MIYAWAKI Series G3N / G5 Users Manual
Contents
1. Replace the trap with a larger Insufficient capacity of condensate capacity See the torque table in Chapter 6 10 11 8 LIMITED WARRANTY Any trap that fails in normal operating conditions will be repaired free of charge WARRANTY TERM This warranty term shall be for the first 12 months of ownership starting from the date of delivery to you WHAT THIS WARRANTY DOES NOT COVER 1 Damage caused by careless use or ignoring the warnings and cautions given in this manual 2 Damage caused by severe shock or an impact which would not be experienced in normal operation 3 Damage caused by unauthorized modifications or repairs 4 Damage caused by fire natural disasters or acts of God 5 Damage caused by inappropriate handling or installation in a way that violates the specifications 6 Damage caused by equipment apparatus or devices that are not provided by MIYAWAKI 7 Damage caused by chlorine or other materials that are corrosive to metals or hasten deterioration 8 Damage caused by a part such as a gasket that is severely deteriorated 9 Damage caused by accumulated dirt or debris on or around the seat WARRANTY SCOPE In any event the scope of the warranty is limited to compensation that does not exceed the purchase price of the product 11 112. ones at each maintenance Gaskets 16 17 24 are fragile so please handle them with care 3 Bolt 18 Bolt 19 25 should be tightened evenly 21 Air Vent 23 Plug 1 Body 19 Bolt 16 Gasket 18 Bolt 2 Cover 3 Float 17 Gasket 20 Screen 23 Plug The clamp torque of the screws will be as per the following chart Torque table 1 e Bot 17 mn 68 inch 40 Nem 400 ern os ok 22mm 088 mem 60 m 9 11 7 TROUBLESHOOTING Float is damaged Replace the float Valve is fallen off Restore the valve Damage wear or corrosion of the valve and or the valve seat valve seat Steam blows through i Clean the valve and or the valve or valve seat AS TE Repair or replace the Automatic Air Vent is failed Automatic Air Vent Bolts are loose Tighten the bolts Gasket is damaged or worn Replace the gasket Steam leaks from the body The sealing surface on the body or Replace the body or the cover the cover is damaged qoem Check if the Automatic Air binding Air Vent failed Float locates incorrectly Locate the Float correctly Float is damaged or filled up with water Replace the Float Insufficient condensate Orifice of valve seat is clogged Clean the Valve Seat discharged or no di i Clean the Screen condensate discharged Screen is clogged Change the pressure or Pressure is too high replace the trap with an appropriate one
3. OM No E G03 03 0801 MIYAWAKI BALL FLOAT STEAM TRAP G3N G5 USER S MANUAL 1 SYMBOL USED 2 SAFETY INSTRUCTIONS 3 SPECIFICATIONS 4 NAMES OF COMPONENTS AND PARTS 5 INSTALLATION 6 MAINTENANCE 7 TROUBLESHOOTING 8 LIMITED WARRANTY Be sure to read this manual to learn the safe and proper operation of this product Store this manual carefully after use M MIYAWAKI INC 1 11 To the owner Ball float steam trap model G3N G5 is designed for large capacities with a built in Diaphragm type air vent and a double ported balance valve In order to get maximum benefit from this product be sure to read this manual before installing it Maintenance If this product functions or looks abnormal take the necessary steps to correct it If it seemingly cannot be corrected ask your MIYAWAKI dealer what to do and give him the following information 1 Model 2 Serial S No 3 Detailed description of the abnormal condition Supply Period for Maintenance Parts We will continue to supply maintenance parts for this product for 5 years after we discontinue production of the primary product The supply of maintenance parts will in principle terminate at the end of the supply period stated above However even after the supply period has run out it is possible to consult with us about the delivery time and prices for parts that are still in stock 2 11 1 SYMBOL USED SYMBOL INDICATION 1 Safety alert
4. Symbol N This is the safety alert symbol When this symbol is on the machine or in this manual be alert to the possibility of personal injury and carefully read the messages that follow 2 Signal words The signal words WARNING CAUTION are used with the safety alert symbol Za WARNING denotes an extreme hazard which will likely result in death or serious personal injury if proper precautions are not taken WARNING 7a CAUTION denotes general precautions that may result in injury or damage to objects if proper precautions are not taken CAUTION 2 SAFETY INSTRUCTIONS Observe the following instructions to insure safe operation If you don t you may be seriously injured and the product may be damaged Be sure not to use this product at a pressure higher than the specified maximum operating pressure PMO or at a temperature higher than the specified maximum operating temperature TMO Pay very careful attention when working in hazardous environments such as Places with any risk of explosion and or the possibility of dangerous gas leaking Always check whether the pipeline contains flammable high pressure or high temperature materials before starting to work Make sure that isolation valves are installed on both the upstream and downstream lines Before installing the product open the isolation valves and the bypass valve if one exists to blow off any debris or dust inside the pipeline When installing
