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VKP 40ExVKP 40Operating instructions 818535-00Steam Trap Testing, Recording & Evaluating System TRAPtest VKP 40 (VKP 40Ex for applicationsin potentially explosive areas) for checking steam traps of all types and makes for steam lossand banking-up of condensate

GESTRA

GESTRA Steam Systems

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Contents

Description

System description VKP 40Ex, VKP 40 .................................................................................................................................................... 3Application VKP 40Ex, VKP 40 ................................................................................................................................................................ 3Scope of supply VKP 40Ex, VKP 40 ......................................................................................................................................................... 3

Safety Notes for VKP 40Ex

Notes ................................................................................................................................................................................................. 4, 5Application ............................................................................................................................................................................................. 5Maintenance notes VKPN 40Ex; VKPS 40Ex ............................................................................................................................................ 5Replacing battery unit of VKPN 40Ex .................................................................................................................................................. 5, 6Environmental requirements .................................................................................................................................................................. 6

Technical Data VKP 40Ex, VKP 40

System requirements ............................................................................................................................................................................. 7Data collector VKPN 40Ex, VKPN 40 ....................................................................................................................................................... 7Measuring transducer VKPS 40Ex .......................................................................................................................................................... 7Connecting cable for VKPA 40 ................................................................................................................................................................ 7Test duration .......................................................................................................................................................................................... 7Dimensions and weights ........................................................................................................................................................................ 8Charging batteries of VKPN 40Ex, VKP 40 ............................................................................................................................................... 8Replacing batteries VKPN 40 (for VKPN 40Ex see section “Safety Notes”) .............................................................................................. 9Maintaining VKP 40Ex, VKP 40 ............................................................................................................................................................... 9Spare parts ............................................................................................................................................................................................ 9

Connecting and Commissioning Data Collector VKPN 40Ex, VKPN 40

Connecting data collector VKPN 40Ex or VKPN 40 to a PC .................................................................................................................... 10Connecting measuring transducer VKPS 40Ex to data collector VKPN 40Ex or VPKN 40 ....................................................................... 10Commissioning data collector VKPN 40Ex or VKPN 40.......................................................................................................................... 11Switching off data collector .................................................................................................................................................................. 12Stand-by mode .................................................................................................................................................................................... 12

TRAPtest software PC program

Installing PC software .......................................................................................................................................................................... 13Starting and quitting program .............................................................................................................................................................. 13Deinstalling PC software ...................................................................................................................................................................... 13Software menus at a glance .......................................................................................................................................................... 13, 14

Data Exchange between PC and Data Collector VKPN 40Ex or VKPN 40

VKPN 40Ex or VKPN 40......................................................................................................................................................................... 15

Checking Steam Traps

Test .............................................................................................................................................................................................. 16 – 18Test measurement ............................................................................................................................................................................... 19Foreign noise ....................................................................................................................................................................................... 20Reference points for measurement ................................................................................................................................................ 20, 21

Fault finding list for troubleshooting

Data collector VKPN 40Ex, VKPN 40 ..................................................................................................................................................... 22Measuring transducer VKPS 40Ex ........................................................................................................................................................ 22Screen display on PC ........................................................................................................................................................................... 22

EC Type Approval

EC type approval .................................................................................................................................................................................. 23

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Description

System description VKP 40Ex, VKP 40

The steam trap testing system consists of the data collector VKPN 40Ex or VKPN 40, the measuring transducer VKPS 40Ex andthe software for data management on the PC. The VKPN 40Ex / VKP 40 can check and evaluate all types and makes of steam trapsfor loss of live steam and banking-up of condensate.The diagnostic system detects and analyses ultrasonic vibrations on the trap body caused by live steam flowing through the streamtrap. The ultrasonic vibration is transmitted through the trap body and picked up by the hand-held probe by pressing the sensor tiponto a point of the trap body that is characteristic of the respective trap type. The ultrasonic vibration is then converted into electricpulses and – in the form of digital signals – fed via cable to the data collector VKPN 40Ex or VKPN 40. The display of the datacollector shows the signals received during the test as a standing curve. With this graphical representation one can see at oncewhether the tested steam trap is working with or without loss of steam. The recorded ultrasonic vibration is analysed by the datacollector and evaluated in accordance with certain empirically ascertained limit values that depend on the trap type. During the testthe temperature of the steam trap is measured, too. Provided that a service pressure has been specified (on the PC), the diagnosticsystem identifies blocked steam traps that cause banking-up of condensate. .

If the annual operating hours and the steam costs have been entered in the system, the software can calculate the financial losscaused by faulty steam traps. To quantify the steam loss caused by faulty steam traps, empirically obtained test values are used asreference.

