Operating and installation instructions
Steam traps for quick assembly/disassembly
®
CONA
Universal/ CONA®Connector
ANSI300
- with Universal-Flange
2 x 3/8“ UNC thread (BR 604....1)
ANSI300
- with Universal-Flange
2 x 3/8“ UNC thread (BR 628....1)
Contents
1.0 General information on operating
instructions................................................... 2
2.0 Notes on possible dangers............................ 2
2.1 Significance of symbols ..........................................2
2.2 Explanatory notes on safety information .................2
3.0 Storage and transport ...................................2
4.0 Description...................................................... 3
4.1 Scope of applications ..............................................3
4.2 Operating principles ................................................3
4.2.1 CONA Universal................................................3
4.2.2 CONA Connector ..............................................4
4.3 Diagram ..................................................................6
4.4 Technical data - remarks .........................................7
4.5 Marking ..................................................................8
5.0 Installation....................................................... 8
5.1 General notes on installation...................................8
5.2 Installation instructions for welding .........................9
5.3 Installation position..................................................9
ANSI300
- with Universal-Flange
2 x 3/8“ UNC thread (BR 622....1)
ANSI300
- with Universal-Flange
2 x 3/8“ UNC thread (BR 642/643....1)
5.4 Steam trap testing through
ultrasonic measurement......................................... 9
6.0 Putting the valve into operation ................. 10
7.0 Care and maintenance..................................11
7.1 Disassembling/assembling complete
shut-off valve assembly.........................................11
7.2 Replacing the packing rings ..................................11
7.3 Replacing packing rings of the secondary
sealing gland packing........................................... 12
7.4 Cleaning / replacing.............................................. 12
7.5 Changing the installation position......................... 14
7.6 Tightening torques................................................ 14
8.0 Troubleshooting ........................................... 15
9.0 Troubleshooting table ................................. 15
10.0 Dismantling the valve or the connector .. 16
11.0 Warranty / Guarantee ................................. 16
12.0 EC declaration of conformity.................... 17
Rev. 0040808001 0611 englisch
Operating and installation instructions
®
CONA
Universal / CONA®Connector
1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
ATTENTION !
. . .
Warning of general danger.
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valves must not be used to take external forces, e.g. they are not designed for
use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage.
Do not damage paint protection.
Page 2 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
Universal / CONA®Connector
4.0 Description
4.1 Scope of applications
CONA Universal Steam traps for quick assembly/disassembly to CONA Connector or
foreign system connectors are used for the drainage of industrial steam facilities.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.
The information complies to the Pressure Equipment Directive 97/23/EC.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
4.2.1 CONA Universal
a) Bimetallic steam trap BR604
(refer to Fig. 1 page 6)
(detailed description of the control system Operating and installation instructions CONA B
BR600)
For regulation the steam trap uses both condensate temperature as well as available
upstream pressure and back pressure.
The steam trap vents air automatically during system start-up and operation.
The steam trap has a corrosion-resistant, water hammer-proof bimetallic controller, nonreturn protection, and a factory setting for average condensate sub-cooling of approx. 15K
(PN16-40)
b) Thermostatic steam trap BR622
(refer to Fig. 2 page 6)
(detailed description of the control system Operating and installation instructions CONA M
BR610)
The steam trap uses the condensate temperature and available upstream pressure for
control. It vents automatically during system start-up and operation. It has a corrosionresistant, water hammer-proof diaphragm capsule which always discharges the
consistently supercooled condensate a few degrees below the upstream pressuredependent boiling temperature (ca. 10K).
Rev. 0040808001 0611 Page 3
Operating and installation instructions
®
CONA
c) Thermodynamic steam trap BR642/643
(refer to Fig. 4 page 6)
(detailed description of the control system Operating and installation instructions CONA TD
BR640)
For control the steam trap uses the condensate temperature as well as the available
upstream pressure and back pressure (intermittent operation).
