintenance can be ...

Page 19: ...rench Ratchet 0 100 N m 0 73 lbf ft 1 2 3 4 5 6 2 Sockets Distance across flats S 13 mm 19 mm 22 mm 7 8 3 4 6 2 5 4 S 3 Extension Bar L 150 mm 57 8 5 4 Offset Wrench 13 mm 19 mm 22 mm 7 8 3 4 6 2 4 5 Adjustable Wrench L 200 300 mm 8 12 1 6 6 Needle Nose Pliers 3 7 Hex Key 2 5mm 3 32 6 8 Internal Snap Ring Pliers 4 1 N m 10 kg cm2 L S ...

Page 20: ...pressure and discharge fluid Take care to avoid being burned by fluid discharge Opening this plug may help to discharge condensate in the body more easily when the drain plug is opened Wrap threads with 3 3 5 turns of sealing tape or apply sealing compound Tighten to a torque of 30 N m 22 lbf ft Drain Plug Using an adjustable wrench slowly loosen plug to release pressure and discharge fluid take c...

Page 21: ...ion Unit Part Disassembly Reassembly Bolts Spring Washers Using a 13 mm socket wrench slowly loosen the two bolts that are holding the snap action unit to the cover Coat the bolt threads with anti seize Be sure to reinsert spring washers Assemble the bolts and spring washers then finger tighten Tighten to a torque of 35 N m 26 lbf ft Snap Action Unit Support the snap action unit with one hand whil...

Page 22: ... pin and the split pin The coil spring will be inserted later If readjusting the position of the trap valve refer to Positioning Adjustment of Trap Valve to adjust the position of the trap valve before reattaching the float Trap Valve Connecting Pin Spring Washer Split Pin Replace trap unit if the trap valve is damaged Remove the trap valve by removing the connector pin while pulling out the split...

Page 23: ...ing surface in the cover In order to orient the hinge of the valve upwards be sure the indentation is pointed upwards Tighten to a torque of 10 N m 7 lbf ft Outlet Check Valve Spring Holder Coil Spring Gasket Take out the outlet check valve unit before removing the trap unit Remove the spring holder with a 22 mm 7 8 socket wrench Be careful not to let the coil spring and the gasket fall Be sure to...

Page 24: ... with your fingers Remove the X element Remove the air vent valve seat with a 19 mm socket wrench Remove the X element Guide Make sure that the check valve a small steel ball in the air vent valve seat can open and close smoothly with the spring Tighten to a torque of 35 N m 26 lbf ft 1 N m 10 kg cm2 X element Air Vent Unit Spring Clip Air Vent Valve Seat and steel ball X element Guide Cover Cover...

Page 25: ...2 allen wrench loosen both stopper screws which fix the bolt M10 located above the trap valve To determine proper float orientation adjust bolt M10 so that there is a gap between the snap action lever and the bolt M10 when the float is in the lowered position Push the trap valve against the trap valve seat and hold it with one finger while adjusting the bolt M10 so that there is no gap between the...

Page 26: ...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 from closing operating properly 2 Changes in the amount of condensate infl...

Page 27: ... G and Corrective Measures Causes 1 5 G 1 2 1 2 F 3 1 1 1 1 E 1 5 2 3 1 3 4 5 2 4 5 1 2 D 1 1 1 2 3 C 1 2 1 2 3 B 2 1 A 1 2 3 1 4 Is there a continuous flowing sound from the exhaust pipe NO YES NO NO YES NO NO YES NO NO YES Has pumped medium accumulated in the equipment or has water hammer occurred Has steam leaked in the outlet side or has water hammer occurred in outlet piping Has reverse flow ...

Page 28: ... pipe or connect to a separate high pressure line If the back pressure has increased check to see if a steam trap connected to the pumped medium recovery line is blowing see Steam System Example and check for any valves that have been left closed on the pumped medium recovery line The motive medium pressure must be about 0 1 MPa 15 psi 1 bar higher than the back pressure 2 Insufficient motive medi...

Page 29: ... Dirt or scale is caught in the intake exhaust valve seat or the valve seat is worn 3 The snap action unit is obstructed by dirt or scale or its operation is otherwise faulty 4 The float is broken or filled with water 5 Dirt or scale is caught in the trap unit resulting in faulty valve opening closing If the PowerTrap does not operate for long periods of time in spite of the fact that pumped mediu...

Page 30: ...d 2 Dirt or scale is caught in the pumped medium outlet check valve or the valve is worn or getting hung up The discharged pumped medium has flowed back into the PowerTrap causing the interval at which the unit operates to grow shorter and reducing its discharge capacity Disassembly and inspection is required G Degradation or damage of gasket and O ring 1 Damage when assembling 2 Aging degradation...

Page 31: ...vidually only together in kits Dimensions mm in 5 7 Float 4 315 16 4 Spring Washer 5 Snap Action Unit Coil Spring Hex Bolt X element Spring Clip Air Vent Valve Seat and Steel Ball X element Guide 15 16 2 Screen Bolt Intake Exhaust Valve Seat Steel Ball O Ring Gasket 3 9 16 Intake Exhaust Valve 2 3 8 Gasket Bolt O Ring Inlet Check Valve 2 2 11 16 Trap Valve Seat Coil Spring Holder Bolt Gasket Gaske...

Page 32: ...maged 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 t...

Page 33: ...el 1 704 597 9070 Fax 1 704 583 1610 In Mexico and Latin America Av Jesús del Monte 39 B 1001 Col Hda de las Palmas Huixquilucan Edo de México 52763 Mexico Tel 52 55 5359 7949 Fax 52 55 5359 7585 In Europe Daimler Benz Straße 16 18 74915 Waibstadt Germany Tel 49 0 7263 9150 0 Fax 49 0 7263 9150 50 Star Lodge Montpellier Drive Cheltenham Gloucestershire GL50 1TY U K Tel 44 0 1242 227223 Fax 44 0 12...

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