All curves recorded for a steam trap as well as the associated numerical test results and the corresponding analysis by the systemcan be stored and printed out.

For more detailed information on the system and its functions refer to the “Online Documentation” of the TRAPtest PCprogram.

Application VKP 40Ex, VKP 40

Scope of supply VKP 40Ex, VKP 40

The carrying case TRAPtest VKP 40Ex / VKP 40 contains:1 Hand-held data collector (probe) VKPN 40ex / VKPN 401 Measuring transducer VKPS 40ex1 Connecting cable VKPA 40 incl. power supply unit and connecting cable with serial connector for PC3 Adaptor plugs for international application of the power supply unit1 Strap for data collector1 Holster for measuring transducer1 TRAPtest software on CD Rom1 Operating manual

■■■■■ Use VKP 40Ex / VKP 40 only for testing steam traps!For more information on the test procedure see section “Checking Steam Traps”.

■■■■■ Use the equipment only on voltage-free and earthed pipe systems! Mortal danger is imminent if you carry outmeasurements on voltage-carrying objects.

■ In explosion-risk areas only the measuring transducer VKPS 40Ex connected via cable with the data collectorVKPN 40Ex may be used.

■■■■■ For more information see section “Safety Notes for VKP 40Ex”!

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Safety Notes for VKP 40Ex

This section of the operating manual refers to the hand-held data collector VKPN 40Ex, the measuring transducer VKPS 40Ex andthe connecting cable VKPA 40.

■ The connecting cable VKPA 40 must not be used in explosion-risk areas!

Notes

The equipment to be used in explosion-risk areas bears the following labelling:

Measuring transducer VKPS 40Ex:

Data collector VKPN 40Ex:

Attention

■ The data collector VKPN 40Ex and the measuring transducer VKPS 40Ex are connected via cable. This connectionmust not be opened when the equipment is used in an explosion-risk area.

■ Do not open the data collector VKPN 40Ex and the measuring transducer VKPS 40Ex in explosion-risk areas!

■ In case of visible signs of damage or malfunctions take the data collector VKPN 40Ex and the measuringtransducer VKPS 40Ex immediately out of the explosion-risk area.

■ Tests must only be carried out by specially trained personnel and on voltage-free test objects.

The data collector VKPN 40Ex is provided with a rechargeable battery for power supply..■ The rechargeable battery must only be charged outside the explosion-risk area with the aid of the

connecting cable VKPA 40.

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Safety Notes for VKP 40Ex -continued-

Notes -continued-

The display of the data collector VKPN 40Ex shows the current battery charge. If the charging process takes extremely long or a fullcharge cannot be achieved, the rechargeable battery might have a malfunction and should therefore no longer be used but must bereplaced. Note that only a genuine GESTRA rechargeable battery with protective circuit breaker must be used as replacement. Formore information on how to change the battery of the VKPN 40Ex see section “Replacing batteries”.

If the battery is sufficiently charged for the planned steam trap testing, the data collector VKPN 40Ex can be unplugged from theconnecting cable. Before entering the explosion-risk area connect the measuring transducer VKPS 40Ex to the data collector VKPN40Ex. The connection between the data collector VKPN 40Ex and the measuring transducer VKPS 40Ex must not be opened in anexplosion-risk area.

The switched-on or switched-off equipment can be carried into the explosion-risk area.

Application

■■■■■ Use VKP 40Ex only for checking steam traps!

■ Use the equipment only on voltage-free pipe systems. Mortal danger is imminent if you carry out measurements onvoltage-carrying objects.

For more information on the test procedure refer to section “Checking steam traps”.

Maintenance notes VKPN 40Ex, VKPS 40Ex

In case of visible signs of damage (e. g. cracks in the casing, faulty display, worn down probe tip, …) do not use theequipment in explosion-risk areas. Please contact GESTRA AG or a GESTRA company in your country.The equipment is provided with a rechargeable battery. To change this battery the equipment must be opened. Only trained personnelconversant with the explosion protection directive is allowed to perform the replacement. Only genuine GESTRA replacement partsmust be used.

Replacing battery unit of VKPN 40Ex

■ Make sure that the data collector is switched off before replacing the rechargeable battery!

■ Make sure that the data collector is not connected via connecting cable VKPA 40 when replacing therechargeable battery.

