GESTRA Steam Systems
AK 45
Installation Instructions 810467-02
Condensate Drain Valve
AK 45
1
Contents
Page
Important Notes
Usage for the intended purpose .............................................................................................................4
Safety note ............................................................................................................................................ 4
Danger ...................................................................................................................................................4
Attention .................................................................................................................................................4
PED (Pressure Equipment Directive) ........................................................................................................5
ATEX (Atmosphère Explosible) .................................................................................................................5
Explanatory Notes
Scope of supply ...................................................................................................................................... 6
System description ............................................................................................................................... 6
Function ................................................................................................................................................6
Technical Data
Corrosion resistance ...............................................................................................................................7
Sizing .....................................................................................................................................................7
Name plate / marking ............................................................................................................................. 7
Component Parts
AK 45 ....................................................................................................................................................8
Key ......................................................................................................................................................... 9
Installation
AK 45 ...................................................................................................................................................10
Flanged design .................................................................................................................................... 10
Screwed design .................................................................................................................................... 10
Steam trap with socket-weld ends .......................................................................................................11
Steam trap with butt-weld ends ............................................................................................................ 11
Attention .............................................................................................................................................. 11
Heat treatment of welds .......................................................................................................................11
Draining of steam main ........................................................................................................................12
Draining of a water pocket ................................................................................................................... 12
Commissioning
AK 45 ...................................................................................................................................................12
2
Contents – continued –
Page
Operation
AK 45 ...................................................................................................................................................13
Maintenance
Clean drain valve ................................................................................................................................. 13
Tools ....................................................................................................................................................13
Replace hand purging knob and valve insert ........................................................................................14
Tools ....................................................................................................................................................14
Torques for tightening ...........................................................................................................................14
Spare Parts
Spare parts list ....................................................................................................................................15
Decommissioning
Danger .................................................................................................................................................15
Disposal ...............................................................................................................................................15
3
Important Notes
Usage for the intended purpose
Use condensate drain valve AK 45 only for the discharge of condensed water in pipe lines or for
air-venting within the admissible pressure/temperature ratings. Check the corrosion resistance and
chemical suitability of the drain valve for the application in question.
For information on the application in potentially explosive areas see section “ATEX Directive 94/9/EC,
1999/92/EC” on page 5.
Safety note
The equipment must only be installed and commissioned by qualified staff.
Maintenance and service work must only be performed by adequately trained persons who have a
recognized level of competence.
Danger
The equipment is under pressure during operation.
When loosening flanged connections or sealing plugs, hot water and/or steam may
escape.
This presents the risk of severe scalding.
Installation and maintenance work should only be carried out when the system is
depressurized (0 bar): isolate the equipment from both upstream and downstream
pressure.
The equipment becomes hot during operation. This presents the danger of severe burns
to hands and arms. Installation and maintenance work should only be carried out when
the system is cold.
Before carrying out any kind of maintenance work or undoing flanged connections or
sealing plugs make sure that all connected lines are depressurized (0 bar) and cooled
down to room temperature.
Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial
gloves when replacing the regulator or the strainer.
Attention
The name plate indicates the technical specification of the equipment.
Do not commission or operate a steam trap without name plate.
4
Important Notes – continued –
PED (Pressure Equipment Directive)
The equipment fulfils the requirements of the Pressure Equipment Directive 97/23/EC.
AK 45 can be used with fluids of group 2.
The equipment is not CE marked according to section 3.3 of the PED.
ATEX (Atmosphère Explosible)
The equipment does not have its own potential source of ignition and is therefore not subject to the
ATEX Directive 94/9/EC. The equipment can be used in potentially explosive areas 0, 1, 2, 20, 21, 22
(1999/92/EC). The equipment is not Ex marked.
5
Explanatory Notes
Scope of supply
AK 45
1 Condensate drain valve AK 45
1 Installation manual
System description
The AK 45 automatically discharges condensed water from steam systems during start-up, until the
pressure in the system has reached the adjusted valve closing pressure.
At shut-down or when the pressure falls below the closing pressure the valve opens and accumulated
condensate is automatically discharged.
