Mankenberg KA Installation instructions

Original operating manual
Steam trap
Originalbetriebsanleitung
Kondensatableiter
KA
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com

2
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
Table of contents EN
1 Introduction ................................................................................................................................................ 4
2 Intended use ............................................................................................................................................... 4
3 Safety instructions ..................................................................................................................................... 5
3.1 General precaution............................................................................................................................... 5
3.2 Special safety instructions for the plant operator ................................................................................. 5
3.3 Special hazards.................................................................................................................................... 5
4 Marking of the fitting.................................................................................................................................. 6
5 Transport and storage ............................................................................................................................... 7
6 Installation .................................................................................................................................................. 8
6.1 General notes....................................................................................................................................... 8
6.2 Installation preparations ....................................................................................................................... 8
6.3 Installation steps .................................................................................................................................. 9
7 Pressure testing the pipeline section....................................................................................................... 11
8 Initial start-up.............................................................................................................................................. 12
9 Normal operation........................................................................................................................................ 13
10 Use in hazardous areas ............................................................................................................................. 13
11 Maintenance................................................................................................................................................ 13
12 Troubleshooting help................................................................................................................................. 15
13 Information on REACH and RoHS ............................................................................................................ 17
13.1 Declaration on the REACH Regulation 1907/2006 .............................................................................. 17
13.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 17
14 Further information .................................................................................................................................... 17

Inhaltsverzeichnis DE
1 Einleitung .................................................................................................................................................... 18
2 Bestimmungsgemäße Verwendung ......................................................................................................... 18
3 Sicherheitshinweise................................................................................................................................... 19
3.1 Allgemeiner Sicherheitshinweis ........................................................................................................... 19
3.2 Spezielle Sicherheitshinweise für den Betreiber .................................................................................. 19
3.3 Besondere Gefahren............................................................................................................................ 19
4 Kennzeichnung der Armatur ..................................................................................................................... 20
5 Transport und Lagerung............................................................................................................................ 21
6 Einbau ......................................................................................................................................................... 22
6.1 Allgemeines.......................................................................................................................................... 22
6.2 Vorbereitung zum Einbau..................................................................................................................... 22
6.3 Schritte beim Einbau ............................................................................................................................ 23
7 Druckprüfung des Rohrleitungsabschnitts ............................................................................................. 25
8 Erste Inbetriebnahme................................................................................................................................. 26
9 Normalbetrieb ............................................................................................................................................. 27
10 Einsatz im Ex-Bereich................................................................................................................................ 27
11 Wartung....................................................................................................................................................... 27
12 Hilfe bei Störungen .................................................................................................................................... 29
13 REACH- und RoHS-Auskunft .................................................................................................................... 31
13.1 Erklärung zur REACH-Verordnung 1907/2006 .................................................................................... 31
13.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 31
14 Weitere Informationen ............................................................................................................................... 31
3
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com

Original operating manual
Steam trap KA
4
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
1 Introduction
This manual is intended to assist users of a MANKENBERG steam trap during installation, operation and
maintenance. Read the manual thoroughly before installing or putting this valve into service.
caution
Failure to follow the following instructions – particularly the cautionary and warning
notes – may lead to hazards MANKENBERG is at your servíce for any assistance and
queries. See Further information [Page17] for the addresses.
Technical information is also available at
2 Intended use
A MANKENBERG steam trap KA is intended to drain accruing condensate from gas or steam leading systems.
To collect the condensate as effectively as possible, the steam trap should be installed at a low point of the
pipeline section.
This is an automatic function and does not need any additional electrical/pneumatic energy: Depending on the
liquid level, a float controls the drainage from the body of the steam trap via a system of levers.
The float is dimensioned for draining (non-foaming) condensate of the density of water condensate at saturated
steam temperature. The use with condensate of other density must be checked with MANKENBERG.
MANKENBERG planning documents are available to give users precise assistance in selecting and designing
the appropriate fitting, e.g.:
In the section <KA: Level control valves>:
<selection guidelines: dimensioning of lines downstream of the steam trap>
<Type sheet KA...> with technical data and tables of the setting ranges and the dimensions.
note
Metallic sealed steam traps are no shut-off elements ensuring a tight closing of the valve. In
ac-cordance with DIN EN 60534-4 and/or ANSI FCI 70-2 they may feature a leakage rate in
closed position in compliance with the leakage class III:
Leakage class III (metal sealing cone) = 0.1 % Kvs value
MANKENBERG valves are supplied as standard for screw-mounted or flange-mounted pipeline/tank
connections – also for special connections if required.
The upper limit of the permitted operating data is permanently marked on each fitting supplied.