The rechargeable battery must be replaced when its charging capacity is no longer sufficient for the required test tasks. For thispurpose remove the 6 screws from the bottom of the equipment. Detach the upper part of the equipment from the lower part.Attention: The upper part is connected to the lower part via a ribbon cable. This cable connection does not have to be detached. Therechargeable battery unit is embedded with protective elements on a green board. This unit is fixed to the bottom of the equipmentby means of 4 screws. In order to exchange the battery this whole unit has to be replaced by a genuine GESTRA AG sparepart. Undo the 4 screws and remove the battery unit. Put the new battery unit onto the two centric items of the connector. Insert the4 screws (M 2.5, M 3) and fasten them moderately. Then mount the two halves of the equipment together, making sure that thegasket is properly inserted and the ribbon cable is not jammed between the two equipment parts. Then mount the 6 casingscrews and tighten them with a torque of 0.8 Nm. The battery can now be charged as described in section “Charging batteries”.Note that the full performance of a new rechargeable battery is achieved only after about 5 complete charge and discharge cycles.Environmental regulations have to be taken into account when disposing of rechargeable batteries.

Attention

■■■■■ When opening the equipment make sure that neither the connecting cable VKPA 40 nor the measuringtransducer VKPS 40Ex is connected.

■ Do not open the equipment in explosion-risk areas! To prevent damage to electronic components shield theequipment against electrostatic discharges (e.s.d).

■ Any type of work on the equipment – apart from replacing the rechargeable battery – must only beperformed by GESTRA AG.

When used for its intended purpose the diagnostic system is maintenance-free. However, we recommend that the system should besent to GESTRA AG Bremen every 5 years for a general inspection.

Attention

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Environmental requirements

Temperature rating for VKPN 40Ex:Operating temperature: –10 °C to 50 °C

Temperature rating for VKPS 40Ex:Operating temperature: –10 °C to 60 °C

The equipment approval corresponds to protection class “II 2G EEX ib IIC T4”:Explosion group IIcGASCategory 2Temperature class T4Intrinsically safe according to “ib”

Max. operating voltage:Data collector VKPN 40Ex: 3.3 VMeasuring transducer VKPS 40Ex: 5.0 V

Max. power consumption:Data collector VKPN 40Ex: 0.25 AMeasuring transducer VKPS 40Ex: 0.03 A

Board with battery unit

Ribbon cable

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Lower part of VKPN 40Ex

Safety Notes for VKP 40Ex -continued-

Replacing battery unit of VKPN 40Ex -continued-

Gasket➞

Data collector VKPN 40Ex (opened)

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Technical Data VKP 40Ex, VKP 40

System requirements

Operating system:Windows 98, 2000, NT 4 (SP6) XP.CD ROM drive

Minimum requirementsComputer with Pentium® compatible processor with 700 MHz100 MB free hard disk memory128 MB RAM800 x 600 screen resolution

Recommended:Computer with Pentium® compatible processor with 1.2 GHz200 MB free hard disk memory256 MB RAM

Data collector VKPN 40Ex, VKP 40

Plastic casing with backlit display. Illumination can be switched on and off.Illumination switches off automatically after 10 sec. if no key is pressed.Resolution of graphic display: 128 x 64 pixels.Membrane keypad with 5 buttons.Storage capacity sufficient for approx. 1200 steam traps allocated to max. 500 test tasks.Power supplied by two pre-installed Li-Polymer rechargeable batteries, capacity 1800 mAh.4 hours charging empty battery provides approx. 8 hours operating time.Max. operating voltage 3.3 VMax. power consumption 0.25 AOperating temperature –10 °C to 50 °CMax. admissible service temperature: 50 °CMin. admissible service temperature: –10 °CDegree of humidity: 0 % to 90 % (not condensed)Protection IP 65

VKPN 40Ex: Approval BVS 04 ATEX E 234CE 0158 Ex II 2G EEX ib IIC T4

Measuring transducer VKPS 40Ex

Casing made of titanium (3.7035)Operating temperature –10 °C to 60 °CMeasuring range for surface temperature: 0 °C to 350 °CMax. admissible service temperature: 60 °CMin. admissible service temperature: –10 °CPower supplied by rechargeable battery of the data collector.Max. operating voltage 5.0 VMax. power consumption 0.03 A

VKPS 40Ex: Approved BVS 04 ATEX E 234CE 0158 Ex II 2G EEX ib II T4

Connecting cable VKPA 40

The connecting cable VKPA 40 consists of the power supply unit with integrated connecting cable and circular plug for connectingthe data collector VKPN 40Ex or VKPN 40 and the connecting cable with a serial connector for connecting the PC. With the powersupply unit connected, the connecting cable connects the equipment with the PC and provides charging of the batteries installed inthe data collector. To adapt the connector to national standards choose a suitable adaptor plug. Remove the adaptor plug from thepower supply unit and attach the appropriate adaptor plug for your country.

