Rifox 1200 User manual

Operating Manual
RIFOX - Hans Richter GmbH Spezialarmaturen Fon: [phone] - 0 Internet: www.rifox.de
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: [phone] - 40 Email: [email protected]
11/2021 -Di. Subject to modifications
Page 1 of 7
Model: 1200
Model: 1200-G
Model: 1200-N
Float-Controlled Condensate Trap, PN 40
1 Safety instructions
1.1 Proper use
Any improper use, intervention in the design and deviation from the design data automatically lead to termination of the
warranty. The float-controlled condensate trap is designed for the discharge of condensate from steam, compressed air and
pressure gas systems. Any other usage is not permitted. The manufacturer is not liable for damage resulting from any other
usage. The user or operator bears the risk in this case. This also applies analogously to incorrect assembly, start-up, use and
maintenance.
1.2 Warnings and symbols
■Personal risk due to escaping operating medium because of pressure, temperature and weight. Failure to comply with
these warnings results in the risk of accidents.
■Follow the instructions in this operating manual.
■The operator must ensure that this operating manual and, if necessary, other relevant documents are available on site.
■Only trained or instructed personnel may be assigned to handling this equipment.
■Any mode of operation that may impair safety must be avoided.
2 General description and usage
2.1 Design of the condensate trap
Additional equipmentAdditional equipment
Picture 1: Model 1200
Model 1200-G
Picture 2: Model 1200-N: without RIFObi air venting
1Housing flange part
2Housing gasket
3Housing side part
4Control screw
5Housing screws
6Screw plug
7Protective sleeve
8Supporting screw
9Float control assembly
10 Supporting body assembly with
rotary valve and cotter pin
11 Float with fork
12 Maxosglas
13 RWG frame
14 2 Gaskets for RWG
15 RWG screws
16 Gasket
17 Gasket
18 Gasket

Operating Manual
RIFOX - Hans Richter GmbH Spezialarmaturen Fon: [phone] - 0 Internet: www.rifox.de
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-Di. Subject to modifications
2.2 Operation limits of housing material (Design)
■For Model 1200:
max. operating pressure (bar g) 40 37 35 32 28 24 21
max. operating temperature (°C) <120 150 200 250 300 350 400*
* only with screw material A4-70/ 1,4571/ 1.4104
■For Model 1200-G:
max. operating pressure (bar g) 40 37 33 27
max. operating temperature (°C) -10/20 100 200 300
■For Model 1200-N:
max. operating pressure (bar g) 40 33,7 29,7 27,4
max. operating temperature (°C) 100 200 300 400
2.3 Function limit of control unit
Cross section
max. line pressure in bar g
Steam Compressed air
IIa 32 40
III 12 16
IV 11 14
V 2,5 3
VI 20 30
VIa 32 32
VII 18 25
VIIIa 4,5 5,5
2.4 Discharge capacity
Discharge capacity in kg/h
0,1 0,2 1 1,5 2 3 640,01 0,02 0,03 0,05 0,3 0,80,5 8 32 401310 2516
30
20
80
60
40
200
150
100
300
600
400
800
1000
1500
2000
3000
4000
DN 15/20/25
Pressure difference in bar (with reference to atmospheric pressure)
Discharge capacity in kg/h
0,1 0,2 1 1,5 2 3 640,01 0,02 0,03 0,05 0,3 0,80,5 8 32 401310 2516
80
60
200
150
100
300
600
400
800
1000
1500
2000
3000
4000
6000
8000
10000
DN 40/50
Pressure difference in bar (with reference to atmospheric pressure)
Picture 4
Picture 3
For the cold condensate the discharge capacity is higher because of medium temperature and density.
2.5 Function
■Due to the gravity the condensate flows downwards to the lowest point, which is the condensate trap housing. In the
lowest position of the float the outlet cross-section is close. Rising of the liquid level lifts the float and opens the outlet.
Condensate will be discharged through the upturned immersion tube. Decreasing condensate level closes the outlet again.
2.6 Compensation line
■In order to get proper function, the non-condensable gas must be able to leave the housing. Due to the vertical installation,
the non-condensable gas is able to leave the housing and flows into the steam/gas chamber above it, which has the same

