AWH DN25-DN100 / PN 10 User manual

Armaturenwerk Hötensleben GmbH
Operating Instructions
Dirt Trap
Type: DN25 - DN100 / PN10
(Translation)

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
2
Note
This instruction manual is part of the installation procedure and has to be acces-
sible for operators and maintenance personnel at any time. The safety instructions
contained therein have to be observed. In case of a resale of the installation the
instruction manual has to be delivered with the installation.
Translation
For deliveries to countries of the European Economic Area (EEA), the assembly instructions are to be
translated into an ofcial language of the European Community accepted by the manufacturer of the
machine / installation into which these dirt traps are to be integrated. In case of inconsistencies in the
translated text, the original assembly instructions (in German) are to be consulted for clarication or the
manufacturer is to be contacted.
Copyright
Any dissemination or copying of this document, the exploitation and disclosure of its contents are
prohibited unless expressly authorized. Violations will result in claims for damages.

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
1. Contents
1.1 Table of Contents
Page
1. Contents 3
1.1 Table of Contents 3
1.2 Table of Pictures 3
1.3 Declaration of Installation 5
2. Overview and Intended Use 7
2.1 Overview 7
2.2 Intended Use 8
3. Technical Data 9
3.1 Materials in Contact with the Product 9
3.2 Connection Variants, Type Series, Dimensions 9
3.3 General Data 11
4. Safety / Hazards 12
4.1 Advices / Explanations 12
4.2 Labelling of the Dirt Trap 13
4.3 Safety Measures (to be executed by the operator) 13
4.4 Operator’s Duties 13
5. Hazard Warnings 15
5.1 Hazards 15
5.2 Hazardous Area of the Dirt Trap 15
5.3 Installing Replacement and Wearing Parts 15
5.4 Shutdown Procedures 16
6. Installation 17
6.1 Scope of Delivery 17
6.2 Transport and Packaging 17
6.2.1 Delivery (including also of spare an replacement parts) 17
6.2.2 Temporary Storage 17
6.3 Installation 18
6.3.1 Installation of the Dirt Trap - Installation Position 18
6.3.2 Installation of the Dirt Trap with Thread/Thread 19
6.3.3 Installation of the Dirt Trap with Clamp/Clamp 19
6.3.4 Installation of the Dirt Trap with Weldon Ends 19
7. Structure / Function 21
8. Assembly / Disassembly 22
8.1 Disassembly from the System 22
8.2 Assembly with Packing and Insert Renewal 22
9. Maintenance / Cleaning 23
10. Malfunction, Cause, Remedy 24
11. Emergency 25
12. Disposal 26
3
Page
Pic. 2-1 Exploded View 7
Pic. 3-1 Connection Congurations 10
Pic. 3-2 Variants Insert 11
Pic. 6-1 Installation Position 19
Pic. 7-1 Dirt Trap 22
1.2 Table of Pictures

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
Guideline/ standard Title Version Comments
DIN EN 62079 Preparation of instructions - structuring,
content and presentation
2001
97/23/EC EC Pressure Equipment Directive 2003
DIN EN 12516-2 Industrial  ttings – Shell design strength
- Part 2: Calculation method for steel
 tting shells
10/2004
AD 2000 data sheets Speci cations for pressure equipment
(national standards)
The  ttings are designed for liquids of  uid group 1 and for gases of  uid group 2. According to this,
the nominal diameters are categorised as DN25 – DN100 in accordance with article 3, section 3.
2006/42/EC EC Directive: Machinery 2006
DIN EN ISO 12100 Safety of machinery -
General principles for design -
Risk assessment and risk reduction
2010
AWH Armaturenwerk Hötensleben GmbH
Schulstraße 5 - 6
D-39393 Hoetensleben
Declaration of Installation
as required by the
-EC Directive: Pressure Equipment Directive 97/23/EC, Annex II A
- EC Directive: Machinery 2006/42/EG, Annex II B
We hereby declare that design of
Description: Dirt Trap
Type: DN25 - DN100 / PN 10
in its delivered version is consistent with the listed directives and standards
(harmonised standards in accordance with the directives):
5
1.3 Declaration of Installation
If any modi cations are made to the non-return valve without our agreement, this declaration is void.
Note:
Commissioning is prohibited until it is certain that the overall system fulfi ls the provisions of the
directives. For information about proper use of the fi ttings, see the operating instructions.
Hoetensleben, of October 24th, 2013
..............................................................................
Thomas Erhorn / CEO
Person authorised to compile the technical documentation:
Armaturenwerk Hötensleben GmbH
Mr. Guth, Schulstr. 5 - 6, D-39393 Hoetensleben
Hoetensleben, of October 24th, 2013
..............................................................................
Thomas Erhorn / CEO
Person authorised to compile the technical documentation:

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
2. Overview and Intended Use
1 Housing
2 Heavy duty clamp
3 Sealring
4 Insert
5 O-ring (only contained in the variant with a gap width of 0.25 mm)
Pic. 2-1 Exploded View
2.1 Overview
7
1
2
3
4
5

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
The „Intended Use“ also calls for meeting the conditions and requirements specied by the manufacturer
for operation, maintenance and repair.
The work described in this instruction manual is detailed such that only a specialist can understand and
carry out such work.
Expert
A person who, given his/her technical and functional knowledge, and experience, can judge assigned
work and realise potential risks and hazards that may exist.
8
AWH dirt traps have been specically designed and manufactured for installation in piping systems with
the aim of tration liquid ow in trade and industrial applications (food industry, chemical industry,
pharmaceutical industry and minimum-germ processes).
Fluids intended to be handled include water, steam, mineral oil, foodstuffs, liquids used in chemical and
the pharmaceutical industries, which are subject to a hygiene standard.
2.2 Intended Use
WARNING
This dirt trap is exclusively intended for the purpose detailed above. Any use
other than that outlined above or any modication made to the dirt trap without
manufacturer‘s prior written authorization shall be considered „not intended“,
and the manufacturer shall not accept liability for any damage that may result
from such use or modication not intended. The risk involved shall be solely borne
by the operating company. The dirt trap must not be commissioned until it has
been ensured that all safety devices are functioning and that the installation into
which this strainer has been integrated is in conformity with the EU Guidelines.

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
3. Technical Data
3.1 Materials in Contact with the Product
See Pic. 2-1:
Housing (pos. 1) 1.4301 / 1.4307 / 1.4404 / 1.4435
Insert (pos. 4) 1.4404 / 1.4435
Sealring (pos. 3; 5) selected acc. to operating conditions
Sealing material
EPDM: max. short-time sterilisation temperature: 140 °C
VMQ: max. short-time sterilisation temperature: 130 °C
FKM: max. short-time sterilisation temperature: 130 °C
Max. temperature short-term 15 - 20 minutes, depending on the medium.
CAUTION
The dirt trap‘s area of application shall always be adjusted to the relevant
operating conditions and the materials that come into contact with the product.
Surfaces
Outer surface: metal bright/polished
Inner surfache in contact with product: Ra < 0.8 µm (except weld seams and can)
NOTE
For technical datasheet please refer to the current AWH catalogue.
9
If used with free-from-chlorine potable water, the service life of the strainer will be approx. 10 years.
If used with aggressive media, the service life will be shorter.
3.2 Connection Variants, Type Series, Dimensions
NOTE
Typical connection con gurations of the dirt trap are shown below. The mounting
position should be done according to the  gures. For dimensions refer to the table
overleaf.
You can  nd the technical datas heet on the product pages of the current
AWH „Strainers and Sight Glases“ catalogue online or you can request it directly
from Armaturenwerk Hötensleben GmbH. The names of the data sheet and the
operating instructions must be identical.

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions



L1
D2
D3
L4 L5
45°
D2
E
L2
L4 L5
45°
L3
D2
D4
L4 L5
45°
D1
D1
D1
DN L1 L2 L3 L4 L5 D1 D2 D3 D4 E
25 147 205 190 103.5 45 53 26 29 50.5 Rd 52 x 1/6
40 172.5 240 217 129 45 70 38 41 50.5 Rd 65 x 1/6
50 187 257 230 129 45 70 50 53 64 Rd 78 x 1/6
65 215.5 296 272 149 58 85 66 70 91 Rd 95 x 1/6
80 240.5 330.5 296.5 164 59 104 81 85 106 Rd 110 x 1/6
100 269.5 380 328 189 62 129 100 104 119 Rd 130 x 1/4
10
Pic. 3-1 Connection Congurations
butt weld / butt weld thread / thread
clamp / clamp

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
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DN D5 L6
25 38 100
40-50 57 125
65 73 145
80 85 160
100 110 185
Pic. 3-2 Variants Insert
NOTE
Further customisation is possible subject to prior agreement, e.g. dimensions in
Inches and SMS and  ange connection.
Attention: DN25 - DN50, handle in spherical shape
DN65 - DN100, handle in thumb-grip shape
DN25 - DN50 DN65 - DN100
D5
L6
D5
L6
Ambient-temperature range
Min. temperature limit: + 5°C
Max. temperature limit: + 90°C
Max. permissible operating pressure: 10 bar
Max. permissible operating temperature: depending of sealant in conjunction with
operating  uid and cleaning medium
3.3 General Data

