1 Safety instructions Model: 1200 Model: 1200-G Model: 1200-N Float-Controlled Condensate Trap, PN 40 1.1 Proper use 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 usage is not permitted. The manufacturer is not liable for damage resulting from any other usage. The user or operator bears the risk in this case. This also applies analogously to incorrect assembly, start-up, use and maintenance. 1.2 Warnings and symbols Personal risk due to escaping operating medium because of pressure, temperature and weight. Failure to comply with these warnings results in the risk of 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 usage 2.1 Design of the condensate trap 1 Housing flange part 2 Housing gasket 3 Housing side part 4 Control screw 5 Housing screws 6 Screw plug 7 Protective sleeve 8 Supporting screw Picture 1: Model 1200 Model 1200-G 9 Float control assembly 10 Supporting body assembly with rotary valve and cotter pin 11 Float with fork 12 Maxosglas 13 RWG frame 14 2 Gaskets for RWG 15 RWG screws 16 Gasket 17 Gasket Picture 2: Model 1200-N: without RIFObi air venting 18 Gasket Page 1 of 7 01/2017 -Di. Subject to modifi cations
2.2 Operation limits of housing material (Design) For Model 1200: max. operating pressure (bar g) 40 37 35 32 28 24 21 max. operating temperature ( C) <120 150 200 250 300 350 400* * only with screw material A4-70/ 1,4571/ 1.4104 For Model 1200-G: max. operating pressure (bar g) 40 37 33 27 max. operating temperature ( C) -10/20 100 200 300 For Model 1200-N: max. operating pressure (bar g) 40 33,7 29,7 27,4 max. operating temperature ( C) 100 200 300 400 2.3 Function limit of control unit max. line pressure in bar g Cross section Steam Compressed air IIa 32 40 III 12 16 IV 11 14 V 2,5 3 VI 20 30 VIa 32 32 VII 18 25 VIIIa 4,5 5,5 2.4 Discharge capacity -Di. Subject to modifications 01/2017 Page 2 of 7 Discharge capacity in kg/h 2.5 Function 4000 3000 DN 15/20/25 2000 1500 1000 800 600 400 300 200 150 100 80 60 40 30 20 0,01 0,02 0,03 0,05 0,1 0,2 0,3 0,5 0,8 1 1,5 2 3 4 6 8 10 13 16 25 32 40 Pressure difference in bar (with reference to atmospheric pressure) Picture 3 Discharge capacity in kg/h 10000 8000 6000 4000 3000 2000 1500 1000 800 600 400 300 200 150 100 80 DN 40/50 60 0,01 0,02 0,03 0,05 0,1 0,2 0,3 0,5 0,8 1 1,5 2 3 4 6 8 10 13 16 25 32 40 Pressure difference in bar (with reference to atmospheric pressure) Picture 4 For the cold condensate the discharge capacity is higher because of medium temperature and density. 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. Bimetal 2.7 Automatic venting For Model 1200 and 1200-G: RIFObi-automatic bimetal venting valve (venting to interior): The valve is opened in cold conditions, e.g. during the start-up and when air comes into the steam trap during the operation. The valve is closed when only steam exists in the steam trap. See Picture 5. For Model 1200-N: without RIFObi-automatic bimetal venting valve Picture 5 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 Direction Vario WR Vario WL Vario SO Vario SU Picture 6 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 3.2 Modification for a different flow direction The RIFOmat Vario is delivered according to the purchasing specification, as shown in Picture 6. It can be quickly installed on site for a different flow direction, without any problem. Hier s an Example: The RIFOmat Vario 1200 / 1200-G / 1200-N has been delivered as Vario-SU and has to be mounted as Vario-WR. Unscrew the housing hexagon nuts and remove the housing side part (3) sideways. Loosen the supporting screw (8) by unscrewing it for 1-2 full turns. Use a plastic hammer to loosen the float control assembly (9) from its conic housing seat by lightly stroking on the the supporting screw (8). Reposite the housing flange part (1) by turning it 90. Reposite the float control assembly (9), so that the tube (T) pointing vertical downwards. Screw in the supporting screw (8) with gasket (17). Tighten it with a standard ring wrench or a open jawed wrench, size 27. Tightening torque according to Section 6.6. Replace the housing gasket (2) if damaged, and mount on the lateral part of housing side part (3). Tighten housing bolts evenly crosswise. Tightening torque according to Section 6.6. 