GESTRA VKP 40Ex Manual

1
GESTRA Steam Systems
VKP 40Ex
VKP 40
Installation & Operating Instructions 81853502
Steam Trap Testing, Recording & Evaluation System TRAPtest VKP 40 (VKP 40Ex for applications
in potentially explosive areas) for checking steam traps of all types and makes for steam loss and
banking-up of condensate
EN
English

2
Contents
Description
System description VKP 40Ex, VKP 40..................................................................................................................................................... 3
Application VKP 40Ex, VKP 40 ................................................................................................................................................................. 3
Scope of supply VKP 40Ex, VKP 40.......................................................................................................................................................... 3
Safety Notes for VKP 40Ex
Notes.................................................................................................................................................................................................. 4, 5
Application ............................................................................................................................................................................................ 5
Maintenance notes VKPN 40Ex; VKPS 40Ex............................................................................................................................................. 5
Replacing storage batteries VKPN 40Ex............................................................................................................................................... 5, 6
Environmental requirements ................................................................................................................................................................... 6
System description VKP 40Ex, VKP 40
System requirements.............................................................................................................................................................................. 7
Data collector VKPN 40Ex, VKPN 40 ........................................................................................................................................................ 7
Measuring transducer VKPS 40Ex ........................................................................................................................................................... 7
Connecting cable VKPA 40 ...................................................................................................................................................................... 7
Test duration........................................................................................................................................................................................... 7
Dimensions and weights......................................................................................................................................................................... 8
Charging storage batteries of VKPN 40Ex, VKP 40 .................................................................................................................................. 8
Replacing storage batteries of VKPN 40 (VKPN 40Ex see section “Safety Notes”) .................................................................................... 9
Maintaining VKP 40................................................................................................................................................................................. 9
Spare parts............................................................................................................................................................................................. 9
Connecting and Commissioning Data Collector VKPN 40Ex, VKPN 40
Connecting data collector VKPN 40Ex or VKPN 40 to a PC ..................................................................................................................... 10
Connecting measuring transducer VKPS 40Ex to data collector VKPN 40Ex or VKPN 40 ......................................................................... 10
Commissioning data collector VKPN 40Ex or VKPN 40........................................................................................................................... 11
Switching off data collector................................................................................................................................................................... 12
Automatic de-activation........................................................................................................................................................................ 12
TRAPtest Software PC Program
Installing PC software ........................................................................................................................................................................... 13
Starting and quitting program ............................................................................................................................................................... 13
Deinstalling PC software ....................................................................................................................................................................... 13
Software 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 – 18
Test measurement ................................................................................................................................................................................ 19
Foreign noise........................................................................................................................................................................................ 20
Reference points for measurement ................................................................................................................................................. 20, 21
Troubleshooting
Data collector VKPN 40EX, VKPN 40 ...................................................................................................................................................... 22
Measuring transducer VKPS 40Ex ......................................................................................................................................................... 22
PC screen display ................................................................................................................................................................................. 22
EC Type Approval Certificate
EC Type Approval .................................................................................................................................................................................. 23

3
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 and
the software for data management on the PC. The VKP 40Ex or VKP 40 can check and evaluate all types and makes of steam traps for
loss of live steam and banking-up of condensate.
The testing equipment detects and evaluates ultrasonic vibrations on the surface of the trap body caused by the media flowing through
the steam trap. The ultrasonic vibrations are transmitted through the trap body and picked up by the hand-held probe VKPS 40Ex by
pressing the sensor tip onto a point of the trap body that is characteristic of the respective trap type. The ultrasonic vibration is then
converted into electric pulses and – in the form of digital signals – fed via cable to the data collector VKPN 40Ex or VKPN 40. The
display of the data collector shows the signals received during the test as a standing curve. With this graphical representation one can
see at once whether the tested steam trap is working with or without loss of steam. The recorded ultrasonic vibration is analysed by
the data collector and evaluated in accordance with certain empirically ascertained limit values that depend on the trap type. During
the test the temperature of the steam trap is measured, too. Provided that a service pressure has been specified (on the PC), the
diagnostic system 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 loss
caused by faulty steam traps. To quantify the steam loss caused by faulty steam traps, empirically obtained test values are used as
reference.
All curves recorded for a steam trap as well as the associated numerical test results and the corresponding analysis by the system can
be stored and printed out.
For more detailed information on the system and its functions refer to the “Online Documentation” of the TRAPtest
PC program.
Scope of supply VKP 40Ex, VKP 40
The carrying case TRAPtest VKP 40Ex or VKP 40 contains:
1 Hand-held data collector VKPN 40ex / VKPN 40
1 Measuring transducer VKPS 40ex / VKPS 40
1 Connecting cable VKPA 40 incl. power supply unit and connecting cable with serial connector for PC
3 Adaptor plugs for international application of the power supply unit
1 Strap for data collector
1 Holster for measuring transducer
1 TRAPtest software on CD Rom
1 Operating manual
Apply VKP 40Ex / VKP 40 only for testing steam traps that are used in steam and condensate systems. Note that banking
up of condensate can only be detected if the pressure in the system is at least 1.1 barg.
For more information on the test procedure see section “Checking Steam Traps”.
Use the equipment only for measurements carried out on voltagefree and earthed pipe systems! Mortal danger is
imminent if you carry out measurements on voltagecarrying objects.
In explosionrisk areas only the measuring transducer VKPS 40Ex connected via cable with the data collector VKPN 40Ex
may be used.
For more information see section: Safety Notes for VKP 40Ex!
Application VKP 40Ex, VKP 40
Attention
Do not connect the data collector to or disconnect it from the measuring transducer in explosionrisk areas!