Original operating manual
Steam trap KA
5
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
3 Safety instructions
3.1 General precaution
The same safety regulations apply to a fitting as to the system into which it is installed. These instructions only
give those safety recommendations that have to be additionally observed for the fitting.
3.2 Special safety instructions for the plant operator
The following requirements for the intended use of a fitting are not the responsibility of the manufacturer but
have to be guaranteed by the user.
» The fitting may only be employed for the purpose described in Intended use [Page4].
» Only competent specialist personnel may install, operate and service the fitting. Competent as defined in
these instructions refers to persons who, because of their training, specialist knowledge and professional
experience, are capable of correctly assessing and properly executing the work with which they are
entrusted and of recognizing and rectifying hazards.
» The pipeline system must be properly designed and installed so that the fitting can be mounted and
operated without any tension.
» The fitting must be properly installed in the correct mounting position.
» The usual flow rates should not be exceeded in the pipeline section during continuous operation, and
abnormal operating conditions such as vibrations, water shocks and cavitation should be avoided or – if
unavoidable – clarified with the manufacturer in advance.
» The prevailing operating conditions must comply with the limits of the design data stated in the
MANKENBERG order confirmation.
» Hard or sharp objects in the flowing medium could damage internal functional parts of the fitting. A strainer
or filter should be installed upstream of the fitting.
» The corrosion protection for the fitting must be adapted to the local environmental conditions.
» The fitting must not be coated with thermal insulation.
Detailed notes are provided on some of these prerequisites in the following sections.
3.3 Special hazards
danger of
fatalities
Before a fitting is removed from the system or before a fitting is dismantled but partially
remains in place, the pressure in the system on both the inlet and outlet side must be
completely reduced so that there is no uncontrolled flow of the medium out of the system.
In the case of toxic or hazardous media, the system must be completely drained before the
fitting is removed.
Caution is required with residues that might continue flowing.
caution
If a fitting is removed from a system with a toxic medium and is taken out of the plant:
it must be properly decontaminated before repair.

Original operating manual
Steam trap KA
6
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
4 Marking of the fitting
Each fitting bears the following markings as a minimum:
For Marking Remark
Manufacturer MANKENBERG See Further information [Page17] for the
address
Fitting design steam trap + type Design name as per accompanying
MANKENBERG data sheet
Nominal diameter e.g. DN or G and numerical value Numerical value for DN in [mm], for G in
[inches]
Nominal pressure PN or Class and numerical value Numerical value for PN in [bar], for Class in
[lbs/square inch], pressure data are
displayed as overpressure above the
atmospheric pressure, Numerical value for
the lower and upper limit
Working pressure
range
Operating pressure range and
numerical values
Max. permitted
temp.
Temperature and numerical value Temperatures above 50 °C entail a reduced
pressure resistance. This must be
considered for the corresponding material in
accordance with the DIN EN 1092 standard
Body material e.g. CrNiMo steel CrNiMo steel = high-alloy austenitic steel
Flow direction Indicated by an arrow
ATEX protection
class
outside Ex II 2G IIB TX
+1°C<Ta<80°C
inside Ex II 1G IIB TX
+1°C<Ta<80°C
only for devices with conformity certification
according to ATEX
The markings (in the case of fittings made of deep-drawn stainless steel, they are etched into the body)should
neither be covered nor painted over, so that the fitting remains identifiable.

