Steam Traps
GK 11
GK 21
with stage nozzle
for large quantities of condensate
Original Installation Instructions
813078-02
Contents
Foreword ............................................................................................................................................ 3
Availability ............................................................................................................................................. 3
Formatting features in the document ...................................................................................................... 3
Safety .................................................................................................................................................. 3
Use for the intended purpose ................................................................................................................. 3
Basic safety notes ................................................................................................................................. 4
Qualification of personnel ....................................................................................................................... 4
Protective gear ...................................................................................................................................... 5
Typographic features of warning notes .................................................................................................... 5
Formatting features for warnings of property damage .............................................................................. 5
Description ......................................................................................................................................... 5
Scope of supply and equipment specification .......................................................................................... 5
Task and function .................................................................................................................................. 8
Storing and transporting the equipment ........................................................................................... 9
Storing the equipment ........................................................................................................................... 9
Transporting the equipment ................................................................................................................... 9
Mounting and connecting the equipment ....................................................................................... 10
Preparing installation ........................................................................................................................... 10
Connecting the equipment ................................................................................................................... 10
Orientation of the equipment ................................................................................................................ 11
Operation .......................................................................................................................................... 12
Adapting settings ............................................................................................................................. 13
After operation ................................................................................................................................. 15
Removing external dirt deposits ............................................................................................................ 16
Maintaining the equipment ................................................................................................................... 17
Servicing the equipment and installing spare parts ................................................................................ 18
Troubleshooting ............................................................................................................................... 27
Adjusting the gland seal ....................................................................................................................... 30
Putting the equipment out of operation .......................................................................................... 31
Removing harmful substances .............................................................................................................. 31
Removing the equipment ..................................................................................................................... 31
Re-using equipment after storage ......................................................................................................... 31
Disposing of the equipment .................................................................................................................. 32
Technical data .................................................................................................................................. 33
Dimensions and weights ...................................................................................................................... 33
Pressure & temperature ratings ............................................................................................................ 34
Manufacturer's declaration ............................................................................................................. 35
3
Foreword
This installation & operating manual will help you
use the following types of equipment safely and
efficiently for their intended purpose.
GK 11, DN65–DN150
GK 21, DN50
These steam traps will be called equipment in this
document.
This installation & operating manual is intended for
anyone commissioning, using, operating, servicing,
cleaning or disposing of this equipment and, in
particular, for professional after-sales service
technicians, qualified personnel and authorised and
trained staff.
All of these persons must read and understand the
content of this installation & operating manual.
Following the instructions given in this installation &
operating manual helps avoiding danger and
increases the reliability and service life of the
equipment. Please note that in addition to the
instructions given in this installation & operating
manual you must also observe all locally applicable
rules and regulations concerning the prevention of
accidents as well as approved safety guidelines for
good professional practice.
Availability
Keep this installation & operating manual together
with the plant documentation for future reference.
Make sure that this installation & operating manual
is available to the operator.
The installation & operating manual is part of the
equipment. Please hand over this installation &
operating manual when selling the equipment or
passing it on.
Formatting features in the
document
Certain text elements of this installation & operating
manual feature a specific typographic design. You
can easily distinguish the following text elements:
Standard text
Cross-reference
Listing
Sub-items in listings
Steps for action.
Here you will find additional useful
information and tips serving to assist you
in using the equipment to its fullest
potential.
Safety
Use for the intended purpose
The thermodynamic steam traps mentioned below
are installed in pipes:
GK 11, DN65–DN150
GK 21, DN50
These steam traps are used to remove large
volumes of continuously forming condensate from
steam, and for venting pipes.
The equipment must only be used within the
allowable pressure and temperature limits and only
if the chemical and corrosive influences on the
equipment are taken into account.
Correct use includes compliance with the
instructions given in this installation & operating
manual, in particular obedience to all safety
instructions.
Any other use of the equipment is considered to be
improper.
Note that the equipment is also used incorrectly if
the materials of the equipment are not suitable for
the fluid.
4
Basic safety notes
Risk of severe injuries
The equipment is under pressure and can get
hot during operation. Only perform work on the
equipment if the following conditions are
satisfied:
The pipes must be isolated from pressure.
All medium must be thoroughly removed
from pipes and the equipment.
Before carrying out any work, the higher-
level system must be switched off and
secured so it cannot be switched back on by
unauthorised persons.
Pipes and the equipment must have cooled
to around 20 °C (lukewarm).
The equipment may only be used with media
that are not aggressive in contact with material
and seals. Otherwise, there may be leaks and
hot or toxic medium may escape.
The equipment and its components may only be
installed or removed by specialist personnel.
Specialist personnel must have knowledge and
experience of the following areas:
Producing connections on pipes.
Selecting suitable lifting gear for the product,
and using it safely.
Working with hazardous (contaminated, hot
or pressurised) media.