4
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 and
the 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 connection must not be made, opened or undone if 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 measuring
transducer 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 storage battery for power supply.
The storage battery must only be charged outside the explosionrisk area with the aid of the connecting cable
VKPA 40.
The display of the data collector VKPN 40Ex shows the current battery charge. If the charging process takes extremely long or a
full charge cannot be obtained, the storage battery might have a malfunction and should therefore no longer be used but must be
replaced. Note that only a genuine GESTRA storage battery with protective circuit breaker must be used as replacement.
For more information on how to change the battery of the VKPN 40Ex see section “Replacing storage battery unit”.

5
Safety Notes for VKP 40Ex  continued 
Notes  continued 
If the battery is sufficiently charged for the planned steam trap testing, the data collector VKPN 40Ex can be unplugged from the
connecting cable. Before entering the explosion-risk area connect the measuring transducer VKPS 40Ex to the data collector
VKPN 40Ex. The connection between the data collector VKPN 40Ex and the measuring transducer VKPS 40Ex must not be opened in an
explosion-risk area.
The equipment can be carried into the explosion-risk area when it is switched on and when it is switched off.
Application of VKP 40Ex
Use VKP 40Ex only for testing steam traps!
Use the equipment only for measurements carried out on voltagefree and earthed pipe systems!
Mortal danger is imminent if you carry out measurements on voltagecarrying objects.
For more information on the test procedure see section “Checking Steam Traps”.
Maintenance notes VKPN 40Ex, VKPS 40Ex
Do not use the equipment in explosionrisk areas in case of visible signs of damage (e. g. cracks in the casing, faulty display,
worn down probe tip, …). Please contact GESTRA AG or a GESTRA company in your country.
The equipment is provided with a storage battery. To change this battery the equipment must be opened. Only trained personnel
conversant with the explosion protection directive is allowed to perform the replacement. Only genuine GESTRA replacement parts
must be used.
Replacing storage battery unit VKPN 40Ex
Make sure that the data collector is switched off before replacing the storage battery!
Save data before replacing the storage battery in order to avoid loss of data.
Make sure that the data collector is not connected via connecting cable VKPA 40 when replacing the storage
battery.
Incorrect charge levels are indicated after the replacement of the storage battery unit. It takes two charging/
discharging processes before the correct state of charge can be indicated.
The storage battery must be replaced when its charging capacity is no longer sufficient for the required test tasks. For this purpose
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 must not be detached. The storage
battery unit is embedded with protective elements on a green board. This unit is fixed to the bottom of the equipment by means of
4 screws. In order to exchange the battery this whole unit has to be replaced by a genuine GESTRA AG spare part.
Undo the 4 screws and remove the battery unit. Put the new battery unit onto the two centring pieces of the connector. Insert the
4 screws (M 2.5, M 3) and fasten them moderately. Then mount the two halves of the equipment together, making sure that the
gasket is properly inserted and the ribbon cable is not jammed between the two equipment parts. Then mount the 6 casing
screws and tighten them with a torque of 0.8 Nm. The battery can now be charged as described in section “Charging storage
batteries”. Note that the full performance of a new storage battery is achieved only after about 5 complete charge and discharge
cycles. Environmental regulations have to be taken into account when disposing of storage batteries.
Attention
When opening the equipment make sure that neither the connecting cable VKPA 40 nor the measuring
transducer VKPS 40Ex is connected.
Do not open the equipment in explosionrisk areas! To prevent damage to electronic components shield the
equipment against electrostatic discharges (e.s.d).
Any type of work on the equipment – apart from replacing the storage battery – must only be performed by
GESTRA AG.
When used for its intended purpose the diagnostic system is maintenance-free. However, we recommend that the system should be
sent to GESTRA AG Bremen every 5 years for a general inspection.
Attention