Original operating manual
Steam trap KA
7
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
5 Transport and storage
A fitting must be handled, transported and stored with care:
» The fitting must be transported and stored in its protective packaging until it is installed.
caution
The fitting has moving internal parts.
Even packaged fittings should be transported smoothly without any shocks.
caution
In the case of a fitting that can no longer be transported by hand, the lifting gear must be
attached to a suitable position on the housing (branches).
Under no circumstances may the lifting gear be affixed to any attachments.
» When the fitting is stored prior to installation, it should be kept in closed rooms and protected against
harmful influences such as dirt, moisture and frost.
» n special cases, the fitting is supplied free of oil, grease or silicone and is marked accordingly. A fitting such
as this must not come into contact with oil/grease/silicone during storage and handling (particularly when
subsequently unpacked).
» A MANKENBERG fitting generally has functional and/or sealing parts made of elastomer materials. These
cannot be stored for an unlimited period.
note
ISO 2230 describes the storage conditions for elastomers in detail and specifies the
permissible storage period.
Functional and sealing parts must be replaced well before the storage period expires.
They are available from MANKENBERG as a “service set”. See also Troubleshooting help
[Page15].
note
MANKENBERG fittings of small and medium nominal diameters are largely made of stainless
steel (high-alloy CrNiMo steel).
If, under exceptional circumstances, fittings are stored in a unpacked state, they must be
protected against ferritic dust to avoid corrosion.
note
The fitting is generally not capable of standing alone:
Handle with care so that the fitting does not tip over during transport/storage.

Original operating manual
Steam trap KA
8
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
6 Installation
6.1 General notes
The same installation regulations apply to a fitting as to the system into which it is installed. The following
additional notes apply:
»Transport and storage [Page7] should also be observed during transport to the installation site.
» The installation site to allow perfect functioning of a fitting should be a section of pipe without any flow
disruptions, without any angles and without any restrictors or shut-off devices close to the fitting, either
upstream or downstream (optimum distance = 10 x DN). If this does not apply, the installation situation
should be checked with the plant operator and/or MANKENBERG.
» The statics of the pipeline must be designed so as to take account of the weight of the fitting – particularly
those with an eccentric mass. If required, the pipeline may have to be properly supported on both sides next
to the fitting (or at the fitting itself) – particularly in the case of fittings with a substantial mass and especially
if vibrations are to be expected in the system. When the fitting is supported, it is important to check that all
functioning parts (manual vents, levers, floats) remain capable of moving freely and are not blocked.
» The fitting must not be coated with thermal insulation.
caution
A fitting that is operated at a medium temperature above 130°C needs undisrupted removal of
heat if it is to function perfectly.
Failure to observe this instruction may cause damage to the fitting and hence in the
pipeline system as well.
» To protect internal functional parts (e.g. the seat) against damage and/or blockages, it may be necessary to
install a strainer and/or filter upstream of the fitting.
note
The mesh size of the sieve/filter for protecting against aggregates in the pipe section should be
selected by the plant operator according to the operating conditions.
Failure to observe this instruction may impair the function of the fitting and lead to
damage.
6.2 Installation preparations
» It is necessary to ensure that a fitting is not installed unless its matches the operating conditions in terms of
function, pressure and temperature, range, body material as well as connection type and dimensions.
danger of
fatalities
No fitting may be operated that does not have a sufficient pressure and temperature range for
the operating conditions – see Intended use [Page4] and markings on the fitting. The
manufacturer MANKENBERG should be consulted in the case of any applications outside of
this range.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pressure-regulating valve.
» Newly installed tanks and pipeline sections must be thoroughly rinsed and cleaned before commissioning.
» The corrosion protection for the fitting must be adapted to the local conditions:

Original operating manual
Steam trap KA
9
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
danger of
fatalities
As a general rule, the body part of a steam trap bearing the moving float should be installed
vertically. See sectional drawing in the type sheet <KA...> also.
Failure to observe this instruction may cause functional faults.
caution
When draining compressed air or gases, the condensate collecting tank or the pipeline has to
be connected to the taphole in the housing cover (Niagara) or to the threaded bushing at the
housing upper section (KA 2, KA 2K, KA 2X, KA 3) by an additional compensation pipe.
6.3 Installation steps
» Fittings should only be finally unpacked at the installation site and inspected for damage prior to assembly.
Damaged fittings must not be installed.
» It is necessary to ensure that the covers have been removed from all the connection branches before
installation.
» The fitting should be inspected to ensure that it is clean. Interior parts must be free of liquid (e.g.
condensate): if necessary, connecting branches should be cleaned before installation with clean
compressed air.
» The type and dimensions of the line or tank connections must match the fitting to be installed and be flush
with the connecting surfaces of the fitting as well as in a parallel plane to the fitting itself.
» If the fitting is marked with an arrow on the housing, the flow in the pipe section must match the marked
direction of flow.
caution
If installed in the opposite direction to the arrow, the fitting will not perform its intended
function.
» The fitting mist be installed without any tension. In the case of an already installed system, the geometry of
the pipeline must match the face-to-face length of the fitting.
note
It is necessary to ensure that even under operating conditions no tension from the pipeline
is transferred to the fitting..
» The drainage of the condensate from the steam trap at the lower housing nozzle must be provided by the
customer.
note
A MANKENBERG fitting made of "high grade" or "high grade pure" stainless steel (austenite,
e.g. 1.4404 or 1.4435) does not need any surface protection for normal environmental
atmosphere and for normal weather conditions.
External parts of the fitting made of low-alloy or non-alloy materials that are supplied ex-works
with a primer have to be provided with a suitable coating by the customer.
Caution: Never paint over the marking(s) of the fitting (either etched into the body or on
nameplate).

Original operating manual
Steam trap KA
10
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
In addition, the following applies to the pipeline connection:
with flanges:
note
The sealing surfaces on the body of the fitting are formed in accordance with the
MANKENBERG order confirmation. The accompanying flange seals are generally not
included in the MANKENBERG supply schedule..
» During installation, centre the fitting by means of the flange screws on the mating flange before the screws
are tightened.
with screw-mountings:
note
The connecting surfaces on the body of the fitting are formed in accordance with the
MANKENBERG order confirmation. The required seals are generally not included in the
MANKENBERG supply schedule..
with welding ends:
» Properly performed welding must ensure that no significant tension is transferred to either the section of
pipeline or the body of the fitting.
» Under no circumstances may the body of the fitting exceed the temperature marked on it; otherwise the
sealing and functional parts will be damaged and the whole fitting will become unserviceable.
Achtungc
aution
When a fitting with a body made of "high grade" or "high grade pure" deep-drawn parts (visible
on the body connection with clamp rings) is welded, the welding joint must be carried out with
special care; it is recommended that the body should be kept cool with a damp cloth..
Failure to observe this instruction may cause distortion of the fitting body: even 0.1 mm of
permanent distortion in the seat region may render the fitting unserviceable..

Original operating manual
Steam trap KA
11
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
7 Pressure testing the pipeline section
The valve has already been pressure-tested by the manufacturer. The following points should be observed
when conducting a pressure test on a pipeline section with a steam trap installed:
Under no circumstances may the test pressure exceed the value marked „PN“ or „Class“ on the body.
If necessary, the test pressure is limited by the maximum permissible pressure load of the float (see order
confirmation).
If any leakage occurs on the valve, section Troubleshooting help [Page15] should be observed.
caution
To prevent the float of the fitting from being damaged by pressure surge, the pipeline section
has to be filled slowly.
Failure to observe this instruction may cause damage to the valve.
note
When the housing is filled with water, the steam trap is not sealed. During the pressure test it
may be necessary to install a shut-off valve in the drain pipe.
note
If the pipe section is flushed and/or dried after assembly or pressure testing, it is necessary to
make sure that the valve has not been damaged by corrosion or excessively high temperature.