3.3 Modification for restricted space and horizontal flow In the case of only minimal space for the housing, which projects to the side, the housing side part (3) can be mounted towards to the front or towards the rear by repositioning the housing flange part (1) for the purpose of better maintenance or better visual inspection of a built-on reflective water level gauge, etc. 3.4 Installation The condensate trap Vario 1200 / 1200-G / 1200-N has to be screwed into a pipeline between flanges. Remove transport caps from inlet and outlet. Fitting direction: according to Picture 6. The condensate flow is in the direction of the arrow (note arrow on housing flange part (1) ). The housing is positioned to the side. The word TOP on the housing side part is at the top and must be legible horizontally. Page 3 of 7 01/2017 -Di. Subject to modifications
Supporting brackets: The supporting brackets are not necessary for DN15/DN20/DN25 if the pipeline is adequately supported before and after the condensate trap. Condensate traps for DN40/DN50 weight over 37 kg, ensure thus proper fixing of the pipeline in front of and behind the condensate trap. To avoid downtimes, it is recommended to install stop valves with bypass to pipeline, both in front of and behind the condensate trap. 4 Start-Up The pressure build-up and heating-up of the housing should not take place abruptly. If leakage is detected after the first inspection, the screws (4 / 5 / 6 / 8 / 15) can be fixed under consideration of the given torque moments, as given in Section 6.6. The screws can only be tightened on when the housing is unpressurized and at room temperature. 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 (11) can be easily moved. If necessary, disassemble and clean the float control assembly (9). If damages/ wears are detected on parts or on the sealing surface, the complete float control assembly (9) should be replaced. 6 Maintenance / Inspection 6.1 Opening the steam trap and dismantling the float control The steam trap must be depressurized. Shut off the system securely in front of and behind the steam trap. Release any remaining pressure in the housing by loosening the control screw (4) by only a quarter turn. Dismantle the steam trap from the pipeline system. Condensate traps for DN40/DN50 weight over 37 kg, apply thus lifting device. Loosen the housing screws (5) evenly crosswise. Remove the housing side part (3). Loosen the supporting screw (8) and screw out 1 to 2 turns. With a few light strokes using plastic hammer on the front side of the supporting screw (8) to loosen the float control assembly (9) from the conic housing seat. b p v Screw out the supporting screw (8) completely. Take out the float control assembly (9). 6.2 Disassembling, cleaning and assembling the float control (Picture 7) After removing the cotter pin (p), the rotary valve (v) can be simply pulled out to the side. Clean the parts using, for example, benzine. Check the rotary valve (v) for wear along the sealing edge. If wear is detected, the support body (b) together with the rotary valve (v) must be replaced. The Picture 7 exactly leakage test must be carried out by RIFOX. During assembly ensure that the notch in the rotary valve (v) points to the punch mark on the support body (b) and the cotter pin (p) is inserted and secured again carefully. It must be possible to move the float up and down easily by hand. -Di. Subject to modifications 01/2017 Page 4 of 7
6.3 Installation of the float control assembly and assemble the condensate trap To install the control unit in Model 1200-N (Housing material: stainless steel), please use the delivered installation set. (Copper gasket and installation bolt). The complete float control assembly (9) is inserted into the conical housing seat with the support body. It must be ensured that the tube is positioned vertically downwards. Screw in the installation bolt with copper gasket into the thread of the supporting body and tighten it with a wrench. (Tighten torque see Sec. 6.6). Screw out the installation bolt, replace the copper gasket with a standard gasket (11). Attention: This step is only for Model 1200-N! Screw in the supporting screw (8) with gasket (17) and tighten evenly crosswise using a standard ring wrench. Tightening torque according to Section 6.6. Check the housing gasket (2), replace it it is damaged. Put on the housing flange part (1). 