Risk of burns during setting work.
Settings can only be performed when the
equipment is at operating temperature. Wear
suitable protective clothing for the operating
temperature of the medium. Do not touch any
parts of the system.
Risk of minor injuries
Sharp edges on internals present the danger of
cuts to hands. Always wear industrial gloves
when servicing the equipment.
If the support of the equipment during
installation is insufficient the equipment might
fall down, thereby causing bruises or injuries.
Make sure the equipment is safely held in place
during installation and cannot fall down. Wear
protective safety footwear.
Information on property damage or
malfunctions
Malfunctions will occur if the equipment is
installed in a wrong position or with the flow
arrow pointing in the opposite direction of the
fluid flow. This may result in damage to the
equipment or the installation. Make sure that
the flow arrow on the equipment body matches
the indicated direction of the fluid flow in the
pipe.
If the material is unsuitable for the fluid,
increased wear may occur and fluid may
escape. Make sure that the material is suitable
for the fluid used in your installation.
Qualification of personnel
A qualified person must be acquainted with and
experienced in the following:
the pertinent on-site rules and regulations for
preventing fire and explosions as well as
industrial safety regulations
working on pressure equipment
making pipe connections
working with dangerous (hot or pressurized)
fluids
lifting and transporting loads
observing all notes and instructions in this
installation & operating manual and the
applicable documents
5
Protective gear
The operator must ensure that anyone working on
the equipment must wear the required protective
clothing and safety gear stipulated for the site of
installation. The protective clothing must be suitable
for the used media and must protect the wearer
against safety and health hazards associated with a
particular job to be carried out at the site of
installation. Protective clothing & equipment must
provide protection from potential hazards, in
particular from injuries to:
Head
Eyes
Body
Hand
Feet
Hearing
Note that this list is not exhaustive. The operator
must establish personal protective equipment
guidelines and specify any additional protective
gear that is required if the worker is exposed to a
specific risk at the site of installation.
Typographic features of warning
notes
DANGER
Notes with t
he heading DANGER warn
against imminent dangerous situations that
can lead to death or serious injuries.
WARNING
Notes with the heading WARNING warn
against possibly dangerous situations that
could lead to death or serious injuries.
CAUTION
Notes with the heading CAUTION warn
against dangerous situations that could
lead to minor or moderate injuries.
Formatting features for warnings
of property damage
Attention!
This information warns of a situation
leading to property damage.
Description
Scope of supply and equipment
specification
Scope of supply
Our equipment is delivered packed and ready for
assembly.
6
Component parts
The diagram below shows a GK 11 DN80 steam
trap. The other steam traps have the same basic
construction.
No.
Designation
1
Direction of flow arrow
2
Rating plate
3
Sealing plug (both sides)
4
Body
5
Stage plunger
6
Lid 7 Screw spindle with handwheel
No.
Designation
8 Counter nut for fixing threaded spindle in
place
9
Scale with pointer and "Operation" sign
10
Sight glass lid
11
Sight glass
12
VAPOSOSCOPE insert
7
Installation positions
The following installation positions are possible:
Horizontal installation with direction of flow from left
to right (standard in GK 21)
Horizontal installation with direction of flow from
right to left (standard in GK 11)
Vertical installation with direction of flow from
bottom to top
Vertical installation with direction of flow from top to
bottom
You can change the installation position of the
equipment. The steam trap must always be
installed in the pipe with the screw spindle
horizontal.
To change the installation position, you must realign
the VAPOSCOPE insert.
To do this, proceed as described in the section
"
Positioning the equipment
" on page 11.
8
End connections
The equipment is available with the following end
connections:
Flanges
Name plate
The following items are indicated on the name
plate:
Manufacturer
Type designation
Nominal size
Pressure rating
Design temperature
Design pressure
Max. service temperature
Max. admissible differential pressure
CE marking
Date of manufacturing
The following items are indicated on the equipment
body:
Material
Batch code
Direction of flow
Application of European Directives
Pressure Equipment Directive
The equipment conforms to this directive (see
"Manufacturer's Declaration" section) and can be
used for the following media:
Fluids of group 2
ATEX Directive
The equipment has classification: CE Ex II 2G/D c X.
For use in potentially explosive atmospheres in
zones (surrounding atmosphere to Directive
1999/92/EC) 1, 2, 21 and 22, please read and
observe the following information:
The sign "X" in the Ex label signifies that operation
at an excessive surface temperature caused by the
medium must be avoided. The equipment itself
does not generate additional surface temperatures.
Once installed, static electricity may arise between
the equipment and the connected system. During
use in potentially explosive atmospheres, the
discharge or prevention of possible electrostatic
charging is the responsibility of the manufacturer or
owner of the system. If there is a possibility that
medium might escape, e.g. via actuating devices
or leaks in screwed couplings, the manufacturer or
owner of the system must take this into
consideration when dividing the area into zones.