Original operating manual
Steam trap KA
12
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
8 Initial start-up
During the initial and every renewed start-up, it has to be checked if the fitting is functioning correctly and/or is
sealed without condensate drain pipe.
If required, the design of the steam trap can be checked in the <Selection guidelines> of the MANKENBERG
catalogue, section <KA>. MANKENBERG is at your servíce for any assistance and queries, for the addresses
see Further information [Page17].
danger of
fatalities
No fitting may be operated that does not have a sufficient pressure and temperature range for
the operating conditions – see Intended use [Page4] and markings on the fitting. The
manufacturer MANKENBERG should be consulted in the case of any applications outside of
this range.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pressure-regulating valve.
note
To function correctly, the system pressure must lie within the range of the working pressure of
the steam trap.
In cases of doubt contact MANKENBERG service. See Further information [Page17] for the
addresses.
caution
Open the air bleed valve and bleed the system at the beginning of the start-up. After closing
the air bleed valve, the regulator works automatically.
danger
At the beginning of or shortly after the initial start-up, the sieve or the filter insert of any
installed strainer/filter should be cleaned in order to avoid blocking the strainer/filter.
caution
After the initial start-up:
Check the seals on screw-mounted parts of the body and reseal if necessary. Ask
MANKENBERG for tightening torque, if necessary.
Observe the relevant notes in Troubleshooting help [Page15].

Original operating manual
Steam trap KA
13
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
9 Normal operation
A properly designed steam trap works automatically and does not need any form of auxiliary energy.
It is equipped with a device that drains air and other gases that have accumulated inside the housing of the
fitting. This device is operated either manually or de-aerates permanently - temperature controlled - via a
nozzle.
To manually exfiltrate solid particles (e.g. dirt) accumulated in the condensate, the MANKENBERG steam trap
KA Niagara is equipped with a drain plug.
As a feature, the MANKENBERG steam traps KA 3 and KA Niagara 83 are equipped with a temperature
controlled shut-off valve that automatically drains air and other gases by thermic steam ventilation.
danger of
fatalities
It is necessary to ensure that the materials selected for the parts of the fitting in contact with
media are suitable for the media in use. The manufacturer accepts no liability for any damage
due to corrosion by aggressive media on parts made of unsuitable materials.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pipeline system and to the fitting.
note /
danger
Shortly after start-up it has to be checked on steam traps equipped with drain screws whether
dirt has accumulated during installation or longer standstill.
Open drain screw only at low pressure in the fitting.
The drain flow must not be directed at persons
Open carefully when handling hot or toxic media, wear protective clothes, use
protective gloves!
It is recommended that the fitting should be inspected to ensure that it is functioning correctly after each new
start-up.
10 Use in hazardous areas
With an ATEX declaration of conformity are available for use in hazardous areas up to Zone 1.
note
A compensation line is to be connected to the threaded socket on the upper section of the
housing (KA 2K) and connected to the condensate collecting tank or pipe.
11 Maintenance
The automatic function of the fitting requires maintenance to ensure that it continues to operate perfectly. It is
important for maintenance work to take place in a planned manner at periodic intervals. The maintenance
plan is a recommendation by the manufacturer MANKENBERG, which should be supplemented by practical
experience gained by the user under the prevailing operating conditions. MANKENBERG shall assume no
liability resulting from improper maintenance and/or repairs.
danger
During maintenance work (apart from visual inspections) the relevant recommendations and
warning notes in Troubleshooting help [Page15] should be observed.
Failure to observe this warning may mean danger to life and limb and may cause
damage to the pipeline system and to the fitting.

Original operating manual
Steam trap KA
14
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
When a fitting that has previously been dismantled is being put back into service, the fitting should be checked
for proper sealing capacity and function as well as correct adjustment of the functional components!
Sample plan for maintenance work
Type of maintenance Work to be performed Period 1)
Check function Check whether function is fulfilled as per Intended use
[Page4]
at least 1x per
week
De-aerate housing MANKENBERG steam traps are equipped with de-
aeration. When operated manually: de-aerate until steam
or gas escape
Risk of injury
To prevent any risk for operating personnel, the drain flow
must not be directed at persons. Wear suitable protective
equipment!
Depends on the
properties of the
medium
Clean condensate tank Some MANKENBERG steam traps are equipped with a
drain screw: Remove accumulated dirt
Risk of injury
To prevent any risk for operating personnel, make sure that
this is carried out at low pressure in the fitting. Wear
suitable protective equipment!
Depends on the
properties of the
medium
Check seals on the body
and the pipe connection
Visual inspection at least 1x per
month
If installed upstream of
the fitting:
clean strainer
According to the manufacturer's instructions Depends on the
contamination of
the medium
Preventive maintenance Dismantle fitting, see Troubleshooting help [Page15].
Visual inspection of the functional parts. Replace all parts
of the maintenance set 2)
at least 1x per
year
1) See comment at the beginning of this section: The time intervals are guides which should be adapted to
match the prevailing operating conditions, the properties of the medium in the system and the user's
experience.
2) Request maintenance set and replacement instructions from MANKENBERG

