1 Safety instructions 1.1 Proper use Model: 1400 Model: 1400-N RIFOmat Float-Controlled Condensate Traps, PN 100 Any improper use, intervention in the design and deviation from the design data automatically lead to termination of the warranty. The fl oat-controlled condensate trap is designed for the discharge of condensate from steam, compressed air and pressure gas systems. Any other use is not permissible. The manufacturer is not liable for damage resulting from any other use. The user or operator bears the risk in this case. This also applies analogously to incorrect assembly, startup, use and maintenance. 1.2 Warnings and symbols There is a risk of personal injury due to escaping operating medium as well as because of pressure, temperature. Failure to comply with these warnings may lead to accidents. Follow the instructions in this operating manual. The operator must ensure that this operating manual and, if necessary, other relevant documents are available on site. Only trained or instructed personnel may be assigned to handling this equipment. Any mode of operation that may impair safety must be avoided. 2 General description and use 2.1 Design of the condensate trap Picture 1: Vario 1400 / 1400-N Flanged Picture 2: Vario 1400 / 1400-N Butt weld 1 Upper housing 8 Complete supporting body 2 Housing gasket 9 Float 3 Lower housing 10 Support bolt 4 Control screw 11 Gasket 5 Set of stud bolts and nuts 12 Gasket 6 Screw plug 13 Gasket 7 Float control assembly complete 14 Protecting cap Page 1 of 5 04/2017 -Di. Subject to modifi cations
2.2 Operation limits of housing material (Design) Housing Material P250GH: Max. operating pressure (bar g) 100 92,8 83,3 69 59,5 Max. operating temperature ( C ) -10/20 100 200 300 400 Housing Material 13CrMo4-5: Max. operating pressure (bar g) 100 90 84 68 15 Max. operating temperature ( C ) up to 300 400 450 490 550 Housing Material 10CrMo9-10: Max. operating pressure (bar g) 100 92 88 78 21 Max. operating temperature ( C ) 300 400 450 470 550 Housing Material 1.4571: Max. operating pressure (bar g) 100 93,3 83,3 78 Max. operating temperature ( C ) 100 200 300 400 2.3 Function limit of control unit (for all four versions) Max. Line Pressure (bar g) Cross Section Hot Condensate Cold Condensate Iax 50 85 Ibx 44 70 Icx 32 50 2.4 Performance (for all four versions) for Model 1400 for Model 1400-N Picture 3 For the cold condensate the discharge capacity is Picture 4 For the hot condensate the discharge capacity is higher because of medium temperature and density. lower because of medium temperature and density. -Di. Subject to modifications 04/2017 2.5 Function Page 2 of 5 Due to the gravity the condensate flows downwards to the lowest point, which is the condensate trap housing. In the lowest position of the float the outlet cross-section is close. Rising of the liquid level lifts the float and opens the outlet. Condensate will be discharged through the upturned immersion tube. Decreasing condensate level closes the outlet again. 2.6 Compensation line In order to get proper function, the non-condensable gas must be able to leave the housing. Due to the vertical installation, the non-condensable gas is able to leave the housing and flows into the steam/gas chamber above it, which has the same pressure level. If the self-venting through the pipe must be extended, the control screw (4) can be replaced by a cutting ring screw bolt and a compensation line can be installed leading upwards.
2.7 Automatic venting In the case of steam applications, automatic venting must be provided (vent jet). 2.8 Gastight under-level float control (only for gas applications) For gas applications, a gastight under-level float control is nearly exclusively used. Consult with Rifox, if necessary. 3 Assembly 3.1 Flow directions Picture 5 Vario-WR: Flow direction horizontal from right to left Vario-WL: Flow direction horizontal from left to right Vario-SO: Flow direction vertical from top to bottom Vario-SU: Flow direction vertical from bottom to top Vario-EL: Flow direction angular from top to left Vario-ER: Flow direction angular from top to right 3.2 Installation The condensate trap can be screwed into a pipeline between flanges or it can be welded in directly by means of welding ends. In special cases a screwed connection is also implemented. Remove protective caps from inlet and outlet. Fitting position according to Picture 4, variable Support: The support is not necessary if the pipeline is adequately supported before and after the condensate trap. Steam Trap weight: approx. 38-50 kg. To avoid down times, it is recommended that provision be made for a shut-off device with a bypass line both in front of and behind the condensate trap. 4 Start-up Shut off the float-controlled condensat trap on both sides during the strength tests, because the control unit is not suitable for the design test pressure according to the nameplate. The pressure build-up and heating-up of the housing should not take place abruptly. If leaks occur due to so-called settling after the first start-up, the screws (4 / 5 / 6 / 10) can be retightened taking into account the indicated torque. Retightening may only be carried out when the housing is depressurized and warm to the touch. 