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
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4. Safety / Hazards
4.1 Notes / Explanations
Hazard
„DANGER“ warns about dangerous situations. Avoid such dangerous situations!
Otherwise, death or serious injuries are result.
WARNING
„WARNING“ warns about dangerous situations. Avoid such dangerous situations!
Otherwise, death or serious injuries may result.
CAUTION
„CAUTION“ in connection with the warning sign warns about serious situations.
Avoid such dangerous situations! Otherwise, minor or slight injuries may be the
result.
NOTE
„ADVICE“ offers recommended procedures the disregard of which will not result
in personal injury. However, follow this advice to avoid material damage and
problems!
NOTE
The installation instructions are binding;
indicated by a book symbol.
Hazard
This symbol indicates crushing hazards.
Hazard
This symbol indicates a risk of burning.
NOTE
Environmental symbol
This marks measures to protect the environment.

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
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4.2 Labelling of the Dirt Trap
The information in these operating instructions only applies to the dirt trap of the type and version
speci ed on the title page.
If you have any queries, specify the following correctly:
- the nominal diameter (DN)
- the sealing material
- the body material
- the connection types (butt weld/butt weld, threaded, clamp/clamp)
This is the only way to ensure ef cient, quick processing.
4.3 Safety Measures (to be executed by the operator)
Note that
- The user needs to train his operators and maintenance personnel and supervise same with regards
to their adherence to the safety regulations including the wearing of personal protective gear.
- The user has to make sure that any access of the dangerous area(s) of the machine (into which the
dirt trap was incorporated) by unauthorized personnel (no operators or maintenance personnel) is
prevented.
- The assembly of the dirt trap must not be carried out unless the pipes have been emptied.
- The disconnection of the energy sources has to be made in such a way technically as to ensure that
the shutdown procedures listed in point 5.4 can be executed.
This instruction manual has to be stored for future use. It has to be available near installation into which
the dirt trap installed incorporated. The prescribed frequency of inspections and control checks must be
observed.
The work described in the sections on transport, installation, assembly, maintenance, malfunction /
cause / remedy shall only be carried out by experts.
Expert
A person with appropriate training, suitable instruction and experience who is in a position to identify
risks and avoid hazards.
4.4 Operator’s Duties
NOTE
Within the EEA (European Economic Area) the national implementation of the
outline directive (89/391/EWG) as well as the related individual guidelines and
of these the guideline (2009/104/EG) on the minimum provisions for safety and
health protection in the use of working materials by employees during their work
in particular, all in their valid version, have to be observed and adhered to. Within
Germany, the regulations on work safety of October 2002 have to be observed.

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
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The operator shall comply with local statutory provisions for:
- safety of personnel (accident prevention regulations),
- safety of work equipment (protective equipment and maintenance),
- disposal of products (waste management laws),
- disposal of materials (waste management laws),
- cleaning (cleaning agents and disposal) and
- environmental protection requirements.
- The installer/operator shall ensure that all  ange or pipe unions are leak-proof.
- Tensile and compression stresses shall be ruled out after installation in the pipeline.
In addition, the operator shall ensure
- During maintenance and repair work at the strainer, there is a risk of irritation or burns by residual
media and  ltered particles.
- When using hazardous materials, protective measures shall be speci ed in accordance with the safety
datasheets and operating instructions shall be compiled for hazardous materials. Personnel shall be
instructed in this  eld. This also applies to hazardous materials that could be produced in the operating
process.
- A continuous risk assessment shall be carried out for workplaces, including temperature conditions for
the medium and the place of use (falling). The measures shall be recorded in operating instructions
and personnel shall be instructed accordingly.
- Supervisors shall monitor compliance with the measures speci ed in the operating instructions.
- Training of operating personnel shall be ensured.
- Wherever large pneumatic pressures occur, there is a possibility of sudden failure of or damage to the
lines and connectors. This poses a hazard.
- The installer of the overall system shall install and provide certi cation for the control units and safety
equipment needed for setting up, checking, shutting down (including emergency shutdown), operating,
maintaining, cleaning and repairing the system.
- The operator shall provide technical  re protection equipment, such as appropriate hand  re extinguishers,
in suf cient quantities and dimensions at easily accessible points and shall instruct employees in  re
safety.
- Warnings from the documentation for supplied assemblies shall be observed and integrated in the
workplace-speci c risk assessments.
- The operator is obliged to operate the dirt trap in perfect condition at all times.
Connections
Before operating the machine with the strainer, the operator shall ensure that the local speci cations were
followed during assembly and commissioning, if these were carried out by the operator.
NOTE
Illumination level
The user has to ensure suf cient and uniform lighting in all areas of the installation.
The recommended illumination intensity is 300 Lux (maintenance level; in Germany,
the ASR 7/3 applies).
NOTE
In accordance with the Ordinance on Industrial Safety and Health (BetrSichV), the
operator shall provide its personnel with safety instruction at least once a year.