Original operating manual
Steam trap KA
15
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
12 Troubleshooting help
Be sure to observe Safety instructions [Page5] when rectifying faults. Spare parts must be ordered with all the
details on the nameplate. Only original parts from the manufacturer MANKENBERG may be installed.
MANKENBERG experts are available to help in rectifying faults as quickly as possible. See Further information
[Page17] for the addresses.
note
If functional or corrosion damage is detected during maintenance or after a fault:
consult MANKENBERG to find out whether a more suitable fitting is available or whether the
damaged part can be supplied in a better-suited material.
Type of fault Action
Leakage at a connection
body parts (flange or clamp
ring):
reseal connection
Tighten the screws clockwise (tighten flange screws crosswise).
If the screws of the body connection have to be loosened or removed (=
unscrewing in the anticlockwise direction):
Danger of fatalities
To prevent any risk for operating personnel, make sure that this repair
measure is only carried out on a section of pipe that is not under pressure.
Take note of Special hazards [Page5] and then Installation [Page8].
Functional fault
Medium is constantly
draining from leakage of the
seat:
Clean the functional parts
Possible reasons:
» A foreign object may be jammed in the seat and be preventing proper
sealing
» or float/lever are moving to heavy due to dirt, deposits or corrosion
Cleaning is necessary: The fitting must be disassembled
Danger of fatalities
To prevent any risk for operating personnel, make sure that this repair
measure is only carried out when the fitting is not under pressure. Take note
of Special hazards [Page5].
When the fitting is not under pressure, disassemble the fitting by releasing
the screw connection of the housing (clamp rings or flange) and dismantle
the functional parts for cleaning. Here all parts of the maintenance set
should be renewed.
Afterwards, assemble the fitting and reassemble it, as described in
Installation [Page8].

Original operating manual
Steam trap KA
16
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
Type of fault Action
Functional fault:
Cleaning alone – see above
– cannot rectify the fault:
The fitting must be
repaired
If during cleaning it is found that the seat sealing, the float, the lever or other
functional parts are damaged:
Repair is necessary: damaged parts have to be replaced
If the repair is to be carried out in the customer's workshop:
make a note of all data according to the markings on the fitting and order the
spare parts and necessary instructions from MANKENBERG. See Further
information [Page17] for addresses.
or:
Send the fitting to the manufacturer for repair. See Further information
[Page17] for the addresses

Original operating manual
Steam trap KA
17
KA-4.X.23.1 Issue 18.12.2023 www.mankenberg.com
13 Information on REACH and RoHS
13.1 Declaration on the REACH Regulation 1907/2006
The Mankenberg product provided may contain candidate substances (SVHC) in a concentration of less than
0.1% (w/w) in accordance with the Candidate List (REACH Regulation, Article 33); as per January 2021.
13.2 Declaration on the RoHS Directive 2011/65/EU
Mankenberg products are not electrical or electronic equipment and therefore do not fall within the scope of
RoHS Directive 2011/65/EU (RoHS, Article 2, paragraph 1 or Annex I).
14 Further information
You can obtain these instructions, the MANKENBERG data sheets quoted as well as further information –
including English language versions – from the following addresses:
Mankenberg GmbH
Spenglerstrasse 99
D-23556 Lübeck
Phone [phone]
Fax [phone]
E-Mail [email protected]
www.mankenberg.de