Task and function
The equipment is used for automatically draining off
large volumes of condensate where pressure and
the condensate flowrate fluctuate greatly.
The equipment vents automatically during start-up
and operation.
The equipment may also be used as a peak limiter.
You can infinitely adjust the aperture of the stage
nozzle using the handwheel.
The flow of medium is displayed in the integrated
VAPOSCOPE.
9
Storing and transporting the
equipment
Attention!
Equipment can be damage
d if stored or
transported improperly.
Close all openings with the sealing
plugs or covers supplied with the
equipment or use similar sealing
covers.
Protect the equipment against
moisture and corrosive atmospheres.
Please contact the manufacturer if the
specified transport and/or storage
requirements cannot be met.
Storing the equipment
Please observe the following items when storing
the equipment:
Do not store the equipment for more than 12
months.
Use the supplied sealing plugs or other suitable
seal caps in order to seal off all openings of the
equipment.
Protect the sealing surfaces and contact areas
against mechanical damage.
Protect the equipment and all components
against hard shocks and impacts.
Store the equipment only in closed rooms that
meet the following environmental conditions:
Air humidity below 50 %, not condensing
Indoor air: clean, salt-free and non-corrosive
Temperature 5–40 °C.
Make sure that all these requirements are
always met when storing the equipment.
Please contact the manufacturer if you cannot
comply with the recommended storage
conditions.
Transporting the equipment
C
AUTION
Do not drop the equipment. If it falls down
it may cause bruises and injuries.
To transport and mount the equipment
safely use suitable lifting gear.
Connect the noose strap of the lifting
gear to the body.
Provide sufficient support for the
equipment during transport and
installation.
Wear protective safety footwear.
Lightweight equipment may be transported and
mounted without using any lifting gear.
To lift equipment the weight of which exceeds
approx. 25 kg, you need the help of a second
person or suitable lifting gear.
Your physical strength and on-site regulations and
conditions determine what weight can be lifted and
if support is required.
Meet the requirements for storage also when
transporting the equipment.
Prior to transport seal off connections with
sealing plugs.
If you do not have the sealing plugs
supplied with the equipment us
e
appropriate seal caps to seal off the
connections.
For short distances (only a few metres) you can
transport the equipment unpacked.
When transporting the equipment over larger
distances use the original packaging.
If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.
10
For
a short period of time the equipment
may be transported even if the
temperature is below 0
°C, provided that
the equipment is completely empty and
dry.
Mounting and connecting the
equipment
Preparing installation
Take the equipment out of the transport
packaging.
Check the equipment for transport damage.
Contact the manufacturer if you detect any kind
of shipping damage.
When supplied by the factory, the connections may
be sealed off with sealing plugs.
Remove sealing plugs before mounting the
equipment.
Keep the sealing plugs and the packing for
further use.
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necess
ary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
Drain pipes until they are empty.
Switch the installation off and protect it against
unauthorised or unintended re-activation.
Connecting the equipment
DANGER
Incorrectly connected equipment can
ca
use fatal accidents or severe injuries.
Make sure that only qualified skilled
personnel connect the equipment to
pipes.
Make sure that the flow arrow on the
equipment body matches the direction
of flow in the pipe.
Specialist personnel must be highly qualified and
fully experienced in making pipe connections for the
respective type of end connection.
11
Attention!
Equipment will be damaged if the end
connections are undersized.
Make sure that the connections are
strong and rigid enough to support the
weight of the equipment and to
withstand the forces that occur during
operation.
To allow easy access for routine servicing and
exchanging components observe the indicated
withdrawal distances and allow for clearances to
adjacent installation parts.
For more information see section “
Dimensions and
weights„
” on page 33.
Make sure that the pipe system of the plant is
clean.
Make sure that the equipment is free from
foreign matter.
Attention!
An incorrect installation position can
prevent the equipment from functioning
correctly.
If an installation position described
here is not possible in your system,
please contact the manufacturer.
You can change the installation position of the
equipment. The steam trap must always be
installed in the pipe with the screw spindle
horizontal.
To change the installation position, you must realign
the VAPOSCOPE insert.
To do this, proceed as described in the section
"
Positioning the equipment
" on page 11.
Mount the equipment in the desired installation
position.
Make sure that the equipment is safely mounted
and that all connections are made correctly.
Orientation of the equipment
Attention!
The VAPOSCOPE may show incorrect
displays if in the wrong installation
position.
Only install the VAPOSCOPE in one of
the installation positions described
here.
The deflector tip of the VAPOSCOPE insert must
always point downwards.
To position the VAPOSCOPE insert, you
need only remove a sight glass. You need
to replace the sight
glass seals only if the
equipment had already been in operation.
If you are positioning the insert before
bringing the equipment into service for the
first time, you can reinstall the seals.