5 Observation and check The function s failure can be observed either as condensate blockage or as gas/ steam leakage. Condensate blockage can be determined by a): loosen the control screw (4) for a quarter rotation, while no condensate leakage should occur; and by b): a surface thermometer on the housing for steam applications (if necessary, please consult with Rifox). Gas / steam leakage: can be determined by an ultrasonic measuring device, and for steam applications by a surface thermometer. In case of steam leakage, open the condensate trap according to Section 6.1. Make sure that float can be easily moved. If necessary, disassemble and clean the float control assembly. If damages/ wears are detected on parts or on the sealing surface, the complete float control assembly should be replaced. Page 3 of 5 04/2017 -Di. Subject to modifications
6 Maintenance / inspection 6.1 Opening the condensate trap and dismantling the float control The condensate trap must be depressurized. Shut off the system in front of and behind the condensate trap. Release any residual pressure by loosening the screw (4) by only a quarter turn. Loosen hexagon nuts (5) evenly crosswise and take off sealing plug (3) (approx. 8 kg). Loosen and screw off protective cap (14). Loosen support screw (10) and unscrew 1-2 turns. The control is detached from the conical housing seat by means of gentle blows with a hammer on the front end of the support screw (10). Screw out the support screw (10) completely. Remove float control. 6.2 Disassembling and cleaning the float control (Picture 6) After removing the cotter pin (s), the rotary valve (d) is simply pulled out to the side. Clean the parts using, for example, benzine. Check the rotary valve (d) for wear along the sealing edge. If wear is detected, the support body (t) together with the rotary valve (d) must be replaced. A precise leakage test must be carried out by Rifox. During assembly ensure that the notch in the rotary valve (d) points to the punch mark on the support body (t) and the cotter pin (s) is inserted and secured again carefully. The float must be able to move up and down without resistance. Picture 6 6.3 Installing the control and assembling the condensate trap The complete float control is inserted into the conical housing seat with the support body (8). It is important to ensure that the immersion tube is vertically downwards The support body (8) is fixed in place by means of a light tap with a plastic hammer on the front end of the immersion tube in the conical housing seat. Screw in support screw (10) with gasket (11) and tighten with a standard ring wrench. Tightening torque according to Section 6.5. Screw in protective cap (14) and fix with a locknut using moderate force. Check the housing gasket (2) and replace necessary. Tighten the housing screws (10) evenly crosswise. Tightening torque according to Section 6.5. 6.4 Care and maintenance In the case of a great risk of dirt accumulation, the housing should be rinsed thoroughly from time to time, but while depressurized. If necessary, the float control should also be checked according to point 6.2. Dirt that has collected in the housing can be removed after taking off the screw plug (12). In special cases, it may be advisable to install a separate upstream dirt trap. The float control usually does not require special care; maintenance primarily depends on the wear resistance of the valve seal. See points 6.1 and 6.2 in this connection. 6.5 Tightening torque Position Part Name Tightening Torque (Nm) 4 Control screw 20 5 Set of stud bolts and nuts 70 6 Screw plug 30 10 Support bolt 25 -Di. Subject to modifications 04/2017 Page 4 of 5
6.6 Spare parts Only genuine spare parts may be used. Picture 7: Vario 1400 / 1400-N Flanged Picture 8: Vario 1400 / 1400-N Butt weld Pos. Part name Version P250GH Version 13CrMo4-5 Version 10CrMo9-10 Version 1.4571 1 Upper housing P250GH 13CrMo4-5 10CrMo9-10 1.4571 2 Housing gasket Weicheisen / 1.4571 1.4571 1.4571 1.4571 3 Lower housing P250GH 13CrMo4-5 10CrMo9-10 1.4571 4 Control screw 1.4571 1.4571 1.4571 1.4571 5 Set of stud bolts and nuts 21CrMoV5-7 / 24CrMo5 21CrMoV5-7 21CrMoV5-7 A4-70 / A4 6 Screw plug 1.4571 1.4571 1.4571 1.4571 7 Float control assembly complete 1.4112/ 1.4057/ 1.4301 1.4112/ 1.4057/ 1.4301 1.4112/ 1.4057/ 1.4301 oder komplett 1.4571 oder komplett 1.4571 oder komplett 1.4571 1.4571 8 Complete supporting body 1.4112/ 1.4057/ 1.4301 1.4112/ 1.4057/ 1.4301 1.4112/ 1.4057/ 1.4301 oder komplett 1.4571 oder komplett 1.4571 oder komplett 1.4571 1.4571 9 Float 1.4571 1.4571 1.4571 1.4571 10 Support bolt 1.4571 1.4571 1.4571 1.4571 11 Gasket 1.4571 1.4571 1.4571 1.4571 12 Gasket Weicheisen / 1.4571 1.4571 1.4571 1.4571 13 Gasket Weicheisen / 1.4571 1.4571 1.4571 1.4571 14 Protecting cap 1.4571 1.4571 1.4571 1.4571 7 Conformity assessment The pressure equipment 1400 / 1400-N is in accordance with the Pressure Vessel Directive 2014/68/EU. The conformity is verifi ed through the identifying mark: CE0525. A detailed declaration of conformity assessment according to PED is available as separate document. Please request if necessary, if not attached. Model 1400 in 13CrMo4-5 or 10CrMo9-10 is not applicable for media of fl uid group 1. Page 5 of 5 04/2017 -Di. Subject to modifi cations