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UNA 23

UNA 25

UNA 26

GESTRA Steam Systems

GESTRA

Installation Instructions 810516-05Steam TrapsUNA 23, UNA 25, UNA 26

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Contents

Usage for the intended purpose .............................................................................................................. 7

Safety note ............................................................................................................................................. 7

Danger ................................................................................................................................................... 7

Ratings pursuant to article 9 of the PED ................................................................................................. 7

Important Notes

Page

Explanatory Notes

Scope of supply ...................................................................................................................................... 8

Description ............................................................................................................................................. 8

Function ................................................................................................................................................. 8

Technical data ................................................................................................................................. 9, 10

Corrosion resistance ............................................................................................................................ 10Sizing ................................................................................................................................................... 10

Name plate / marking ........................................................................................................................... 10

UNA 23, 25, 26 .................................................................................................................................... 11

Heat treatment of welds ....................................................................................................................... 12

Hand vent valve .................................................................................................................................... 12

Installation

Maintenance

Check steam trap ................................................................................................................................. 13

Clean / exchange control unit ................................................................................................................ 13

Clean / exchange sightglass cover ........................................................................................................ 14

Torques ................................................................................................................................................ 15

Spare Parts

Spare parts list ............................................................................................................................... 16, 17

Hand vent valve .................................................................................................................................... 12

Float lifting lever .................................................................................................................................. 12

Operation

Commissioning

UNA 23, 25, 26 .................................................................................................................................... 12

Annex

Declaration of conformity ..................................................................................................................... 18

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PMX

QC

[kg/h]

QH

[kg/h]xF

1 1.1 1.18 1.2 1.3 1.4 1.48 1.53

AO 13

AO 4

[kg/h]

70006000

5000

4000

3000

2000

1000

800

600

500

400

300

200

100

Factor F

[lb/h]

20000

15000

10000

8000

6000

5000

4000

3000

2000

1000

800

600

500

400

300

200

1 2 3 4 6 8 10 20 30 40 60 80100 200 300 465 psi

Orifice 32

Orifice 13Orifice 4

Capacity Chart

Fig. 1

Orifice 2, DN 40+ 50 mm (1+ 2")

Orifice 4, DN 40+ 50 mm (1+ 2")

Orifice 8, DN 40+ 50 mm (1+ 2")

Orifice 13, DN 40 + 50 mm (1 + 2")

Orifice 22, DN 40 + 50 mm (1 + 2")

Orifice 2, DN 15 25 mm ( 1")

Orifice 32, DN 40 + 50 mm (1 + 2")

Orifice 4, DN 15 25 mm ( 1")

Orifice 8, DN 15 25 mm ( 1")

Orifice 13, DN 15 25 mm ( 1")

Orifice 22, DN 15 25 mm ( 1")

Orifice 32, DN 15 25 mm ( 1")

1

2

3

4

5

5

6

7

8

9

0

!

12

7

0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 6 8 10 20 32 bar

34

5

6

80

!

9

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Dimensions

Fig. 2

A

C

D

E

FH

F

FI

H

F

J

K

O

NM

L

B

G

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Parts Drawings

Fig. 4

Fig. 3

P

BO

Q

V

T

T S

R

U

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Key

A Hexagon-socket screw

B Name plate

C Control unit Simplex

D Body gasket (graphite/CrNi)

E Hand vent valve

F Gasket 17 x 23

G Control unit Duplex

H Plug 3/8" BSP

I Float lifting lever with handle

J Cover

K Hexagon-socket screw

L Orifice

M Seat gasket (graphite/CrNi)

N Deflector

O Body

P Hexagon nut

Q Fixing stud

R Hexagon-socket screw

S Flange for sightglass cover

T Gasket (graphite/CrNi)

U Water-level gauge glass

V Sightglass cover

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Category

Nominal size DN 15 25 40 50 40 50 40 50

CE marking no no yes no

Type all UNA 23 UNA 25/26

Important Notes

Usage for the intended purpose

Use steam trap type UNA 23 / UNA 25 / UNA 26 only for the discharge of condensate within theadmissible pressure/temperature ratings.Contact the factory for specific recommendations concerning the chemical resistance and suitability ofthe valve material for the application in question.