You require the following tools to position the
VAPOSCOPE insert:
Combination wrench to DIN 3113, type B (size
11, 17, 18, 19 or 24, depending on equipment
type)
Torque wrench to DIN ISO 6789
Temperature-resistant lubricant is required for
lubricating the system. The lubricant must have the
same properties as OKS 217.
Allen key to DIN ISO 2936 (size 6 or 10,
depending on equipment type)
Screwdriver
The types
of equipment differ in the
number of hexagon
-head bolts and
whether they are equipped with a spherical
washer.
In GK 11 steam traps, the lid of the sight glass
is fastened with six hexagon-head bolts.
In GK 21 steam traps, the lid of the sight glass
is fastened with four hexagon-head bolts.
12
A spherical washer is only fitted between the
sight glass lid and the sight glass in GK 21
steam traps.
Otherwise, the same procedure is used for the
different types of equipment.
Slacken the hex nuts (17) in the sight glass lid.
Remove the sight glass lid (10).
In GK 21 steam traps, remove the spherical
washer (16) from the sight glass.
Remove the sight glass seal (15).
Remove the sight glass (11).
Remove the mica disc (14).
Remove the sight glass seal (13).
Slacken the shoulder screw (18) on the body.
Turn the VAPOSCOPE insert (12) to the desired
position.
Coat the thread and contact surfaces with
temperature-resistant lubricant.
The lubricant must have the same properties as
OKS 217.
Insert one sight glass seal.
Insert the mica disc.
Insert the sight glass.
Insert the second sight glass seal.
In type GK 21, insert the spherical washer in the
upper sight glass.
Insert the sight glass lid.
The necessary torque for tightening the hex nuts
varies depending on type.
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
25 Nm
30 Nm
90 Nm
90 Nm
Tighten the hex nuts to the specified torque.
The necessary torque for tightening the shoulder
screw varies depending on type.
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
4.5 Nm
20 Nm
20 Nm
20 Nm
Tighten the shoulder screw to the specified
torque.
Operation
Do not work on the equipment while it is operating.
If necessary, change the equipment settings.
13
Adapting settings
CAUTION
Severe injuries from burns are possible
when changing the equipment settings.
Do not touch any parts of the system.
Wear suitable protective clothing for
the operating temperature of the
medium, and use suitable personal
protective equipment if necessary.
Make sure that no unauthorised
persons are in the vicinity of the
equipment.
You will find information on suitable protective
clothing and personal protective equipment in the
safety data sheet of the medium used.
The system must be at operating temperature for
setting the equipment.
Set the equipment such that the display in the sight
glass conforms to the diagram on the left below.
Normal condensate level
Banking-up of
condensate
Penetration of live steam
if medium throughput is
excessive
Penetration of live steam
due to leaks or other
major disruptions
Setting correct
Change setting: Increase
flow
Change setting: Reduce
flow
Change setting: Reduce
flow
14
You can find information on what to do in
the event of problems in section
"
Troubleshooting
" on page 27.
You require the following tools for working on the
equipment:
Combination wrench to DIN 3113, type B (size
24, 30, or 36, depending on equipment type)
Slacken the two counter nuts (8) on the
handwheel (7).
Screw the counter nuts upwards to the end of
the screw spindle.
To increase the flow, turn the handwheel
anticlockwise.
The pointer on the scale moves towards the "O"
(OPEN) mark.
To reduce the flow, turn the handwheel
clockwise.
The pointer on the scale moves towards the "C"
(CLOSED) mark.
Set the equipment such that a normal
condensate level is visible in the sight glass.
Hand-tighten the counter nuts.
The equipment can now only be opened as far as
this position. It can still be fully closed, however.
You can affix the supplied "Operation" sign to mark
this setting.
Affix the "Operation" sign so that it is opposite
the pointer on the spindle.
After draining, turn the handwheel as far as it
will go.
The stage plunger is now once more in normal
operating position.
If you make a mark on the scale in the
operating position, it will show you the
correct setting.
An "Operation
" sign is supplied with the
equipment.
15
After operation
DANGER
If fluid escapes personnel may suf
fer
severe injuries, poisoning or even loss of
life.
After working on the equipment make
sure that all connections and valves
are tight.
Make sure that the gaskets of the
body are leakproof.
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the eq
uipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
Attention!
Frost damage may occur when the
installation is shu
t down.
Drain the equipment if ambient
temperatures below 0 °C (frost) are to
be expected.
You require the following tools to drain the
equipment:
Combination wrench to DIN 3113, type B (size
16, 17, 18, or 19, depending on equipment
type)
Torque wrench to DIN ISO 6789
Temperature-resistant lubricant is required for
lubricating the system. The lubricant must have the
same properties as OKS 217.
16
A sealing plug (3) is mounted on the top
and on the bottom of the body. For
drainage, open the bottom sealing plug.
Make sure that medium exiting the system is
caught.
