Ball Float Steam Trap
UNA 43
PN 16/CL 125/JIS 10K
UNA 46
PN 40/CL 150/CL 300/
JIS 10K/JIS 20K
Original Installation Instructions
819565-00
Contents
Foreword ............................................................................................................................................ 3
Availability ............................................................................................................................................. 3
Formatting features in the document ...................................................................................................... 3
Safety .................................................................................................................................................. 4
Use for the intended purpose ................................................................................................................. 4
Basic safety notes ................................................................................................................................. 4
Information on property damage or malfunctions ..................................................................................... 5
Qualification of personnel ....................................................................................................................... 5
Protective gear ...................................................................................................................................... 5
Typographic features of warning notes .................................................................................................... 6
Formatting features for warnings of property damage .............................................................................. 6
Description ......................................................................................................................................... 6
Scope of supply and equipment specification .......................................................................................... 6
Task and function ................................................................................................................................ 10
Storing and transporting the equipment ......................................................................................... 11
Storing the equipment ......................................................................................................................... 11
Transporting the equipment ................................................................................................................. 11
Mounting and connecting the equipment ....................................................................................... 12
Preparing installation ........................................................................................................................... 12
Orientation of the equipment ................................................................................................................ 12
Connecting the equipment ................................................................................................................... 13
Operation .......................................................................................................................................... 15
After operation ................................................................................................................................. 16
Removing external dirt deposits ............................................................................................................ 17
Maintaining the equipment ................................................................................................................... 17
Servicing the equipment and installing spare parts ................................................................................ 22
Troubleshooting ............................................................................................................................... 26
Putting the equipment out of operation .......................................................................................... 28
Removing harmful substances .............................................................................................................. 28
Removing the equipment ..................................................................................................................... 28
Re-using equipment after storage ......................................................................................................... 29
Disposing of the equipment .................................................................................................................. 30
Technical data .................................................................................................................................. 31
Dimensions and weights ...................................................................................................................... 31
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.
UNA 43
UNA 46
These types 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 addition
al useful
information and tips serving to assist you
in using the equipment to its fullest
potential.
4
Safety
Use for the intended purpose
Steam traps type UNA 43 and UNA 46 are designed
for draining condensate from steam systems.
Steam traps type UNA 43 can also be used for
removing condensate from compressed air
systems.
Steam traps type UNA 46 can also be used for
removing condensate from gases or gas mixtures.
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.
Do not expose the membrane regulator capsule of
the DUPLEX control unit to superheat conditions
above 5 K.
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.
Basic safety notes
Risk of severe injuries
The equipment is under pressure during
operation and may be hot. Before carrying out
any work on the equipment make sure that the
following requirements are met:
The pipes must be depressurized (0 bar).
The fluid must be completely removed from
the pipes and the equipment.
During work on the equipment the
installation must be switched off and
protected against unauthorised or
unintended activation.
The pipes and the equipment must have
cooled down to room temperature (approx.
20 °C).
If the equipment is used in contaminated areas
there is a risk of severe injuries or death caused
by harmful substances in or on the equipment.
Before working on the equipment make sure
that it is completely decontaminated. Always
wear the protective clothing prescribed for
contaminated areas when working on the
equipment.
The equipment must only be used with fluids
that do not attack the material and the gaskets
and sealings of the equipment. Otherwise leaks
may occur and hot or toxic fluid could escape.
The equipment and its component parts must
only be mounted or removed by qualified
personnel. A qualified person must be
acquainted with and experienced in the
following:
Making pipe connections.
Selecting suitable lifting gear and
understanding the rules for its safe use.
Working with dangerous (contaminated, hot
or pressurized) fluids.
If the admissible operating limits are exceeded,
the equipment may be destroyed and hot or
pressurised medium may escape. Make sure
that the equipment is always used within the
admissible operating limits.
You can find information on the operating limits
in the "
Technical data
" section.
5
If unsuitable lifting gear is used or the gear is
used improperly the equipment or parts of it
could fall down.
Make sure that only qualified personnel lifts
the equipment or parts of it.
Make sure that nobody is standing or
working below the hoisted equipment.
Make sure that the lifting gear is of sufficient
strength for the load to be hoisted and that
the load is properly secured and attached to
it. For more information on the nature and
weight of the components and safe lifting
points please contact the manufacturer.
