GESTRA UNA 45 MAX Original Installation Instructions Download

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Ball Float Steam Trap

UNA 45 MAX

UNA 46 MAX

UNA 46A MAX

Original Installation Instructions

819401-02

Summary of Contents for UNA 45 MAX

Page 1: ...Ball Float Steam Trap UNA 45 MAX UNA 46 MAX UNA 46A MAX Original Installation Instructions 819401 02 ...

Page 2: ...ng the equipment 11 Transporting the equipment 11 Mounting and connecting the equipment 12 Preparing installation 12 Orientation of the equipment 13 Connecting the equipment 14 Operation 17 After operation 17 Removing external dirt deposits 18 Maintaining the equipment 19 Servicing the equipment and installing spare parts 24 Troubleshooting 32 Retighten the stuffing box packing 34 Putting the equi...

Page 3: ...ment 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 use...

Page 4: ...oyed and hot or pressurized fluid may escape Make sure that the equipment is only operated within the admissible service range and limits For more information on limits and pressure temperature ratings see name plate and the section Technical Data 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 su...

Page 5: ...t 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 the heading DANGER warn against imminent dangerous situations that can lead to death or serious injuries WARNING Notes with the he...

Page 6: ...mbly Equipment specification Item no Designation 1 Direction of flow arrow 2 Body 3 Body gasket 4 Capsule support with membrane regulator capsule 5 Adapter shown here control unit DUPLEX Item no Designation 6 Control unit 7 Name plate 8 Cover shown here standard cover 9 Drain with sealing plug 10 Hexagon head cap screws 4 pcs ...

Page 7: ...hand vent valve can also be used for connecting a balance line 13 Cover with integrated reflexion water level sightglass for checking the performance Item no Designation 14 Gasket 15 Float lifting lever with socket spanner 16 Adaptor with control unit SIMPLEX 17 Cover with connections for electrodes NRG 16 19 or NRG 16 27 In equipment with control unit SIMPLEX the hand vent valve is included as st...

Page 8: ...t is available with the following end connections Flanges Screwed sockets Socket weld ends Butt weld ends via transition pieces Screwed sockets are only available for sizes DN 40 and 50 Name plate The following items are indicated on the name plate Manufacturer Type designation Design Nominal size Pressure rating Design temperature Design pressure Max service temperature Max admissible differentia...

Page 9: ...up 2 UNA 46 MAX and UNA 46A MAX 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 ...

Page 10: ...lve 18 allowing a small amount of fluid to flow through the pilot valve The fluid compresses the bellows of the control unit and as a consequence the discharge orifice 20 is completely uncovered 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...

Page 11: ... 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 Lightweight equipment may be transported and mounted without us...

Page 12: ...g 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 ...

Page 13: ... on the cover must point upwards Contact the manufacturer if you want to mount the equipment in a different position of installation To change the position of installation remove the adapter with the control unit attached to it In equipment with control unit DUPLEX the capsule support is also attached to the adapter To remove the adapter proceed as follows Detach the cover from the body as describ...

Page 14: ...t 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...

Page 15: ... 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 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 air balance pipe must have the following end connection dimensions Standard cover and sightglass cover G...

Page 16: ...t 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 ...

Page 17: ...rge 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 socket spanner from the tip of the arrow towards the end of the arrow To close the orifice turn the socket spanner from the end of the arrow towards the tip of the arrow After operation DANGE...

Page 18: ...tinent instructions for handling the hazardous substances in question 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 9 at the bottom of the body Allow all liquid to escape and wait until the body is completely empty To ...

Page 19: ...es 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 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 The following drawings ...

Page 20: ...f dirt in the system The operator must determine the maintenance intervals Remove any parts that are dirty and cannot be cleaned properly To clean the inside of the equipment proceed as follows Detach the cover from the body as described on page 19 Remove the control unit as described on page 20 To remove dirt deposits rinse the equipment with fresh water and wipe it with a clean lint free cloth T...

Page 21: ...described in section Exchanging the membrane regulator capsule on page 30 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 mem...

Page 22: ...ty 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 26 for the control unit into the ad...

Page 23: ...e 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 four hexagon head cap screws 10 into the bores of the body Refit the cover 8 onto the body such that the name plate 7 points upwards Tighten the hexagon head cap screws with a torque of 140 Nm If nec...

Page 24: ...24 Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage UNA 45 MAX UNA 46 MAX and UNA 46A MAX with standard cover ...

Page 25: ...cket spanner all 560676 14 15 30 Float lifting lever cpl with joint ring and socket spanner all 560678 3 Body gasket1 all 560680 22 Adapter gasket1 all 560682 14 Joint ring for sealing plug manual float lifting lever hand vent valve1 all 5604862 or 5605142 26 Gasket for control unit3 all 560547 3 14 22 26 Gasket set4 all 560684 30 Socket spanner all 560700 1 Delivery quantity 20 pcs 2 560486 Mater...