6
Environmental requirements
Temperature rating for data collector VKPN 40Ex:
Operating temperature: –10 °C to 50 °C
Temperature rating for measuring transducer VKPS 40Ex:
Operating temperature: –10 °C to 60 °C
The equipment approval corresponds to protection class “II 2G EEX ib IIC T4”:
Explosion group IIc
GAS
Category 2
Temperature class T4
Intrinsically safe according to “ib”
Max. operating voltage:
Data collector VKPN 40Ex: 3.3 V
Measuring transducer VKPS 40Ex: 5.0 V
Max. power consumption:
Data collector VKPN 40Ex: 0.25 A
Measuring transducer VKPS 40Ex: 0.03 A
Board with storage
battery unit
Ribbon cable


Lower part of VKPN 40Ex
Safety Notes for VKP 40Ex  continued 
Replacing storage battery unit of VKPN 40Ex  continued 
Gasket

Data collector VKPN 40Ex (opened)

7
System description VKP 40Ex, VKP 40
System requirements
Operating system:
Windows 98, 2000, NT 4 (SP 6) XP.
CD ROM drive
Minimum requirements
Computer with Pentium®compatible processor with 700 MHz
100 MB free hard disk memory
128 MB RAM
800 x 600 screen resolution
Recommended:
Computer with Pentium®compatible processor with 1.2 GHz
200 MB free hard disk memory
256 MB RAM
Data collector VKPN 40Ex, VKPN 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. 750 steam traps with 1 up to 256 test jobs.
Power supplied by two pre-installed Li-Polymer storage batteries, capacity 1800 mAh.
4 hours charging time for an empty battery provides approx. 8 hours operating time.
Max. operating voltage 3.3 V
Max. power consumption 0.25 A
Operating temperature –10 °C to 50 °C
Max. admissible service temperature: 50 °C
Min. admissible service temperature: –10 °C
Degree of humidity: 0 % to 90 % (not condensed)
Protection IP 65
VKPN 40Ex: Approval BVS 04 ATEX E 234
CE 0158 Ex II 2G EEX ib IIC T4
Measuring transducer VKPS 40Ex
Casing made of titanium (3.7035)
Operating temperature –10 °C to 60 °C
Measuring range for surface temperature: 0 °C to 350 °C
Max. admissible service temperature: 60 °C
Min. admissible service temperature: –10 °C
Power supplied by storage battery of the data collector.
Max. operating voltage 5.0 V
Max. power consumption 0.03 A
VKPS 40Ex: Approval BVS 04 ATEX E 234
CE 0158 Ex II 2G EEX ib IIC T4
Connecting cable VKPA 40
The connecting cable VKPA 40 consists of the power supply unit with integrated connecting cable and circular plug for connecting the
data collector VKPN 40Ex or VKPN 40 and the connecting cable with a serial connector for connecting the PC.
With the power supply unit connected, the connecting cable connects the equipment with the PC and allows charging of the batteries
installed in the data collector. To adapt the connector to national standards choose a suitable adaptor plug. Remove the adaptor plug
from the power supply unit and attach the appropriate adaptor plug for your country. (Please order separate adaptor for the USA)
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 be
finished after 10 seconds. Otherwise the test takes 20 seconds.
For more information refer to the PC Online Documentation.