Make sure that all locally applicable
regulations on safety and the prevention of
accidents are strictly adhered to.
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
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.
6
Typographic features of warning
notes
DANGER
Notes with the 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 s
erious injuries.
CAUTION
Notes with the heading CAUTION warn
against dangerous situations that c
ould
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.
7
Component parts
Item
no.
Designation
1
Hexagon nuts
2
Body
3
Body gasket
4
Control unit DUPLEX
5
Stud bolts
Item
no.
Designation
6
Cover
7
Drain with sealing plug
8
Name plate
9
Adapter
10
Direction of flow arrow
8
Optional extras
The following items are available as optional extra:
Item
no.
Designation
11
Control unit SIMPLEX
12 Hand-vent valve with socket spanner
(socket spanner not shown)
The vent hole in the cover for the handvent valve can also be used for
connecting a balance line.
Item
no.
Designation
13
Sealing plug
14
Electrodes NRG 16-19 or NRG 16-27
15
Manual float-lifting lever
16
Lever extension
In equipment with control unit SIMPLEX the
hand
-vent valve is included as standard.
If you want to mount the optional level
indicator please contact the manufacturer
and refer to the installation and operating
manual for the level indicator.
9
The different equipment versions allow you to adjust
the flow direction of the equipment to the flow
pattern of your installation. The flow arrow must
correspond to the direction of the fluid flow. The
following positions of installation are possible:
"v" for installation in vertical pipework with
downward flow
"hl" for flow from right to left (when viewed from
the body end)
"hr" for flow from left to right (when viewed from
the body end)
End connections
The equipment is available with the following end
connections:
Flanges
Name plate
The indications on the name plates vary according
to the equipment type.
The name plate may specify the following:
Manufacturer
Type designation
Design
Nominal size
Pressure rating
Design pressure
Design temperature
Max. service temperature
Max. admissible differential pressure
Material number
CE marking
Date of manufacturing
The following items are indicated on the equipment
body:
Material
Identification marking of material testing
Batch code
Direction of flow
The following items are indicated on the end
connections:
Flange face type (RJ number)
10
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:
UNA 43
Fluids of group 2
UNA 46
Fluids of group 1
Fluids of group 2
ATEX Directive
The equipment does not have its own potential
ignition source and is not subject to this directive
(see "Manufacturer's Declaration" section).
When installed, static electricity may arise between
the equipment and the connected system.
When used in potentially explosive atmospheres,
the plant manufacturer or plant operator is
responsible for discharging or preventing possible
static charge.
If it is possible for medium to escape, e.g. through
actuating mechanisms or leaks in threaded joints,
the plant manufacturer or plant operator must take
this into consideration when dividing the area into
zones.
Task and function
Purpose
UNA 43-PS and UNA 46-PK is steam process
equipment designed for the effective removal of
condensate from steam systems.
Steam traps type UNA 43 can also be used for
removing condensate from compressed air
systems.
Steam traps type UNA 46 can also be used for
removing condensate from gases or gas mixtures.
Function
A ball float opens the orifice as a function of the
liquid level. A rising level results in a proportional
opening of the equipment. The max. discharge
capacity depends on the orifice size when the ball is
completely lifted off its seat and the orifice is fully
open.
Equipment with control unit SIMPLEX is particularly
suitable for cold condensates and superheated
steam.
Equipment with control unit DUPLEX may also be
used for air venting the installation. The control unit
DUPLEX consists of a float operated rolling ball
valve mechanism and, in addition, a temperature
dependent air-venting facility. Air venting is
controlled by the membrane regulator. Equipment
with this type of control unit is particularly suitable
for saturated steam systems.
Do not expose the membrane regulator capsule of
the DUPLEX control unit to superheat conditions
above 5 K.
The optional hand-vent valve attached to equipment
with control unit SIMPLEX allows you to manually air
vent pipes.
11
Storing and transporting the
equipment
Attention!
Equipment can be damaged 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
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.
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 equip
ment use
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.
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.
12
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
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.
Drain pipes until they are empty.
Make sure that all pipelines upstream and
downstream of the equipment are
depressurised.
Switch the installation off and protect it against
unauthorised or unintended re-activation.
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 arrangemen
t upstream of the
equipment.