Page 26: ...26 UNA 45 MAX with cover for installing electrodes ...

Page 27: ...oat lifting lever cpl with joint ring and socket spanner all 560678 3 Body gasket1 all 560680 22 Adapter gasket1 all 560682 14 Joint ring for sealing plug manual float lifting lever hand vent valve1 all 5604862 or 5605142 26 Gasket for control unit3 all 560547 3 14 22 26 Gasket set4 all 560684 30 Socket spanner all 560700 1 Delivery quantity 20 pcs 2 560486 Material 1 4301 560514 Material 1 4571 3...

Page 28: ...28 UNA 45 MAX with sightglass cover ...

Page 29: ...th joint ring and socket spanner all 560676 14 15 30 Float lifting lever cpl with joint ring and socket spanner all 560678 3 Body gasket1 all 560680 22 Adapter gasket1 all 560682 14 Joint ring for sealing plug manual float lifting lever hand vent valve1 all 5604862 or 5605142 26 Gasket for control unit3 all 560547 31 33 Reflexion water level gauge with 2 gaskets all 560480 30 Socket spanner all 56...

Page 30: ...ne regulator capsule Attach the cover to the body as described on page 23 Replacing the sightglass of the sightglass cover Remove the socket head cap screws 36 Detach the flange 32 from the sightglass cover 13 Remove the outer gasket 31 Remove the sightglass 33 Remove the inner gasket 31 For the disposal of the gaskets observe the pertinent on site regulations concerning waste disposal Attention E...

Page 31: ...rings never use force Make sure that the packing rings are correctly positioned and not skewed Insert the gasket supplied with the float lifting lever into the tapped hole in the body Screw the new float lifting lever into the tapped hole Tighten the hexagon head cap screw of the float lifting lever with a torque of 75 Nm an Exchanging the hand vent valve To replace a damaged hand vent valve proce...

Page 32: ...he connections Remove the equipment Remove the sealing plugs Mount the equipment 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 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 d...

Page 33: ...ne 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 Fluid escapes equipment is leaking The equipment or the body is damaged Replace the equipment...

Page 34: ... stuffing box packing until the following requirements are met The stuffing box must not leak The movement of the float lifting lever must not be impaired by the stuffing box Fasten the hexagon head cap screw on the float lifting lever 15 Allow the fluid to flow through the equipment Move the float lifting lever several times over the full length Make sure that the float lifting lever can move fre...

Page 35: ...mental 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 Remove all residues from the equipment For the disposal of all residues observe the pertinent legal regulations concerning waste disposal Removing the equip...

Page 36: ...t the equipment onto a suitable base Store the equipment as described in section Storing the equipment from page 11 onwards 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 If necessary r...

Page 37: ...Component part Type EN ASTM Body UNA 45 MAX UNA 46 MAX 1 0460 A105 UNA 46A MAX 1 4404 A182 F316L Cover UNA 45 MAX sightglass cover cover for installing electrodes 5 3103 A3951 UNA 46 MAX 1 0619 SA216 WCB UNA 46A MAX 1 4408 A351 CF8M Body gasket controller gasket adapter gasket gasket for reflexion water level gauge all Graphite CrNi Membrane regulator capsule all Hastelloy stainless steel Other co...

Page 38: ...38 Technical data Dimensions and weights The drawing shows equipment with standard cover and flanged connection for vertical downward flow ...

Page 39: ...9 H2 mm in all 182 7 2 1 H mm in all 280 11 0 1 L1 mm in all 160 6 3 2 X mm in all 13 0 5 Weight kg Standard cover 33 3 35 1 37 4 Sightglass cover 37 5 39 0 41 3 Cover for mounting electrodes 35 5 36 9 39 3 Weight lb Standard cover 73 4 77 4 82 5 Sightglass cover 82 7 86 0 91 0 Cover for mounting electrodes 78 3 81 3 86 6 1 If equipped with hand vent valve add 25 mm 1 in 2 If equipped with float l...

Page 40: ...9 H2 mm in all 182 7 2 1 H mm in all 280 11 0 1 L1 mm in all 160 6 3 2 X mm in all 13 0 5 Weight kg Standard cover 32 6 34 6 38 2 Sightglass cover 36 5 38 5 42 1 Cover for mounting electrodes 34 5 36 5 40 1 Weight lb Standard cover 71 9 76 3 84 2 Sightglass cover 80 5 84 9 92 8 Cover for mounting electrodes 76 1 80 5 88 4 1 If equipped with hand vent valve add 25 mm 1 in 2 If equipped with float l...

Page 41: ... H1 mm in all 98 3 9 H2 mm in all 182 7 2 1 H mm in all 280 11 0 1 L1 mm in all 160 6 3 2 X mm in all 13 0 5 Weight kg Standard cover 34 8 36 2 39 9 Cover for mounting electrodes 36 7 38 1 41 7 Weight lb Standard cover 76 7 79 8 88 0 Cover for mounting electrodes 80 9 84 0 91 9 1 If equipped with hand vent valve add 25 mm 1 in 2 If equipped with float lifting lever add 35 mm 1 4 in ...