Function
When there is no pressure in the system the drain valve is held in the open position by the integrated
spring. As soon as the service pressure has reached the closing pressure to which the AK 45 has been
adjusted, the valve closes (by the differential pressure acting on the valve cone against the force of the
spring). When the pressure drops below the closing pressure, the AK 45 opens by spring force.
A hand purging knob is provided, so that the AK 45 can be briefly opened by hand with the system
under pressure to clear any deposits from the valve seat area.
The AK 45 is adjusted at our works to close at a differential pressure of 0.8 barg (12 psig).
The AK 45 is provided with a built-in strainer.
6
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Technical Data
Corrosion resistance
When used for its intended purpose, the safe functioning of the equipment will not be impaired by
corrosion.
Sizing
The valve body must not be subjected to sharp increases in pressure.
The dimensional allowances for corrosion reflect the latest state of technology.
Name plate / marking
The temperature/pressure limit is indicated on the valve body or on the name plate. For more information see GESTRA technical documents such as data sheets and Technical Information.
According to EN 19 the type and design must be specified on the name plate and valve body.
■ Name/logo of the manufacturer
■ Type designation: AK 45
■ Pressure rating PN
■ Marking according to ATEX: The equipment is not Ex marked.
■ Material number
■ Max. temperature
■ Max. pressure
■ Flow direction
■ Stamp on name plate, e. g. specifies the manufacturing year and quarter,
(in this case the 1
st
quarter 2005)
1
05
Marking
Fig. 1
7
Component Parts
AK 45
A
B
C
D
E
F
G
H
8
I
J
K
L
Fig. 2
Component Parts – continued –
Key
A Hexagon head screw M 10 x 25, EN 24017, alloy steel 24 CrMo 5 (1.7258)
B Hand purging knob
C Gasket A 14 x 18
D Name plate
E Cover
F Valve insert
G Bushing (interference fitted, no spare part)
H Gasket 40 x 48 x 2
I Body
J Strainer
K Gasket A 24 x 29
L Sealing plug
9
Installation
AK 45
Install the AK so that discharge is to open drain (without back pressure), preferably in a vertical line
with downwards flow.
The AK 45 can be installed in any plane with flow in the direction of the arrow. When the valve is
installed in a horizontal line, the cover must be on top.
If it is necessary to install the AK 45 in a horizontal line, the pipe on the discharge of the trap should
include a 90° downwards bend, Fig. 3, Fig. 4.
Flanged design
1. Observe position of installation.
2. Observe flow direction. The flow direction arrow is located on the valve body.
3. Leave at least
cover E.
4. Remove plastic plugs. They are
5. Clean gasket surfaces of the two flanges.
6. Install condensate drain valve.
Screwed design
1. Observe position of installation.
2. Observe flow direction. The flow direction arrow is located on the valve body.
3. Leave at least
cover E.
4. Remove plastic plugs. They are
5. Clean internal threads.
6. Install condensate drain valve.
40 mm free space around the equipment for subsequent disassembly of the
only used for transit protection.
40 mm free space around the equipment for subsequent disassembly of the
only used for transit protection.
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Installation – continued –
Steam trap with socket-weld ends
1. Observe position of installation.
2. Observe flow direction. The flow direction arrow is located on the valve body.
3. Leave at least
cover E.
4. Remove plastic plugs. They are
5. Remove regulator as described in section
6. Clean socket-weld ends.
7. Apply
ISO 4063).
Steam trap with butt-weld ends
1. Observe position of installation.
2. Observe flow direction. The flow direction arrow is located on the valve body.
3. Leave at least
cover E.
4. Remove plastic plugs. They are
5. Remove regulator as described in section
6. Clean butt-weld ends.
7. Apply electric arc welding process (welding process 111 and 141 in accordance with
ISO 4063) or gas welding (welding process 3 in accordance to ISO 4063).
40 mm free space around the equipment for subsequent disassembly of the
only used for transit protection.
Maintenance.
only electric arc welding process (welding process 111 and 141 in accordance with
40 mm free space around the equipment for subsequent disassembly of the
only used for transit protection.
Maintenance.
Attention
■ Only qualified welders certified e. g. according to EN 287-1 may weld the valve into
pressurized lines.
