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172-65043MA-02 (GP10L/GT10L

PowerTrap

) 9 Mar 2004

Contents

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

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

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

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

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

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

Configuration ...................................................................... 7

Installation .......................................................................... 8

Open System Piping ................................................................................................ 8

Closed System Piping.............................................................................................. 9

Installation Procedure .............................................................................................. 9

Size of the Condensate Receiver / Reservoir Pipe................................................. 14

Installing Several

PowerTrap

Units in Parallel ..................................................... 16

Installation and Maintenance Space ................................ 17

Anchoring the Body................................................................................................ 17

Maintenance Space ............................................................................................... 17

Operation and Periodic Inspection ................................... 18

Operation............................................................................................................... 18

Periodic Inspection and Diagnosis ......................................................................... 19

Disassembly / Reassembly .............................................. 21

Replacement Parts ................................................................................................ 22

Recommended Tools List for Disassembly / Reassembly...................................... 23

1. Removing / Reattaching the Body from / to the Cover ....................................... 24

2. Removing / Reattaching the Float...................................................................... 25

3. Separating / Rejoining the Trap Rod and Trap Unit (GT10L only)...................... 26

4. Removing / Reattaching the Trap Unit (GT10L only) ......................................... 26

5. Removing / Reattaching the Snap-action Unit.................................................... 27

6. Removing / Reinstalling the Motive Medium Intake and Exhaust Valves............ 27

7. Removing / Reinstalling the Motive Medium Intake and Exhaust Valve Seats ... 28

Troubleshooting................................................................ 29

Determining the Problem from the Symptoms ....................................................... 29

Types of Failure and their Causes ......................................................................... 30

Causes and Corrective Measures .......................................................................... 31

Product Warranty.............................................................. 34

Service.............................................................................. 35

Содержание PowerTrap GP10L

Страница 1: ...172 65043MA 02 GP10L GT10L PowerTrap 9 March 2004 GP10L GT10L Copyright 2004 by TLV CO LTD All rights reserved ISO 9001 ISO 14001 Manufacturer Kakogawa Japan is approved by LRQA LTD to ISO 9001 14001...

Страница 2: ...iodic Inspection and Diagnosis 19 Disassembly Reassembly 21 Replacement Parts 22 Recommended Tools List for Disassembly Reassembly 23 1 Removing Reattaching the Body from to the Cover 24 2 Removing Re...

Страница 3: ...inary 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 no...

Страница 4: ...hreat 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...

Страница 5: ...scharge 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 injur...

Страница 6: ...urchased is suitable for use on the type of system that is being planned for installation Type of System Closed System Open System System Overview Benefits No need for external steam trap GT model fea...

Страница 7: ...When the float rises to its 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 t...

Страница 8: ...specifications 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...

Страница 9: ...ive Medium Motive Medium Supply Pressure Pm Pump Exhaust Co Steam Using Equipment Condensate Receiver Ve Vi Back Pressure Pb Steam Trap Flash Steam Temperature Controller Steam Trap Overflow Other Ste...

Страница 10: ...densate Inlet Check Valve Vm Valve on Motive Medium Supply Si Condensate Inlet Pipe Co Condensate Outlet Check Pipe So Condensate Outlet Pipe Valve Ve Valve on Exhaust Pipe Sr Condensate Recovery Line...

Страница 11: ...er reservoir pipe See item St in the drawings on pages 8 and 9 This measure is not necessary when the motive medium is compressed air or nitrogen 3 Pressure Reducing Valve on the Motive Medium Supply...

Страница 12: ...to the exhaust pipe at a point just above where the exhaust pipe exits the unit body Figure 1 b For Open and Closed Systems Add piping connecting the exhaust pipe to the condensate inlet pipe between...

Страница 13: ...steam will cause the condensate to flow out the vent pipe If the vent pipe size is small the pressure in the condensate receiver will rise restricting condensate inflow Be sure to select a condensate...

Страница 14: ...ed 2 3 times 8 Velocity at Outlet Piping The PowerTrap uses the motive medium supply pressure to push out the condensate in the trap The GP10L GT10L can discharge approximately 6 liters 1 6 U S gal of...