Open the sealing plug (3) at the bottom of the
body.
Wait until the equipment has drained fully.
Clean the sealing surfaces of the sealing plug
and body.
Insert a new gasket (19) into the hole in the
body.
Coat the thread and contact surfaces with
temperature-resistant lubricant.
The lubricant must have the same properties as
OKS 217.
The necessary torque for tightening the sealing plug
varies depending on type.
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
100 Nm
190 Nm
190 Nm
190 Nm
Tighten the sealing plug to the specified torque.
Removing external dirt deposits
To remove dirt deposits rinse the equipment
with fresh water and wipe it with a clean, lintfree cloth.
To remove any persistent residues use a
cleaning agent that is suitable for the material
and carefully wipe the equipment with a clean,
lint-free cloth.
17
Maintaining the equipment
The equipment does not require any particular
maintenance.
You should perform regular function tests
to ensure the equipment functions
correctly. The intervals between tests
depend on the type of use and operating
conditions.
For critical applications you should monitor
the equipment continuously.
Cleaning the equipment
Check the equipment at regular intervals for
contamination. The intervals depend on the amount
of dirt in the system. The operator must determine
the maintenance intervals.
Malfunctions may occur if the equipment is
used with different types of condensate:
The following condensates in particular
cause problems:
very oily condensates
condensates that resinify or become
gummy
condensates that recrystallize
condensates that contain solid matter.
In these cases check the equipment at
regular intervals for contamination and, if
necessary, remove dirt deposits.
To reduce contamination we recommend
installing a sedimentation vessel or a dirt
pocket arrangement upstream of the
equipment.
In normal cases, the components inside the
equipment do not need cleaning.
To clean the equipment completely, you must
remove the lid and take out the stage plunger.
To remove dirt deposits rinse the equipment
with fresh water and wipe it with a clean, lintfree cloth.
To remove any persistent residues use a
cleaning agent that is suitable for the material
and carefully wipe the equipment with a clean,
lint-free cloth.
Remove any parts that are dirty and cannot be
cleaned properly.
18
Servicing the equipment and
installing spare parts
You may exchange the following component parts
in case of wear or damage:
19
No.
Designation
GK 11
GK 21
DN65, DN80
DN100
DN150
DN50
Sight glass set, comprising:
369605
369606
360606
369604
11
2 × sight glasses
14
2 × mica discs
13.15
4 × sight glass seals
Stage plunger set, comprising:
369608
369609
369610
369607
5
1 × stage plunger
20
1 × sealing ring for collar screw
21
1 × nozzle insert seal
22
1 x nozzle insert
23
1 × threaded pin for stage
plunger (3 × for DN150)
24
1 x body gasket
Seal set, comprising:
369719
369720
369721
369718
24
1 x body gasket
21
1 × nozzle insert seal
19
4 × sealing ring for sealing plug
20
1 × sealing ring for collar screw
23
1 x threaded pin
25
Stuffing box1
26
1 × sealing ring for shoulder
screw
1
5 × DN50
7 × DN65–DN80
6 × DN100–DN150
20
Replacing the sight glass
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
You require the following tools to replace the sight
glass:
Combination wrench to DIN 3113, type B (size
11, 17, 18, 19 or 24, depending on equipment
type)
Torque wrench to DIN ISO 6789
Temperature-resistant lubricant is required for
lubricating the system. The lubricant must have the
same properties as OKS 217.
The types of equipment differ in
the
number of hexagon
-head bolts and
whether they are equipped with an
additional spherical washer.
In GK 11 steam traps, the lid of the sight glass
is fastened with six hexagon-head bolts.
In GK 21 steam traps, the lid of the sight glass
is fastened with four hexagon-head bolts.
A spherical washer is only fitted between the
sight glass lid and the sight glass in GK 21
steam traps.
Otherwise, the same procedure is used for the
different types of equipment.
Slacken the hex nuts (17) in the sight glass lid.
Remove the sight glass lid (10).
In GK 21 steam traps, remove the spherical
washer (16) from the sight glass.
Remove the sight glass seal (15).
Remove the sight glass (11).
Remove the mica disc (14).
Remove the sight glass seal (13).
Remove the second sight glass and its seal in
the same way.
Dispose of the removed sight glasses, mica
discs and seals in accordance with regulations
at the location of use.
21
DANGER
Burns or intoxication from
escaping
medium may cause extremely severe or
even fatal injuries.
Only insert new sight glasses in
perfect condition.
Clean all VAPOSCOPE components
before installation.
Remove foreign objects.
Tighten the hex nuts in the sight glass
lid evenly to the specified torque.
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
Coat the thread and contact surfaces with
temperature-resistant lubricant.
The lubricant must have the same properties as
OKS 217.
Insert the new inner sight glass seal.
Insert the new mica disc.
Insert the new sight glass.
Insert the new outer sight glass seal.