Danger

The steam trap is under pressure when the system is operating.When loosening flanged connections or plugs hot water or steam might escape.This presents the danger of severe scalding. Before carrying out any installation ormaintenance work it is therefore essential to isolate and depressurize the trap.

The trap is hot during operation. This presents the danger of severe burns. Before carryingout any installation or maintenance work make sure that the trap is cold.

Sharp-edged internals might cut your hands. Wear protective gloves when replacinginternals.

Safety note

The equipment may only be installed by qualified staff.

Qualified staff are those persons who through adequate training in engineering, the use andapplication of equipment in accordance with regulations concerning steam systems, and first aid &accident prevention have achieved a recognised level of competence appropriate to the installation

and commissioning of this device.

Ratings pursuant to article 9 of the PED1)

Fluid gas liquid

Fluid group 1 2 1 2

Use no yes no yes

Exception pursuant

to article 3.3

UNA 26HFlange Class 150

Exception pursuant

to article 3.3

Exception pursuant

to article 3.3

1) PED = Pressure Equipment Directive

I

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Explanatory Notes

Scope of supply

UNA 23

1 Steam trap UNA 231 Installation manual

UNA 25

1 Steam trap UNA 25

1 Installation manual

UNA 26

1 Steam trap UNA 26

1 Installation manual

Description

UNA 23, UNA 25 and UNA 26 are ball float traps with rolling ball closing mechanisms.The steam traps work independently of back pressure, thus ensuring universal application.UNA 23/UNA 25/UNA 26 features a body with bolted cover and a control unit. Two different controlunits are available: Level-dependent SIMPLEX control for cold condensate and temperature-dependent DUPLEX control with automatic deaeration for saturated steam systems.

Optional item: sightglass cover with integral water-level gauge glass (UNA 23, PN 16).

suitable for large condensate flowrates

asbestos-free body gasket (graphite/CrNi)

horizontal or vertical installation (dependent on body design)

Function

The ball valve of the control unit is operated by the float as a function of the condensate level in thetrap. The cross-sectional area (CSA) of the orifice dictates the max. flowrate when the valve iscompletely open. The max. admissible differential pressure of the control unit is a function of the CSAof the orifice and the density of the fluid to be discharged. There are six different closing units (orifices)

available which can also be exchanged subsequently. Float traps equipped with control units DUPLEXenable automatic temperature-dependent deaeration of saturated steam systems during start-up andin continuous operation.

UNA 2. . . with Simplex control1 Hand vent valve with gasket

Design with float lifting leverFloat lifting lever installed1 Lever extension

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Technical Data

Pressure/Temperature Ratings*) UNA 23 H / V, PN 16

Body material Gey cast iron EN-JL 1040 (GG-25)

Nominal sizes (DN) 15, 20, 25, 40, 50 mm

End connections Flanged to EN 1092-2, form B

Max. service pressure PMA [barg] 16 (230 psig) 11.2 (163 psig) 9.6 (140 psig)

Related temperature TMA [C] 120 (248 F) 250 (482 F) 300 (572 F)

*) When used for the intended purpose.

Explanatory Notes continued

Orifices (O)UNA 23 UNA 25, UNA 26

O 2 2 bar ( 30 psi) X X

O 4 4 bar ( 60 psi) X X

O 8 8 bar (115 psi) X X

O 13 13 bar (185 psi) X X

O 22 22 bar (320 psi) X

O 32 32 bar (465 psi) X

Max. admissible dif-ferential pressure 1) 2)

PMX [bar]

1) Observe pressure/temp. specifications.2) Inlet pressure minus outlet pressure.