Power supply unit: 100 – 240 V / 47 – 63 Hz; output 12 V

Test duration

Min. 10 sec., max. 20 sec.If the sound level exceeds or falls below the threshold value during a test before 10 seconds have passed, the test procedure wil befinished after 10 seconds. Otherwise the test takes 20 seconds.

For more information refer to the PC Online Documentation.

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Technical Data VKP 40Ex, VKP 40 -continued-

Dimensions and weights

Dimensions[mm]Carrying case: approx. 370 x 135 x 550Data collector VKPN: approx. 125 x 95 x 227

approx. 115 x 95 x 227 without strap(width x height x length)

Measuring transducer VKPS(without connecting cable): approx. 36 x 210 (diameter x length)

WeightsCarrying case with contents approx.: 5.1 kgData collector VKPN 40Ex approx.: 600 gData collector VKPN 40 approx.: 540 gMeasuring transducer VKPS 40Ex approx.: 440 g

Charging batteries of VKPN 40Ex, VKP 40

■ Use only the supplied connecting cable VKPA 40 for charging the rechargeable batteries!

■ Charge only the rechargeable battery unit supplied by GESTRA AG!

■ Note that the connecting cable VKPA 40 must not be used in explosion-risk areas!The battery of the VKPN 40Ex must only be charged outside an explosion-risk area!

■ The charging of an empty battery takes approximately 4 hours.

■ With the power supply unit connected, the data collector cannot be switched off.By pressing ESC key in the main menu you can view the charge level indicator in the title window.

Circular plug

Adaptor forconnector

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Data collector VKPN 40Ex withconnecting cable VKPA 40

The battery pack becomes warm during recharging. This is normal and not a malfunction or defect.Connect the data collector VKPN 40Ex or VKPN 40 with the connecting cable VKPA 40: Insert the circular plug in the left-hand jack ofthe data collector – cf. picture below – and plug the power supply unit into an earthed socket (100 – 240 V / 47 – 63 Hz).When the data collector VKPN 40Ex / VKPN 40 is switched on, the title window of the TRAPtest program indicating the versionnumber, the current date and the charge level appears. During first commissioning or if the batteries are flat the date 2000.01.01 willbe shown. The date will be automatically updated during the next communication between the data collector and the PC.The charging process is indicated on the display by a scrolling battery indicator bar. Once the battery is fully recharged the blackindicator bar stops scrolling.Pull the sleeve of the plug to unplug the device.

Attention

Power supplyunit

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Connecting cableVKPN 40

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Technical Data VKP 40Ex, VKP 40 -continued-

Replacing batteries VKPN 40

■ Make sure that the data collector is switched off before replacing the rechargeable battery!

■ Make sure that the data collector VKPN 40 is not connected via connecting cable VKPA 40 when replacing therechargeable battery.

■ Do not remove the battery pack as some of the acid electrolyte might escape during the process.

■ Do not throw rechargeable batteries in water or fire (risk of explosion)!

■ Old batteries should not be disposed of with normal household waste – hand them in at your recycling centre.

Maintaining VKP 40Ex, VKP 40

When used for its intended purpose the diagnostic system is maintenance-free. However, we recommend that the system should besent to GESTRA AG Bremen every 5 years for a general inspection.

Spare Parts

Designation Stock code

Complete battery unit for VKPN 40Ex/VKPN 40 (incl. 1 set of screws) 052474Strap 052479Holster for VKPS 40Ex 052478Connecting cable VKPA 40 compl., incl. power supply unit 052476Adaptor set for connector 052477

The rechargeable battery must be replaced when its charging capacity is no longer sufficient for the test tasks. For this purposeremove the 6 screws from the bottom of the equipment. Detach the upper part of the equipment from the lower part. Attention: Theupper part is connected to the lower part via a ribbon cable. This cable connection does not have to be detached. The rechargeablebattery unit is embedded with protective elements on a green board. This unit is fixed to the bottom of the equipment by means of4 screws. In order to exchange the battery this whole unit has to be replaced by a genuine GESTRA AG spare part. Undo the4 screws and remove the battery unit. Put the new battery unit onto the two centric items of the connector. Insert two M2.5 mmscrews and fasten them with 2 Nm, then insert the other two M3 screws and fasten them with 2.5 Nm. Then mount the two halves ofthe equipment together, making sure that the gasket is properly inserted and the ribbon cable is not jammed between the twoequipment parts. Mount the 6 casing screws and tighten them with a torque of 0.8 Nm. The battery can now be charged asdescribed in section “Charging batteries”. Note that the full performance of a new rechargeable battery is achieved only after about5 complete charge and discharge cycles. Environmental regulations have to be taken into account when disposing of rechargeablebatteries.(See pictures in section “Replacing battery unit”).

