GESTRA UNA 43 User manual

Ball Float Steam Trap
UNA 43
PN 16/CL 125/JIS 10K
UNA 46
PN 40/CL 150/CL 300/
JIS 10K/JIS 20K
Original Installation Instructions
819565-00

Contents
Foreword ............................................................................................................................................3
Availability.............................................................................................................................................3
Formatting features in the document ......................................................................................................3
Safety..................................................................................................................................................4
Use for the intended purpose .................................................................................................................4
Basic safety notes .................................................................................................................................4
Information on property damage or malfunctions .....................................................................................5
Qualification of personnel.......................................................................................................................5
Protective gear......................................................................................................................................5
Typographic features of warning notes....................................................................................................6
Formatting features for warnings of property damage ..............................................................................6
Description .........................................................................................................................................6
Scope of supply and equipment specification ..........................................................................................6
Task and function................................................................................................................................10
Storing and transporting the equipment.........................................................................................11
Storing the equipment .........................................................................................................................11
Transporting the equipment .................................................................................................................11
Mounting and connecting the equipment.......................................................................................12
Preparing installation ...........................................................................................................................12
Orientation of the equipment ................................................................................................................12
Connecting the equipment ...................................................................................................................13
Operation ..........................................................................................................................................15
After operation .................................................................................................................................16
Removing external dirt deposits............................................................................................................17
Maintaining the equipment...................................................................................................................17
Servicing the equipment and installing spare parts ................................................................................22
Troubleshooting ...............................................................................................................................26
Putting the equipment out of operation..........................................................................................28
Removing harmful substances..............................................................................................................28
Removing the equipment .....................................................................................................................28
Re-using equipment after storage.........................................................................................................29
Disposing of the equipment..................................................................................................................30
Technical data..................................................................................................................................31
Dimensions and weights ......................................................................................................................31
Pressure & temperature ratings............................................................................................................34
Manufacturer's declaration.............................................................................................................35

3
Foreword
This installation & operating manual will help you
use the following types of equipment safely and
efficiently for their intended purpose.
UNA 43
UNA 46
These types will be called equipment in this
document.
This installation & operating manual is intended for
anyone commissioning, using, operating, servicing,
cleaning or disposing of this equipment and, in
particular, for professional after-sales service
technicians, qualified personnel and authorised and
trained staff.
All of these persons must read and understand the
content of this installation & operating manual.
Following the instructions given in this installation &
operating manual helps avoiding danger and
increases the reliability and service life of the
equipment. Please note that in addition to the
instructions given in this installation & operating
manual you must also observe all locally applicable
rules and regulations concerning the prevention of
accidents as well as approved safety guidelines for
good professional practice.
Availability
Keep this installation & operating manual together
with the plant documentation for future reference.
Make sure that this installation & operating manual
is available to the operator.
The installation & operating manual is part of the
equipment. 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 addition
al useful
information and tips serving to assist you
in using the equipment to its fullest
potential.

4
Safety
Use for the intended purpose
Steam traps type UNA 43 and UNA 46 are designed
for draining condensate from steam systems.
Steam traps type UNA 43 can also be used for
removing condensate from compressed air
systems.
Steam traps type UNA 46 can also be used for
removing condensate from gases or gas mixtures.
The equipment must only be used within the
allowable pressure and temperature limits and only
if the chemical and corrosive influences on the
equipment are taken into account.
Do not expose the membrane regulator capsule of
the DUPLEX control unit to superheat conditions
above 5 K.
Correct use includes compliance with the
instructions given in this installation & operating
manual, in particular obedience to all safety
instructions.
Any other use of the equipment is considered to be
improper.
Note that the equipment is also used incorrectly if
the materials of the equipment are not suitable for
the fluid.
Basic safety notes
Risk of severe injuries
The equipment is under pressure during
operation and may be hot. Before carrying out
any work on the equipment make sure that the
following requirements are met:
The pipes must be depressurized (0 bar).
The fluid must be completely removed from
the pipes and the equipment.
During work on the equipment the
installation must be switched off and
protected against unauthorised or
unintended activation.
The pipes and the equipment must have
cooled down to room temperature (approx.
20 °C).
If the equipment is used in contaminated areas
there is a risk of severe injuries or death caused
by harmful substances in or on the equipment.
Before working on the equipment make sure
that it is completely decontaminated. Always
wear the protective clothing prescribed for
contaminated areas when working on the
equipment.
The equipment must only be used with fluids
that do not attack the material and the gaskets
and sealings of the equipment. Otherwise leaks
may occur and hot or toxic fluid could escape.
The equipment and its component parts must
only be mounted or removed by qualified
personnel. A qualified person must be
acquainted with and experienced in the
following:
Making pipe connections.
Selecting suitable lifting gear and
understanding the rules for its safe use.
Working with dangerous (contaminated, hot
or pressurized) fluids.
If the admissible operating limits are exceeded,
the equipment may be destroyed and hot or
pressurised medium may escape. Make sure
that the equipment is always used within the
admissible operating limits.
You can find information on the operating limits
in the "
Technical data " section.