8
Technical Data VKP 40Ex, VKP 40  continued 
Dimensions and weights
Dimensions
[mm]
Carrying case: approx. 370 x 135 x 550
Data 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)
Weights
Carrying case with contents approx.: 5.1 kg
Data collector VKPN 40Ex approx.: 600 g
Data collector VKPN 40 approx.: 540 g
Measuring transducer VKPS 40Ex approx.: 440 g
Charging storage batteries of VKPN 40Ex, VKP 40
Use only the supplied connecting cable VKPA 40 for charging the storage batteries!
Charge only the storage battery unit supplied by GESTRA AG!
Attention: The connecting cable VKPA 40 must not be used in explosionrisk areas!
The storage battery of the VKPN 40Ex must only be charged outside of an explosionrisk area!
The charging of an empty battery takes approximately 6 hours (ambient temperature 20 °C).
With the power supply unit connected, the data collector cannot be switched off.
By pressing the ESC key in the main menu you can view the charge level indicator in the title window.
Circular plug
Adaptor
for
connector


Data collector VKPN 40Ex with
connecting cable VKPA 40
The storage 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 of
the 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 version number,
the current date and the charge level appears. During first commissioning or if the batteries are flat the date 2000.01.01 will be
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 an arrow to the left of the charge indicator. Once the battery is fully recharged the
charge indicator is shown as a black bar.
Pull the sleeve of the plug to unplug the device.
Attention
Power supply
unit

Connecting cable
VKPN 40


9
Technical Data VKP 40Ex, VKP 40  continued 
Replacing storage batteries VKPN 40
Make sure that the data collector is switched off before replacing the storage battery!
Save data before replacing the storage battery unit in order to avoid loss of data.
Make sure that the data collector is not connected via connecting cable VKPA 40 when replacing the storage
battery.
Incorrect charge levels are indicated after the replacement of the storage battery unit. It takes two charging/
discharging processes before the correct state of charge can be indicated.
Do not remove the storage battery pack as some of the acid electrolyte might escape during the process.
Do not throw storage batteries in water or fire (risk of explosion)!
Old storage batteries should not be disposed of with normal household waste – hand them in at your recycling
centre.
Maintaining VKP 40
When used for its intended purpose the diagnostic system is maintenance-free. However, we recommend that the system should be
sent to GESTRA AG Bremen every 5 years for a general inspection.
Spare Parts / Accessories
The storage battery must be replaced when its charging capacity is no longer sufficient for the required test tasks. For this purpose
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 must not be detached. The storage
battery unit is embedded with protective elements on a green board. This unit is fixed to the bottom of the equipment by means of
4 screws. In order to exchange the battery this whole unit has to be replaced by a genuine GESTRA AG spare part. Undo the
4 screws and remove the battery unit. Put the new battery unit onto the two centring pieces of the connector. Insert two M2.5 mm
screws 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 of
the equipment together, making sure that the gasket is properly inserted and the ribbon cable is not jammed between the two
equipment parts. Then mount the 6 screws and tighten them with a torque of 0.8 Nm. The battery can now be charged as described
in section “Charging storage batteries”. Note that the full performance of a new storage battery is achieved only after about 5
complete charge and discharge cycles. Environmental regulations have to be taken into account when disposing of storage batteries.
(See pictures in section “Replacing storage battery unit”).
Attention
Designation Stock code
Complete storage battery unit for VKPN 40Ex / VKPN 40 (incl. 1 set of screws) 052475
Strap 052479
Holster for VKPS 40Ex 052478
Connecting cable VKPA 40 compl., incl. power supply unit 052476
Adaptor set for connector 052477
VKP 40 USB / Serial adaptor and software 052480
Name plates, label 389299
Charging set 11.. (for car) 15 VDC 1502770

10
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 connecting
cable 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.
Connnect the serial plug of the connecting cable with the PC. Use a commercially available interface connection USB-RS 232 to
connect the data collector via a USB interface to the PC. Then confirm the selected interface (Com 1, Com 2, Com 3, Com 4 or Com 5)
in the TRAPtest menu EXTRAS/Interface on the PC.
Attention: Do not use the connecting cable VKPA40 in explosionrisk areas!
Connecting the measuring transducer VKPS 40Ex to the data collector VKPN 40Ex or VKPN 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 you
enter 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 carrried into an explosion-
risk area.
Do not use the data collector VKPN in explosionrisk areas!
Insert the circular plug of the connecting cable VKPS 40Ex into the right-hand jack of the data collector VKPN 40Ex / VKPN 40. To prevent
loss of data switch off the data collector VKPN 40 / VKPN 40 EX before establishing or undoing the connection to the measuring transducer
VKPS 40 / VKPS 40 Ex.
To disconnect the device pull the sleeve of the plug.
Danger

Circular plug

Data collector VKPN 40Ex with connecting cable VKPA 40
Serial plug Adaptor for connector

Power supply unit

Connecting cable
VKPA 40
Data collector VKPN 40Ex,
VKPN 40 with the measuring transducer VKPS 40Ex
Measuring transducer
VKPS 40Ex