In type GK 21, insert the spherical washer in the
upper sight lass.
Insert the sight glass lid in the body.
The necessary torque for tightening the hex nuts
varies depending on type.
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
25 Nm
30 Nm
90 Nm
90 Nm
Tighten the hex nuts to the specified torque.
Secure the second sight glass in the same way.
Removing the lid
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necess
ary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
You require the following tools to remove and fit the
lid:
Combination wrench to DIN 3113, type B (size
17, 18, 19, 24 or 30, depending on equipment
type)
Torque wrench to DIN ISO 6789
22
Temperature-resistant lubricant is required for
lubricating the system. The lubricant must have the
same properties as OKS 217.
Attention!
Equipment may not work properly or get
damaged if parts are canted or tilted
during removal work.
Use suitable lifting gear to lift the
components off the body.
Make sure that the components are
not canted or tilted.
Make sure that the component parts
are not damaged by physical shocks.
The required bearing capacity of the lifting gear
depends on the equipment type. Contact the
manufacturer for more information on the weights
of the individual parts.
You can remove the lid together with the spindle
and stage plunger.
The lid is secured to the body with hex nuts (27).
The number of hex nuts varies depending on type:
GK 11, DN65–80: 12
GK 11, DN100: 16
GK 11, DN150: 20
GK 21, DN50: 8
Slacken the hex nuts (27) on the lid (6).
Remove the lid from the body.
Remove the body gasket (24).
23
Replacing the stage plunger and nozzle insert
You require the following tools to replace the stage
plunger and nozzle insert:
Combination wrench to DIN 3113, type B (size
11, 17, 18, 19 or 24, depending on equipment
type)
Torque wrench to DIN ISO 6789
Temperature-resistant lubricant is required for
lubricating the system. The lubricant must have the
same properties as OKS 217.
Allen key to DIN ISO 2936 (size 6 or 10,
depending on equipment type)
Screwdriver
Remove the lid, as described on page 21.
The stage plunger is fastened to the
spindle by one or two threaded pins.
GK
11, DN150 steam traps have two
threaded pins. The other types have one
threaded pin.
Remove the threaded pins (23) from the stage
plunger (5).
Completely unscrew the stage plunger from the
spindle (28).
Position the new stage plunger on the spindle
such that the two holes for the threaded pins
are one above the other.
By hand, screw the threaded pins into the holes.
Remove the collar screw (29).
Remove the sealing ring (20) of the collar screw.
Lift the nozzle insert (22) out of the body.
Lift the seal (21) for the nozzle insert out of the
body.
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
The gaskets of the equipment must be replaced
in any case.
Insert the new sea for the nozzle insert into the
body.
Insert the new nozzle insert in the body.
Insert the new sealing ring of the collar screw in
the body.
Screw the collar screw into the body.
24
The necessary torque for tightening the collar screw
varies depending on type.
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
140 Nm
140 Nm
370 Nm
670 Nm
Tighten the collar screw to the specified torque.
Fit the lid, as described on page 25.
Replacing the stuffing box
Remove the lid, as described on page 21.
Remove the stage plunger from the spindle, as
described on page 23.
Remove the two counter nuts (8) from the
handwheel.
Remove the tapered groove pin (30) from the
pointer (9).
Slacken the two hex nuts (31) on the stuffing
box gland (32).
Screw the spindle (28) downwards out of the
threaded sleeve (33).
When the spindle is unscrewed from the
threaded sleeve, pull the pointer (9) upwards
and off the spindle.
Pull the spindle downwards out of the lid.
You can now replace the stuffing box.
Proceed as follows to replace the stuffing box:
Remove the two hex nuts (31) and the stuffing
box gland (32).
You do not need to remove the stuffing box bush
(33) in order to replace the stuffing box.
Remove the packing rings (25) from the lid.
Replace the packing rings with the same
number of new ones.
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
The gaskets of the equipment must be replaced
in any case.
Position the stuffing box gland on the studs in
the lid.
By hand, screw the two hex nuts onto the studs.
Push the spindle through the gland seal from
below.
Screw the spindle into the threaded sleeve.
Align the pointer so that the holes for the
tapered groove pin are situated one above the
other.
Knock in the tapered groove pin to secure the
pointer.
By hand, screw the two counter nuts onto the
spindle and pointer.
Coat the thread and contact surfaces with
temperature-resistant lubricant.
The lubricant must have the same properties as
OKS 217.
The necessary torque for tightening the hex nuts on
the stuffing box gland varies depending on type.
25
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
20 Nm
20 Nm
70 Nm
70 Nm
Tighten the hex nuts to the specified torque.
Fit the lid, as described on page 25.
Mounting the lid
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
You require the following tools to remove and fit the
lid:
Combination wrench to DIN 3113, type B (size
17, 18, 19, 24 or 30, depending on equipment
type)
Torque wrench to DIN ISO 6789
Temperature-resistant lubricant is required for
lubricating the system. The lubricant must have the
same properties as OKS 217.