Attention

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Connecting and Commissioning Data Collector VKPN 40Ex, VKPN 40

Connecting data collector VKPN 40Ex or VKPN 40 to a PC

Connect the power supply unit of the connecting cable VKPA 40 with an earthed socket and insert the circular plug of the connectingcable into the left-hand jack of the data collector VKPN 40Ex / VKPN 40.

■ If the power supply unit is not connected the data collector cannot communicate with the PC.

Connect the serial plug of the connecting cable with the PC. Then confirm the selected interface (Com 1, Com 2, Com 3, Com 4 orCom 5) in the TRAPtest menu EXTRAS/Interface on the PC.

■ Attention: Do not use the connecting cable VKPA 40 in explosion-risk areas!

Circular plug

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Data collector VKPN 40Ex with connecting cable VKPA 40

Serial plug ➞

Connecting measuring transducer VKPS 40Ex to data collector VKPN 40Ex or VPKN 40

■ Note when using the VKPN 40Ex in explosion-risk areas:Make sure that the measuring transducer VKPS 40Ex is connected to the data collector VKPN 40Ex before youenter an explosion-risk area. Do not open this connection in explosion-risk areas. The two connected devices(VKPN 40Ex with VKPS 40Ex) can be in switched-on or switched-off mode when they are carried into an explosion-risk area.

■ Do not use the data collector VKPN 40 in explosion-risk areas.

Data collector VKPN 40Ex/VKPN 40 with measuring transducer VKPS 40Ex

Insert the circular plug of the connecting cable VKPS 40Ex into the right-hand jack of the data collector VKPN 40Ex / VKPN 40.

To unplug the cable pull the sleeve of the connector.

Danger

Adaptor forconnector

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Power supplyunit

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Connecting cableVKPA 40

Measuring transducerVKPS 40Ex

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In the menu TEST steam traps can be checked for loss of live steam – provided that data records and test tasks have beenentered previously on the PC. The recorded sound values are assessed immediately after each steam trap test by the datacollector. The test results will be saved.

In the menu TEST MEASUREMENTS steam traps can be checked for loss of live steam – without prior input of data records andwithout the creation of test tasks. The recorded sound values are assessed immediately after each steam trap test by the datacollector. The test results will not be saved.

The menu DATA EXCHANGE enables communication with the PC and the organization of the data collector on the PC: test tasksare transferred from the PC to the data collector and test results are sent from the data collector to the PC. Test tasks for the datacollector can be deleted on the PC..

■ Use the arrow buttons , to select (mark) the desired menu and then press the ENTER key. The current position of the cursoris indicated by .

Connecting and Commissioning Data Collector VKPN 40Ex, VKPN 40 -continued-

Commissioning data collector VKPN 40Ex or VKPN 40

■ Do not use a ball pen or any other sharp object for pressing the buttons of the data collector!

Press button START to start the data collector VKPN 40Ex / VKPN 40. The title window of the TRAPtest program appears, showing theversion number and the current date.When the equipment is commissioned for the first time or if the battery is empty the date is indicated as 2000.01.01. During the nextcommunication between the data collector and the PC the date will be automatically updated.

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■ When the date 2000.01.01 is shown the data collector can only be commissioned if the battery has beenrecharged. For more information see section “Charging batteries” and “Fault finding list for troubleshooting”.During the next communication between the data collector and the PC the date will be updated.

Press the ENTER key to call up the main menu::

Main menu of the data collector

Note

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■ Use arrow button to select (mark) the item QUIT of the main menu of the data collector and press the ENTER key. The datacollector is now switched off.

■ As long as the power supply unit is connected, the data collector cannot be switched off.In the main menu you can press the ESC key to show the battery charge level in the title window.

For more information please refer to the Online Documentation on the PC.

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Connecting and Commissioning Data Collector VKPN 40Ex, VKPN 40 -continued-

Switching off data collector

If the data collector is not operated for more than 10 minutes, it switches into stand-by mode. Press the ENTER key to switch thedata collector back to operating mode.

Stand-by mode

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Exit all open applications on your computer.Insert the supplied CD in your CD-ROM drive.Upon insertion of the TRAPtest software CD the installation program starts automatically. Follow the on-screen prompts to completethe installation.The installation setup creates the folder GESTRA where the TRAPtest VKP 40 program will be stored. A new program icon is createdon the desktop.