Orientation of the equipment
The different equipment versions allow you to adjust
the flow direction of the equipment to the flow
pattern of your installation. The following positions
of installation are possible:
with horizontal connections "hl" and "hr" for
installation in horizontal pipes
with vertical connections "v" for installation in
vertical pipework with downward flow
Attention!
Malfunctions may occur if the control unit
is installed incorrectly.
When installing the equipment make
sure that the name plate points
upwards and the float arm is free to
move up and down.
Make sure that the flow arrow on the
equipment body matches the direction
of flow in the pipe.
13
To avoid malfunctions make sure the following
requirements are met when mounting the
equipment:
The flow arrow on the equipment body must
match the fluid flow direction.
The name plate on the cover must point
upwards.
Contact the manufacturer if you want to mount
the equipment in a different position of
installation.
Detach the cover from the body as described on
page 18.
Remove the control unit as described on
page 18.
The equipment has three connections where the
control unit can be fitted. Two connections are
sealed with a blind flange. The control unit is
attached to the third connection. To change the
flow direction you have to reposition the control unit
to the lower connection. To do so proceed as
follows:
Turn the body by 90° or 180° into the desired
position of installation.
Remove the socket-head cap screws at the
lower blind flange on the body.
Remove the blind flange.
Fix the control unit to the body as described on
page 20.
Make sure that the opening of the air vent at the
orifice points upwards.
Make sure that the float arm is free to move up
and down.
Make sure that the flow arrow on the equipment
body matches the flow direction of the fluid.
Use the two socket-head cap screws to attach
the blind flange to the open connection on top of
the body.
Tighten the two socket-head cap screws with a
torque of 30 Nm.
Attach the cover to the body as described on
page 21.
To prevent ordering the wrong type when replacing
the equipment note the modification you made on
the name plate.
Change the type marking according to the
actual flow direction.
Obliterate the stock code number as to make it
indecipherable .
Connecting the equipment
Depending on the purpose of usage you
may insulate the equipment.
For more inform
ation please contact the
manufacturer.
DANGER
Incorrectly connected equipment can
cause fatal acc
idents 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.
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.
14
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.
Consider space required for servicing the
equipment and/or exchanging components and
observe the necessary withdrawal distance to
remove the cover. For more information on the
required withdrawal distances see section
"
Dimensions and weights
" on page 31.
Some applications require that the
equipment is fitted
with an air-balance
pipe: float traps for compressed air line
drainage and equipment installed in plants
where condensate is lifted upstream of the
equipment.
In this case connect the air balance pipe
to the bore on top of the cover.
Make sure that the pipe system of the plant is
clean.
Make sure that the equipment is free from
foreign matter.
Attention!
Malfunctions may occur if the equipment is
installed incorrectly.
The equipment must be installed with
the inlet end at the top and with the
float arm in a horizontal plane so that
it rises and falls vertically.
Mount the equipment in the desired installation
position.
Make sure that the pipes meet the following
requirements:
The layout of the pipelines must prevent the
formation of water pockets.
The pipeline must have a gradient so that the
condensate is free to fall towards the equipment
The cross section of the air balance pipe must
be at least DN 8 (¼ ") .
If the equipment is fitted with control unit
SIMPLEX, an air balance pipe must be
connected to the vent hole for the hand-vent
valve. The balance line must have a ⅜ ” BSP
end connection.
If one or more of the above mentioned
requirements cannot be met, please contact our
Technical Service or authorized agency in your
country.
Connect the end connections of the equipment
properly to the pipes.
If necessary, connect the air balance pipe to the
equipment as shown in the following drawing.
Make sure that the equipment is safely mounted
and that all connections are made correctly.
Mounting the measuring electrode
You can attach one or two measuring electrodes
(14) of the following type:
To detect banking-up of condensate: NRG 16-
19 or NRG 16-27 installed on top of the body
To detect loss of water seal: NRG16–19 or
NRG16–27 installed at the side of the body
The following tool is required for installation work:
Combination spanner to DIN 3113 form B:
⅜ ” BSP connection: A. F. 17
NRG 16-19: A. F. 22
NRG 16-27 (new): A. F. 27
NRG 16-27 (old): A. F. 32
15
Torque spanner (US: wrench) 60-120 Nm to
DIN ISO 6789
Attention!