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
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5. Hazard Warnings
The safety systems described and the safety instructions given in this instruction manual must be taken
into account and followed, respectively. The dirt trap is designed to be operated manually and locally.
CAUTION
Dirt trap, length and quality of the pipes has to meet the requirements. The
assembly is to be checked by quali ed personnel. The parameters listed on the
datasheet have to be adhered to at all times.
HAZARD
A risk of burns exists during the operation or maintenance if  ow media are used
at temperatures exceeding 60°C.
5.2 Hazardous Area of the Dirt Trap
The area around the dirt trap has to be kept accessible for the operator.
CAUTION
The hazardous area for set-up, maintenance and repair work is 1 m around the
machine or vessel. The swivel range of the opening switch cabinet doors is to be
taken into account. The operator shall ensure that persons are prevented from
entering the hazardous area during motion sequences.
5.3 Installing Replacement and Wearing Parts
We express clearly that spare and wear parts that are not delivered by AWH, are neither inspected nor
certi ed or released by AWH either. The installation and/or application of such products can, under these
circumstances, modify the constructional speci ed properties of your machine in a negative way.
5.1 Hazards
NOTE
Damage caused by usage of non-original parts and equipment are excluded from
the liability by the company Armaturenwerk Hötensleben GmbH.

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
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5.4 Shutdown Procedures
WARNING
Before cleaning, maintenance or repair work is carried out (by experts only), the
following shutdown procedure must always be completed.
1. Switch off power to higher-level plant / machine / device.
2. Seal off the pneumatics
- Close shut-off valve.
- Check that the system is non-pressurised.
- Secure the shut-off valve against opening.
3. Shut off the ow of media, relieve the pressure in the pipelines and then drain
them (take particular care with hazardous materials). Check that an inow of media
is prevented and insert dummy discs if necessary. Note that if the media tempe-
ratures exceed 60°C, a cooling off phase must be observed.
Failure to do so could endanger the life and health of personnel.

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
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6. Installation
6.1 Scope of Delivery
NOTE
The detailed scope of delivery is provided in the con rmation of order.
6.2 Transport and Packaging
Products from Armaturenwerk Hötensleben GmbH is carefully checked and packed before shipping,
however the product may become damaged during transport.
6.2.1 Delivery (including also of spare an replacement parts)
Unpacking
- Remove the protective caps from the pipe connections (if present).
- Remove the packaging residue.
Incoming goods check
- Check that the product was delivered in full against the delivery note!
In the event of damage
- Check the delivery for damage (visual inspection)!
In the event of complaints
If the delivery was damaged during transport:
- Contact the last shipment agent immediately.
- Retain the packaging (for possible checking by the shipment agent or for a return delivery).
Packaging for return delivery
If possible, use the original packaging and the original packaging material.
If neither is available any more, request a packaging company with experts.
If there are any questions about the packaging and transport safety equipment, please contact
Armaturenwerk Hötensleben GmbH.
6.2.2 Temporary Storage
Storage in a closed room
Storage conditions
– temperature 10°C to 45°C
– humidity < 60 %

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
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6.3 Installation
NOTE
The installation of the dirt trap is carried out in conformity with the structural
design of the pipe system and the technical data of the connection variants.
The installation position should correspond to the illustrations in these operating
instructions. For the installation dimensions please refer to the scale drawings of
the AWH product drawing. The required space for operation and servicing is to be
provided. The  oor space required for operation and repairs must be guaranteed.
Ensure that the  ange connection and the pipe or hose connections are tight and
leakage-proof.
Tensile and compression stress are to be excluded.
6.3.1 Installation of the Dirt Trap - Installation Position
In order to guarantee the perfect function of the strainer the recommended installation position should
be as shown.
Pic. 6-1 Installation Position