Originalbetriebsanleitung
Kondensatableiter KA
18
KA-4.X.23.1 Stand 18.12.2023 www.mankenberg.com
1 Einleitung
Diese Anleitung soll den Anwender eines MANKENBERG Kondensatableiters KA bei Einbau, Betrieb und
Wartung unterstützen. Lesen Sie diese Anleitung komplett durch, bevor Sie diese Armatur einbauen oder in
Betrieb nehmen.
Achtung
Wenn die nachfolgende Anleitung – insbesondere die Achtungs- und Warnvermerke –
nicht befolgt wird, könnten daraus Gefahren entstehen und die Gewährleistung des
Herstellers unwirksam werden. Für technische Hilfestellung und Rückfragen steht
MANKENBERG zur Verfügung. Adressen siehe Abschnitt Weitere Informationen [Seite31]
Technische Informationen auch unter www.mankenberg.com
2 Bestimmungsgemäße Verwendung
Ein MANKENBERG Kondensatableiter KA ist dazu bestimmt, anfallendes Kondensat aus gas- oder
dampfführenden Systemen abzuleiten. Der Ableiter soll zu diesem Zweck an einem Tiefpunkt des
Rohrleitungsabschnitts installiert sein, um möglichst effektiv das Kondensat zu sammeln.
Diese Funktion erfolgt automatisch (ohne zusätzliche elektrische/pneumatische Energie): Abhängig vom
Flüssigkeitsstand regelt ein Schwimmer mit Hebelübersetzung den Abfluss aus dem Gehäuse des
Kondensatableiters.
Der Schwimmer in der Armatur ist für (nicht schäumendes) Kondensat mit einer Dichte wie Wasserkondensat
bei Sattdampftemperatur dimensioniert. Die Verwendung für Kondensat mit abweichender Dichte muss mit
MANKENBERG abgestimmt sein.
Für die Auswahl und Auslegung der passenden Armatur geben MANKENBERG-Planungsunterlagen dem
Anwender präzise Hilfestellung, z.B.:
Im Abschnitt <KA: Regelarmaturen für Niveau>:
<Auswahlrichtlinien: Bemessung von Leitungen hinter dem Kondensatableiter>
<Typblätter KA...> mit technischen Daten und Tabellen der Abmessungen.
Hinweis
Kondensatableiter mit metallischer Dichtung sind keine Absperrorgane, die einen dichten
Ventilabschluss gewährleisten. Sie können in der Schließstellung nach DIN EN 60534-4 und/
oder ANSI FCI 70-2 eine Leckrate entsprechend der Leckageklasse III aufweisen:
Leckageklasse III (metallisch dichtender Kegel) = 0,1 % Kvs-Wert
MANKENBERG-Armaturen werden standardmäßig für verschraubte oder geflanschte Rohrleitungs-/
Behälteranschlüsse geliefert – auf Wunsch auch für Sonderanschlüsse.
Die obere Grenze der zulässigen Betriebsdaten Druck und Temperatur ist auf jeder gelieferten Armatur
dauerhaft gekennzeichnet.