The measuring electrode might get
damaged if it is mounted incorrectly.
Do not insulate the equipment after
installation of the measuring
electrode.
Observe and follow all instructions
given in the installation & operating
manual for the measuring electrode.
To mount the measuring electrodes proceed as
follows:
Apply heat resistant lubricant to the threads and
the terminal box side of the measuring
electrode.
The lubricant must have the same properties as
OKS
®
217.
Use a suitable combination spanner to screw
the measuring electrode into the desired
connection on the body.
Tighten the measuring electrode with a torque
of 75 Nm.
Connect the body to the pipework as described
in the previous section.
Attach an air balance pipe to the ⅜ ” BSP
connection.
Operation
WARNING
Hot liquids and steam can cause scalding.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
Protective clothing and protective gear must protect
the whole body against contact with escaping hot
steam.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
During operation you can undertake the following
work:
Open and close the optional hand-vent valve
Open and close the optional manual float-lifting
lever
The optional hand vent valve allows manual air
venting.
To air vent the equipment turn the hand-vent
valve (viewed from top) anticlockwise.
To close the hand-vent valve after air-venting
turn it clockwise.
Fasten the hand-vent valve hand tight.
To operate the manual float-lifting lever a lever
extension is supplied with the equipment.
The optional float-lifting lever allows the float to be
manually lifted irrespective of the liquid level. It can
be used to purge any dirt away from the seat area
and out of the equipment by opening the orifice and
draining the liquid.
The cast arrow on the body indicates the correct
direction of rotation.
To open the orifice turn the lever extension from
the tip of the arrow towards the end of the
arrow.
16
To close the orifice turn the lever extension from
the end of the arrow towards the tip of the
arrow.
To operate the hand vent valve use the socket
spanner (stock code number 526110) supplied with
the equipment.
If an optional level indicator is fitted you can read
off the fluid level during operation.
For more information see the separate installation
and operating manual for the level indicator.
After operation
DANGER
If fluid escapes personnel may suffe
r
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 equi
pment 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.
DANGER
If the equipment is used in contaminated
areas there is a ris
k of severe injuries or
death caused by harmful substances in or
on the equipment.
Only qualified personnel are allowed to
perform work on contaminated
equipment.
Always wear the protective clothing
prescribed for contaminated areas
when working on the equipment.
Make sure that the equipment is
completely decontaminated before
carrying out any service work.
Follow the pertinent instructions for
handling the hazardous substances in
question.
17
Attention!
Frost damage may occur when the
installation is shut down.
Drain the equipment if ambient
temperatures below 0 °C (frost) are to
be expected.
Provide a device that collects any fluid that may
escape.
Remove the sealing plug (7) at the bottom of the
body.
Allow all liquid to escape and wait until the body
is completely empty.
To seal the drain hole screw in the sealing plug
and tighten it with a torque of 75 Nm.
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.
Maintaining the equipment
For work on the equipment you will need the
following tools:
Combination spanner to DIN 3113 form B in
various sizes:
Several torque spanners to DIN ISO 6789,
covering a torque range of 10-300 Nm
Hexagon offset screwdriver ("Allen key") to DIN
ISO 2936
Screwdriver 5.5/125 to DIN 5265
Normally you do not have to clean the internal parts
of the equipment.
To clean the equipment completely take off the
cover and remove the control unit.
18
Removing cover
Remove the measuring electrode(s) if
mounted, before lifting off the cover.
Use a suitable combination spanner to
DIN 3113, form B, to remove the
measuring electrode.
Unscrew the eight hexagon nuts (1) off the stud
bolts (5) on the body.
Take the cover (6) off the body.
Remove the body gasket (3).
For the disposal of the body gasket observe the
pertinent on-site regulations concerning waste
disposal.
Removing control unit
Detach the cover from the body as described on
page 18.
Remove the two socket-head cap screws (20).
Remove the control unit (4) together with the
adapter (18) from the body.
Remove the adapter gasket (17).
Detach the control unit from the adapter.
Remove the gasket (19) for the control unit.
For the disposal of the gaskets observe the
pertinent on-site regulations concerning waste
disposal.
19
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 probl
ems:
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.
To clean the inside of the equipment proceed as
follows:
Detach the cover from the body as described on
page 18.