10.3 Tighten the housing screws (5) evenly crosswise. Tightening torque according to Section 10.5 6.6. 6.4 RIFObi automatic venting valve for Model 1200 / 1200-G (Picture 8) Function: Startup and continuous venting takes place inward, i.e. towards the condensate side. Near the temperature of ebullition the bimetal valve closes. When the temperature drops, the bimetal valve opens. Replace the bimetal valve (10.3): Dismantle the complete float control assembly (9) as described in Section 6.1. Loosen the hexagon nut (10.5) with wrench size 5. Dismantle the Bimetal valve (10.3). Visual check the seat part of valve gate (10) and of bimetal valve (10.3) for wear (cross scoring). Replace the bimetal valve (10.3). Install the float control assembly (9) as described in Section 6.3. Picture 8 6.5 Care and maintenance In the case of a great risk of dirt accumulation, the housing, when it is depressurized, should be rinsed thoroughly from time to time. If necessary, the float control assembly (9) should also be checked according to Section 6.2. The dirt, which has been accumulated in the housing, can be removed away by screwing off the screw plug (6). For special applications, it is advisable to install a separate upstream strainer. The float control assembly (9) usually does not to be special maintained. The maintenance depends primarily on the wear resistance of the valve gasket. See Section 6.1 and 6.2. Page 5 of 7 01/2017 -Di. Subject to modifications
6.6 Tightening torque Tightening Torque (Nm) Position Part Name DN15, DN20, DN25 DN40, DN50 Cu WE PTFE 1.4571 Cu WE PTFE 1.4571 4 Control screw 40 50 7 28 40 50 7 28 5 Housing screw - 35 - - - 55 - - 6 Screw plug 100 120 17 70 100 120 17 70 8 Supporting screw 98 120 17 70 98 120 17 70 15 RWG screw - 20 6.7 Spare parts: Only original spare parts can be used. Picture 9: Model 1200 Model 1200-G Picture 10: Model 1200-N: without RIFObi air venting -Di. Subject to modifi cations 01/2017 Page 6 of 7
Pos. Part Name Model 1200 Model 1200-G Model 1200-N 1 Housing flange part GP240GH EN-JS 1049 1.4581 / 1.4408 2 Housing gasket Soft iron Soft iron PTFE or 1.4571 3 Housing side part GP240GH EN-JS 1049 1.4581 / 1.4408 4 Control screw: G¼ (BSP) 1.4104 1.4104 1.4571 5 Housing screws A4-70 acc. DIN 939/934 8.8 acc. DIN 939 / ISO 4032 A4-70 acc. DIN 939 / ISO 4032 6 Drain plug: G½ (BSP) DIN 910-5.8 DIN 910-5.8 DIN 910 - A4 7 Protective sleeve 1.4057 1.4057 1.4571 8 Supporting screw 1.4104 1.4104 1.4571 9 Float control assembly 1.4057/1.4112/1.4301/1.4104 1.4057/1.4112/1.4301/1.4104 1.4571 9.2 Complete float control with built-on 1.4057/1.4112/1.4301/1.4104/ 1.4057/1.4112/1.4301/1.4104/ bi-meatellic venting valve RIFObi SS-Hastelloy SS-Hastelloy 1.4571 10 Supporting body assembly with rotary 1.4057/1.4112/1.4301/1.4104 1.4057/1.4112/1.4301/1.4104 valve and cotter pin 1.4571 Complete Supporting Structure incl. 10.2 rotary slide valve, cotter pin and builton 1.4057/1.4112/1.4301/1.4104 1.4057/1.4112/1.4301/1.4104 1.4571 RIFObi bi-metallic venting valve 11 Float with fork 1.4301 or 1.4571 1.4301 or 1.4571 1.4571 12 Maxosglas as per DIN 7081 as per DIN 7081 as per DIN 7081 13 RWG frame P265GH P265GH 1.4571 14 2 Gaskets for RWG poor graphite with SS Sigraflex Novaphite 15 RWG screws A4-70, DIN 938/934 A4-70, DIN 938/934 A4-70, DIN 938/934 16 Gasket for control screw Soft iron Soft iron PTFE or 1.4571 17 Gasket for supporting screw Soft iron Soft iron PTFE or 1.4571 18 Gasket for drain plug Soft iron Soft iron PTFE or 1.4571 7 Conformity assessment The pressure equipment described is a pressure-keeping component in accordance with the Pressure Equipment Directive 2014/68/EU. DN15, DN20, DN25: according to Art. 4, Subs. 3, no CE-Mark. DN40, DN50: Conformity verified through the identifying mark: CE 0525. A detailed declaration of conformity assessment according to PED is available as separate document. Please request if necessary, if not attached. Page 7 of 7 01/2017 -Di. Subject to modifications