TRAPtest software PC program

Installing PC software

Starting the programTo start the program click the Start button, point to Programs and then click TRAPtest VKP 40 or double-click on the TRAPtest VKP 40icon on the desktop.Quitting the programTo quit the program click the QUIT button in the main menu of the TRAPtest program.

Starting and quitting program

To de-install the program click Start / Programs / GESTRA / TRAPtest VKP 40 / Uninstall.

Deinstalling PC software

Menu Test ObjectsIn the menu Test Objects all steam trap related data and the associated plant sections are entered and organized.

Menu Test TasksIn the menu Test Tasks task lists detailing the steam traps to be tested are created and organized.

Menu Data CollectorIn the menu Data Collector the communication between the PC and the data collector is established and the test tasks for the datacollector are organized.

Menu ExtrasThe menu Extras comprises the following submenus:

Manufacturer ImportTester Organize companyLimit values Load updateLanguage InfoInterfaceOptionsOrganize steam traps

In the menu Manufacturer you can take down the particulars of the steam trap manufacturer whose steam traps are installed in theplant.

In the menu Tester the names of the employees entrusted with the task of checking the steam traps are entered.

In the menu Limit Values the specified limit sound values of the different steam trap systems are indicated.

In the menu Language you can select, edit or add a language.

In the menu Interface all available ports that can be selected are shown.

In the menu Options the units [bar, °C, kg/h] or [psi, °F, lb/h] for calculating the loss can be selected.

In the menu Organize steam trap all steam trap types and names can be listed and organized. The system features a default list of allGESTRA trap designations including the associated functional types.

In the menu Import all data records created with the predecessor version (VKP 30) can be imported.

In the menu Organize company the designation of the respective database (e. g. the name of the company, department, section orbuilding) is entered here.

Software menus at a glance

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TRAPtest software PC program -continued-

■ When a designation is deleted the whole database created under this designation will be deleted!

Software menus at a glance -continued-

The Import/Export function allows the import of databases (companies) created with other PCs and the export ofdatabases (companies) to other PCs.

In the menu Load Update you can install software updates for the data collector VKPN 40Ex / VKPN 40.

The menu Info gives information on the manufacturer, version number of the installed software and the currently selected databasedesignation (name of the company).

Menu Financial AnalysisProvided that the specific steam costs and annual operating hours have been entered in the system, the annual loss caused by faultysteam traps can be calculated and analysed in this menu. The estimated steam loss caused by defective traps is based onempirically ascertained reference values.

Online DocumentationThe Online Documentation offers a detailed description of the functions of the diagnostic system. It is available in GERMAN andENGLISH. Should you require a translation in your language please contact the manufacturer or its subsidiary or agency in yourcountry.

Attention

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Data Exchange between PC and Data Collector VKPN 40Ex or VKPN 40

The menu Data Collector enables the communication between the data collector and the PC and the organization of the datacollector via PC. For more information refer to section “Transferring test tasks to data collector”, “Deleting test tasks for datacollector” and “Transferring test results from data collector to PC” in the Online Documentation of the PC program.

Make sure that the data collector is connected and ready for use and then select the submenu “Data exchange” of the main menu ofthe data collector (“Connecting and Commissioning” see pages 10 – 12).

When selecting the menu “Data exchange” the following display appears:

During the data transfer the following display appears:

During a data exchange information on the transferred data is also indicated:“Tasks to VKPN” (if test tasks are transferred to the data collector) or“Delete task” (if test tasks are deleted on the data collector).

■ If the power supply unit is not connected the data collector cannot communicate with the PC.

Attention

■ A safety protocol is created in order to prevent any loss of data during the transfer.Consequently, the transfer rate can vary between 30 seconds and 1.5 minutes for 100 steam traps.

Once the data transfer is completed the display “Waiting for data” appears.Press the ENTER key to return to the main menu of the data collector.

Note

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In the menu TEST steam traps can be checked for loss of live steam – provided that data records and test tasks have beenentered previously on the PC. The test results will be saved.

Checking Steam Traps

Test

Note

Connect the measuring transducer VKPS 40Ex with the data collector (“Connecting and commissioning” see pages 10 – 12).When the data collector is ready for operation select the submenu Test.The display will show the test tasks transferred from the PC to the data collector as well as their counting numbers, the associatedplant designation and the designation of the plant section.

■ During a test the measuring transducer VKPS 40Ex also measures the surface temperature of the steam trap. If theservice pressure prevailing at the place of installation has been specificied, the diagnostic system will be able toidentify the steam trap that causes the banking-up of condensate by comparing the boiling temperature associatedwith the service pressure and the temperature measured at the steam trap.(For more information see Online Documentation / Menu Test Objects / Creating Test Objects).