5. er Valve Seat Valve Holder Lever Nut Nut 10 Connector 11 Nut 12 Guide Wing 13 Pin 14 Baffle Plate 15 Nut 16 Gasket 17 Gasket 18 Bolt 19 Bolt 20 Screen 21 Air Vent 22 Bush 5 11 25 26 27 28 29 30 31 32 Flange Name Plate Rivet Pipe for only G3N R Flange for only G3N R Pin Stopper MODEL G5 MODEL G5 R Body Cover Float Lever Valve Seat Valve Holder Lever Nut Nut 10 Connector 11 Nut 73 f SEE i EX ru LS Guide Wing 23 Plug Pin 24 Gasket Baffle Plate 25 Bolt Nut 26 Flange Gasket 27 Name Plate Gasket 28 Rivet Bolt 29 Pipe Reducer for only G5 R Bolt 30 Flange for only G5 R Screen 31 Bush Air Vent Eyebolt 6 11 5 INSTALLATION N Before installing the product open the isolation valves and the bypass valve if one exists to blow off any debris or dust inside the pipeline CAUTION 1 G3N G5 are for horizontal installation 2 Check the flow direction marked on the side of the body and match it with the arrow on the trap body 3 Be sure to create a slight downhill gradient so that the condensate will flow in and out smoothly 4 The product should be installed for easy maintenance check b Open the isolation valve on the primary line slowly and make sure the product work
6. s properly The example of correct installation is shown below Recovery Main Branch Line Condensate Tank Model G Check Valve 7 11 6 MAINTENANCE When taking apart the trap from the line close the both primary and secondary stop valve and cool down the trap itself first to avoid the danger of steam and WARNING Condensate blowout The performance of steam traps deteriorates over time due to wear corrosion or dirt accumulating around the valve seat To keep steam systems and equipment working well periodic maintenance of the steam traps is essential Tools for testing steam traps In order to test steam traps ultrasonic testers sound detectors and thermometers have been used for years These tools are relatively easy to use and are useful for making rough estimates of the level of deterioration in a defective trap However to determine deterioration levels and steam losses quantitatively special tools are required for testing steam traps Dr Trap and Dr Trap Jr are testing equipment that were developed specifically for diagnosing steam traps and analyzing survey results automatically Use these tools to avoid tiresome jobs on sites and save working time Working conditions of a steam trap Steam trap failures can be classified as either Leaking or Plugged The level of steam leaks is generally determined by the intensity of the ultrasonic vibration generated in the valve seat inside of a steam trap The pl
7. the product be sure to leave clearance for the maintenance When replacing parts make sure the replacement parts are supplied by MIYAWAKI 3 11 3 SPECIFICATIONS CONNECTION MODEL NO G3N 10 Duct anged Cast 1 Table A Dimensions and Weight of MopEL No SIZE mm inch G3N 16 Duct Cast 1 G5 10 G5 16 Duct Cast 1 G3N 10R G3N 16R G5 10R Duct 50 100 Cast I 2 4 G5 16R Refer to Table A BODY FCD450 FCD450 FCD450 FCD450 OPERATING MAX PRESSURE TEMP DIMENSIONS mm inch WEIGHT MPa psig CC F 1b 0 01 1 0 1 45 145 198 22 001 1 6 7 8 484 1 45 230 270 45 10 6 99 0 198 7 8 270 10 6 ile ron 235 455 265 10 4 235 9 3 95 3 7 0 01 1 0 1 45 145 0 01 1 6 1 45 230 0 017 1 0 1 457145 0 01 1 6 1 45 230 0 017 1 0 145 145 0 01 1 6 1 45 230 ile ron 339 13 3 315 12 4 110 235 455 4 3 235 455 235 455 Flange Types FLANGE RATING WEIGHT mm inch kg lb ile ron 235 9 3 95 3 7 ile ron 315 12 4 110 4 3 427 270 JIS10K 16K 20K 17 0 60 25 1 32 1 1 4 40 1 1 2 G3N 10R 50 2 65 2 1 2 80 3 50 2 65 2 1 2 G5 10R G5 16R 80 3 100 4 4 1i 4 MODEL NAME OF COMPONENTS AND PARTS MODEL G3N R Body Cover Float Lev
8. ugged is diagnosed by measuring the surface temperature As the degree of plugging increases due to a buildup of dirt in the trap it will finally become completely plugged If this occurs the surface temperature will drop to around 40 degrees centigrade or lower Repairs When a trap fails it is necessary to clean the internal parts and replace damaged parts Take the failed trap apart following the steps below A Take apart the body of the trap 1 Remove the trap from the piping Take off the Bolt 25 and remove the connection flange 2 Remove the screen 20 3 Remove the Bolt 19 and the Cover 2 4 4 Firm the Cover 2 with a vice and remove the Bolt 18 with a wrench The valve unit Lever 4 Valve Seat 5 Valve 6 Holder 7 Lever Nut 8 Nut 9 Connector 10 Nut 11 Guide Wing 12 Pin 13 Baffle Plate 14 Nut 15 comes apart The Float 3 and the Air Vent 21 can be removed with a wrench 8 11 Cleaning checking repairing 1 After A is removed clean and check repair if needed each part 2 If the Float 3 is damaged loosen the Nut 15 of the Lever 4 and unscrew the Float 3 by hand and then replace it 3 If the Valve 6 and Valve Seat 5 are worn or defected replace the whole valve unit C Re assemble the body 1 After cleaning checking repairing if needed the trap re assemble the parts in reverse order 2 Replace the Gaskets 16 17 24 to new
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