Pressure/Temperature Ratings*) UNA 25 H / V, PN 40

Body material S.G. (ductile) iron EN-JS 1025 (GGG-40.3)


End connections Flanged to DIN PN 40

Max. service pressure PMA [barg] 38 (550 psig) 32 (465 psig) 25 (360 psig)


Pressure/Temperature Ratings*) UNA 26 H, PN 40

Body material Cast steel 1.0460 (C 22.8) / ASTM A 105

Nominal sizes (DN) 15, 20, 25 mm

End connections Flanged to DIN PN 40, ASME Class 300

Screwed BSP or NPTButt-weld, socket weld



Pressure/Temperature Ratings*) UNA 26 H, PN 40

Body material Cast steel 1.0619 (GS-C 25)

Nominal sizes (DN) 40, 50 mm

End connections Flanged to DIN PN 40, ASME Class 300Screwed BSP or NPT

Butt-weld, socket weldMax. service pressure PMA [barg] 33 (479 psig) 26 (377 psig) 21 (305 psig)


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Explanatory Notes continued

Technical Data continued

When used for its intended purpose the safe functioning of the steam trap will not be impaired bycorrosion.

Corrosion Resistance

The trap body must not be subjected to sharp increases in pressure. Welds and flanges of the trap aredesigned to withstand dynamic loading (bending and alternative stress).The dimensional allowances for corrosion reflect the latest state of technology.

Sizing

Design specifications and ratings according to EN 19 and EN ISO 26652 are indicated on the name plate

and trap body / cover. Design UNA 2 . . . h: for horizontal lines

UNA 2.. . v: for vertical lines

SIMPLEX / DUPLEX: Type of control unit (cf. Description)additional P: with Perbunan ball (max. 40 C)additional R: with inner vent tube

Orifice: Type of orifice

Stamp on name plate, e. g. specifies the manufacturing year and the quarter,

in this case the 4th quarter in 2000.

Pressure/Temperature Ratings*) UNA 26 H , Flanged to Class 150

Body material Cast steel 1.0460 (C 22.8) / ASTM A 105 DN 15, 20, 251.0619 (GS-C 25) DN 40, 50


End connections Flanged to ASME Class 150

Max. service pressure PMA [barg] 16.9 (247 psig) 12.1 (174 psig) 6.5 (94.3 psig)


Pressure/Temperature Ratings*) UNA 26 V, PN 40

Body material Cast steel 1.0619 (GS-C 25)


End connections Flanged to DIN PN 40



*) When used for the intended purpose.

4

00

Name Plate/ Marking

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1. Take care of correct position of installation. Name plate B must always be on top.

2. Take care of flow direction. The flow arrow is on the trap body.

3. Remove plastic plugs. They are only used as transit protection.

4. Clean socket-weld ends.

5. Arc-weld trap only manually (welding process 111 and 141 in accordance with DIN EN 24063).

Socket-Weld Traps




4. Clean seating surfaces of both flanges.

5. Install steam trap.

Flanged Traps




4. Clean threads of screwed sockets.

5. Install steam trap.

Screwed-Socket Traps

1 Take care of correct position of installation. Name plate B must always be on top.



4. Clean butt-weld ends.

5. Arc-weld trap only manually (welding process 111 and 141 in accordance with DIN EN 24063) oruse gas-welding process (welding process 3 in accordance with DIN EN 24063).

Butt-Weld Traps

Installation

The float traps can depending on their body design be installed in horizontal or vertical pipelines withdownward flow.

UNA 23, UNA 25, UNA 26

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Installation continued

Attention

Only qualified welders certified e.g. according to DIN EN 287 may weld the steam trapinto pressurized lines.

A subsequent heat treatment of the welds is not required.

Heat treatment of welds

1. Remove plug H.

2. Insert gasket F, fit hand vent valve E in place and tighten with a torque of 75 Nm.

3. Close the hand vent valve.

Hand vent valve

Spanner A.F. 17mm to DIN 3113, form B

Torque spanner 20 120 Nm, to DIN ISO 6789

Tools

CommissioningBefore commissioning make sure that the hand vent valve and the float-lifting lever are firmly attachedto the trap and do not leak.

