User Manual for MIYAWAKI models including: DC1 Balanced Pressure Thermostatic Steam Trap, DC1, Balanced Pressure Thermostatic Steam Trap, Thermostatic Steam Trap, Steam Trap
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BALANCED PRESSURE THERMOSTATIC STEAM TRAP
DC1
USER'S MANUAL
SAFETY GUIDE
The Model DC1 is a balanced pressure thermostatic steam trap equipped with a membrane capsule (thermo element). The steam trap discharges the condensate automatically at a temperature 5°C/9°F (capsule H) or 15°C/27°F (capsule L) below saturation temperature.
In order to get maximum benefit from this product, be sure to read this manual before installing it.
The following warnings and cautions are shown at appropriate places in this manual.
WARNING
Failure to observe this type of precaution may lead to serious injury or death.
CAUTION
Failure to follow this type of precaution can lead to injury or damage to equipment and property.
Table of Contents
1 SPECIFICATIONS AND MARKINGS
1
2 CONSTRUCTION DETAILS
2
3 INSTALLATION
3
4 OPERATION
4
5 MAINTENANCE
5
6 TROUBLESHOOTING
8
7 WARRANTY
9
8 SERIAL NUMBER (S. No.) DESIGNATION
10
9 GUIDANCE FOR READING SPECIAL PRODUCT NAME
11
1 SPECIFICATIONS AND MARKINGS
WARNING Be sure not to use this product at higher pressures than the specified maximum allowable pressure (PMA) or at temperatures higher than the specified maximum allowable temperature (TMA).
The following items are displayed on the name plate or the side of the product. Check the operating characteristics to avoid misuse of the product. 1) Maximum allowable pressure (PMA): 2.1 MPa (305 psig) 2) Maximum allowable temperature (TMA): 220 °C (428 °F) 3) Maximum operating pressure (PMO): 2.1 MPa (305 psig) 4) Maximum operating temperature (TMO): 220 °C (428 °F) 5) Size: 8 - 25 mm (1/4" 1") 6) Year of production: The two leftmost digits in the four-digit or nine-digit "S. No." are
the last two digits of the year of production. 7) Flow direction: Shown by an arrow 8) Body material: Stainless steel SCS13A 9) Model: Showing the product model name
z Some pictures and illustrations in this manual are examples of DC1 models. For more details regarding dimensions and other specifications, please refer to the catalog.
The model DC1 fully complies with the requirements of the European Pressure Equipment
Directive 2014/68/EU. It is classified according to Article 4, Section 3 of the PED, which
does not allow to bear the CE marking.
1
2 CONSTRUCTION DETAILS
2
3 INSTALLATION
WARNING Pay very careful attention when working in hazardous environments. There is a risk of explosion and the possibility of dangerous gases leaking. Always check whether the pipeline contains flammable, high pressure or high temperature materials before starting to work. z Make sure that isolation valves are installed on both the upstream and downstream
lines.
CAUTION
Before installing the product, open both isolation valves and the bypass valve, if
one exists, to blow out any debris or dirt inside the pipeline. After blowing out the
line, before starting to work, close the isolation valves and allow time for the
temperature to drop to a safe working temperature.
When installing the product, be sure to leave clearance for maintaining it.
1) Remove the dustproof seals covering both connections.
Products shipped in plastic bags may not have dustproof seals.
2) Check the flow direction indicated on the body.
3) The DC1 can be used for both horizontal and vertical lines. However, be sure not to
install it upside-down in a horizontal line, as it will cause the trap to malfunction.
When installing a DC1 in a horizontal line, be sure to maintain a slight slope to the
line, so that any condensate will flow smoothly to the trap.
4) Open the isolation valve on the upstream line slowly and make sure the product
works normally.
3
4 OPERATION
CAUTION Before starting operation, open the bypass valve or blow valve completely and blow off the scale in the piping.
4.1 Operation procedure
1) After blowing off the scale from the piping, close the bypass valve or blow valve. 2) Open the stop valve on the trap outlet side. 3) Open the stop valve on the trap inlet side.
4.2 Stop procedure
1) Close the stop valve on the trap inlet side. 2) Close the stop valve on the trap outlet side.