Take out the control unit, as described on page
18.
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.
Fit the control unit to the equipment, as
described on page 20.
Attach the cover to the body as described on
page 21.
Cleaning and checking the membrane
regulator capsule
To clean the membrane regulator capsule of
equipment with a DUPLEX control unit proceed as
follows:
Detach the cover from the body as described on
page 18.
Remove the control unit as described on
page 18.
Remove the membrane regulator capsule as
described in section "
Exchanging the membrane
regulator capsule
" on page 24.
Clean the membrane regulator capsule with cold
clean water.
Use a depth gauge to check the dimension x of
the membrane regulator capsule as shown in
the following drawing.
The membrane regulator capsule is intact if
dimension x exceeds 4.0 mm.
Discard and replace defective membrane
regulator capsule with a new one.
Mount the membrane regulator capsule as
described in section "
Exchanging the membrane
regulator capsule
" on page 24.
20
Fitting control unit in place
A
ttention!
Malfunctions may occur if the control unit
is installed incorrectly.
When installing the equipment make
sure that the name plate points
upwards and the float arm is free to
move up and down.
Make sure that the flow arrow on the
equipment body mat
ches the direction
of flow in the pipe.
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
Apply high-resistant lubricant to all threads,
bearing faces of screws, nuts and bolts.
The lubricant must have the same properties as
OKS® 217.
Attention!
Equipment may leak if the gasket is
damaged.
Replace all gaskets that you loosen
during your work.
Use only new gaskets of the same
type.
Replace all gaskets with new ones of the same
type.
Insert a new gasket (19) for the control unit into
the adapter (18).
Attach the control unit (4) to the adapter.
Insert a new adapter gasket (17) in the adapter
(18).
Attach the control unit (4) together with the
adapter to the body (2) using the two sockethead cap screws (20).
Tighten the socket-head cap screws with a
torque of 30 Nm.
Attach the cover to the body as described on
page 21.
21
Mounting cover
Attention!
Equipment may leak if the gasket is
damaged.
It is therefore essential that you
always insert a new gasket before reattaching the cover.
Make sure that the cover is not tilted
or skewed when refitted.
Clean the gasket surfaces of the cover and
body.
Apply heat resistant lubricant to the threads and
bearing faces of the screws.
The lubricant must have the same properties as
OKS
®
217.
Put a new body gasket (3) onto the body (2).
Insert the eight stud bolts (5) into the bores of
the body.
Refit the cover (6) onto the body such that the
name plate (8) points upwards.
The torque required for tightening the eight
hexagon nuts (1) depends on the type.
Tighten the hexagon nuts for UNA 43 with a
torque of 80 Nm.
Tighten the hexagon nuts for UNA 46 with a
torque of 230 Nm.
Fasten the hexagon nuts with the specified
torque.
If necessary, mount the measuring electrode as
described on page 14.
22
Servicing the equipment and
installing spare parts
You may exchange the following component parts
in case of wear or damage:
23
Item no.
Designation
Orifice
Stock code #
DUPLEX
SIMPLEX
3, 4/11, 17, 19,
20
Control unit including orifice, cpl. with body gasket,
adapter gasket and gasket for control unit, sockethead cap screws
2
560720
560727
4
560721
560728
8 560722 560729
13
560723
560730
22
560724
560731
32
560725
560732
40
560726
560733
3, 17, 19, 22, 23,
Gasket set1
all
560750
12, 22 Hand-vent valve, cpl. with joint ring and socket
spanner
all 560676
15, 16, 23
Manual float lifting lever, cpl. with gasket and lever
extension
all
560749
3, 21
Membrane regulator capsule 5N2, cpl. with body
gasket
all
560748
24 Orifice 2 560734 560741
4
560735
560742
8
560736
560743
13
560737
560744
22
560738
560745
32
560739
560746
40 560740 560747
– Socket spanner for hand vent valve all 560700
1
Comprises:
4 gaskets ⅜‘‘ BSP
1 gasket ⅜‘‘ 'BSP
1 body gasket
1 gasket for control unit
1 adapter gasket
24
Exchanging the control unit
Take out the control unit, as described on page
18.
Fit the control unit to the equipment, as
described on page 20.
Exchanging the membrane regulator capsule
Detach the cover from the body as described on
page 18.