Attention

■ For a correct temperature measurement it is important that the surface of the reference point on the trapwhere the tip of the measuring probe is applied is smooth and metallically bare. Otherwise considerabledeviations between the temperature reading and the actual temperature will be the consequence, resulting infaulty analysis and incorrect evaluation.

Use the arrow buttons , to mark the test task in question and press the ENTER key. The cursor position is indicated by .The display shows the task number, the plant designation and the designation of the plant section as well as the task list of thesteam traps to be checked (test objects) and the individual traps with their places of installation.

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Use the arrow buttons , to select (mark) the respective comment of the list and press the ENTER key.By pressing the ENTER key the comment will be saved and the task list with the cursor positioned beside the next steam trap to betested appears. To test the selected steam trap, put the tip of the measuring transducer probe VKPS 40Ex vertically onto the surfaceof the trap body on the specified reference point (see section “Reference point for measurement”). The test starts once themeasuring transducer is pressed down to the stop. The LED of the measuring transducer lights up and the display of the datacollector shows the text “Test running”.During the test the recorded readings are shown as a graph.

Checking Steam Traps -continued-

If the selected steam trap cannot or should not be checked for reasons given in the following list of comments, call up this list by usingthe arrow buttons or .

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Test -continued-

■■■■■ The connection between the data collector and the measuring transducer must not be undone during thisoperating condition.

■■■■■ The rechargeable batteries of the data collector supply the measuring transducer with power. Avoid longinterruptions between selecting the steam trap for testing (graphical representation on the display) and thetest start so that the battery can hold charge for a longer period of time.

Note

■ As soon as the graphical representation is displayed by the data collector, the measuring transducer will beautomatically switched off. (The LED of the measuring transducer lights up when the test starts).

Attention

Limit value (LV)Threshold value (TV)

Use the arrow buttons , to mark the steam trap to be tested and press the ENTER key. The cursor position is indicated by .The limit sound value (LV) and the threshold value (TV) are displayed as horizontal lines in the graphical representation ofthe sound level.

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If the sound level reaches or falls below the threshold value of the sound level during a test before 10 seconds have elapsed, the testwill be automatically finished after 10 seconds. Otherwise the test takes 20 seconds.

After the test the test result will be shown:

Checking Steam Traps -continued-

Test -continued-

Possible evaluations:OK: Yes Trap works without steam lossOK: No Trap defectiveOK: BC Banking-up of condensate possible (only if the service pressure has been specified on the PC)OK: FN Trap influenced by foreign noise (see section “Foreign noise”)

For more information refer to section “Evaluation criteria” and “Evaluating steam traps” in the Online Documentation.

If you want to repeat the test, use the down arrow button and then press the ENTER key. (The display shows again the graphicalrespresentation with the limit and threshold sound values LV and TV in the form of horizontal lines).To save the test result press the ENTER key.After saving the test results the task list appears. Checked steam traps are ticked off ✓.

➔

The next steam trap to be tested is marked in the list with the symbol .

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Use the arrow buttons , to select (mark) the functional type of the steam trap used and then press theENTER key.

The display shows the following graphic:

Use the arrow buttons , to select (mark) the place of installation of the steam trap and then press theENTER key.

The display shows the list TYPE.

Test measurement

In the menu TEST MEASUREMENT steam traps can be checked for loss of live steam – without prior input of data records andwithout the creation of test tasks. The test results will not be saved.

When the data collector is ready for operation select the submenu TEST MEASUREMENT (“Connecting and Commissioning” seepages 10 – 12).

The display shows the list LOCATION.

➔

➔

➔

➔

Checking Steam Traps -continued-

For the rest of the steam trap test proceed as described in section TEST.Note that the test results will not be saved.

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Press the tip of the measuring probe at various points in the close vicinity of the steam trap (supports, uninsulated pipes upstream anddownstream of the trap) to detect the respective sound levels.By comparing the MEAN VALUE with the MEASURED VALUE the influence of foreign noise on the test can be confirmed or ruled out.

If the detected sound level is below the mean value of the trap test (MEASURED VALUE < MEAN VALUE), an influence of foreign noisecan be ruled out.In this case use the arrow buttons , to mark FOREIGN NOISE: NO.

If the detected sound level exceeds the mean value of the trap test (MEASURED VALUE > MEAN VALUE), the place where the steamis installed is influenced by foreign noise. In this case use the arrow buttons , to mark FOREIGN NOISE: YES.

Press the ENTER key to show the recorded sound curve and its evaluation on the display.