Operating Manual
RIFOX - Hans Richter GmbH Spezialarmaturen Fon: [phone] - 0 Internet: www.rifox.de
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: [phone] - 40 Email: [email protected]
11/2021 -Di. Subject to modifications
Page 3 of 7
pressure level. If the self-venting through the pipe must be extended, the control screw (4) can be
replaced by a cutting ring screw bolt and a compensation line can be installed leading upwards.
2.7 Automatic venting
■For Model 1200 and 1200-G: RIFObi-automatic bimetal venting valve (venting to inte-
rior): The valve is opened in cold conditions, e.g. during the start-up and when air comes into the
steam trap during the operation. The valve is closed when only steam exists in the steam trap.
See Picture 5.
■For Model 1200-N: without RIFObi-automatic bimetal venting valve
2.8 Gastight under-level float control (only for gas applications)
■For gas applications, a gastight under-level float control is nearly exclusively used. Consult with Rifox, if necessary.
When using submerged-gastight control units, please note:
The valve orifice is always under an condensate surface.
If the gas is mixed or dissolved with the condensate, there can be no separation inside the steam trap.
Small amounts of gas can separate from the condensate at the outlet.
In these cases a degassing line at the outlet towards uncritical areas (via the roof for example) may be recommended.
A horizontal inflow can calm the condensate flow and support the self-degassing to separate the gas from the condensate.
When using an angular version (EF) condensate enters from above and can also bring gas into the housing.
With an inlet from below, the degassing happen before the trap, the automatic degassing is most effective.
Traps with submerged-gastight control units should not be used at above 90°C or its use should be clarified with RIFOX in
advance.
3 Assembly
3.1 Flow Direction
Picture 6
Vario WR Vario WL Vario SO Vario SU
■Vario-WR: Flow direction horizontal from right to left
■Vario-WL: Flow direction horizontal from left to right
■Vario-SO: Flow direction vertical from top to bottom
■Vario-SU: Flow direction vertical from bottom to top
3.2 Modification for a different flow direction
The RIFOmat Vario is delivered according to the purchasing specification, as shown in Picture 6. It can be quickly installed
on site for a different flow direction, without any problem. Here is an example:
The RIFOmat Vario 1200 / 1200-G / 1200-N has been delivered as Vario-SU and has to be mounted as Vario-WR.
■Unscrew the housing hexagon nuts and remove the housing side part (3) sideways.
■Loosen the supporting screw (8) by unscrewing it for 1 - 2 full turns.
■Use a plastic hammer to loosen the float control assembly (9) from its conic housing seat by lightly stroking on the the
supporting screw (8) .
■Reposite the housing flange part (1) by turning it 90°.
■Reposite the float control assembly (9), so that the tube (T) pointing vertical downwards.
■Screw in the supporting screw (8) with gasket (17). Tighten it with a standard ring wrench or a open jawed wrench, size
27. Tightening torque according to Section 6.6.
■Replace the housing gasket (2) if damaged, and mount on the lateral part of housing side part (3).
Picture 5
Bimetal