* When stopping for a long time, completely drain the condensate from the piping and trap and close the valves before and after the trap.
4
5 MAINTENANCE
WARNING z Before removing the trap from the pipe or disassembling it, be sure to close the
isolation valves. Then, release the residual pressure from the trap body (make sure that the pressure in the main body is equal to the atmospheric pressure). After it has fully cooled down (after the temperature of the main body has reached ambient temperature), confirm for safe conditions and then begin to work. z Even when the isolation valves are closed, there may be residual internal pressure due to leaks from the isolation valves. Therefore, be very careful.
CAUTION z When replacing parts, make sure the replacement parts are supplied by
MIYAWAKI.
The performance of steam traps deteriorates gradually over time due to wear, corrosion or dirt accumulating around the valve and the valve seat. Please conduct periodic diagnosis of traps in order to keep steam control systems and equipment working well.
5.1 Tools for Diagnosis Steam Traps
Dr. Trap Dr. Trap is a sophisticated steam trap management system for diagnosing steam traps automatically by measuring the vibration and temperature of the steam trap. Survey results are stored in the testing equipment and transferred to a steam trap analysis software. The software aggregates and analyses steam trap survey data, identifying faulty steam traps, providing steam loss and financial loss data, estimating CO2 emissions corresponding to leaking steam traps and providing many other analyze possibilities to manage the steam trap population easily.
Dr. Trap Jr. Dr. Trap Jr. is an inexpensive and easily to handle steam trap diagnostic system consisting of an ultrasonic checker, temperature probe and a sophisticated analysis software. The software allows to determine the condition of a steam trap, to estimate steam and financial losses and the related CO2 emissions.
For more details, please, check our homepage: https://www.miyawaki.net/en/products/steam-trap-management-system or ask our local representative.
5
5.2 Repairs
When a trap fails, it is necessary to clean the internal parts and to replace damaged parts. Take the failed trap apart following the steps below.
5.2.1 Disassembling the trap 1) Remove the cover bolts (9) and remove the cover (2) from the body (1). 2) Remove the stop spring (5) from the cover (2) and take out the membrane capsule
(thermo element) (3). Then loosen and remove the valve seat (4). 3) Remove the cover gasket (8), seat gasket (7) and screen (6).
CAUTION Clean the Body and Cover with care not to damage the sealing surface. Scratches on the sealing surface may cause steam leakage.
Take appropriate measures according to "6. Troubleshooting". After cleaning the trap and replacing damaged parts, reassemble the parts in reverse order as follows. Refer to the torque table for each part.
5.2.2 Reassembling the trap 1) Attach the screen (6) to the body (1). 2) Attach the seat gasket (7) to the body (1) and screw the valve seat (4) into the body. 3) Put the membrane capsule (thermo element) (3) in the groove of the valve seat (4). 4) Install the stop spring (5) on the cover (2).
* Since the stop spring (5) is curved, fit it in the correct orientation as shown in the illustration. (The trap will not work properly if the stop spring (5) is installed in reverse.) 5) Mount the cover gasket (8) on the body (1), put the cover (2) on the body (1) and tighten the cover bolts (9).
Torque table
Parts Valve Seat (4) Cover Bolt (9)
Tools Torque wrench Torque wrench
Across the flats 17 mm (0.67") 10 mm (0.39")
Torque 22 1ÂP 8.8 1ÂP
CAUTION
When reassembling always replace the gaskets (7) and (8) with new ones. Tighten
the bolts (9) evenly crosswise.
6
9. Bolt
2. Cover
5. Stop Spring
8. Cover Gasket
3. Membrane Capsule (Thermo Element)
4. Valve Seat
7. Seat Gasket 6. Screen
1. Body
7
6 TROUBLESHOOTING
Problem
Steam leaks or blows through.
Possible cause
Solution
Too high operating pressure.
Check operating conditions. Reduce the inlet pressure or change to another trap with higher pressure capability.
A foreign object is caught between the valve of the membrane capsule (thermo element) (3) and the valve seat (4).