The steam trap vents air automatically during system start-up and operation, but with a time
lag. The steam trap acts as a non-return valve.
d) Ball float steam trap BR628
(refer to Fig. 5 page 6)
(detailed description of the control system Operating and installation instructions CONA SC
BR634)
The steam trap is controlled by a swivel-mounted ball float (pos. 24.16) (level control).
An integrated diaphragm capsule (pos. 24.17) ensures automatic start-up air venting when
cold.
Universal / CONA®Connector
If the amount of inflowing condensate is less than the possible valve output or if there is no
condensate flow, the ball float (pos. 24.16) falls and the valve ball (pos. 24.4) rolls back
onto the valve bore. The valve is now closed.
4.2.2 CONA Connector
System connector for minimization of installation and maintenance space saving and
compact design.
a) System connector BR681
(refer to Fig. 6 page 7)
b) System connector with outside strainer BR682
(refer to Fig. 7 page 7)
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Operating and installation instructions
®
CONA
c) System connector with stop function at inlet BR683
(refer to Fig. 8 page 7)
The valve is based on an integrated, Low-maintenance stop valves with gland seal
(also as low-maintenance bellows seal stop valve with approval acc. to TA-Luft ):
(refer to Fig. 10 page 11 - Fig. 11 page 12)
- safety back-sealing mechanism
with stuffing box: stem (pos. 11) / screw fitting (pos. 15)
with bellows seal: stem (pos. 11) / stem guide (pos. 16)
This valve is recommended specially for the CODI as steam trap.
ATTENTION !
Do not use shut-off valves for OPEN-SHUT function to throttle volume flow.
Valve position:
OPEN - Safety back-sealing mechanism effective when valve fully open.
SHUT - Valve plug (pos. 4) / chamfer at seat (Pos 3) seal effective.
Universal / CONA®Connector
d) System connector with stop function at inlet and outlet BR684
(refer to Fig. 9 page 7)
same as c) but with two stop valves
Easy replacement of the connected steam traps by shutting-off
of inlet and outlet.
Rev. 0040808001 0611 Page 5
Operating and installation instructions
®
CONA
Universal / CONA®Connector
4.3 Diagram
Fig. 1: CONA®B Universal - BR604 Fig. 2: CONA®M Universal - BR622
Fig. 3: CONA®TD Universal - BR642 Fig. 4: CONA®TD Universal - BR643
Fig. 5: CONA®S Universal - BR628
Page 6 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
Fig. 6: CONA® Connector 681 Fig. 7: CONA® Connector 682
Universal / CONA®Connector
Fig. 8: CONA® Connector 683 Fig. 9: CONA® Connector 684
Refer to the data sheet for information about materials with designations and figure numbers.
4.4 Technical data - remarks
for
- Principal dimensions,
- Pressure-temperature-ratings, operating limits,
- Valves with different types of connection , etc.
refer to datasheet.
Rev. 0040808001 0611 Page 7
Operating and installation instructions
®
CONA
Universal / CONA®Connector
4.5 Marking
AWH
Typ Type
Bj. Year of manufacture
PS/TS Pressure / Temperature indication
Material / Charge
According to the Pressure Equipment Directive appendix 2 diagram 7 valves acc. to article
1 paragraph 2.1.2 (pipes) only show the CE-marking from DN40 onwards.
Manufacturer
Address of manufacturer:
refer to item 11.0 Warranty / Guarantee
5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Installation in any position (except screw cap/cover downwards). Note
installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valves must not be used to take external forces, e.g. they are not designed for
use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See data sheet for weights.
- Centre gaskets between the flanges.
- Precautions against freezing should be taken as a matter of course in any
facilities susceptible to frost.
- Planners / construction companies or operators are responsible for positioning and
installing products.
- The valves are designed for application, not influenced from weather.
- For application outside or in adverse environments like corrosion-promoting conditions
(sea water, chemical vapours, etc.), special constructions or protective measures are
recommended.