Operating Manual
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■Tighten housing bolts evenly crosswise. Tightening torque according to Section 6.6.
3.3 Modification for restricted space and horizontal flow
In the case of only minimal space for the housing, which projects to the side, the housing side part (3) can be mounted to-
wards to the front or towards the rear by repositioning the housing flange part (1) for the purpose of better maintenance or
better visual inspection of a built-on reflective water level gauge, etc.
3.4 Installation
■The condensate trap Vario 1200 / 1200-G / 1200-N has to be screwed into a pipeline between flanges.
■Remove transport caps from inlet and outlet.
■Fitting direction: according to Picture 6. The condensate flow is in the direction of the arrow (note arrow on housing flange
part (1) ). The housing is positioned to the side. The word TOP on the housing side part is at the top and must be legible
horizontally.
■Supporting brackets: The supporting brackets are not necessary for DN15/DN20/DN25 if the pipeline is adequately sup-
ported before and after the condensate trap. Condensate traps for DN40/DN50 weight over 37 kg, ensure thus proper fixing
of the pipeline in front of and behind the condensate trap.
■To avoid downtimes, it is recommended to install stop valves with bypass to pipeline, both in front of and behind the con-
densate trap.
4 Start-Up
The pressure build-up and heating-up of the housing should not take place abruptly. If leakage is detected after the first
inspection, the screws (4 / 5 / 6 / 8 / 15) can be fixed under consideration of the given torque moments, as given in Section
6.6. The screws can only be tightened on when the housing is unpressurized and at room temperature.
5 Observation and check
The function’s failure can be observed either as condensate blockage or as gas/ steam leakage.
■Condensate blockage can be determined by a): loosen the control screw (4) for a quarter rotation, while no condensate
leakage should occur; and by b): a surface thermometer on the housing for steam applications (if necessary, please consult
with Rifox).
■Gas / steam leakage: can be determined by an ultrasonic measuring device, and for steam applications by a surface
thermometer. In case of steam leakage, open the condensate trap according to Section 6.1. Make sure that float (11) can be
easily moved. If necessary, disassemble and clean the float control assembly (9). If damages/ wears are detected on parts or
on the sealing surface, the complete float control assembly (9) should be replaced.
6 Maintenance / Inspection
6.1 Opening the steam trap and dismantling the float control
■The steam trap must be depressurized. Shut off the system securely in front of and behind the steam trap.
■Release any remaining pressure in the housing by loosening the control screw (4) by only a quarter turn.
■Dismantle the steam trap from the pipeline system. Condensate traps for DN40/DN50 weight over 37 kg, apply thus lifting
device.
■Loosen the housing screws (5) evenly crosswise.
■Remove the housing side part (3).
■Loosen the supporting screw (8) and screw out 1 to 2 turns.
■With a few light strokes using plastic hammer on the front side of the supporting screw (8) to loosen the float control as-
sembly (9) from the conic housing seat.
■Screw out the supporting screw (8) completely. Take out the float control assembly (9).

Operating Manual
RIFOX - Hans Richter GmbH Spezialarmaturen Fon: [phone] - 0 Internet: www.rifox.de
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Page 5 of 7
6.2 Disassembling, cleaning and assembling the float control (Picture 7)
■After removing the cotter pin (p), the rotary valve (v) can be simply pulled out
to the side.
■Clean the parts using, for example, benzine.
■Check the rotary valve (v) for wear along the sealing edge. If wear is detected,
the support body (b) together with the rotary valve (v) must be replaced. The
exactly leakage test must be carried out by RIFOX.
■During assembly ensure that the notch in the rotary valve (v) points to the
punch mark on the support body (b) and the cotter pin (p) is inserted and secured
again carefully.
■It must be possible to move the float up and down easily by hand.
6.3 Installation of the float control assembly and assemble the condensate trap
■ To install the control unit in Model 1200-N (Housing material: stainless steel), please use the delivered installation set.
(Copper gasket and installation bolt).
■The complete float control assembly (9) is inserted into the conical housing seat with the support body. It must be ensured
that the tube is positioned vertically downwards.
■ Screw in the installation bolt with copper gasket into the thread of the supporting body and tighten it with a wrench.
(Tighten torque see Sec. 6.6). Screw out the installation bolt, replace the copper gasket with a standard gasket (11). Atten-
tion: This step is only for Model 1200-N!
■Screw in the supporting screw (8) with gasket (17) and tighten evenly crosswise using a standard ring wrench. Tightening
torque according to Section 6.6.
■Check the housing gasket (2), replace it it is damaged.
■Put on the housing flange part (1).
■Tighten the housing screws (5) evenly crosswise. Tightening torque according to Section 6.6.
6.4 RIFObi automatic venting valve for Model 1200 / 1200-G (Picture 8)
Function: Startup and continuous venting takes place inward, i.e. towards the conden-
sate side. Near the temperature of ebullition the bimetal valve closes. When the tempera-
ture drops, the bimetal valve opens.
Replace the bimetal valve (10.3):
■Dismantle the complete float control assembly (9) as described in Section 6.1.
■Loosen the hexagon nut (10.5) with wrench size 5.
■Dismantle the Bimetal valve (10.3).
■Visual check the seat part of valve gate (10) and of bimetal valve (10.3) for wear (cross
scoring).
■Replace the bimetal valve (10.3).
■Install the float control assembly (9) as described in Section 6.3.
6.5 Care and maintenance
■In the case of a great risk of dirt accumulation, the housing, when it is depressurized, should be rinsed thoroughly from
time to time. If necessary, the float control assembly (9) should also be checked according to Section 6.2.
■The dirt, which has been accumulated in the housing, can be removed away by screwing off the screw plug (6).
■For special applications, it is advisable to install a separate upstream strainer.
■The float control assembly (9) usually does not to be special maintained. The maintenance depends primarily on the wear
resistance of the valve gasket. See Section 6.1 and 6.2.
bpv
Picture 7
10.3
10.5
Picture 8