Страница 15: ...tent heat of steam at condensate receiver set pressure P2 b Determining the condensate receiver diameter and vent pipe diameter according to the amount of flash steam In the following table the receiv...

Страница 16: ...5 3 0 2000 2 0 1 3 0 6 4000 6 5 4 0 1 5 3000 2 0 0 9 0 5 5000 5 0 2 5 4000 1 2 0 7 6000 5 5 2 5 1 5 5000 1 4 0 8 0 5 7000 6 5 3 0 1 5 6000 1 7 1 0 0 6 8000 3 5 2 0 7000 2 0 1 2 0 7 9000 4 0 2 5 1 5 8...

Страница 17: ...C TLV p g b v TLV p g b v TLV p g b v NOTE This sketch is for explanation purposes only and is not intended as an installation design Number of PowerTrap Units Installed Condensate Inlet Pipe Size Pum...

Страница 18: ...85 mm TLV CKF3M Wafer Check Valve Flange Connection Pipe Flange PN 25 is cast steel only Maintenance Space The maintenance space shown in the figure below should be provided to enable inspection and d...

Страница 19: ...d 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 Fai...

Страница 20: ...e 29 Periodic Inspection and Diagnosis There are two types of periodic inspection the visual inspection and the disassembly inspection 1 Visual Inspection As a general rule this inspection should be p...

Страница 21: ...and down smoothly as it opens and closes c Make sure the valve shafts in the intake motive medium and exhaust valves move up and down smoothly d Make sure the float is not damaged and has not filled w...

Страница 22: ...ON Use the procedures on the following pages to remove components Use the same procedures in reverse to reassemble Installation inspection maintenance repairs disassembly and adjustment should be done...

Страница 23: ...n kits Units mm 1 Cover Gasket 2 Float 3 Snap action Unit 4 Motive Medium Intake Valve Unit Split Pin 2 Hex Bolt 2 Spring Washer 2 5 Exhaust Valve Unit 6 Trap Unit for GT10L Hex Bolt 2 Spring Washer 2...

Страница 24: ...Torque Wrench Ratchet 30 110 N m 22 81 ft lb 1 5 7 1 4 5 7 2 Sockets Distance across flats S 17 mm 11 16 19 mm 22 mm 7 8 24 mm 15 16 1 7 5 7 1 1 7 4 5 7 1 S 3 Extension Bar L 150 mm 57 8 7 4 7 4 Offse...

Страница 25: ...kets on their base bolts so that they will not interfere with removal of the body from the cover Reverse steps in disassembly Body Cover Make sure to secure sufficient space around the body to allow i...

Страница 26: ...make sure all parts have been replaced and are in the proper order It is very important that washers and spacers are in the correct order in order to prevent loosening of the float due to vibration du...

Страница 27: ...t necessary to remove the trap unit when only the intake motive medium and exhaust valves or the snap action unit is to be serviced or replaced It is possible to remove the snap action unit without re...

Страница 28: ...snap action unit as intake motive medium and exhaust valves may fall off When working with the snap action unit take care not to pinch fingers etc Reinsert the snap action unit very carefully inserti...

Страница 29: ...hen hand tighten Remove the plug from the top with a 300 mm 12 adjustable wrench Drop the screen straight into the hole and then drop in the ball Wrap plug threads with 3 3 5 turns of sealing tape or...

Страница 30: ...N Installation inspection maintenance repairs disassembly and adjustment should be done only by trained maintenance personnel CAUTION When the desired performance is not attained with the system in ma...

Страница 31: ...nuous 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 conden...

Страница 32: ...15 psi 1 bar higher than the back pressure see page 11 2 Insufficient motive medium If the motive medium supply pipe is too small change to a larger size pipe the pipe should be at least 15 mm 3 When...

Страница 33: ...m trap to the exhaust pipe at a point just above where the exhaust pipe exits the body of the unit For the GT Add piping connecting the exhaust pipe to the condensate inlet pipe between the reservoir...

Страница 34: ...Check other possible factors that might hinder operation After performing the above inspection repair any defects discovered or replace the PowerTrap 1 Dirt or scale is caught in the condensate inlet...

Страница 35: ...n damaged 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 du...

Страница 36: ......

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