Page 8 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
Universal / CONA®Connector
5.2 Installation instructions for welding
(refer to Fig. 1 - Fig. 5 page 6)
It should be noted that fittings must only be welded by qualified persons using appropriate
equipment and working in accordance with technical regulations.
The responsibility lies with the system operator.
Please refer to the catalogue sheet for information on type and instructions relating to
welding socket weld ends/butt weld ends.
When welding products to the pipeline system they should be adequately cooled to prevent
any adverse effect on the complete controller assembly (pos. 24) or possibly the sealing
ring (pos. 17). The heat-affected zone should be restricted to the immediate weld seam
area!
If there are plans to acid clean the facility before putting it into operation the module stop
valve cpl. (pos. 8) should be dismantled completely, replaced by acid cleaning inserts, and
reassembled after acid cleaning (see item 7.1). In such an event please contact the
manufacturer.
5.3 Installation position
Einbaulage in Bezug auf Durchströmung beachten, siehe Kennzeichnung auf der Armatur.
a) Bimetallic steam trap BR604 / Thermodynamic steam trap BR622
The steam trap can be installed in any position except screw cap (pos. 6) down.
(refer to 7.5 Changing the installation position)
b) Thermodynamic steam trap BR642/643
Fig. 642: The steam trap can be installed in any position
(refer to 7.5 Changing the installation position)
Fig.643: outside screen (pos. 7) always downwards.
c) Ball float steam trap BR628
Plug (pos. 50) always downwards.
.
5.4 Steam trap testing through ultrasonic measurement
Testing the operation of the steam trap in the installed state is straightforward with the
“ARImetec®-S” mulitfunctional testing device.
Refer to data sheet “ARImetec®-S”.
Rev. 0040808001 0611 Page 9
Operating and installation instructions
CONA
6.0 Putting the valve into operation
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
®
Universal / CONA®Connector
Page 10 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
Universal / CONA®Connector
7.0 Care and maintenance
Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work!
- refer to item 6.0 before restarting the plant!
Prior to installation, threads and seal faces should be coated with temperaturestable lubricant (e.g. “OKS Anti-Seize Paste” white/metal-free).
7.1 Disassembling/assembling complete shut-off valve assembly
(refer to Fig. 8 page 7 - Fig. 9 page 7)
- Open stem (pos. 11) fully as far as the stop.
- Unscrew shut-off valve assembly (pos. 8) from body (pos. 1) by rotating to the left.
- Remove graphite insert (pos. 7).
- Unscrew hollow-core screw (pos. 14) using AWH assembly spanner.
- Remove seat (pos. 3).
- Assemble in reverse order (refer to item 7.6).
7.2 Replacing the packing rings
- Dismantle shut-off valve assembly (pos. 8) as described in 7.1.
ATTENTION !
It is vital to avoid damage to stem surface and
packing chamber surface.
- Rotate stem (pos. 11) in closing direction.
- Slacken cheese-head screw (pos. 18).
- Pull handle (pos. 19) away from stem (pos. 11).
- Release lock nut (pos. 13).
- Unscrew threaded bush (pos. 12).
- Withdraw stem (pos. 11) downwards from threaded bush (pos. 12).
- Dismantle cover ring (pos. 20) and packing rings (pos. 5).
- Clean packing chamber and stem surface.
- Push stem (pos. 11) into screw fitting (pos. 15) and fit new packing
rings (pos. 5).
- Assemble in reverse order (refer to item 7.6).
Fig. 10
Rev. 0040808001 0611 Page 11
Operating and installation instructions
®
CONA
Universal / CONA®Connector
7.3 Replacing packing rings of the secondary sealing gland packing
- Dismantle shut-off valve assembly (pos. 8) as described in item 7.1.
ATTENTION !
It is vital to avoid damage to stem surface and
packing chamber surface.
- Rotate stem (pos. 11) in closing direction.
- Slacken cheese-head screw (pos. 18).