Operating Manual
RIFOX - Hans Richter GmbH Spezialarmaturen Fon: [phone] - 0 Internet: www.rifox.de
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11/2021
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-Di. Subject to modifications
6.6 Tightening torque
Position Part Name
Tightening Torque (Nm)
DN15, DN20, DN25 DN40, DN50
1200/ 1200-G 1200-N 1200 1200-G 1200-N
soft iron PTFE-
special 1.4571 soft iron soft iron PTFE- special 1.4571
4 Control screw 40 20 50 40 40 30 50
5 Housing screw 55 25 60 80 110 80 100
6 Screw plug 120 50 120 120 120 90 120
8 Supporting screw 110 50 95 110 110 75 98
15 RWG screw 20 20
6.7 Spare parts: Only original spare parts can be used.
Additional equipment
Additional equipment
Picture 9: Model 1200
Model 1200-G
Picture 10: Model 1200-N:
without RIFObi air venting

Operating Manual
RIFOX - Hans Richter GmbH Spezialarmaturen Fon: [phone] - 0 Internet: www.rifox.de
Bertha-von-Suttner-Str. 9 D-28207 Bremen Fax: [phone] - 40 Email: [email protected]
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Page 7 of 7
Pos. Part Name Model 1200 Model 1200-G Model 1200-N
1 Housing flange part GP240GH EN-GJS-400-18-LT (5.3103) 1.4581 / 1.4408
2 Housing gasket Soft iron Soft iron PTFE-special or 1.4571
3 Housing side part GP240GH EN-GJS-400-18-LT (5.3103) 1.4581 / 1.4408
4 Control screw: G¼“ (BSP) 1.4104 1.4104 1.4571
5 Housing screws A4-70/A4 acc. DIN 939/934 8.8 acc. DIN 939 / ISO 4032 A4-70 acc. DIN 939 / ISO 4032
6 Drain plug: G½“ (BSP) DIN 910 - 5.8 DIN 910 - 5.8 DIN 910 - A4
7 Protective sleeve 1.4571 1.4057 1.4571
8 Supporting screw 1.4104 1.4104 1.4571
9 Float control assembly 1.4057/1.4112/1.4301/1.4104
or complete 1.4571
1.4057/1.4112/1.4301/1.4104
or complete 1.4571 1.4571
9.2 Complete float control with built-on
bi-meatellic venting valve RIFObi
1.4057/1.4112/1.4301/1.4104/
SS-Hastelloy
1.4057/1.4112/1.4301/1.4104/
SS-Hastelloy 1.4571
10 Supporting body assembly with rotary
valve and cotter pin
1.4057/1.4112/1.4301/1.4104
or complete 1.4571
1.4057/1.4112/1.4301/1.4104
or complete 1.4571 1.4571
10.2
Complete Supporting Structure incl.
rotary slide valve, cotter pin and built-
on RIFObi bi-metallic venting valve
1.4057/1.4112/1.4301/1.4104 1.4057/1.4112/1.4301/1.4104 1.4571
11 Float with fork 1.4301 or 1.4571 1.4301 or 1.4571 1.4571
12 Maxosglas as per DIN 7081 as per DIN 7081 as per DIN 7081
13 RWG frame P265GH P265GH 1.4571
14 2 Gaskets for RWG poor graphite with SS Sigraflex Novaphite
15 RWG screws A4-70, DIN 938/934 A4-70, DIN 938/934 A4-70, DIN 938/934
16 Gasket for control screw Soft iron Soft iron PTFE -special or 1.4571
17 Gasket for supporting screw Soft iron Soft iron PTFE -special or 1.4571
18 Gasket for drain plug Soft iron Soft iron PTFE-special or 1.4571
7 Conformity assessment
The pressure equipment described is a pressure-keeping component in accordance with the Pressure Equipment Directive
2014/68/EU.
DN15, DN20, DN25: according to Art. 4, Subs. 3, no CE-Mark.
DN40, DN50: Conformity verified through the identifying mark: CE 0525.
A detailed declaration of conformity assessment according to PED is available as separate document. Please request if
necessary, if not attached.