OK: No Trap defectiveor

OK: FN Trap influenced by foreign noise

Press the ENTER key to save the result.

Foreign noise

Checking Steam Traps -continued-

➔

➔

➔

➔

■ Make sure that the measuring probe is applied to the same points on the trap bodies of steam traps of the same type sothat the test results of the steam traps can be compared and changes can be ascertained when repeating the tests.

■■■■■ Provided that the upstream pressure has been specified on the PC, the temperature of the steam trap body will also bemeasured and used for the analysis. In this case the surface of the reference point on the trap where the tip of themeasuring probe is applied has to be smooth and metallically bare. Otherwise considerable deviations between thetemperature reading and the actual temperature will be the consequence, resulting in faulty analysis and incorrectevaluation.

Note that the probe shall be applied at right angles to the trap surface.

Reference points for measurement

If sound levels (means values) exceed the specified limits, the display shows the screen Foreign Noise Test.For more information refer to section “Evaluation criteria” and “Evaluating steam traps” of theOnline Documentation.

21

The reference point of thermostatic bimetallic and membrane steam traps is located on the cover between the cover and the coverflange or at the side of the cover.

Reference points for measurement -continued-

Checking Steam Traps -continued-

Example: Bimetallic steam trap type BK 45

Example: Membrane steam trap type MK 45

Example: Bimetallic steam trap type BK 15

The reference point of float traps is located on the highest point on the cover or at the side of the cover.

Example: Float trap type UNA 2

Example: Float trap type UNA 1

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Data collector VKPN 40Ex, VKPN 40

Fault finding list for troubleshooting

Fault: No indication on the display (power supply unit not connected).Possible cause: Rechargeable batteries are empty.Remedy: Connect the data collector with the connecting cable VKPA 40, plug the power supply unit into an earthed

socket and recharge the battery for at least 4 hours (see section “Charging batteries”).

Fault: No indication on the display (connecting cable VKP 40A connected, power supply unit plugged in earthedsocket).

Possible cause: Rechargeable batteries are defective.Remedy: Replace the battery unit (see section “Replacing battery unit”).

Fault: Date indicated 2000.01.01.Possible cause: If the battery voltage is below 2.5 V the protective circuit-breaker switches off the battery. The date is set to

2000.01.01.Remedy: Connect the data collector with the connecting cable VKPA 40, plug the power supply unit into an earthed

socket and recharge the battery for at least 4 hours (see section “Charging batteries”).

Measuring transducer VKPS 40Ex

Fault: LED not illuminated.Possible cause: The LED lights up only when the measuring transducer is switched on by the data collector.Remedy: When the graphic appears on the display of the data collector, the measuring transducer will be switched on.

(See section “Checking Steam Traps”). The LED lights up only when the measuring transducer is presseddown to the stop onto the trap body.

Fault: LED not illuminated although the display of the data collector shows the graphic and the testhas been started.

Possible cause: LED defective.Remedy: Please send the measuring transducer to GESTRA AG for repair.

Screen display on PC

Fault: The text on the buttons is incomplete.Possible cause: The screen resolution setting is probably unsuitable.Remedy: Choose a suitable screen resolution setting.

Fault: There are numbers (instead of text) on the buttons.Possible cause: The terms listed in the language table may have been deleted (menu Extras /Language).Remedy: Enter the missing term in the menu Extras/Language.

refsnartataD.onedocrorre

egassemCP gnitoohselbuort/esuaC

0 noitareporofydaertonrodetcennocton04NPKV ”refsnartataD“unemnitonrodetcennoctonrotcellocataD

3 noitpeceratadgnirudtuoemiT refsnarttaepeR

5 resuybdetroba04NPKV refsnarttaepeR

01 tneiciffuston04NPKVfoyticapacegarotS refsnarttaeperdna04NPKVnosksattseteteleD

11 04NPKVrofelbaliavasksatoN refsnarttaeperdnasksattsetdneS

31 04NPKVnoderotsydaerlaksaT refsnarttaeperdnaksattseteteleD

51 dnammocgnorW refsnarttaepeR

71 deteledebtondluocyromemmargorP refsnarttaepeR

23

EC Type Approval

24

818535-00/205cm · © 2005 GESTRA AG · Bremen · Printed in Germany

GESTRA AGP. O. Box 10 54 60, D-28054 BremenMünchener Str. 77, D-28215 Bremen

Telephone +49 (0) 421 35 03 - 0, Fax +49 (0) 421 35 03 - 393

E-Mail gestra.ag@flowserve.com, Internet www.gestra.de

GESTRA

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