Close the inlet valve once, cool the trap, and then open the inlet valve. (Blow off)
If the foreign matter cannot be removed even after blow off, disassemble and clean the membrane capsule (thermo element) (3) and valve seat (4). *1
The valve of the membrane capsule (thermo element) (3) and/or the valve seat (4) are damaged.
Replace the valve seat (4) and/or the membrane capsule (thermo element) (3) with new ones.
Steam leaks From the
from the
connection
body.
between the
body and
cover
Insufficient condensate
discharged, or no
condensate discharged.
The membrane (thermo element) damaged.
capsule Replace the membrane (3) is capsule (thermo element) (3).
The cover bolts (9) are loose. Tighten the cover bolts (9). *2
The cover gasket (8) is Replace the cover gasket (8). damaged.
Dirt accumulated in the fluid Clean the body (1). passage of the body (1)
Dirt has built up on or around Clean the valve seat (4). the valve seat (4).
The screen (6) is clogged.
Clean the screen (6).
The membrane (thermo element) damaged.
capsule Replace the membrane (3) is capsule (thermo element) (3).
*1 and *2:
Insufficient condensate capacity.
Replace the trap with a larger capacity trap.
Refer to the torque tables in Section 5, "Maintenance" to retighten the parts with
the correct torque.
8
7 WARRANTY
7.1 Warranty period The warranty period is 18 months after shipment or 12 months after installation, whichever occurs first.
7.2 Details of the warranty If the product stops working correctly within the warranty period, we will repair or replace the product free of charge if the cause of the trouble is not one of the following items. 1) The precautions described in this manual were not observed. 2) User's errors or mistakes such as an inappropriate installation or incorrect handling,
or an excessively large impact caused by dropping 3) Problems caused by devices or equipment other than MIYAWAKI's, or a disallowed
use environment 4) When a repair or modification has been performed by anyone other than MIYAWAKI
or people who are authorized to make such repairs 5) Intrusion of salt or other substances that promote significant rust or corrosion or
problems from fluids that contain the same substances 6) Consumable parts such as Packing, Gasket, O-ring, Diaphragm, etc. 7) Attachment or accumulation of foreign matter in the pipe, such as dust and scale 8) Problems from fires, natural disasters, or other force majeure which is not
MIYAWAKI's responsibility
7.3 Warranty limitation
The remedy available under the warranty shall not exceed the sales price of the products
delivered, for any cause whatsoever.
9
8 SERIAL NUMBER (S. No.) DESIGNATION
The following 4-digit or 9-digit "S. No." is displayed on the product.
)RU4-digit display
S.No.
Represents the day.
Represents the month.
Represents the year. (last two digits of the
year according to the Western calendar)
Example of serial number designation
1 7 1 1 Jan.1, 2017
2 9 X M Oct. 21, 2029
)RU9-digit display
S.No.
MIYAWAKI identification number
Represents the month.
Represents the year. (last two digits of the
year according to the Western calendar)
Example of serial number designation
1 7 1 1 2 C 0 2 0 Jan., 2017
2 9 X 0 5 M 0 5 0 Oct., 2029
Month designation system
Day designation system
10
9 GUIDANCE FOR READING SPECIAL PRODUCT NAME
Special symbol: The symbol applies only to special products (Please refer to table 1 for details)
Model symbol: Product model number
Table 1 Symbol description
Suffix Special contents
A
Trap for high-pressure gas installed property (only for Gas Trap)
C
Blow valve attached
K
Change of gasket
L
Special face to face dimension
M
Change of parts material
P, T Change of operating pressure, temperature, condensate capacity, etc.
R
Change of screen mesh
V
Change of air vent
X
Other than mentioned above or complex of special contents above
11
For any questions about the product that you purchased or about the details in this user's manual, please contact the following.
© 2020 MIYAWAKI INC.
This user's manual may not be reproduced or copied in whole or in part, without the written consent of MIYAWAKI INC. Some special specifications of the product you have, may found to be different from the ones in the user's manual. If you have any question, please contact MIYAWAKI, our local authorized agent, or the company where you purchased the product. In the interest of the development and improvement of our products, MIYAWAKI Inc. reserves the right to change the specification of the products without prior notice.