- Pull handle (pos. 19) away from stem (pos. 11).
- Unscrew sleeve nut (pos. 6).
- Remove pressure plate (pos. 21).
- Unscrew stem guide (pos. 16) from screw fitting (pos. 15) and
withdraw from stem (pos. 11).
- Dismantle packing rings (pos. 10).
- Clean packing chamber and stem surface.
- Push stem (pos. 11) into stem guide (pos. 16) and fit new packing
rings (pos. 10).
- Assemble in reverse order (see 7.6).
Fig. 11
7.4 Cleaning / replacing
a) Bimetallic steam trap BR604
(refer to Fig. 1 page 6)
The bimetallic steam trap is based on a compact welded structure.
Disassembly is not possible therefore.
If the operator thinks there is unwarranted leakage of steam at the steam trap, we
recommend replacing the complete bimetallic steam trap.
That means:
- Release pressure from the steam trap (shut-off inlet; with back pressure also shut-off
behind the steam trap)
- Loosen the two hexagon screws (pos. 27)
- Remofe steam trap and gaskets (pos. 11, 17)
- Clean the sealing surface of the CONA®-Connector
- install new trap with new gaskets
Page 12 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
b) Thermostatic steam trap BR622
(refer to Fig. 2 page 6)
The thermostatic steam trap is based on a compact welded structure.
Disassembly is not possible therefore.
If the operator thinks there is unwarranted leakage of steam at the steam trap, we
recommend replacing the complete steam trap.
That means:
- Release pressure from the steam trap (shut-off inlet; with back pressure also shut-off
behind the steam trap)
- Loosen the two hexagon screws (pos. 27)
- Remofe steam trap and gaskets (pos. 11, 17)
®
- Clean the sealing surface of the CONA
- install new trap with new gaskets
c) Thermodynamic steam trap BR642/643
(refer to Fig. 2 page 6 -Fig. 4 page 6 )
-Connector
Universal / CONA®Connector
Die BR642 is based on a compact welded structure.
Disassembly is not possible therefore.
Bei BR643 besteht die Möglichkeit, im drucklosem Zustand, die Ventilplatte (pos. 25) zu
wechseln. Dazu ist die Kappe (pos. 6) zu demontieren/ montieren. Verschlusskappe
(pos. 6) lösen und abschrauben.
If the operator thinks there is unwarranted leakage of steam at the steam trap, we
recommend generally replacing the complete steam trap.
That means
- Release pressure from the steam trap (shut-off inlet; with back pressure also shut-off
behind the steam trap)
- Loosen the two hexagon screws (pos. 27)
- Remofe steam trap and gaskets (pos. 11, 17)
- Clean the sealing surface of the CONA®-Connector
- install new trap with new gaskets
d) Ball float steam trap BR628
(refer to Fig. 5 page 6)
The ball float steam trap is based on a compact welded structure.
Disassembly is not possible therefore.
:
If the operator thinks there is unwarranted leakage of steam at the steam trap, we
recommend replacing the complete steam trap.
That means:
- Release pressure from the steam trap (shut-off inlet; with back pressure also shut-off
behind the steam trap)
- Loosen the two hexagon screws (pos. 27)
- Remofe steam trap and gaskets (pos. 11, 17)
- Clean the sealing surface of the CONA®-Connector
- install new trap with new gaskets
Rev. 0040808001 0611 Page 13
Operating and installation instructions
®
CONA
Universal / CONA®Connector
7.5 Changing the installation position
a) Bimetallic steam trap BR604 / Thermostatic steam trap BR622
(refer to Fig. 1 page 6 bis Fig. 2 page 6)
Installation in any position, except cap (pos. 6) upside down :
- Release pressure from the steam trap (shut-off inlet; with back pressure also shut-off
behind the steam trap)
- Loosen the two hexagon screws (pos. 27)
- Change installation position of the steam trap, take care of the position of the gaskets
(pos. 11, 17)
- Tighten the two hexagon screws (pos.27) (refer to item 7.6).
b) Thermodynamic steam traps BR642
(refer to Fig. 2 page 6)
Installation in any position:
- Release pressure from the steam trap (shut-off inlet; with back pressure also shut-off
behind the steam trap)
- Loosen the two hexagon screws (pos. 27)
- Change installation position of the steam trap, take care of the position of the gaskets
(pos. 11, 17)
- Tighten the two hexagon screws (pos.27) (refer to item 7.6).
