1 Safety instructions Model: 1413 Model: 1418 Float-Controlled Condensate Trap, PN 100 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 Picture 1: Model WO-1413 Picture 2: Model EF-1418 1 Housing 8 Supporting body assembly 2 Housing gasket 9 Float 3 Housing cover 10 Holding screw for float control assembly 4 Control screw 11 Gasket 5 Housing screws 12 Gasket 6 Screw plug 13 Control screw 7 Float control assembly 14 Gasket Page 1 of 5 10/2017 -Di. Subject to modifi cations
2.2 Operation limits of housing material (Design) max. operating pressure (barg) 100 96 82 70 58 56 max. operating temperature ( C) -10/20 100 200 300 400 430 2.3 Function limit of control unit (Control units with oval-float) Cross Section max. line pressure in barg 20/190 50 20/340 39 25/400 32 2.4 Discharge capacity Picture 3 For the cold condensate the discharge capacity is higher because of medium temperature and density. 2.5 Function 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 To get the proper function of the float control assembly in applications of pressure gases, the gases in the condensate trap housing must be led into the gas chamber with the same operating pressure above the condensate trap (pressure compensation). For this purpose the control screw (4) in models 1413 can be replaced by a cutting ring union and a compensating line leading upward can be installed. The pressure compensation for the models 1418 is not strongly recommended. 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. Page 2 of 5
3 Assembly The condensate trap has to be screwed into a pipeline between flanges. Remove transport caps from inlet and outlet. Fitting direction: according to Picture 1 and Picture 2. Supporting brackets: The weight of the condensate trap must be taken up by the supporting brackets, which are welded onto the housing. A operation only on the four feets is not allowed. To avoid downtimes, it is recommended to install stop valves with bypass to pipeline, both in front of and behind the condensate trap. For the model WO-1413-(N), remove the transport sefety device (see Picture 4) before start-up and replace it with the control screw provided. For the model EF-1418-(N), remove the fuse wire completely before start up. 4 Start-Up Picture 4 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 leakage is detected after the first inspection, the screws (4 / 5 / 6 / 13) can be fixed under consideration of the given torque moments, as given in Section 6.5. The screws can only be tightened on when the housing is unpressurized and at room temperature. 5 Observation and control 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 or 13) 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 (7). If damages/ wears are detected on parts or on the sealing surface, the complete float control assembly (7) 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 or 13) by only a quarter turn. Dismantle the steam trap from the pipeline system. Loosen the flange connections and lift out of the pipeline carefully and place on the floor. Attention: The condensate trap weights from 250 up to 262 kg depending on the connection sizes. Lifting device is required. Loosen the housing screws (5) evenly crosswise. Put down the housing cover (3). Attention: the housing cover weights about 25-32 kg. Screws The float control is dismantled with a centering aid that is inserted in the bushing that is provided with 2 slots. By turning counterclockwise (3-4 turns), the bushing is screwed out of the control support body. The control is detached from the seat cone by means of gentle blows with a hammer on the front end of centering aid. Special Float Screw out the bushing completely. Remove float control (7) through the cover opening. Bushing For removal of special float: Loosen, unscrew and remove the screws. See Picture 5. Picture 5 Page 3 of 5
6.2 Disassembling, cleaning and assembling the float control (Picture 6) 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 thorough 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. 6.3 Installation of the float control unit and assemble the steam trap b p v Picture 6 The complete float control assembly (7) 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 bushing into the control support body (b) and tighten with the centering aid described in Section 6.1. Check the housing gasket (2), replace it it is damaged. Put on the housing cover (3). Tighten the housing screws (5) 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, when it is depressurized, should be rinsed thoroughly from time to time. If necessary, the float control assembly (7) 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 drain plug (6). For special applications, it is advisable to install a separate upstream strainer. The float control assembly (7) 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. 6.5 Tightening torque Position Part Name Tightening Torque (Nm) 4 Control screw, G½ 70 5 Housing screw 70 6 Screw plug, G¾ 105 13 Control screw, G¼ 28 Page 4 of 5
6.6 Spare parts Only original spare parts can be used. Picture 7: Model WO-1413 Pos. Bennenung Material 1 Housing 16Mo3 2 Housing gasket 3 Housing cover 16Mo3 4 Control screw EF: G 1/4 (BSP) or WO: G 1/2 (BSP)] 5 Housing screws 21CrMoV5-7 / 24CrMo5 / 6 Screw plug DIN 910 - A4 - G 3/4 (BSP) 7 Float control assembly stainless steel 8 Supporting body assembly stainless steel 9 Float 10 Bush 11 Gasket 12 Gasket G 1/4 (BSP) or G 1/2 (BSP)] 13 Control screw G 1/4 (BSP) or G 1/2 (BSP)] 14 Gasket 21CrMoV5-7 / 24CrMo5 / Picture 8: Model EF-1418 7 Conformity assessment The pressure equipment described is a pressure-keeping component in accordance with the Pressure Vessel Directive 2014/68/EU. DN50 / DN80 / DN100: Conformity verifi ed 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. Model 1413/1418 made of 16Mo3 is not applicable for media of fl uid group 1. Page 5 of 5 10/2017 -Di. Subject to modifi cations