Originalbetriebsanleitung
Kondensatableiter KA
19
KA-4.X.23.1 Stand 18.12.2023 www.mankenberg.com
3 Sicherheitshinweise
3.1 Allgemeiner Sicherheitshinweis
Für eine Armatur gelten dieselben Sicherheitsvorschriften wie für das System, in das sie eingebaut ist. Die
vorliegende Anleitung gibt nur solche Sicherheitshinweise, die für die Armatur zusätzlich zu beachten sind.
3.2 Spezielle Sicherheitshinweise für den Betreiber
Die folgenden Voraussetzungen für die bestimmungsgemäße Verwendung einer Armatur sind nicht in der
Verantwortung des Herstellers, sondern müssen vom Verwender sichergestellt werden:
» Die Armatur darf bestimmungsgemäß nur so verwendet werden, wie im Abschnitt Bestimmungsgemäße
Verwendung [Seite18] beschrieben ist.
» Nur sachkundiges Fachpersonal darf die Armatur einbauen, bedienen und warten. Sachkundig im Sinne
dieser Anleitung sind Personen, die aufgrund ihrer Ausbildung, Sachkenntnis und Berufserfahrung die ihnen
übertragenen Arbeiten richtig beurteilen, korrekt ausführen und mögliche Gefahren erkennen und beseitigen
können.
» Das Rohrleitungssystem muss fachgerecht so ausgelegt und verlegt sein, dass die Armatur spannungsfrei
montiert und betrieben werden kann.
» Die Armatur muss korrekt und in der richtigen Einbaulage eingebaut sein.
» Im Rohrleitungsabschnitt sollen die üblichen Durchflussgeschwindigkeiten im Dauerbetrieb nicht
überschritten werden und abnormale Betriebsbedingungen wie Schwingungen, Wasserschläge und
Kavitation vermieden werden oder – soweit nicht zu vermeiden – im Vorwege mit dem Hersteller abgeklärt
sein.
» Die herrschenden Betriebsbedingungen müssen den Grenzen der Auslegungsdaten, die in der
MANKENBERG-Auftragsbestätigung genannt sind, entsprechen.
» Harte oder scharfe Gegenstände im Durchflussmedium könnten innenliegende Funktionsteile der Armatur
beschädigen.
» Der Armatur soll deshalb ein geeigneter Schmutzfänger oder Filter vorgeschaltet werden.
» Der Korrosionsschutz der Armatur muss den Umgebungsbedingungen vor Ort angepasst werden.
» Die Armatur darf nicht mit einer Wärmeisolierung umhüllt werden.
In den nachfolgenden Abschnitten sind zu einigen dieser Voraussetzungen detaillierte Hinweise gegeben.
3.3 Besondere Gefahren
Lebens-
gefahr
Vor dem Ausbau einer Armatur aus dem System oder Zerlegen einer Armatur, die teilweise
dort verbleibt, muss der Druck im System vordruck- und hinterdruckseitig ganz abgebaut
sein, damit das Medium nicht unkontrolliert austritt.
Bei toxischen oder gefährlichen Medien muss das System vollständig entleert sein, bevor die
Armatur ausgebaut wird.
Vorsicht bei Rückständen, die nachfließen könnten.
Achtung
Wenn eine Armatur aus einem System mit toxischem Medium ausgebaut und aus der Anlage
herausgebracht wird:
Die Armatur muss vor der Reparatur fachgerecht dekontaminiert werden.

Originalbetriebsanleitung
Kondensatableiter KA
20
KA-4.X.23.1 Stand 18.12.2023 www.mankenberg.com
4 Kennzeichnung der Armatur
Jede Armatur trägt mindestens die folgenden Kennzeichnungen:
Für Kennzeichnung Bemerkung
Hersteller MANKENBERG Adresse siehe Abschnitt Weitere
Informationen [Seite31]
Armaturenbauart Kondensatableiter + Typ Bauartbezeichnung lt. zugehörigem
MANKENBERG-Datenblatt
Nennweite z.B. DN oder G und Zahlenwert Zahlenwert für DN in [mm], für G in [inch]
(Zoll)
Nenndruck PN oder Class und Zahlenwert Zahlenwert für PN in [bar], für Class in [lbs/
square inch], Druckangaben sind Überdruck
über dem Atmosphärendruck, Zahlenwerte
der unteren und oberen Grenzen
Arbeitsdruckbereich Betriebsdruck und Zahlenwerte
Max. zul. Temp. Temperatur und Zahlenwert Temperaturen über 50 °C führen zu einer
Abschwächung der Druckfestigkeit. Diese ist
entsprechend der Norm DIN EN 1092 für
den jeweiligen Werkstoff zu berücksichtigen
Gehäusematerial z.B. CrNiMo-Stahl CrNiMo-Stahl = hochlegierter austenitischer
Stahl
Durchflussrichtung mit Pfeil gekennzeichnet
ATEX-Schutzklasse Außen
Ex II 2G IIB TX +1°C<Ta<80°C
Innen
Ex II 1G IIB TX +1°C<Ta<80°C
nur bei Geräten mit ATEX-
Konfirmitätsbescheinigung
Die Kennzeichnungen (bei Armaturen aus tiefgezogenem Edelstahl am Gehäuse eingeätzt) sollen weder
abgedeckt noch überstrichen werden, damit die Armatur identifizierbar bleibt.