For Fig.643 is no change of the installation position possible.
The steam trap must always be installed with strainer plug (pos. 7) downwards.
c) Ball float steam traps BR628
(refer to Fig. 5 page 6)
No change of the installation position possible.
The steam trap must always be installed with plug (pos. 50) downwards.
7.6 Tightening torques
(refer to Fig. 1 page 6 - Fig. 11 page 12)
pos. Torque (Nm)
12 Theaded bush 10
13 Safety nut 70
14 Banjo bolt 70
15 Fitting 90
16 Stem guiding 90
27 Hexagon screws 20
Page 14 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
Universal / CONA®Connector
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-
If malfunctions cannot be eliminate with the help of the following table
“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table
ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work!
- refer to item 6.0 before restarting the plant!
Fault Possible cause Corrective measures
No flow Installed in wrong flow direction Fit valve in direction of flow arrow
Flange covers not removed Remove flange covers
At BR628:
Ball float (pos. 24.16) defective
Little flow Piping system clogged Check piping system
At BR682:
Strainer clogged (pos. 2)
Changed upstream pressure or back
pressure operating conditions
Wrong installation position Note installation position;
No closure, or internal
leakage
External leakage Shut-off valve not properly tightened Tighten; refer to item 7.6
Shut-off valve clogged Clean shut-off valve; refer to item 7.1
Shut-off valve worn Replace shut-off valve; refer to item 7.1
Shot-off valve operated above safe operating pressure
Controller worn out Change steam trap; refer to item 7.4
Diaphragm capsule worn out Change steam trap; refer to item 7.4
Flat gasket (pos. 5, 10) defective Replace sealing;
Flat gasket (pos. 11, 17) defective Replace sealing;
Change steam trap
Clean strainer; refer to item 7.4
Correct selection acc. to flow diagram
refer to item 5.3!
Correct installation position;
refer to item 7.5
Observe operating limits as per data
sheet
refer to item 7.2 and 7.3
refer to item 7.4
Rev. 0040808001 0611 Page 15
Operating and installation instructions
®
CONA
Universal / CONA®Connector
10.0 Dismantling the valve or the connector
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG“ valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.
Technology for the Future.
GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com
Page 16 Rev. 0040808001 0611
Operating and installation instructions
®
CONA
Universal / CONA®Connector
12.0 EC declaration of conformity
®
AWH
HALLE
WERK HALLE GMBH
a member of the ARI group
AWH Armaturenwerk Halle GmbH,
Turmstrasse 118, D-06110 Halle/Saale
EC declaration of conformity
the Pressure Equipment Directive 97/23/EC
We hereby declare
that pursuant to the aforementioned Pressure Equipment Directive the products listed
below were executed and classified in accordance with Directive 97/23/EC (Article 3,
paragraph 3).
ARMATUREN-
as defined by
Pursuant to Article 3, paragraph 3 these products need not carry a CE mark.
Steam traps for quick assembly/disassembly
CONA®Universal / CONA®Connector
Series Nom. pressure Material DN
604 ANSI300 all 2 x 3/8“ UNC
622 ANSI300 all 2 x 3/8“ UNC
642/643 ANSI300 all 2 x 3/8“ UNC
628 ANSI300 all 2 x 3/8“ UNC
Applied standards:
DIN 3840
AD 2000-leaflet
ASME VIII/1
Halle/Saale, 17.02.2011
...................................................
(Brechmann, Managing director)
Rev. 0040808001 0611 Page 17
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