Attention!
Equipment may not work properly or get
damaged if parts a
re tilted or skewed
when installed.
Use suitable lifting gear to mount the
component parts.
Do not tilt or skew the component
parts during installation.
During installation make sure that the
component parts are not damaged by
physical shocks.
The required bearing capacity of the lifting gear
depends on the equipment type. Contact the
manufacturer for more information on the weights
of the individual parts.
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
The gaskets of the equipment must be replaced
in any case.
Coat the thread and contact surfaces with
temperature-resistant lubricant.
The lubricant must have the same properties as
OKS 217.
26
Insert the new body gasket (24) in the body.
Position the lid (6) on the body along with the
spindle and stage plunger.
Tighten the hex nuts (27) on the lid crosswise.
The necessary torque for tightening the nuts on the
lid varies depending on type.
Please refer to the following table for the correct
torque.
GK 21
DN50
GK 11
DN65,
DN80
GK 11
DN100
GK 11
DN150
55 Nm
60 Nm
120 Nm
250 Nm
Tighten the nuts to the specified torque.
If necessary, adjust the stuffing box seal as
described on page 30.
Set the medium flow, as described on page 13.
27
Troubleshooting
Problem
Cause
Remedy
Fluid escapes (equipment is
leaking).
The body has been damaged by
corrosion or erosion.
Replace the equipment with a new one.
Use equipment made of material that is
suitable for the application.
The discharge capacity is too
low.
Insufficient thermal output of
the user.
The differential pressure is too
small.
Increase the steam pressure.
Lower the pressure in the condensate
line.
Use equipment with a larger discharge
capacity.
If
necessary, use a pump steam trap or a
condensate return unit.
Fluid escapes (equipment is
leaking).
The equipment has been
damaged by frost.
Replace the equipment with a new one.
When shutting down the installation
make sure that all lines and the
equipment are completely drained.
The discharge capacity is too
low.
The equipment is cold or only
warm to the touch.
The shut-off valves for fluid flow
are closed.
Fully open the shut-off valves.
The handwheel can only be
moved by exerting a lot of
force.
It has reached its end position for
this direction of rotation.
Turn the handwheel in the other
direction.
The stroke limiter is locked. Slacken the counter nut of the stroke
limiter and reset the stroke limiter.
The handwheel can only be
moved by exerting a lot of
force.
The spindle has insufficient
lubrication.
Lubricate the spindle.
The equipment is cold or only
warm to the touch.
The sealing plugs are still
attached to the connections.
Remove the equipment.
Remove the sealing plugs.
Mount the equipment.
Fluid escapes (equipment is
leaking).
The equipment or the body is
damaged.
Replace the equipment with a new one.
Fluid escapes (equipment is
leaking).
A gasket is damaged.
Replace the gasket with a new one.
Clean gasket seating surfaces.
Fluid escapes (equipment is
leaking).
The connections are not tight.
Provide the connections with leakproof
seals.
28
Problem
Cause
Remedy
Fluid escapes (equipment is
leaking).
The stuffing box packing has not
been tightened enough.
Tighten the stuffing-box packing hand
tight.
Make sure that the stuffing box packing
does not impair the movement of the
internals.
Fluid escapes (equipment is
leaking).
The stuffing-box packing is
damaged.
Replace the stuffing-box packing.
The handwheel can only be
moved by exerting a lot of
force.
The stuffing box is fastened too
tightly.
Slacken the stuffing box screw a little.
Replace the stuffing box if damaged.
The equipment does not
close fully.
Inner parts are damaged or worn.
Replace the inner parts or the
equipment.
The flowrate is too low.
The equip
ment is cold or only
lukewarm.
Insufficient heat output of
consumers.
Contamination in the inflow,
outflow or equipment.
Clean the pipe.
Clean all inner parts.
Replace inner parts or equipment if
damaged.
The sightglass or water level
gauge does not offer an
unambiguous evaluation of
the operating condition.
The sightglass or water level
gauge is dirty, worn or scratched.
Replace the sightglass or water level
gauge.
29
You can recognise and remedy faults due to
incorrect settings as follows:
Normal condensate level
Banking-up of
condensate
Penetration of live steam
if medium throughput is
excessive
Penetration of live steam
due to leaks or other
major disruptions
– Condensate covers the
entire sight glass. No flow
is visible.
The condensate in the
sight glass is being
suppressed. There is a
clearly visible flow.
The sight glass is nearly
opaque.
Do not change the
settings.
Open the equipment until
a normal condensate
level is displayed.
Close the equipment until
a normal condensate
level is displayed.
Close the equipment until
a normal condensate
level is displayed.
Check that the part of the
system and the
equipment are not
leaking and are in perfect
condition.