Operation

1. Take heed of the note Danger on page 7.

2. Open the hand vent valve if necessary.

3. Close hand vent valve firmly after the venting process.

Hand vent valve


2. Attach handle to float-lifting lever I, Fig. 2.

3. Turn float-lifting lever I according to the direction arrow on the cover J.

4. Turn float-lifting lever I in the opposite direction of the arrow to close the valve and remove thehandle.

Float lifting lever

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WINIX 2150 is a registered trademark of WINIX GmbH, Norderstedt


2. Undo the body screws A or hexagon nuts P. Remove cover J from body O.

3. Unscrew hexagon-socket screws K, remove control unit C or G and orifice L.

4. Replace control unit C or G and orifice L in case of visible signs of wear or damage.

5. Clean body, internals and all gasket surfaces.

6. Apply heat-resistant lubricant to all threads and the seating surfaces of the closing unit and cover(use for instance WINIX 2150).

7. Insert orifice L, attach control unit C or G and tighten screws K alternately with a torque of10 Nm (DN 40 and 50 mm) or 5 Nm (DN 15 25 mm).

8. Insert a new body gasket D.

9. Put cover onto the body. Tighten body screws A or hexagon nuts P alternately in several steps tothe torque indicated in the table on page 15.

Clean/exchange control unit

Maintenance

GESTRA steam traps type UNA 2... do not require any special maintenance.However, if used in new installations which have not been rinsed it may be necessary to check andclean the trap.

You can check the trap UNA 2... for steam loss during operation using the ultrasonic measuring unitVAPOPHONE or the test unit TRAPtest.In case of steam loss clean the trap and/or replace the control unit or orifice (closing unit).

Check steam trap

Tools

Spanner A. F. 17, 19, 22 and 24 mm to DIN 3113, form B.

Allen key A.F. 5, 6, 10 mm to ISO 2936

Torque spanner 10 60 Nm, 60 120 Nm; DIN ISO 6789

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Maintenance continued

1. Take heed of note Danger on page 7.

2. Undo hexagon-socket screws R. Remove flange S from body V.

3. Remove and clean water-level gauge glass U.

4. Replace water-level gauge glass U and gaskets T in case of visible signs of wear or damage.

5. Clean all gasket surfaces.

6. Apply heat-resistant lubricant to all threads and seating surfaces of the flange(use for instance WINIX 2150).

7. Insert gasket T and water-level gauge glass U. Install flange S and tighten the screws Ralternately with a torque of 15 Nm.

Clean/ exchange sightglass cover

Attention

Do not change the factory setting of the bellows (thermostatic element).In case of inadvertent misadjustment restore the factory setting. When the float ball ispushed right down the dimension 1 (length of bellows) should be as follows:

DN 15 25 mm ( 1") control unit up to 13 bar 1= 34.5 mm

DN 15 25 mm ( 1") control unit up to 32 bar 1= 32 mm

DN 40+ 50 mm (1 + 2"), 1= 51.5 mm

1


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Torques

Item Steam trap Torque [Nm]

E H I UNA 23, UNA 25, UNA 26, DN 15 50 ( 2") 75

R UNA 23 with sightglass cover, DN 15 50 ( 2") 15

K UNA 23, UNA 25, UNA 26, DN 15 25 ( 1") 5

K UNA 23, UNA 25, UNA 26, DN 25 + 40 (1 + 1") 10

A UNA 23 h, DN 15 25 ( 1") 40

P UNA 23, DN 40 + 50 (1 + 2") 75

P UNA 25, UNA 26, DN 15 25 ( 1") 60

P UNA 25, UNA 26, DN 40 + 50 (1 + 2") 115

All torques indicated in the table are based at a room temperature of 20C.

Apply heat-resistant lubricant, e. g. WINIX 2150, to threads.


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Designation

Ref. no. Ref. no.