Push the mounting clip (25) off the control unit
(1.).
Pull the membrane regulator capsule (21)
upwards and off the seat (26) (2.).
Install the new membrane regulator capsule as
follows:
Press the membrane regulator capsule onto the
seat until it snaps into place.
Slip the mounting clip over the membrane
regulator capsule.
Attach the cover to the body as described on
page 21.
Exchanging the hand-vent valve
Unscrew the hand vent valve or the sealing plug
off the bore.
Danger
Fluid may escape if connections are
leaking or sealing rings are damaged.
Insert a new gasket before re-
installation.
Use the sealing plug to close the vent
hole if you do not mount the hand vent
valve.
Insert a new gasket into the bore.
Screw the hand vent valve or the sealing plug
hand tight into the bore.
Tighten the hand vent valve or the sealing plug
to a torque of 75 Nm.
25
Exchanging the float-lifting lever
If necessary remove the lever extension (16).
Loosen the manual float-lifting lever (15) and
the stuffing-box packing (27).
Remove the float-lifting lever from the body.
Remove the gasket (23).
Danger
Fluid may escape if connections
are
leaking or gaskets are damaged.
When fitting the new manual float-
lifting lever use only the stuffing-box
packing supplied with the equipment.
Replace the gasket with a new one.
Mount the manual float-lifting lever in reverse
order.
The torque required for tightening the float-lifting
lever depends on the type.
For UNA 43 a torque of 75 Nm is required.
For UNA 46 a torque of 140 Nm is required.
Use a torque spanner A.F. 36 to tighten the
float-lifting lever to the specified torque.
Pull the lever out of the stuffing-box packing.
Attach the lever extension.
Turn the float-lifting lever.
Attention!
Equipment may not work properly or get
damaged if the stuffing
-box packing is
tightened with the wrong torque.
Tighten the stuffing-box packing hand
tight.
Make sure that the requirements are
met:
The stuffing box packing must not leak.
The float-lifting lever must be able to move
freely.
Check the float-lifting lever for proper
functioning and the stuffing-box packing for
leaks.
If it is not possible to meet these requirements
you have to replace the float-lifting lever with
the stuffing-box packing.
26
Troubleshooting
Problem
Cause
Remedy
The discharge capacity is too
low.
Insufficient thermal output of
the user.
The equipment is undersized.
Use equipment with a larger discharge
capacity.
The discharge capacity is too
low.
Insufficient thermal output of
the user.
Steam pressure and condensate
flowrate fluctuate considerably.
The pressure upstream of the
equipment is too low for the used
equipment type.
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 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.
Fluid escapes (equipment is
leaking).
The equipment has been
damaged by waterhammer.
Replace the equipment with a new one.
Take appropriate measures to protect the
equipment against waterhammer. Use
e. g. non-return valves or a pump steam
trap.
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.
The discharge capacity is too
low.
Insufficient thermal output of
the user.
Insufficient deaeration.
Connect an additional air vent.
The discharge capacity is too
low.
Insufficient thermal output of
the user.
The pipes do not have a
continuous fall in flow direction.
Make sure that the lines run with a
continuous fall in flow direction.
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.
27
Problem
Cause
Remedy
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 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.
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 discharge capacity is too
low.
The equipment is cold or only
warm to the touch.
Insufficient thermal output of
the user.
The inlet, outlet or the equipment
is dirty.
If fitted, operate the float-lifting lever.
Clean the pipes.
Clean all internals.
If necessary, replace internals or the
whole equipment.
The equipment is blowing off
live steam.
The control unit is damaged or
worn.
Replace the control unit.
The equipment is blowing off
live steam.
Dirt deposits, precipitated solids
or foreign particles have
accumulated in the equipment.
If fitted, operate the float-lifting lever.
Clean the pipes.
Clean all internals.
If necessary, replace internals or the
whole equipment.
If faults occur that are not listed above or cannot
be corrected, please contact our Technical
Service or authorized agency in your country.
28
Putting the equipment out of
operation
Removing harmful substances
DANGER
If the equipment is used in contaminated
areas there is a risk of severe injuries or
death caused by harmful substances in or
on the equipment.
Only qualifie
d personnel are allowed to
perform work on contaminated
equipment.