Fix leaks and damages.
Setting the equipment is described on page 13.
If faults occur that are not listed above or cannot
be corrected, please contact our Technical
Service or authorized agency in your country.
30
Adjusting the gland seal
If the stuffing box is leaking, you must adjust it. To
do so, proceed as follows.
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make
sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
The torque for tightening the hex nuts on the
stuffing box varies depending on type.
The necessary torque for tightening the hex nuts
depends on the condition of the stuffing box.
Tighten the hex nuts sufficiently firmly to ensure the
following conditions are satisfied:
No medium may escape from the gland seal.
The gland seal must not hinder the movement
of the stage plunger.
If these conditions cannot be satisfied at the
same time, you must replace the stuffing box.
Evenly tighten the two hex nuts (31) on the
stuffing box gland (32).
Allow medium to flow through the equipment.
Move the stage plunger fully several times.
Tighten the hex nuts again so that no medium
escapes.
Check that the stage plunger can move easily.
If necessary, slacken the hex nuts evenly.
The stuffing box is correctly adjusted if no medium
escapes and the stage plunger can move easily.
If you are unable to adjust the gland seal as
described, you must replace the stuffing box.
To do so, proceed as described on page24.
31
Putting the equipment out of
operation
Removing harmful substances
For the disposal of all residues observe the
pertinent legal regulations concerning waste
disposal.
Removing the equipment
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
M
ake sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
CAUTION
Do not drop the equipment. If it falls
down
it may cause bruises and injuries.
To transport and mount the equipment
safely use suitable lifting gear.
Connect the noose strap of the lifting
gear to the body.
Provide sufficient support for the
equipment during transport and
installation.
Wear protective safety footwear.
Detach the end connections of the equipment
from the pipes.
Put the equipment onto a suitable base.
Store the equipment as described on page 9.
Re-using equipment after storage
Observe the following instructions if you want to
remove the equipment and use it again somewhere
else:
Make sure that the equipment is free of any
fluid residues.
Make sure that all connections are in good
condition and leak-free.
Use the equipment only for its intended purpose
and the service conditions for which it was
specified.
32
Disposing of the equipment
The equipment is made from the following
materials:
Component
GK 21
DN50
GK 11
DN65, DN80
GK 11
DN100
GK 11
DN150
Body, lid
5.1301 (A126-B*)
Bolts, nuts
1.7709 (A193 B7*/A194 size 4)
Nozzle insert
1.0460 (A105)
1.0619 (A216-WCB*)
Stage plunger
1.0460 (A105)
1.0619 (A216-WCB*)
Spindle
1.4104 (AISI 430 F*)
Handwheel
5.1300
5.3106 (A536 60-40-18*)
Gasket
Graphite-CrNi
Packing rings
Graphite
Sight glass
Borosilicate glass
Mica disc
Mica
*) ASTM material is comparable to EN material. Note the differences in chemical and physical properties.
33
Technical data
Dimensions and weights
GK 21
GK 11
DN [mm] 50 65 80 100 150
Length
L [mm]
320
420
620
900
Width
B1 [mm]
220
275
485
670
B2 [mm]
100
120
200
285
Diameter of
handwheel
D1 [mm]
140
200
315
Height
H [mm]
165
195
326
495
Service
dimension1
S [mm] 90 110 230 300
Weight
[kg]
25
50
52
145
310
1
From upper edge of spindle, equipment fully open
34
GK 21
GK 11
DN
[‘‘] 2 2 ½ 3 4
6
Length
L [in]
12.6
16.5
24.4
35.4
Width
B1 [in]
8.7
10.8
19.1
26.4
B2 [in] 3.9 4.7 7.9 11.2
Diameter of
handwheel
D1 [in]
5.5
7.9
12.4
Height
H [in]
6.5
7.7
12.8
19.5
Service
dimension1
S [in]
3.5
4.3
9.1
11.8
Weight [lb] 55.1 110.2 114.6 319.7 683.4
1
From upper edge of spindle, equipment fully open
Pressure & temperature ratings
You can find the values for your equipment on the
rating plate.
35
Manufacturer's declaration
For more information on the Conformity
Assessment according to European rules refer to
our Declaration of Conformity or our Declaration by
Manufacturer.
To download the current Declaration of Conformity
or Declaration by Manufacturer go to
www.gestra.com/documents or contact:
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon
+49 421 3503-0
Telefax
+49 421 3503-393
E-Mail
info@de.gestra.com
Web
www.gestra.de
This declaration is no longer valid if modifications
are made to the equipment without consultation
with us.
36
Agencies all over the world:
www.gestra.de
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon
+49 421 3503-0
Telefax
+49 421 3503-393
E-Mail
info@de.gestra.com
Web
www.gestra.de
813078-02/07-2017 kx_mm (801123-02) © GESTRA AG Bremen Printed in Germany
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