■ The valve must not be insulated.
Heat treatment of welds
A subsequent heat treatment of the welds is not required.
11
Installation – continued –
Draining of a steam main
Steam
Fig. 3 Draining of a steam main with an elevated condensate line
Draining of a water pocket
Steam
Condensate
AK 45
AK 45
Fig. 4 Draining of a water pocket
Commissioning
AK 45
Make sure that the flanged connections of the AK 45 are tightly bolted together and leakproof.
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Operation
AK 45
The default factory setting of the valve ensures that the AK 45 closes when the steam pressure
reaches 0.8 bar. For other settings/closing pressures please contact GESTRA AG.
Maintenance
The GESTRA Condensate Drain Valve AK 45 requires no special maintenance.
However, if used in new installations which have not been rinsed it may be necessary to inspect and
clean the trap.
Clean drain valve
1. Observe the danger note on page 4!
2. Unscrew body screws
3. Remove and clean valve insert
4. Unscrew sealing plug
5. Clean body, internals and all gasket surfaces.
6. Clean seating surfaces of body and cover.
7. Apply heat-resistant lubricant to all threads, seating surfaces of the valve insert and of the cover
(e. g. WINIX® 2150).
8. Screw in valve insert
Replace gasket H only if there are visual signs of damage.
9. Replace gasket
10. Put cover on valve body. Tighten body screws evenly with
11. Mount sealing plug
A and take the cover E off the body I, Fig. 2
F.
L and strainer J.
F, applying a torque of 90 Nm.
K if there are visual signs of damage.
25 Nm.
L together with strainer J and tighten with 120 Nm.
Tools
■ Spanner 16 mm A. F., DIN 3113, Form B
■ Spanner 22 mm A. F., DIN 3113, Form B
■ Torque spanner 20-120 Nm, DIN ISO 6789
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
13
Maintenance – continued –
Replace hand purging knob and valve insert
1. Observe the danger note on page 4!
2. Unscrew body screws
3. Unscrew hand purging knob
4. Unscrew valve insert
5. Unscrew sealing plug
6. Clean strainer, sealing plug and gasket surfaces.
7. Clean seating surfaces of body and cover.
8. Apply heat-resistant lubricant to all threads, seating surfaces of the valve insert and of the cover
(e. g. WINIX® 2150).
9. Replace gasket
10. Replace gasket
11. Mount new hand purging knob
12. Mount new valve insert
13. Put cover on valve body. Tighten body screws evenly with
14. Mount sealing plug
Tools
■ Spanner 16 mm A.F., DIN 3113, Form B
■ Spanner 19 mm A.F., DIN 3113, Form B
■ Spanner 22 mm A.F., DIN 3113, Form B
■ Torque spanner 20-120 Nm, DIN ISO 6789
A and take the cover E off the body I, Fig. 2
B.
F.
L and strainer J.
H only if there are visual signs of damage.
K if there are visual signs of damage.
F and tighten with a torque of 40 Nm.
B and tighten with a torque of 90 Nm.
25 Nm.
L together with strainer J and tighten with 120 Nm.
Torques for tightening
Item
F
B
Hand purging knob 040
A
L
All torques refer to a room temperature of 20 °C.
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
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Designation Torque [Nm]
Valve insert 090
Body screws 025
Sealing plug 120
Spare Parts
Spare parts list
Item
B
F C
J K L
H
*) Minimum order quantity 50 items. Contact your local dealer for smaller quantities.
Gasket*) 40 x 48 x 2, made of graphite 375159
Designation Stock code
Hand purging knob 375435
Valve insert with gasket 375434
Strainer, cpl. 375113
Decommissioning
Danger
Risk of severe burns and scalds to the whole body!
Before loosening flanged connections or sealing plugs make sure that all connected lines
are depressurized (0 bar) and cooled down to room temperature.
Disposal
Dismantle the valve and separate the waste materials, using the specifications in the table “Materials”
on page 9.
For the disposal of the valve observe the pertinent legal regulations concerning waste disposal.
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www.gestra.de
GESTRA
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810467-02/806cm · 1999 GESTRA AG · Bremen · Printed in Germany
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