Always wear the protective clothing
prescribed for contaminated areas
when working on the equipment.
Make sure that the equipment is
completely decontaminated before
carrying out any service work.
Follow the pertinent instructions for
handling the hazardous substances in
question.
Qualified personnel must have extensive experience
with and a working knowledge of:
pertinent rules and regulations concerning
handling hazardous substances
special regulations for handling the hazardous
substances encountered on site
using the required personal protective
equipment (PPE) and clothing
Caution
Environmental damage may be caused by
poisonous fluid residues.
Before disposing of the equipment
make sure that it is clean and free of
fluid residues.
For the disposal of all materials
observe the p
ertinent legal regulations
concerning waste disposal.
Remove all residues from the equipment.
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 activa
tion.
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.
29
Make sure that all pipelines upstream and
downstream of the equipment are
depressurised.
CAUTION
Do not drop the equipment. If it falls down
it may cause bruises and injuries.
When dismounting the equipment use
suitable lifting gear.
Connect the noose strap of the lifting
gear to the body.
Provide sufficient support for the
equipment.
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 11.
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.
30
Disposing of the equipment
Caution
Environmental damage may be caused by
poisonous fluid residues.
Before disposing of the equipment
make sure that it is clean and free of
fluid residues.
For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
The equipment is made from the following materials:
Component part
Type
EN
ASTM
Body
UNA 43
5.1301
A126-B
UNA 46
1.0619
SA216-WCB
Cover
UNA 43
5.1301
A126-B
UNA 46
1.0619
SA216-WCB
Body gasket, control unit gasket, adapter gasket
all
Graphite-CrNi
Membrane regulator capsule all Hastelloy / stainless steel
Sealing plugs, stud bolts, nuts, manual float-lifting
lever
all
Forged steel, heat resistant
Other components
all
Stainless steel
31
Technical data
Dimensions and weights
The drawing shows equipment with flanged
connection for downward flow.
32
DN 80 (3”)
Abbreviation
End connection
[mm]
["] B all
471
18.5
H1
all
150
5.9
H2
all
273
10.7 H all
423
16.7
L1
all
250
9.8
L2
all
325
12.8
L
Flange to EN
450
17.7
Flange to ASME, JIS
457
18.0 X all
13
0.5
Weights
[kg]
[lb]
Weight
EN PN16/40,
ASME CL 125/150,
JIS 10K, JIS 20K
111
244.7
UNA 46 ASME CL 300
114
251.3
DN 100 (4”)
Abbreviation
End connection
[mm]
["] B all
471
18.5
H1
all
150
5.9
H2
all
273
10.7 H all
423
16.7
L1
all
250
9.8
L2
all
325
12.8
L
Flange to EN
450
17.7
Flange to ASME, JIS
457
18.0 X all
13
0.5
Weights
[kg]
[lb]
Weight
EN PN16/40,
ASME CL 125/150,
JIS 10K, JIS 20K
117
257.9
UNA 46 ASME CL 300
125
275.6
33
DN 150 (6”)
Abbreviation
End connection
[mm]
["] B all
503
19.8
H1
all
150
5.9
H2
all
273
10.7 H all
423
16.7
L1
all
250
9.8
L2
all
325
12.8
L
Flange to EN
500
19.7
Flange to ASME, JIS
502
19.75
X
all
13
0.5
Weights
[kg]
[lb]
Weight
UNA 43 EN PN 16,
ASME CL 125, JIS 10K
132
291.0
UNA 46 EN PN 40,
ASME CL 150, JIS 10K,
JIS 20K
138
304.2
UNA 46 ASME CL 300
150
330.7
34
To remove the cover a withdrawal space S of
350 mm is required.
If the supplied socket spanner or the lever extension
is attached to the equipment an additional
clearance of 150 mm is required.
Pressure & temperature ratings
You can find the values for your equipment on the
rating plate.
The max. differential pressure Δ PMX of the equipment depends on the type of orifice (O) used.
Orifice
ΔPMX [bar]
Diameter of bore [mm]
2
2
32.0
4
4
25.8
8
8
19.8
13
13
16.6
22
22
18.5
32
32
15.9
40
40
14.5
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
819565-00/12-2016 kx_mm (808959-00) © GESTRA AG Bremen Printed in Germany
Loading...