Maintenance Instructions NUFORS-DC VALVE SERVICE Direct Cylinder operated level sensed condensate drain 08/14 GENERAL OPERATION The NUFORS-DC removes condensate from compressed air systems without using electricity. The discharge process is automatic and is based on a 2/2 way level controlled valve principle that operates a direct cylinder valve. The NUFORS-DC is ideally suited in applications where power is not available, too expensive or not reliable. The integrated stainless steel strainer protects the valve, optimising the discharge performance. The condensate level can be viewed through the sight port which offers a visual monitoring of the condensate level. 1
SAFETY INSTRUCTIONS SAFETY AND PROPER USAGE To ensure safe and enduring performance of this product, you must comply strictly with the instructions enclosed herein. Non-compliance with instructions or improper handling of the product will void your warranty! This product is designed to drain condensate from compressed air systems. Usage of this product in conditions not specified in this manual or in contrary to the instructions hereby provided is considered IMPROPER. The manufacturer will not be held liable for any damages resulting from improper use of the product. SAFETY & WARNING INSTRUCTIONS ATTENTION - Observe valid and generally accepted safety rules when planning, installing and using this product. - Take proper measures to prevent unintentional operation of the product or damage to it. - Do not attempt to disassemble this product or lines in the system while they are under pressure. - Always depressurise the compressed air system before working on the system. It is important that personnel use safe working practices and observe all regulations and legal requirements for safety when operating this product. When handling, operating or carrying out maintenance on this product, personnel must employ safe engineering practices and observe all local health & safety requirements & regulations. International users refer to regulations that prevail within the country of installation. Most accidents, which occur during the operation and maintenance of machinery, are the result of failure to observe basic safety rules or precautions. An accident can often be avoided by recognising a situation that is potentially dangerous. Improper operation or maintenance of this product could be dangerous and result in an accident causing injury or death. The manufacturer cannot anticipate every possible circumstance, which may represent a potential hazard. The WARNINGS in this manual cover the most common potential hazards and are therefore not all-inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by the manufacturer he must ensure that the product will not be damaged or made unsafe and that there is no risk to persons or property. GENERAL MAGNET SAFETY ATTENTION The magnets in the operator we use are extremely strong, and must be handled with care to avoid personal injury and damage to the magnets. Fingers and other body parts can get severely pinched between two attracting magnets. The strong magnetic fields of the magnets in the operator can also damage magnetic media such as floppy disks, credit cards, magnetic I.D. cards, cassette tapes, video tapes or other such devices. They can also damage televisions, VCRs, computer monitors and other CRT displays. Never place the operator near electronic appliances. Never allow magnets near a person with a pacemaker or similar medical aid. The strong magnetic fields of the magnets in the operator can affect the operation of such devices. The operator will lose its magnetic properties if heated above 175 F (80 C). 2
EXPLODED VIEW - Main parts Housing bolt (4*) Air plug Washer (4*) Air plug o-ring Test knob Housing front plate Test spring Strainer Valve mounting bolt (4*) Sight glas Test pin + valve O-ring Valve O-ring Air inlet top nut Inlet plug (2*) Valve/operator module Outlet nipple Sight glass gasket Housing back Strainer plug with O-ring Sight glass Housing gasket Sight glass screw (2*) Sight glass screw o-ring (2*) 3
EXPLODED VIEW - Valve/operator module Valve bolt (4*) Top nut air inlet Valve top part Plunger seal o-ring Plunger seal Valve plunger o-ring Air bypass plug Air bypass Plug o-ring Valve middle part Plunger spring Plunger stem Valve bottom part Operator Operator Shaft Operator Spring Operator Plunger Operator valve Screw (2*) Operator valve body Valve O-ring 4
MAINTENANCE INSTRUCTIONS 1. Close the condensate supply, i.e. close the ball valve which is installed in front of the NUFORS-DC. Depressurize the system before installation or maintenance is carried out! 2. Press and hold the TEST button to empty the unit of any residual condensate and to depressurise the NUFORS-DC. 3. Remove the outlet tube. 4. Remove the 4 housing bolts using a 6mm Allen key. 5. Remove the front plate with attached valve assembly. 6. Remove the test knob and underlying spring by screwing it off the test pin using your hands on the knob and Needle nose pliers on the back. 5
MAINTENANCE INSTRUCTIONS 7. Remove the 4 valve mounting bolts using a 3mm Allen key. 8. Take the valve assembly and O-rings off the front plate. 9. Remove the 4 valve bolts using a 3mm Allen key. 10. Take out the valve middle part and remove the plunger seal using needle nose pliers. Do not remove the plunger stem! 11.First clean and then lubricate the plunger seal O-ring and the chamber where you removed it from. 12. Screw the plunger seal back on to the plunger stem using needle nose pliers and move it up and down a couple of times. Make sure it moves easily. Note: the two holes for the pliers should be on top, do not over tighten! 6
MAINTENANCE INSTRUCTIONS 13. screw the three valve blocks back together using the 4 valve bolts. Make sure the three blocks line up perfectly straight at the front (where the O-rings are). 14. Screw the valve assembly back on to the front plate using a 3mm Allen key. Do not over tighten!. Make sure all 4 O-rings are positioned correctly. 15. replace the test spring and test knob and tighten them using your fingers on the test knob and needle nose pliers on the back. Tighten them as far as you can but make sure the test pin can still move when you press the button. 16. Replace the front plate with attached valve assembly on to the reservoir using the 4 housing bolts and a 6mm Allen key. 17. replace the outlet tube and tighten the clamp. 18. Your NUFORS-DC is ready for operation. Push the test button to check the valve function 7