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
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Welding guidelines
The welding into pipes is carried out in accordance with DIN 11850.
Welding process: TIG or orbital welding
Weld type: square butt weld to DIN EN 29692
Installed condition
The dirt trap shall be removed before welding (see section on assembly / disassembly).
Weld seam preparation
- Cut the ends of the pipes level and right-angled.
- Remove burrs from the interfaces.
- Align the housing weldon ends with the pipeline so they are level radially and axially. The weldon ends
must t ush and be welded without a gap.
Filler materials
Base materials Suitable ller materials
1.4301 1.4302, 1.4316, 1.4551
1.4404 1.4430, 1.4455, 1.4576
1.4435 1.4430, 1.4440
6.3.2 Installation of the Dirt Trap with Thread/Thread
When installing the dirt trap, please keep in mind that the nipples and nuts are required to conform
to an identical standard (e.g. DIN 11851 or DIN 11864). Prior to installation, check the sealing ring on
the threaded connection for damage as may have occurred, and make sure the sealing ring is properly
tted. Renew sealing ring if necessary. Care must be taken during installation work not to damage the
thread. The dirt trap is designed to be mounted by the nut using a nut-wrench. The tightening torque
should be strong enough to ensure sufcient leak-tightness.
6.3.3 Installation of the Dirt Trap with Clamp/Clamp
When installing the dirt trap, please keep in mind that the anges are required to conform to an identical
standard (DIN 32676). Prior to installation, check the sealing ring for damage that may have occurred,
and make sure the sealing ring is properly tted. Renew sealing ring of necessary. During assembly, the
seal ring has to be guided through the appropriate lip and be located in the correct installation position.
The dirt trap is designed to be mounted by the heavy duty clamp.
The tightening torque should be strong enough to ensure sufcient leak-tightness.
6.3.4 Installation of the Dirt Trap with Weldon Ends

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Welding
- Connect forming gas before welding.
- Afx 3 to 4 tack welds before welding.
Weld after-treatment
- No treatment is necessary on the interior after welding.
Accessible areas can be ground.
- The exterior can be treated afterwards by staining, brushing, grinding and polishing.
Cleaning
- Clean all welded parts before assembly.

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Dirt Trap - Type: DN25 - DN100 / PN10
Operating Instructions
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7. Structure / Function
Pic. 7-1 Dirt Trap
1 Housing
2 Heavy duty clamp
3 Sealring
4 Insert
5 O-ring
1
2
3
4
5

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Dirt Trap - Type: DN25 - DN100 / PN10 Operating Instructions
8.1 Disassembly from the System
To remove the dirt trap from the system proceed as detailed below:
1. Depressurise the piping.
2. Drain the uid from the piping.
3. Position a suitable collecting tray under the strainer.
4. Remove the heavy duty clamp (Pic. 7-1, position 2).
5. Let residual medium drain.
6. Pull off the lter insert by means of the handle with spherical shape or with thumb-grip shape
(Pic. 7-1, position 4) in axial direction out of the housing (Pic. 7-1, position 1).
7. Clean the lter, particularly the shall (Pic. 7-1, position 4)
8. Clean the installation space and carry out an inspection for possible damage.
8.2 Assembly with Packing and Insert Replacement
CAUTION
Exercise care and caution to avoid damage.
Proceed as detailed below:
1. Perform the Shutdown Procedures accordingly 5.4.
2. Inspect the gasket for damage (visual inspection).
3. Clean the assembly area and check for possible damage.
4. Attach the O-ring (Pic. 7-1, position 5) to the can.
The O-ring is only available for the variant with a gap width of 0.25 mm.
5. Position the seal ring (Pic. 7-1, position 3) at the cover of the insert (Pic. 7-1, position 4).
6. Introduce the lter insert (Pic. 7-1, position 4) carefully into the housing (Pic. 7-1, position 1).
7. Attach the joint clamp (Pic. 7-1, position 2). The tightening torque should be strong enough to
ensure sufcient leak-tightness.
8. Carry out a tightness test under operating conditions.
22
8. Assembly / Disassembly
HAZARD
There is a risk of burning during operation or maintenance if ow media have
temperatures over 60°C.
HAZARD
When using hazardous, toxic or otherwise hazardous media like there is a risk of
poisoning or chemical burns.
WARNING
Prior to maintenance or repair work it is essential that the shutdown procedure
(see section 5.4) be pursued. If the indicated measures do not succeed, please
consult the manufacturer of the plant or Armaturenwerk Hötensleben GmbH.