5
If unsuitable lifting gear is used or the gear is
used improperly the equipment or parts of it
could fall down.
Make sure that only qualified personnel lifts
the equipment or parts of it.
Make sure that nobody is standing or
working below the hoisted equipment.
Make sure that the lifting gear is of sufficient
strength for the load to be hoisted and that
the load is properly secured and attached to
it. For more information on the nature and
weight of the components and safe lifting
points please contact the manufacturer.
Make sure that all locally applicable
regulations on safety and the prevention of
accidents are strictly adhered to.
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 support of the equipment during
installation is insufficient the equipment might
fall down, thereby causing bruises or injuries.
Make sure the equipment is safely held in place
during installation and cannot fall down. Wear
protective safety footwear.
Information on property damage
or malfunctions
Malfunctions will occur if the equipment is
installed in a wrong position or with the flow
arrow pointing in the opposite direction of the
fluid flow. This may result in damage to the
equipment or the installation. Make sure that
the flow arrow on the equipment body matches
the indicated direction of the fluid flow in the
pipe.
If the material is unsuitable for the fluid,
increased wear may occur and fluid may
escape. Make sure that the material is suitable
for the fluid used in your installation.
Qualification of personnel
A qualified person must be acquainted with and
experienced in the following:
the pertinent on-site rules and regulations for
preventing fire and explosions as well as
industrial safety regulations
working on pressure equipment
making pipe connections
working with dangerous (hot or pressurized)
fluids
lifting and transporting loads
observing all notes and instructions in this
installation & operating manual and the
applicable documents
Protective gear
The operator must ensure that anyone working on
the equipment must wear the required protective
clothing and safety gear stipulated for the site of
installation. The protective clothing must be suitable
for the used media and must protect the wearer
against safety and health hazards associated with a
particular job to be carried out at the site of
installation. Protective clothing & equipment must
provide protection from potential hazards, in
particular from injuries to:
Head
Eyes
Body
Hand
Feet
Hearing
Note that this list is not 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.

6
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 heading WARNING warn
against possibly dangerous situations that
could lead to death or s
erious injuries.
CAUTION
Notes with the heading CAUTION warn
against dangerous situations that c
ould
lead to minor or moderate injuries.
Formatting features for warnings
of property damage
Attention!
This information warns of a situation
leading to property damage.
Description
Scope of supply and equipment
specification
Scope of supply
Our equipment is delivered packed and ready for
assembly.

7
Component parts
Item
no.
Designation
1
Hexagon nuts
2
Body
3
Body gasket
4
Control unit DUPLEX
5
Stud bolts
Item
no.
Designation
6
Cover
7
Drain with sealing plug
8
Name plate
9
Adapter
10
Direction of flow arrow

8
Optional extras
The following items are available as optional extra:
Item
no.
Designation
11
Control unit SIMPLEX
12 Hand-vent valve with socket spanner
(socket spanner not shown)
The vent hole in the cover for the hand-
vent valve can also be used for
connecting a balance line.
Item
no.
Designation
13
Sealing plug
14
Electrodes NRG 16-19 or NRG 16-27
15
Manual float-lifting lever
16
Lever extension
In equipment with control unit SIMPLEX the
hand
-vent valve is included as standard.
If you want to mount the optional level
indicator please contact the manufacturer
and refer to the installation and operating
manual for the level indicator.

9
The different equipment versions allow you to adjust
the flow direction of the equipment to the flow
pattern of your installation. The flow arrow must
correspond to the direction of the fluid flow. The
following positions of installation are possible:
"v" for installation in vertical pipework with
downward flow
"hl" for flow from right to left (when viewed from
the body end)
"hr" for flow from left to right (when viewed from
the body end)
End connections
The equipment is available with the following end
connections:
Flanges
Name plate
The indications on the name plates vary according
to the equipment type.
The name plate may specify the following:
Manufacturer
Type designation
Design
Nominal size
Pressure rating
Design pressure
Design temperature
Max. service temperature
Max. admissible differential pressure
Material number
CE marking
Date of manufacturing
The following items are indicated on the equipment
body:
Material
Identification marking of material testing
Batch code
Direction of flow
The following items are indicated on the end
connections:
Flange face type (RJ number)

10
Application of European Directives
Pressure Equipment Directive
The equipment conforms to this directive (see
"Manufacturer's Declaration" section) and can be
used for the following media:
UNA 43
Fluids of group 2
UNA 46
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 is
responsible for discharging or preventing possible
static charge.
If it is possible for medium to escape, e.g. through
actuating mechanisms or leaks in threaded joints,
the plant manufacturer or plant operator must take
this into consideration when dividing the area into
zones.
Task and function
Purpose
UNA 43-PS and UNA 46-PK is steam process
equipment designed for the effective removal of
condensate from steam systems.
Steam traps type UNA 43 can also be used for
removing condensate from compressed air
systems.
Steam traps type UNA 46 can also be used for
removing condensate from gases or gas mixtures.
Function
A ball float opens the orifice as a function of the
liquid level. A rising level results in a proportional
opening of the equipment. The max. discharge
capacity depends on the orifice size when the ball is
completely lifted off its seat and the orifice is fully
open.
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
DUPLEX consists of a float operated rolling ball
valve mechanism and, in addition, a temperature
dependent air-venting facility. Air venting is
controlled by the membrane regulator. Equipment
with this type of control unit is particularly suitable
for saturated steam systems.
Do not expose the membrane regulator capsule of
the DUPLEX control unit to superheat conditions
above 5 K.
The optional hand-vent valve attached to equipment
with control unit SIMPLEX allows you to manually air
vent pipes.