Page 42: ... H2 mm in all 182 7 2 1 H mm in all 280 11 0 1 L1 mm in all 160 6 3 2 X mm in all 13 0 5 Weight kg Standard cover 29 9 30 9 32 2 Sightglass cover 33 8 34 8 36 1 Cover for mounting electrodes 31 7 32 8 34 1 Weight lb Standard cover 65 9 68 1 71 0 Sightglass cover 74 5 76 7 79 6 Cover for mounting electrodes 69 9 72 3 75 2 1 If equipped with hand vent valve add 25 mm 1 in 2 If equipped with float li...

Page 43: ...9 H2 mm in all 182 7 2 1 H mm in all 280 11 0 1 L1 mm in all 160 6 3 2 X mm in all 13 0 5 Weight kg Standard cover 30 1 29 6 Sightglass cover 34 0 33 5 Cover for mounting electrodes 32 0 31 4 Weight lb Standard cover 66 4 65 3 Sightglass cover 75 0 73 9 Cover for mounting electrodes 70 5 69 2 1 If equipped with hand vent valve add 25 mm 1 in 2 If equipped with float lifting lever add 35 mm 1 4 in ...

Page 44: ...all 98 3 9 H2 mm in all 182 7 2 1 H mm in all 280 11 0 1 L1 mm in all 160 6 3 2 X mm in all 13 0 5 Weight kg Standard cover 30 1 30 4 31 3 Sightglass cover 34 0 34 3 35 2 Cover for mounting electrodes 32 0 32 3 33 2 Weight lb Standard cover 66 4 67 0 69 0 Sightglass cover 75 0 75 6 77 6 Cover for mounting electrodes 70 5 71 2 73 2 1 If equipped with hand vent valve add 25 mm 1 in 2 If equipped wit...

Page 45: ...45 Space required for servicing To remove the cover a withdrawal space S of 270 mm is required If the supplied socket spanner is attached to the equipment an additional clearance of 100 mm is required ...

Page 46: ...h orifice 22 32 Admissible service temperature Control unit DUPLEX Saturated steam temperature plus 5 K Pressure1 p psig 232 215 203 193 178 Temperature1 T F 14 68 212 302 392 464 1 Resistance limits for body cover to EN 1092 1 Limiting conditions for UNA 45 MAX with sightglass cover flange Class 150 screwed sockets NPT socket weld end butt weld end Pressure1 p barg 19 6 17 7 15 8 13 8 12 4 Temper...

Page 47: ...2 392 572 662 8422 1 Resistance limits for body cover to EN 1092 1 2 Not for UNA 45 MAX Limiting conditions for UNA 45 MAX and UNA 46 MAX Flange Class 150 Pressure1 p barg 19 6 17 7 13 8 10 2 8 6 5 52 Temperature1 T C 29 20 100 200 300 345 4252 Max admissible differential pressure PMX barg 4 8 13 19 6 bar with orifice 22 32 psi 58 116 188 284 psi with orifice 22 32 Admissible service temperature C...

Page 48: ...er to ASME B 16 5 2 Not for UNA 45 MAX Limiting conditions for UNA 46A MAX flange PN 40 screwed sockets G Pressure1 p barg 40 0 37 9 31 8 27 6 25 7 25 Temperature1 T C 10 20 100 200 300 4002 4502 Max admissible differential pressure PMX barg 4 8 13 22 32 psi 58 116 188 320 465 Admissible service temperature Control unit DUPLEX Saturated steam temperature plus 5 K Pressure1 p psig 580 550 461 400 3...

Page 49: ...t to operating temperatures higher than 300 C unless intercrystalline corrosion can be ruled out Limiting conditions for UNA 46A MAX flange Class 300 screwed socket NPT socket weld end butt weld end Pressure1 p barg 41 4 34 8 29 2 26 1 24 3 23 9 Temperature1 T C 29 20 100 200 300 4002 4252 Max admissible differential pressure PMX barg 4 8 13 22 32 psi 58 116 188 320 465 Admissible service temperat...

Page 50: ... C the glass will wear down faster Equipment with measuring electrode NRG 16 19 or NRG 16 27 PN40 Class300 max service temperature 238 C at 32 bar service pressure Equipment with control unit DUPLEX max service temperature corresponds to the saturation temperature 5 K The max differential pressure Δ PMX of the equipment depends on the type of orifice O used MAX Orifice ΔPMX bar Diameter of bore mm...

Page 51: ...turer 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 ...

Page 52: ...rld 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 819401 02 07 2016 kx_mp 808916 02 GESTRA AG Bremen Printed in Germany ...

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GESTRA UNA 45 MAX, Original Installation Instructions

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