DN 15 25 DN 40 + 50( 1") (1+2")

Body gasket*) (graphite/CrNi) 560 491 560 492

Gasket*) C 17 x 23 mm 560 486 560 486

Sightglass gasket**) (graphite/CrNi) 560 487 560 488

Reflection sightglass

with gasket

560 481 560 480

Seat gasket*) (graphite/CrNi) 560 489 560 490

Control unit Duplex, complete Orifice 32 560 078 560 093

Orifice 22 560 077 560 092

Orifice 13 560 076 560 091

Orifice 8 560 075 560 090

Orifice 4 560 074 560 089

Orifice 2 560 073 560 088

Control unit Simplex, complete Orifice 32 560 072 560 087

Orifice 22 560 071 560 086

Orifice 13 560 070 560 085

Orifice 8 560 069 560 084

Orifice 4 560 068 560 083

Orifice 2 560 067 560 082

Spare part list

Spare Parts

Item

*) Minimum order quantity 20 items.

**) Minimum order quantity 10 items. Contact your local dealer for smaller quantities.

D

F

T

U T

M

G L M

K D

C L M

K D

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Designation

Ref. no. Ref. no.

DN 15 25 DN 40 + 50( 1") (1+2")

Control unit Simplex, complete560 079 560 094

without orifice

Control unit Duplex up to 13 bar, complete560 080 560 095

without orifice

Control unit Duplex above 13 bar, complete560 081 560 096

without orifice

Orifice, complete Orifice 32 560 045 560 051without control unit

Orifice 22 560 044 560 050

Orifice 13 560 043 560 049

Orifice 8 560 042 560 048

Orifice 4 560 041 560 047

Orifice 2 560 040 560 046

Hand vent valvewith gasket

560 058

Spare part list

Spare Parts continued

Item

*) Minimum order quantity 20 items. Contact your local dealer for smaller quantities.

C M K

D

G M K

D

G M K

D

L M K

E F

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Annex

We hereby declare that the pressure equipment UNA 25 and UNA 26, nominal sizes DN 40 50 mm,conform to the following European Directive:

EC Pressure Equipment Directive (PED) No. 97/23 of 29 May 1997

These steam traps are pressure equipment as defined in article 1, section 2.1.4 of the PED.

Applied conformity assessment procedure acc. to Annex III: module A.

This declaration is no longer valid if modifications are made to the equipment without priorconsultation with us.

Declaration of Conformity

Bremen, 27th November 2000GESTRA AG

Quality Assurance Representative

Walter Meyer

Head of Design Dept.

Uwe Bledschun(Academically qualified engineer)

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For your notes

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Great Britain

Flowserve Flow Control (UK) Ltd.Burrel Road, Haywards HeathWest Sussex RH 16 1TLTel. 00 44 14 44 / 31 44 00Fax 00 44 14 44 / 31 45 57

E-mail: [email protected]

Italia

Flowserve S.p.A.Flow Control DivisionVia Prealpi, 30l-20032 Cormano (MI)Tel. 00 39 02 / 66 32 51Fax 00 39 02 / 66 32 55 60E-mail: [email protected]

GESTRA ESPAOLA S.A.Luis Cabrera, 86-88E-28002 Madrid

Tel. 00 34 91 / 51 52 032Fax 00 34 91 / 4 1 36 747; 51 52 036E-mail: [email protected]

Espaa

Flowserve DALCO Steam Products2601 Grassland Drive

Louisville, KY 40299

Tel.: 00 15 02 / 4 95 01 54, 4 95 17 88

Fax: 00 15 02 / 4 95 16 08

E-Mail: [email protected]

USA

Portugal

Flowserve Portuguesa, Lda.Av. Dr. Antunes Guimares, 1159Porto 4100-082Tel. 0 0351 22 / 619 87 70Fax 0 0351 22 / 6 10 75 75

E-mail: [email protected]

Polska

GESTRA POLONIA Spolka z.o.o.Ul. Schuberta 104PL - 80-172 Gdansk

Tel. 00 48 58 /306 10 -02 od 10Fax 00 48 58 /306 33 00E-mail: [email protected]

Agencies all over the world

www.gestra.de

GESTRA AG

P.O. Box 10 54 60, D-28054 BremenMnchener Str. 77, D-28215 Bremen

Telephone +49 (0) 421 35 03 - 0

Fax +49 (0) 421 35 03 - 393E-Mail [email protected]

Internet www.gestra.de

GESTRA

Documents

INS UNA 23-25-26 EN